8. Gleeble 563¶
Fig. 8.1 Gleeble 563.
The Gleeble 563 is the preeminent next-generation Gleeble thermal-mechanical simulation system. To keep pace with an ever evolving and developing set of demands and requirements, Dynamic Systems is proud to offer the Gleeble 563. Built on the new Gleeble 500 Series platform, the Gleeble 563 provides the world-class Gleeble performance in a smaller package. The 500 Series of Gleeble systems are tailored to provide a compact, economical solution for researchers while retaining the industry standard capabilities researchers have come to expect.
Material Testing Capabilities of the Gleeble 563
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The low cost and small footprint of the Gleeble 563 allow it to be placed in laboratories or production environments where larger simulators cannot be installed. The space-saving platform also reduces the weight of the entire system, reducing laboratory facility structural requirements.
The Gleeble 563 features a touchscreen-based control system, making the setup and running of tests much faster and easier than traditional control systems. Installation and training are simple processes, allowing new users to begin producing actionable data faster than ever before.
| Part Number | Description | Sold As |
|---|---|---|
| 563 | Gleeble 563 Physical Simulation System | System |
8.1. Advanced Gleeble Control¶
Gleeble 500 Series systems are equipped with advanced Gleeble control systems similar to the Gleeble Touch Control of the 3000 Series systems. The control system of a Gleeble 500 Series system includes an intuitive user display with a large and easy-to-use touchscreen. Advanced software and hardware provide state-of-the-art performance with accuracy and dependability at the heart of the design.
8.2. Hydro-Mechanical¶
Every Gleeble system derives its power from a servo-controlled hydraulic system. The capabilities of the hydro-mechanical system will vary based on Gleeble options.
| Characteristic | Specification |
|---|---|
| Test Frame | Horizontal aluminum framework and structural vacuum tank |
| Mechanical System | Closed-loop hydraulic servo control |
| Maximum Force in Compression | 30 kN (3,059 kgf, 6,744 lbf) |
| Maximum Force in Tension | 30 kN (3,059 kgf, 6,744 lbf) |
| Maximum Stroke Rate | 200 mm/s (7.87 in/s) |
| Minimum Stroke Rate | 0.01 mm/s (3.94 x 10 -4 in/s) |
| Maximum Stroke Distance | 100 mm (3.94 in) |
Note
The total number of compression hits possible is dependent upon many test characteristics. These include the number of deformations, the initial position of the hydraulic stroke, and time between deformations.
Note
Accuracy is measured at a temperature of 23°C (73°F). Maximum stroke rates are at a hydraulic pressure of 203 bar (2,950 psi) ±3 % and an oil temperature of 30°C (86°F).
Maximum Dynamic Force
The maximum dynamic force for the Gleeble 563 is based on the following graph. For a given stroke speed the hydraulic system will provide a corresponding force. All performance figures for the system are based on operating in the region below the Force vs. Stroke curve. System specifications are not valid for tests conducted outside this operating range.
Fig. 8.2 Force vs. Stroke Velocity.
Hydraulic Servo Response
The Gleeble 563’s servo systems provide the capability to vary the rate of load application in both tension and compression testing. To achieve the system’s rated performance, certain limitations must be observed. For all types of operation, the Stroke rate and Force must be within the operating range as described in the maximum Force vs. Stroke graph.
Fig. 8.3 Time to reach programmed rate.
Fig. 8.4 Distance required to reach programmed rate.
Fig. 8.5 For constant strain rate programs, the duration of the deformation for each hit must be three times the rated response time of the hydraulic servo valve.
Load Cell
The 59002 Load Cell is mounted directly to the stationary jaw. It is used to measure the force exerted on the specimen by the hydraulic system.
| Characteristic | Specification |
|---|---|
| Non-linearity | ±0.1 % of full scale |
| Hysteresis | ±0.08 % of full scale |
| Non-Repeatability (Maximum) | ±0.03 % of full scale |
| Overload Rating | 150 % of capacity |
| Deflection - Full Scale | 0.076 mm (0.003 in) |
| Force Measurement Accuracy | ±1.0 % of full scale |
| Force Measurement Resolution | ±0.1 kgf (0.22 lbf) |
Note
Accuracy is measured at a temperature of 23°C (73°F). Maximum stroke rates are at a hydraulic pressure of 203 bar (2,950 psi) ±3 % and an oil temperature of 30°C (86°F).
