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Testing of media-conducting systems

Commencing with material testing to testing components and up to, and including, inspecting systems: our engineers will be pleased to assist you with the planning, executing, implementation and evaluation of your testing programmes with medial load testing as part of your development and approval processes.

We also draw upon these services to support you with product optimisation. In our efficient laboratories, fitted with modern equipment and explosion protection, we determine the behaviour of your test specimen under the real driving load, combined with temperature changes, pressure changes, volumetric flow and vibration simulation. Special media are applied according to your specifications, regardless of whether we are testing individual circuits, components, units (pressure generators, pressure consumers) or whole systems.

Irrespective of whether this relates to the automotive industry, mechanical engineering, metal and plastic industries, rail vehicle technology and other traffic engineering industries – our accredited test laboratories provide leak tests, pressure tests, functional testing and operating load simulations for inspecting the operating strength, operating resistance and durability.

Our portfolio

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Environmental Simulation and Vibration

External influences such as vibration, impact, cold, heat, moisture or water spray are simulated on vibration tables and in climatic chambers. We subject your product, for example, to vibration testing, shock testing, climatic testing, determination of Woehler-lines, pressure pulse tests, bursting pressure test, leak test, corrosion test and transport simulation.

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Electrical Testing

In terms of development and type testing, we offer a comprehensive range of services for accredited tests ranging from short-circuit tests to performance behavior and insulation behavior. Across sectors, we cover the test areas of renewable energies, automotive / e-mobility, rail applications and beyond.

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Construction Products

Whether product conformity, quality and safety standards, material characterization, service life and condition assessment - IMA Dresden plays a major role here. The independent, recognized and accredited certification body, testing center, and inspection body will assist you with any questions about requirements, test procedures, and requirements of applicable standards, regulations, and laws.

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Materials Testing Metals

Our material specialists accompany you in the implementation of your test programs as well as standardization, approval and certification of materials or manufacturing processes. We stand by your side during the entire test procedure, from the consultation, test planning and sample production, over the test itself up to the finished test report.

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Material Testing for Plastics and Composite Materials

From the base material through the manufacturing technology to the approval of the finished product - our material tests are DAkkS and NADCAP accredited. This includes static, cyclic and dynamic tests as well as static long-term tests, including sample production.

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Materialography

Whether for quality assurance, damage analysis or for research and development - in our accredited materialography laboratories we take a close look at both metallic and non-metallic materials of different composition with qualitative and quantitative characterization methods. This also includes the sample preparation procedures and the analysis, evaluation and documentation of the microscopic examination results.

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Damage analysis

Determining causes and effects experimentally - we assess damage cases and thus support the cause clarification. Our experienced engineers help you to investigate undesirable damage phenomena in detail - for example, by materialography, acoustic damage detection or non-destructive testing methods.

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Automobiles

Powerful for every vehicle type - our strength tests, approval tests or development tests are proven to be reliable for testing the operational strength and service life of automotive components, media-conducting systems, electrical components and materials.

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Railway

At our testing and development center, we test all rail vehicle components and materials for strength and service life. In terms of product and operational safety as well as quality assurance, we bundle the forces of testing and test design in our company with measurement, calculation, simulation and proof of strength as well as construction.

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Measurements and Measurement Runs

Stresses in real use are recorded by measurements, test drives and continuous monitoring, depending on the application. We carry out measurements of mechanical and electrical quantities under static and dynamic load under operating conditions, install complete measuring chains including process adaptation.

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Materials databases

The databases of our WIAM® product line provide material information and characteristic values ​​that are used reliably for material selection, design, standardization, calculation and simulation. The data pool draws on material and fundamental experiments from the last five decades, and new materials are systematically integrated.

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Training and Seminars

Benefit from our cross-industry know-how: In training courses and seminars directly at your company or at our site, you will receive extensive specialist knowledge - from courses for non-destructive testing (ZfP / NDT) about the FKM guideline "Computational Strength Verification of Machine Components" to software user training for WIAM® fatigue RIFEST.

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Software and Software Solutions

We have solved the management of data and documents from processes in the areas of research and development, simulation and calculation, laboratory, quality management, process development and production planning - with the WIAM® database systems we offer suitable software solutions with flexible data structures, display options and evaluations.

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Testing of tanks, fluid technology and media-conducting systems

We can inspect the loading capacity of your test objects under real and extreme conditions in our test laboratory in accordance with generally accepted standards or for your individual specifications.

For example, we inspect all sub-systems for the automotive sector according to OEM specifications or standard provisions. Flexible accreditation from DAkkS (German Accreditation Body) enables us to test materials and components according to different standards, as well as developing new testing procedures.

