cryogenic material testing€¦ · cryogenic material testing special requirements for test setup...
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where Analysis and Test meet
CRYOGENIC MATERIAL TESTING SPECIAL REQUIREMENTS FOR TEST SETUP AND TEST PERFORMANCE DEMONSTRATED ON ADDITIVE MANUFACTURED LIGHTWEIGHT ALLOYS
Christoph Zauner
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Index
• Demand of cryogenic testing
• Cryogenic temperature ranges and cooling methods
• Building cryogenic test setups
– Material
– Design
• Performing cryogenic tests
• Example(s)
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Demand on cryogenic testing
• Space:
– liquid propellant tank structures (20K for LH)
– cryogenic instruments
• Fusion Research:
– superconducting magnet structures (4K)
• Automotive
– liquid hydrogen tank structures
• Goal:
– material characterisation
– component / structure verification
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Temperatures and cooling methods
• Overview on typical temperature ranges, cooling methods and cooling equipment
Temperature Method Equipment
“hot” to -140°C (-180°C)
evaporative cooling of liquid nitrogen
thermal chamber
-196°C (77K) direct immersion in liquid nitrogen
test dewar
-196°C to -263°C (10K)
evaporative cooling of liquid helium
helium dewar gas phase
-269°C (4K) direct immersion in liquid helium
helium dewar liquid phase
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Cooling Fluids
• Comparison of Nitrogen and Helium
Temperature Nitrogen Helium Ratio He /
N2
Temperature -196°C / 77K -263°C / 4K -
Density liquid in kg/L 0,8076 0,1785 0,22
Heat of vaporisation in kJ/kg
199 21,1 0,11
Cost per liter in € 0,1 3 30
Cost per cooling 1kg stainless steel to liquid
temperature in € 0,06 108 1677
Delivery by truck stored
in big tanks On-site helium
liquefier
Gas recoverage not required strongly
recommended
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Thermal chamber (RT to -140°C)
• „+”
– Wide temperature range, and integrated easy control
– Feedthrough of fixed and moving test machine interface
• „-“
– Limited cryogenic range (commercial -140°C, self build to -180°C)
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Direct immersion in liquid nitrogen
• „+”
– High cooling rate
– Flexible cryostat design
• „-“
– Fixed temperature
– Risk of thermoelastic damage of the test setup / test machine during cooling down
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Evaporation of liquid helium
• „+” – Wide temperature
range (77K to ~10K)
• „-“ – Temperature gradient
along specimen needs to be compensated by electrical heating
– Low cooling rate
– High Cost
– Temperature Control and LHe flow control required
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KRP Mechatec GmbH where Analysis and Test meet
Direct immersion in liquid helium
• „+”
– Lowest cryo-temperature
• „-“
– Fixed temperature
– Risk of thermoelastic damage during cooling down
– High cost
– Baffle system required
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Cryogenic test setups - Materials
• Stainless steel is mainly used
– Low embrittlement and thus robust against transient forces during specimen failure
– Low thermal conductivity (good isolation of load bearing parts)
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Cryogenic test setups - Design guidelines
• Mechanical design – “mass is money” at LHe!
– FEM to identify load paths and optimize w.r.t. mass (morphological optimization)
– Assess maximum load capacity of test setup at different temperatures (w.r.t. temperature depended yield strength)
– Take care not to overload stainless steel setups at RT or high temperature
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KRP Mechatec GmbH where Analysis and Test meet
Cryogenic test setups - Design guidelines
• Thermal design
– FEM to identify temperature distribution and achievement
– Evaluate cooling time and cost per test
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Cryogenic setups – Vacuum environment
• Low convective heat transfer
• Two axis friction test 2MN/2MN at -190°C under vacuum – vacuum sealing in
cryogenic temperature: CF flanges
– Internal and external cooling of load bearing paths
LN2 tank fixed 4200l
LN2 tank mobile 100l
N2
LN2-outlet
LN2
LN2 – indirect cooling
vacuum chamber direct
cooling channels
NSE Interface
• Heat transfer coefficient from 150°C to 250°C at 50kN
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Cryogenic test performance
• Select temperature compatible strain gauges, extensometers and temperature sensors
• Protect test machine from condensed water
• Monitor oxygen in test lab • Take into account liquid
oxygen and liquid hydrogen • Provide gaps for different
thermal expansions • Don’t block test machine
during cooling down and heating up – high risk of overload and destruction
Vetronit Isolation
Protective Foil
Stiffness Temperature
CTE
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Application example – 3D printed metals
• Test setup design
– Tension
– Compression
– Shear
– Pin Bearing
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Application example – 3D printed metals
• Temperature levels
– RT
– 200K (-73°C)
– 77K (-196°C)
– 4K (-269°C)
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Application example – 3D printed metals
• Test performance
– Cooling down
– Strain control during yield
– Switch to stroke control after Rp0.2 has been reached
– Retract extensometer
– Load until failure
0 0.005 0.01 0.0150
100
200
300
400
500
600
Strain [mm/mm]
Str
ess [
MP
a]
Stress vs Strain - Extensometer
Et= 78305 MPa R square=0.9999
TYSt= 557 MPa TYS
u= 538 MPa
TUSt= 591 MPa TUS
u= 571 MPa
e=10.5%
0 200 400 600-80
-75
-70
-65
-60
Time [s]
Tem
pera
ture
[°C
]
T specimen top
T specimen bottom
Limits
0 1 2 3 40
100
200
300
400
500
600
Stroke [mm]
Str
ess [
MP
a]
Stress vs Crossheadtravel
0 10 20 30 400
1
2
3
4x 10
-4
Time [s]
Str
ain
rate
[s-1
]
Strain rate history
0 200 400 6000
1000
2000
3000
4000
5000
6000
7000
8000
Time [s]
Forc
e [
N]
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• Keep in mind: Safety first
• Thank you for your attention!
• Questions?
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Further Cryogenic Test Examples
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Further Cryogenic Test Examples
2MN 900kN
Leakage test of LN2 cryostat
Two axis cryogenic loading test