Stroke Transducer
The 59001 Stroke Transducer is mounted directly to the hydraulic system piston. It is used as the main control transducer for movement of the Pocket Jaws.
| Characteristic | Specification |
|---|---|
| Type | LVDT |
| Linear Range | ±50.8 mm (2 in) |
| Non-Linearity | ±0.25% of full scale |
| Stroke Measurement Accuracy | 0.5 % of full scale |
| Stroke Measurement Resolution | 0.0075 mm (2.95 x 10 -4 in) |
Note
Accuracy is measured at a temperature of 23°C (73°F). Maximum stroke rates are at a hydraulic pressure of 203 bar (2,950 psi) ±3 % and an oil temperature of 30°C (86°F).
8.3. Thermal Subsystem¶
The Gleeble 563 offers a high-speed direct resistance thermal system for heating specimens.
Direct resistance heating provides the ability to reproduce the wide variety of thermal profiles that materials undergo in actual processes. This is critical to the success of thermal-mechanical testing and physical simulation. All Gleeble systems have high-speed heating and cooling rates that can accurately replicate nearly any thermal profile required.
| Characteristic | Specification |
|---|---|
| Heating System Type and Control | Direct resistance with closed-loop control |
| Temperature Controller | Digital closed-loop control using an 18-bit ADC and a 32-bit digital processor. |
| Temperature Range | Room temperature to 1,700°C (3,092°F) |
| Response Rate | 10,000°C/s (18,000°F/s) |
| Temperature Monitoring Source | Thermocouple or Optional Pyrometer Control Cameras |
| Thermocouple Sampling Rate | Twice the power line frequency (100 - 120 Hz) |
| Resolution | ±1°C or°F |
| Maximum Number of Simultaneous Thermal Channels | 8 thermocouple channels |
| Accuracy of Control | ±1°C (in steady state) |
| Accuracy of Measurement | ±1 % of temperature plus the accuracy of the thermocouple wire (in steady state) |
Note
As the specimen size, diameter, length, or cross-sectional area increases, the effective heating rate will decrease.
8.3.1. Thermocouple Measurement Assemblies¶
The Dual Channel Thermocouple Input series of modules is designed to add thermocouple input channels to Gleeble 500 Series systems and the HDS-V40. Each module may be connected to any available Gleeble PnP port, providing two thermocouple input channels of a given type.
| Part Number | Thermocouple Type | Description |
|---|---|---|
| 59004 | K | Dual Channel Input Box |
| 59005 | S | Dual Channel Input Box |
| 59006 | R | Dual Channel Input Box |
| 59007 | B | Dual Channel Input Box |
| 59008 | E | Dual Channel Input Box |
| 59014 | J | Dual Channel Input Box |
Note
A single K-type Dual Channel Input Box is included standard if required.
8.3.1.1. Thermocouple Wire Types¶
Gleeble systems are capable of recording specimen temperature with various thermocouple wire types. The following types of thermocouple wire can be used on any Gleeble system.
| Part Number | TC Type | Material | Sold As |
|---|---|---|---|
| Operating Range: 0 - 1,450°C (32 - 2,642°F) | |||
| TC005 | R- or S- | Pt 100% | Inch |
| TC006 | R+ | Pt 87% - Rh 13% | Inch |
| TC009 | S+ | Pt 90% - Rh 10% | Inch |
| Operating Range: -200 - 1,250°C (-328 - 2,282°F) | |||
| TC014 | K- | Alumel | Spool |
| TC015 | K+ | Chromel | Spool |
| Operating Range: 0 - 1,700°C (32 - 3,092°F) | |||
| TC017 | B- | Pt 94% - Rh 6% | Inch |
| TC018 | B+ | Pt 70% - Rh 30% | Inch |
| Operating Range: 0 - 750°C (32 - 1,382°F) | |||
| TC030 | J+ | Fe 100% | Spool |
| TC031 | J- | Constantan | Spool |
| Operating Range: -200 - 900°C (-328 - 1,652°F) | |||
| TC032A | E+ | Chromega | Spool |
| TC033 | E- | Constantan | Spool |
| Operating Range: 0 - 2,320°C (32 - 4,208°F) | |||
| TC010 | C+ | W 95% - Re 5% | Inch |
| C- | W 74% - Re 26% | ||
Note
TC wire types C, K, J, and E have a nominal wire diameter of 0.254 mm (0.01 in). TC wire types R, S, and B have a nominal wire diameter of 0.2032 mm (0.008 in).
