THE ULTIMATE GUIDE TO LIGHTWEIGHT MATERIALS AND PARTS TESTING IN AUTOMOTIVE AND AEROSPACE How to meet the latest drop weight impact test requirements

INTRODUCTION As the demand for lightweight and composite materials continues to grow,1 impact testing is becoming more and more critical to success in design and manufacturing. But how do you ensure that added testing requirements don’t translate into downtime and disruption to just-in-time workflows in automotive and aerospace? This guide will give materials engineers and scientists working in these industries valuable insight into the latest drop weight impact testing methods and technology. It will provide you with useful guidance on how to make composite materials and parts testing simpler,...

LIGHT ALLOYS AND COMPOSITES: EMERGING TRENDS AND CHALLENGES Light Alloys and composites are rapidly becoming the go-to materials for automotive and aerospace manufacturers. According to analysts Market Insight Reports, over the next five years the composite material market is set to grow at a CAGR greater than 5%, mainly due to surging demand from the automotive and aerospace industries.2 Demand for high-performance alloys is also expected to continue growing by over 3% a year between 2020 and 2027.3 What makes light alloys and composites increasingly popular are their key benefits, including...

WHAT IS A DROP WEIGHT IMPACT TEST AND HOW CAN IT BE USED IN TESTING? What happens when a material or component is hit by an external object at speed? This is what a drop weight impact test tries to establish. It involves striking a material/part specimen with a weight falling from a height; the higher and the heavier the weight, the greater the amount of energy impacting the specimen. When it comes to materials, impact tests are regulated by the international standards including ISO 179,12 ISO 6603,13 ISO 8256,14 and ASTM 3763,15 which define specimen characteristics as well as test configurations...

The use of computer-aided engineering (CAE) tools such as LS-Dyna or Abaqus now enable engineers to simulate how materials and parts perform during impact. However, it is always recommended that virtual tests are validated by a physical impact test. This is key to improving the reliability of CAE-based testing As illustrated in the table below, impact testing often needs to be adapted to individual components. Test application Common standards Adhesives Testing Wedge Peel Test Measures dynamic resistance to cleavage [N/mm] by pushing wedge between adherents Tensile impact test Measures the force...

HOW TO INCREASE TESTING CAPACITY WITHOUT REDUCING THROUGHPUT We’ve seen how the volume and variety of materials and parts requiring impact testing is on the rise across automotive and aerospace applications. Ensuring a reliable, repeatable, and efficient testing process is, therefore, key to minimising downtime. There are three key steps you can take to achieve this ambitious goal. 1. Simplify setup: a fast, easy, and flexible setup process is key to switching between different samples quickly and smoothly. Look for drop tower solutions that allow for simple setup of carriage, masses, force sensors...

HOW TO ADAPT TESTING TO NEW MATERIALS AND MANUFACTURING METHODS Adapting to growing volumes of composites isn’t the only challenge testing is up against. It also needs to meet new requirements deriving from the use of new lightweight materials and manufacturing methods. For example, 3D-woven composites are becoming a popular choice in the production of various aircraft and vehicles parts due to their unique properties. But a recent study found that small variations occurring in the weaving process can affect physical and mechanical properties quite significantly . Similarly, the mechanical properties...

HOW TO MAKE TESTING SAFE Safety is another key consideration when selecting and using drop weight impact testing technology. With test conditions involving impact masses weighing up to 70 kg or pushed to a speed of 24 m/s, it is not difficult to understand why protecting the workers operating the machine from impact-related injuries is paramount. Another common risk workers may face is exposure to toxic fumes, vapours, or dust that can be released by specimens of composites when they are hit by the drop tower striker. A study by the Health and Safety Executive, for example, found that 3D-printed...

About Instron At Instron (www.instron.com) we maintain our position at the leading edge of impact testing innovation through design and collaboration,both with our customers, leading university and industry researchers. We lead by example, by meeting customer testing needs across any application requirement. Our Sales, R&D, and Tech Support teams work together with you from initial enquiry through to delivery, offering full access to demonstration models at our design facilities around the world. We lead in calibration, with accredited certification available through our dedicated Service teams....