Physical Testing

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TENSILE TESTING :

Testing forgings for the mechanical properties to confirm their suitability to withstand loads carried by them in service.
Model: BTE II, Weidman Baldwin – U.S.A.
60000 lbs capacity.
Facilities available for proof stress and recording of load – displacement curve.

Purpose

Verification of Tensile , Compression & Bend Properties of Forgings / Plates etc.

Equipment	Make/ Least Count/ Capacity /Accuracy	Features	Reference Standard
Universal Tensile Testing Machine	M/s Wiedemann Baldwin, U.S.A. Model : BTE – II Capacity : 60,000 lbs. Accuracy : ± 1 %	Equipped with Extensometer & Recorder facility for Proof Stress Measurement.	ASTM E 8 – 1998 ASTM A 370-1994 ASTM E 855 –1990 DIN EN 10002 – PART 1 JIS J – 2241 – 1998 BS 18-711 IS – 1608-1995.

IMPACT TEST :

Impact strength of forgings are tested to ensure their ability to withstand shockloads.
Model : SI-IC, Wiedemann Baldwin, U.S.A.
Calibrated with ASTM standard specimen.
Tests are carried out both at room temperature and sub-zero tempetatures.

Purpose

Measurement of Charpy & Izod Impact Strength of Forgings.

Equipment	Make/ Least Count/ Capacity /Accuracy	Features	Reference Standard
Impact Testing Machine	M/s Wiedemann Baldwin, U.S.A. Model : SI – IC Capacity : 0 to 240 Ft. lbs. Accuracy : 1 Ft.lbs or 5 % whichever is more.	Equipped with Extensometer & Recorder facility for Proof Stress measurement.	ASTM E 8 – 1998 ASTM A 370-1994 ASTM E 855 –1990 DIN EN 10002 – PART 1 JIS J – 2241 – 1998 BS 18-711 IS – 1608-1995.

HARDNESS TESTING :

VICKERS CUM BRINELL HARDNESS TESTING

The strength and wear resistance of forgings and componenets are quickly assessed by hardness testing.
Model no. 1777 for testing hardness to brinell and vickers scales with load upto 1777 N tested to standard.

Purpose

To Confirm the Hardness of Forgings

Equipment	Make/ Least Count/ Capacity /Accuracy	Features	Reference Standard
Vickers Cum Brinell Hardness Testing Machine	M/s Heckert, Germany Model : HMO 777 Accuracy : ± 2 %	Used for Multiple Scales i.e. HV & HB	ASTM E 92 –97 DIN – 50133 – 85 JIS J – 2244 – 98

Equipment	Make/ Least Count/ Capacity /Accuracy	Features	Reference Standard
Rockwell Hardness Tester	M/s Wilson , U.S.A. Model : 5 Tr BB Accuracy : ± 1 Scale / 0 to HRc /± 1 Scale	Used for Multiple Hardness Scales like HRc , HRa , HRB etc.	ASTM E 18 –97 JIS J – 2245 – 98

MICRO HARDNESS TESTING :

To check the surface hardness of case hardened components and the decarburised layer on the surface of forgings.
Model : Mini Load , Leitz , Germany. Capacity : 100 gms to 1 kg load

Purpose

Induction Hardened Case Depth measurement.
Decarb Depth Measurement

Equipment	Make/ Least Count/ Capacity /Accuracy	Features	Reference Standard
Micro Hardness Testing Machine	M/s Leitz , Germany Model : Mini Load Capacity : 100 gms - 1 Kg Accuracy : ± 4 %	Able to check Hardness of various phases of microstructure .	ASTM E 384 – 89 Re approved - 1997 DIN 50133 – 85 JIS B 7735

Microficial Hardness Tester :

Purpose

Induction Hardened Case Depth measurement.

Make/ Least Count / Capacity /Accuracy	Features	Reference Standard
M/s Wilson , U.S.A. Model : XY-At Duel Load Capacity : 1 WMN / Upto 940 HV Accuracy : ± 6 WMN	Software Program base Fully Automatic measurement of Case Depth/Hardness Traverse Used for Multiple Scales i.e. HV, HB, HRc, HRA etc. Jominy Hardenability Program NIST calibrated Master Block	ASTM E–8– 1994

Microdur Hardness Tester :

Purpose

To check the hardness of finish ground crankshafts.

Make / Model / Accuracy	Features
M/s Krautkramer Brason, Germany Model : Microdur II Accuracy : ± 1 %	Portable Ultrasonic Hardness Tester. Instant Digital Display. Multiple Scales available e.g. HB, HV, HRc etc.

Equotip Hardness Testing Machine :

Purpose

To Check the hardness of Heavy Forgings / Die Blocks.