Note
Gleeble systems can support additional thermocouple wire types not shown. Contact Dynamic Systems for additional information regarding the use of alternate thermocouple wire types.
Note
Each thermocouple wire type requires a corresponding Dual Channel Thermocouple Input Module for temperature measurement in Gleeble 500 Series systems or the HDS-V40.
8.3.2. Heating Rates¶
Heating rates are based on using a 480 V / 100 A power supply and full contact copper grips and plain carbon steel specimens. See Gleeble Grips for more information regarding the selection of grips.
| Specimen | Free Span | Drawing Number | Maximum Heating Rate |
|---|---|---|---|
| °C/s (°F/s) | |||
| 6 mm dia x 58.26 mm long | 10 mm | SFR002B | 10,000 (18,000) |
| 10 mm dia x 15 mm long (using ISO-T anvils) | SMC203B | 5 (9) | |
| 10 mm x 15 mm x 20 mm | SMC001B | 5 (9) | |
8.3.3. Cooling Rates¶
Free Cooling Rates
The Gleeble system is able to control the specimen cooling rate based on conductive heat transfer. The efficiency and maximum rate of conductive cooling is directly impacted by grip and specimen geometry, material, cleanliness, and system’s chilled process fluid flow rate.
The free cooling rates are achieved using full contact copper grips on 1018 carbon steel specimens. See Gleeble Grips for more information regarding the selection of grips.
| Specimen Type | Free Span | Drawing Number | Temperature Range | Cooling Rate |
|---|---|---|---|---|
| °C (°F) | °C/s (°F/s) | |||
| 6 mm dia x 58.26 mm long | 10 mm | SFR002B | 950 - 800 (1,742 - 1,472) | 140 (252) |
| 800 - 500 (1,472 - 932) | 78 (140.4) | |||
Quench Cooling Rates
The listed cooling rates were achieved using full contact copper grips on 1018 carbon steel specimens. Specimens were water quenched using a 59013 Quench Tanks system and 59024 Standard Quench Nozzle kit. See Gleeble Grips for more information regarding the selection of grips.
| Specimen Type | Free Span | Drawing Number | Temperature Range | Cooling Rate |
|---|---|---|---|---|
| °C (°F) | °C/s (°F/s) | |||
| 6 mm dia x 73.26 mm long | 25 mm | SFR006B | 1000 - 800 (1,832 - 1,472) | 6,000 (10,800) |
| 800 - 500 (1,472 - 932) | 10,000 (18,000) | |||
| 10 mm dia x 73.26 mm long | 25 mm | SFR054B | 1000 - 800 (1,832 - 1,472) | 6,000 (10,800) |
| 800 - 500 (1,472 - 932) | 5,000 (9,000) | |||
| 11 mm square x 73.26 mm long | 25 mm | SFS024B | 1000 - 800 (1,832 - 1,472) | 6,000 (10,800) |
| 800 - 500 (1,472 - 932) | 3,300 (5,940) | |||
ISO-Q Quench System
The listed cooling rates were achieved using full contact copper grips on 1018 carbon steel specimens quenched internally with compressed air. See Gleeble Grips for more information regarding the selection of grips.
| Specimen Type | Free Span | Drawing Number | Temperature Range | Cooling Rate |
|---|---|---|---|---|
| °C (°F) | °C/s (°F/s) | |||
| 10 mm dia x 71.37 mm long | 10 mm reduced to 6 mm dia x 6 mm long | SFR203B | 950 - 800 (1,742 - 1,472) | 250 (450) |
| 800 - 500 (1,472 - 932) | 375 (675) | |||
| 10 mm dia x 71.37 mm long | 10 mm reduced to 5 mm dia x 5 mm long | SFR202B | 950 - 800 (1,742 - 1,472) | 375 (675) |
| 800 - 500 (1,472 - 932) | 375 (675) | |||
| 10 mm dia x 71.37 mm long | Hollow center - 3 mm dia through hole | SFR202B Modified | 800 - 500 (1,472 - 932) | 1,500 (2,700) |
Note
The cooling rate of 1,500°C/s (2,700°F/s) using a modified SFR202B specimen is achieved using water. The supply and return hoses of the ISO-Q kit must be positioned on the same side of the specimen to enable smooth flow of the quench water through the specimen.