Irrespective of fuel systems using SCR systems or brake and lubrication systems, there are many test examples: Tanks, fuel lines, rails, connections, valves, seals, pressure regulators, radiators, heat exchangers, evaporators, condensers, auxiliary heaters, electric heaters, independent vehicle heaters, expansion tanks, circuits, tubes, filler pipes, SCR circuits, intercoolers, charge air pipes.

Testing media

  • Air: -1 to 300 bar relative
  • Fuel (Otto, diesel and alternative)
  • Coolants
  • Lubricants (various oils)
  • Special fluids (e.g. urea/AdBlue®)

Testing methods

  • Impermeability with excess pressure and/or vacuum
  • Internal high-pressure testing of fuel-carrying systems
  • Tightness test using total pressure change methods (Group D – DIN EN 13184)
  • Flow measurement
  • Pressure threshold testing
  • Bursting pressure testing
  • Motion simulation
  • Function testing

Testing methods for tanks and tank system testing

  • Fuel permeation for tank systems in accordance with GS 97014 (SHED test)
  • Pressure / vacuum test
  • Pressure change loading
  • Slosh testing on car tank system (starting and stopping)
  • Vibration testing
  • Tightness testing, including with helium

Special testing

We are well known for not just testing as “Standard”. We also like to upgrade our test benches according to your requirements and jointly develop your testing sequences.

  • Component testing and system testing with a focus on development, design and construction of test benches according to customer-related specifications
  • Assembly / dismantling for component groups, assemblies and plug-in connectors
  • Reaction force determination on coupler plug-in connections (force – path – evaluation)
  • Evaluating reaction forces in the component operation
  • Climatic testing with overlaying mechanical and fluid technical influences
  • Hot gas testing
  • Measuring components for emissions (HC-Emissions)
  • Splash water test
  • Steam jet test
  • Damage analysis

Electrical Testing

Operating behaviour is decisively influenced in fluid technology due to the increasing use of electrical /electronic systems and components within the sensors and actuators periphery. It is therefore important to ensure the safe and reliable use of components. We can inspect the performance capability under specified loads.

Typical tests:

  • Electrical supply for components according to the technical specification requirements with voltages up to 24V / high voltage up to 1000 V
  • Signal recording
  • Characteristic curve evaluation

Material loads

Different external loads and strains can have an effect on your product within their utilisation capability or even during manufacturing and these can corrode, deform or decompose the material, but also make it brittle. We can expose your products precisely to these loads or stresses in our experimental halls in order to inspect to which extent the characteristics and functions may be impaired.

  • Medial exposure with testing for chemical resistance and / or corrosion behaviour
  • Overlaying pressure, temperature and mechanical stress or load
  • Chemical stresses, among other things, according to ISO 16750-5, VDA 230-207

PRESSURE Pulse Test

We can execute pressure impulse testing, leak tests, burst pressure tests on hydraulic components, pipework, fittings, fittings, fuel lines, injection systems and rails. This enables the pressure pulse strength to be tested with indoor dynamic tests. Combining pressure pulse tests and vibration tests in accordance with IACS and DNVGL Type Approval also enables hydraulic fittings to be tested for bending with loads for internal pressure.

Certification tests for hydraulic systems are just one part of our testing spectrum as well as comprehensive validation inspections e.g. for fuel rails.

Testing spectrum

  • Pressure impulse testing
  • Hydro pulse tests
  • Combined pressure pulse testing and vibration testing (IACS, DNVGL)
  • Bursting pressure test
  • Leakage tests with various media (oil, water, nitrogen, helium among others)
  • Pull-Out-Test
  • Vacuum testing

Test Standards (selection)

IACS Req. 2006International Association of Classification SocietiesRequirements concerning pipes and ressure vessels
P2.11 Type Approval of Mechanical Joints
GLGermanischer LloydClassification Provisions and Construction Provisions for Pipework Fittings
DNVDet Norske VeritasStandards for Certification No. 2.9
Type Approval Programm No. 5-792.20
Pipe Couplings
BS 4368 Part 4British StandardCompression Couplings for Tubes
ISO 19879International Organisation for StandardisationTest procedure for metallic pipe fittings utilising fluid Technology
ISO 6605International Organisation for StandardisationHydraulic fluid power. Hoses and hose assemblies. Test methods

Test parameters

Pressure, dynamicalDynamic maximum pressure up to 1,400 bar
Typical pulse frequency 1 Hz
Up to 30 Hz sinusoidal
VibrationBending frequency of hydraulic pipes or tubes up to 20Hz
Curve shapesSine, triangle, trapezoidal or standardised curves e.g. according to IACS P2.11.5.5.3, among other things, DNVGL
TemperatureAmbient temperature -40°C up to 140°C
Pressure, staticBurst pressure testing up to 4,000 bar