Make/ Model / Accuracy	Features
M/s Proceq SA Zurich, Switzerland Model : D / D+15 Accuracy : ± 0.5 % or ± 4 L	Portable Hardness tester with Rebound Hardness test principle. Multidirectional hardness testing For all metallic materials Multiple Scale available e.g. HRc.HRB.Equotip, HV HB, Shore D etc. Instant Digital Display.

FRACTOGRAPHY :

Purpose

For detail study on Fractography.
Helpful in Field Failure analysis.

Equipment	Make/ Least Count/ Capacity /Accuracy	Features
Scanning Electron Microscope	JEOL - Japan Model : JSM 5800 Magnification : 18 X to 300,000 X	Camera attachment for Photo Micrographs. Higher Magnification.

MICROSTRUCTURE :

Purpose

To confirm the desired phases / Grain Size / Inclusion Rating etc.

Equipment	Make/ Least Count/ Capacity /Accuracy	Features	Reference Standard
i. Optical Microscope	M/s Nikon, Japan Model : EPIPHOT Magnification : 100 X to 1000 X	Camera Attachment for Photomicrographs.	GB/T 13299-1991
ii. Optical Microscope	M/s Carl Zeiss, Germany Model : Neophot32 Magnification : 50 X to 2000 X	Camera Attachment for Photomicrographs. Attached with Image Analysis Software for – (a) Inclusion Rating. (b) Grain Size. (c) 2 / 3 Phase Analysis.	ASTM E 1245-95

RESIDUEL STRESS MEASUREMENT :

Purpose

Surface Residual Stress Measurement

Equipment	Make/Model	Features
Stress Analyser	Rollscan , U.S.A. Model : Rollscan 200	Nondestructive measurement method of checking Hard Spots/Soft Spots in finish ground components. Works on Magneto-elastic Barkhasen noise effect principle. Able to detect Grinding Burn

ULTRASONIC TEST :

Purpose

To confirm Internal Soundness of Forgings & Raw Material Steel Bars

Equipment	Make/ Least Count/ Capacity /Accuracy	Features	Reference Standard
Ultrasonic Testing Machine	Krautkrammer, Germany Model : USL 32 Capacity : 10–5000 mm Accuracy : ± 0.5 dB	Compact , top quality instrument for Portable & stationary use. Extremely good linearity of the Horizontal & vertical echo representation 100 dB gain adjusting range.	ASTM A 388 – 94 ASTM E 317- 94 JIS J – 2344 – 93 API 6 A BFL STD. WS 002

JOMINY HARDENABILITY :

Purpose

To confirm the Hardenability of the Raw Material

Equipment	Reference Standard
Jominy Hardenability Equipment & Rockwell Hardness Tester	ASTM A 255-89 SAE J 406 – 95 DIN 50191-87 JIS- G-0561-98

GRAIN SIZE :

Purpose

To Confirm Grain Size

Equipment	Make/Model	Reference Standard
Microscope	M/s Nikon, Japan Model : EPIPHOT	ASTM E 112 –96 DIN 50601-85 JIS G –0551-98

INCLUSION RATING :

Purpose

To confirm material cleanliness.

Equipment	Make/ Model	Reference Standard
Microscope	M/s Nikon, Japan Model : EPIPHOT	ASTM E 45 – 97 DIN 50602 – 85 JIS G – 0555-98 GB/T 10561-1989

MACRO ETCHING :

Purpose

To check Internal Quality of Raw Material.

Equipment	Reference Standard
HOT PLATE , ACID	ASTM E 381 – 94 JIS G – 0553 – 96

STEP DOWN TEST :

Purpose

To check Surface & Sub Surface defects.

Reference Standard

BFL STD. WS 003
JIS 556-98
IS 4075 – 67
AMS –2301 G
AMS 2304

BLUE BRITTLE TEST :

Purpose

To check macro inclusions.

Reference Standard

BFL STD. WS 001
SEP–1548

SPARK TEST :

Purpose

To confirm Material Grade

Reference Standard

JIS GO 566 – 1980

VISCOSITY TEST FOR POLYMER :

Purpose

To check Polymer Concentration ( Heat treatment – Quenchant )

Equipment	Reference Standard
Kinematic Viscosity Meter	ASTM D-446-1993

MILLIPORE TEST :

Purpose

To Check cleanliness of Finished Crankshaft

Equipment	Make	Reference Standard
Millipore Kit	M/s Millipore India, Bangalore	CES 16233

DESIGN AND ENGINEERING | TOOL & DIE MANUFACTURING | FORGING FACILITY | HEAT TREATMENT FACILITY

PROCESSING FACILITY | MACHINING FACILITY | INSPECTION & TESTING | LOGISTICS