8.3.4. Temperature Uniformity Within the Specimen¶
The Gleeble system has the unique ability to control the temperature uniformity and thus the thermal gradient within the test specimen. Tests can be performed with very uniform temperature within the specimen work zone, equivalent to a furnace-based test, or with the large thermal gradients needed to accurately simulate welding and other processes.
When using Joule heating, the current density in a Gleeble specimen is uniformly distributed across the entire specimen cross-sectional area, meaning that the Gleeble is able to heat the entire specimen simultaneously, from surface to center. Since the Gleeble grips are cool, the heat generated in the specimen will diffuse into the grips, creating a thermal gradient with the ends of the specimen generally being cooler than the center. The severity of the steady state thermal gradient is defined by the rate of heat generated in the specimen, offset by the heat lost to the grips. This gradient can be controlled by utilizing grips of materials with differing thermal and electrical conductivity and contact area. Thermally and electrically conductive grips with a large specimen contact area will be kept cold more readily with the water-cooled jaws, and will accept significant heat from the specimen, resulting in “cold ends” and a very steep thermal gradient.
Grips with smaller contact area and higher thermal resistance will pull much less heat from the specimen. Grips manufactured from material with higher electrical resistance will, themselves, heat under the same current that is heating the specimen. These factors will result in very little heat being pulled from the specimen and a very flat thermal gradient. In some cases the grips or anvils holding the specimen may reach temperatures equal to or higher than the specimen, creating a “reverse” thermal gradient.
When considering Gleeble thermal gradients, it is also critical to differentiate between the axial thermal gradient (along the length of the specimen), and the transverse thermal gradient (across the diameter or cross section of the specimen). Even in situations where a specimen experiences a very high axial thermal gradient, the transverse, or crosswise thermal gradient will be very small. This ability to generate isothermal planes is a critical benefit of the Gleeble. In contrast to furnace or induction heating methods, where the specimen can only be heated on the surface or to a limited “skin depth”, the center of a Gleeble specimen is heated at the same rate as the surface regardless of the heating rate. This ability to generate isothermal planes allows for the Gleeble platform to perform dilatometry and welding heat affected zone experiments at heating and cooling rates relevant to welding and other processes on specimens that are large enough for subsequent mechanical property or toughness testing. This is not feasible on furnace or inductively-heated systems that rely on thermal conduction to heat the center of the specimen. Axial thermal uniformity within a specimen is reported as the difference between the specimen’s center to edge thermal measurements and is dependent upon:
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Reproducibility
Thermal gradients in resistance-heated specimens are dependent upon on the properties of the specimen. All specimens with the same physical, mechanical, electrical, and chemical properties will have the same gradients within the accuracy of the thermal system, provided that the specimen grips are in good condition.
8.4. Specimen Size Considerations¶
Gleeble systems are capable of testing a wide variety of material compositions and specimen geometries. Inherent limitations of the system, such as distance between the jaw or anvil faces, the maximum or minimum stroke speed, test temperature, and force limitations for the individual system must be considered when selecting a specific specimen geometry.
The target temperature of a test will also impact the size of a specimen that can safely be tested with a Gleeble system. For example, when considering a standard uniaxial compression specimen, it is possible for a soft material such as aluminum or copper to be tested at ambient temperature. Harder materials, such as steel or titanium alloys, are expected to be tested at elevated temperatures.
Fig. 8.6 Small-Format Round Specimen - SFR115.
The Gleeble 500 Series’s vacuum tank configuration limits the maximum and minimum specimen geometry that can be tested. The maximum specimen length for a tensile specimen is 95 mm. The minimum specimen size should have a free span no smaller than 8 mm.
Specimen geometry will vary with by test type. DSI has identified recommended specimen geometries for commonly performed simulation tests. Contact Dynamic Systems for assistance identifying a recommended specimen geometry as needed.
| Popular Specimen Sizes | |||
|---|---|---|---|
| Specimen Length | Specimen Width | Specimen Thickness | Drawing Number |
| Specimens | |||
| 106.2 mm | 10 mm dia | N/A | SFR115 |
| 58.26 mm | 6 mm dia | N/A | SFR002 |
| 101.2 mm | 6 mm dia | N/A | SFR106 |
| 58.26 mm | 11 mm Sq | N/A | SFS002 |
| Flat Specimens | |||
| 100 mm | 10 mm | 1 mm | SMF002 |
Note
The use of hot grips is recommended for highly conductive specimens. See Gleeble Grips for more information regarding the selection of grips.
