Element Berlin EN

BERLIN

ELEMENT BERLIN

ELEMENT BERLIN IS A SPECIALIST PROVIDER OF MATERIALS, PRODUCT QUALIFICATION, AND SYSTEMS TESTING TO THE G LO B A L A E R O S PA C E I N D U S T RY.

ABOUT US

OUR SERVICES

Our experts support customers testing requirements and can help develop bespoke test plans in support of qualification requests. We understand that timing and quality of service are key and work with customers from early idea conception through to final decision.

Our services include: · Vibration testing · Spin testing · High Cycle Fatigue testing · Fluid testing · Structures testing · Test concept definition and rig design

TRUSTED THROUGH INNOVATION Element Berlin is at the forefront of innovation and continuously invests in knowledge and technology to solve our customer's technical and operational challenges. Examples of our innovative services include: · Thermal Shock: Preconditioning and aging of the test specimens with high-temperature gradients. · Partial Air: Simulation to get even more realistic results in spin testing using a defined amount of oxygen. · Wind Milling: Prove Sustained Engine Imbalance vibration scenarios. · Duct & Valve Tests: Complex life cycle testing for in-service life expectancy. · Chopped Air: High Cycle Fatigue testing of larger components by using pulsed air facility.

The Element Berlin laboratory is accredited to comply with EN 9100 and delivers customer projects in accordance with all the relevant standards.

INDUSTRIES WE SERVE · · · · ·

Aerospace Energy Automotive Railroad Industrials

ELEMENT MATERIALS TECHNOLOGY

· Computer simulation

HIGH CYCLE FATIGUE TESTING (HCF) High cycle fatigue testing is useful for materials that experience low applied forces and where deformation is primarily elastic. Our facility can run up to six tests in parallel with up to two tests in hot conditions.

We offer a range of extraction methods to include: · Constant air jet for 1st and 2nd mode, using the airfoil geometry · Piezo-shaker excitation up to 25 kHz at ambient conditions · Piezo-shaker excitation up to 25 kHz at hot conditions up to 950° C on the airfoil · Electro dynamical Shaker up to 2 kHz · Chopped air (pulsed air/siren) up to 3,5 kHz at ambient conditions and up to 100° C using air foil Non-destructive materials testing (NDT): · FPI fluorescent penetrant inspection · Red dye penetrant inspection

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ELEMENT BERLIN VIBRATION TESTING

SPIN TESTING

Our vibration testing facilities ensure your products are robust and perform safely during operation or transit. We have both electrodynamic shakers and a hydraulic test rig to detect performance issues and potential failures.

We offer spin tests under numerous conditions to include: · Overspeed spin testing · Cyclic LCF spin testing · Hot and cold spin testing +800° C and - 60° C · Crack propagation testing · Intended burst Ttesting · Rub testing · Balancing · Containment testing · Torque testing · Break system testing · Blade excitation/damping · Rotor characterization

Electro-dynamical Shakers: · Various systems conducted from 0,4 to 56 kN, up to 210 g, up to 10.000 Hz · Standard tests at ambient condition · Negative temperatures up to -50° C · Hot conditions up to 550° C · Tests with fluids inside · Pressurized specimen tests Hydraulic rig for SEI / wind milling: · Customized rig with hydraulic actuators acc. to required test conditions.

SUSTAINED ENGINE IMBALANCE (SEI) TEST RIG Element's experts have developed a special SEI test rig with hydraulic actuators, which can be adapted to our customer's needs. The SEI tests can also be combined with pressure and temperatures between -30° C to +260° C on the specimen.

Customized test rigs acc.

To requested test conditions

fmin/fmax

>0/100 Hz

amax

40 g

smax

400mm p-p (depends on used hydraulic cylinder)

vmax

5 m/s (depends on used hydraulic cylinder)

Fmax

Depends on amount of hydraulic cylinders

STRESS CALCULATION IN-HOUSE

Applications: aero engines, turbine compressors, turbochargers and blowers under realistic conditions using highly sophisticated spin test rigs with speeds up to 200,000 rpm depending on the size of the specimen; with temperatures of more than 800° C, whereby axial and radial temperature gradients can be generated.

STRUCTURES TESTING The complex stresses that occur during the operation of technical structures must be examined under static and dynamic operational loads to assess the impact of fatigue and also to determine accurate in-service life predictions. We have multiple hydraulic cylinders and high capacity measuring systems to include: · Static and dynamic loading testing (uniaxial and multiaxial) · Functional testing · Mechanical tests combined with temperature, pressure, and vibration · Component calibration · Friction testing · Impact testing · Temperature pre-conditioning · Hydraulic testing · Element & Component Testing · Instrumentation · Deformation measurement (2D/3D) · Acoustic defect detection · Consulting Hardware: · Hydraulic and pneumatic actuators from 1 - 1000 kN · 8 control systems with up to 32 synchronized control channels · Bespoke load frames up to 1000 kN · Various t-slotted test beds up to 10 x 5m with 8m / 5t crane · Autoclave 2.5m in length and 0.8m in diameter, from 100 mbar up to 10 bar in a range of -70° C to +260° C · Bespoke autoclaves · Bespoke temperature chambers from -160° C up to +700° C · Mobil gas gun for impacting and notching · Pendulum for impacting and notching · Data acquisition systems with up to 256 channels

ELEMENT MATERIALS TECHNOLOGY

WWW.ELEMENT.COM/DE

ELEMENT BERLIN FLUID TESTING Element Berlin provides a variety of hydraulic fluid dynamics and pneumatic test services for aerospace and transportation engines, under a wide range of environmental conditions: · Pressure testing with gas and oil · Pressure endurance, fatigue or cycling testing · Pressurization combined with temperature, mechanical loading and vibration · Leakage testing · Flow measurement / flow check · Pressure drop testing · Temperature pre-conditioning · Thermal shock · Temperature cycling · Functional checks · Corrosion testing · Flexure testing Hardware: · Compressors 500 g/s @ 10bar from -70° C up to 300° C · Compressors 10 g/s @ 35 bar · Compressed gas up to 300 bar · Air heater system with 280 kW · Compressed air supply from -100° C up to +500° C · Hydraulic pressure intensifier up to 700 bar · Bespoke temperature chambers from -160° C up to 700° C · Autoclave 2,5 m in length and 0,8 m in diameter, from 100 mbar up to 10 bar in a range of -70° C to +260° C · Bespoke autoclaves · Pneumatic servo valves · Flow sensors from 0,005 g/s up to 600 g/s air. · Pressure sensors up to 1000 bar

TEST CONCEPT DEFINITION AND RIG DESIGN Our portfolio also includes customized engineering, design, and assembly services to ensure proper connection to the testing facilities.

For example, we use HCF holding blocks tailored to the airfoils' root, vibration adapters, fixtures, and support frames.

For a comprehensive list of our services, accreditations, and approvals, please visit www.element.com

ELEMENT BERLIN Friedrich-Wöhler-Straße 1 12489 Berlin

T: +49 (0)30 76 75 98 100 F: +49 (0)30 63 92 74 70 Email:sales.berlin@element.com

G e n e r a l I n q u i r i e s : c o n t a c t . u s @ e l e m e n t . c o m w w w. e l e m e n t . c o m United Kingdom: +44 808 234 1667

Germany: +49 800 000 5137

Amercas: +1 888 786 7555

Middle East: +971 800 353 636 2022.06