Compression Specimens
| Popular Specimen Sizes | |||
|---|---|---|---|
| Specimen Length | Specimen Width | Specimen Thickness | Drawing Number |
| Uniaxial Compression | |||
| 9 mm | 6 mm dia | N/A | SMC206 |
| 12 mm | 8 mm dia | N/A | SMC200 |
| Plane Strain | |||
| 20 mm | 15 mm | 10 mm | SMC001 |
8.5. Additional Features¶
Vacuum Tank
One of the distinguishing features of a Gleeble system is the ability to test materials in a controlled atmosphere. Researchers can simulate processes and test specimens in standard atmosphere, in rough vacuum, in high vacuum or in an inert gas environment. This environmental control is possible due to the large vacuum tank, also referred to as a “test chamber,” that is incorporated into every Gleeble. The vacuum tank is fully integrated into the Gleeble system and can be controlled with manual controls or through software controls. A popular approach to atmosphere control in the Gleeble includes “washing cycles” which involve pumping down to a rough vacuum in the tank and then backfilling with an inert gas. This can be conducted multiple times to ensure that the desired atmosphere is achieved.
Gleeble vacuum tanks include a large viewing port incorporated into the tank door to allow visual observation of simulations. In some cases, viewing windows are removed or covered to protect users from the light intensity of specimens at elevated temperatures.
Feedthroughs are an important feature in the Gleeble vacuum tanks. They allow researchers to install equipment that can measure or interact with the specimen during a test while still controlling the atmosphere. For example, vacuum-sealed electrical feedthroughs allow communication with transducers such as thermocouples, load cells, and strain transducers. Piping feedthroughs enable atmosphere control (e.g. inert gas backfill and vacuum supply) as well as allowing quenching media to be utilized.
Warning
The Gleeble vacuum tank is designed to operate under vacuum or atmospheric pressure, with either air or an inert gas surrounding the specimen. Positive atmospheric pressure, explosive, flammable or corrosive gases, or any mixtures of these gases, should never be used as part of the vacuum tank atmosphere.
Hydraulic Power Unit
The Gleeble 500 Series systems are equipped with an integrated hydraulic power unit (HPU). The HPU is the primary source of mechanical motion for these Gleeble systems. The HPU is capable of regulating the output pressure of the hydraulic fluid, based on the Gleeble system configuration. Typical configurations allow the user to choose between a high and low output pressure. These pressures can be manually selected with a button on the HMI or through the programming of a Gleeble test.
The Gleeble HPU is fully integrated into the 500 Series systems. This means that the system uses a single chilled process fluid supply for system temperature regulation and hydraulic oil temperature regulation. By automatically regulating the temperature of the hydraulic oil, the Gleeble is capable of maintaining peak performance in a variety of ambient temperature environments. The HPU is protected by a high oil temperature, high oil level, and low oil level sensors.
| Characteristic | Specification | |
|---|---|---|
| Pump Motor | 5 hp | |
| Variable Pressure Output | Low Pressure | 68.94 bar (1000 psi) |
| High Pressure | 206.84 bar (3000 psi) | |
| Hydraulic Oil Reservoir | 38 L (10 gal) | |
8.6. Gleeble Physical Dimensions¶
The Gleeble 500 Series systems were designed to fit through a standard entryway. With a depth measuring just 87 cm (34 in), with the Lower Console Assembly removed. The system will occupy a space of 3 x 4 m (9.84 x 13.12 ft) for general operation. This does not include the additional space required for options such as a freestanding vacuum system option.
| Equipment | Height | Depth | Width | Weight |
|---|---|---|---|---|
| 500 Series System | 125 cm (49 in) | 97 cm (38 in) | 202 cm (80 in) | 800 kg (1,800 lb) |
8.6.1. Frame and Machine Stiffness¶
Gleeble 500 Series systems have a frame stiffness of 3.85 x 10-8 m/N (6.74 x 10-6 lbf).