11. Specialty Gleeble System Solutions

11.1. HDS-V40

Fig. 11.1 Gleeble HDSV-40.

Unparalleled Technology for Process Development

Continuous casting followed by direct rolling (CC-DR) offers steelmakers the opportunity for substantial energy savings and reduced capital expenditures which, in turn, can lower costs and increase profits.

The HDS-V40 is the only commercially available laboratory system capable of simulating direct rolling, from the continuous caster to the end of the hot rolling process, all in one continuous sequence, using a single specimen. Steelmakers can explore the promise of continuous casting and direct rolling (CC-DR) on an affordable, reproducible, laboratory scale. In addition to direct rolling, this system can be used for simulating semi-solid rolling (liquid metal core reduction), plane strain compression, hot rolling and forging.

Thermal and Mechanical Systems

The HDS-V40 uses the Gleeble direct resistance heating method, but expands the technology to permit the use of larger specimens. The larger specimens allow materials properties testing after deformation.An innovative melting containment system features a crucible that holds the molten material in place and can be removed prior to deformation.

Unprecedented Flexibility

No other system offers so much flexibility to perform melting, solidification and deformation simulations in a controlled atmosphere. The HDS-V40 can perform plane strain compression tests on different material conditions including:

• Different parts of the melt zone
• Semi-solid material
• Previously melted material
• Re-solidified material

Additionally, the deformation anvils have separate heating controls. The temperature of the anvils can be adjusted independent of the specimen, simulating an actual rolling mill. An optional optical dilatometer allows collection of transformation data as the specimen cools.

Feedback Control

On the HDS-V40, the user can control the test process using either stroke or strain as the feedback variable to the control software. Strain control is based on the stroke feedback loop. Constant strain rates and non-linear strain rates can be programmed using stroke as the feedback variable within the limits of high-speed testing described in the previous section.

HDS-V40 Capabilities at a Glance

Continuous Casting–Direct Rolling, liquid metal core reduction, hot rolling and hot forging simulations Direct resistance heating for high-speed thermal capability and precise control Twin hydraulic systems with exact control of strain and strain rate Variable deformation speeds

Simulations can be run in air, vacuum or inert gas Quench in-situ at any time during simulation Precise digital control system Large sample sizes

Part Number	Description	Sold As
HDS-V40-1.7-150	Gleeble HDS-V40 Direct Rolling Simulator	System

11.1.1. Hydro-Mechanical

The HDS-V40 offers a high-speed mechanical system with unmatched performance. The latest in state-of-the-art hydraulic valves combined with an innovative hydraulic system create a high-speed servo system. The unique, patented Hydrawedge system allows independent control and programming of Strain and Strain Rate. The overall system has eight (8) control axes. Five are servo-hydraulic, three are thermal.

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Another feature of this physical simulator is a mechanical system that permits moving the entire specimen and jaw system off the anvil centerline. Normally, the specimen is deformed at the center of the mid-span, where the liquid thickness during solidification is the same on both sides of the anvil. However, as a means of more accurately simulating semi-solid rolling, the specimen can be moved from side to side, enabling sequential compressions to deform the thickest part of the specimen.

Characteristic	Specification
Test Frame	Vertical type with dual 120 mm (4.9 inches) diameter columns
Mechanical System	Closed-loop hydraulic servo control
Data Acquisition Channels	User selectable, up to 16 channels simultaneously, 18-bit ADC
Data Sampling Rate	User selectable, up to 50 kHz.
Maximum Static Force in Compression	40,000 kgf (~ 88,184 lbf) (392 kN)
Maximum Stroke Rate - Both Rams Compressing Simultaneously	1,700 mm/s (66.92 in/s) in compression
Maximum Stroke Rate - Each Ram Compressing Individually	850 mm/s (33.47 in/s) in compression
Minimum Stroke Rate	0.005 mm/s (1.96x10-4 in/s) compression
Maximum Combined Stroke Distance	40 mm (1.57 in)
Maximum Number of Compression Hits	No Specific Limit

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).

Load Cell

Characteristic	Specification
Hysteresis	±0.08 % of full scale
Overload Rating	150 % of capacity
Deflection - Full Scale	0.076 mm (0.003 in)
Force Measurement Accuracy	±0.5 % of full scale
Force Measurement Resolution	±1.5 kgf (3.2 lbf) (0.014 kN)
Force Measurement Response Time	0.1 msec

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 opposing anvils of the HDS-V40 system is equipped with a measurement transducer. The stroke transducer serves to control the rate of specimen deformation.

Characteristic	Specification
Type	LVDT
Linear Range	±50.8 mm (±2. in)
Stroke Measurement Accuracy	±0.25 % of full scale
Stroke Measurement Resolution	0.0027 mm (1.063x10-4 in)
Stroke Measurement Response Time	0.5 msec

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).

Wedge Transducer

The opposing anvils of the HDS-V40 system is equipped with a measurement transducer. The wedge transducer serves to control the amount of specimen deformation.

Characteristic	Specification
Type	LVDT
Linear Range	±50.8 mm (±2. in)
Wedge Measurement Accuracy	±0.25 % of full scale
Wedge Measurement Resolution	0.0027 mm (1.063x10-4 in)
Wedge Measurement Response Time	0.5 msec

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

Maximum Dynamic Force 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. The specifications are not valid for tests conducted outside this operating range.

Fig. 11.2 Force vs. Stroke Velocity for HDS-V40.

The above chart shows the optimal performance of the system when both hydraulic rams are operating at full compression speed. The rated performance specification is for the maximum stroke rate with no load, using both rams.

Limits of High-Speed Testing

While the high-speed servo-systems provide the capability for high-speed compression and tension testing, there are certain limitations in the overall system which 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.

For constant Strain Rate programs the duration of the deformation for each hit must be ten times the rated response time of the hydraulic servo valve. The Gleeble system uses high-speed valves with a rated response time of 0.006 seconds. Therefore the duration of the actual deformation of the material during the hit must be equal to or greater than 0.060 seconds.

11.1.2. Thermal Subsystems

The mechanical configuration of the HDS-V40 is based on handling a large melt zone. Since the specimen has no strength while in the liquid state, a composite crucible is used to support the melted material. The crucible has an open top an open top, but supports both the sides and the bottom of the specimen. The unique composite crucible permits a cooling medium to be sprayed around the specimen’s top, sides, and bottom. The volume of cooling media can be adjusted to provide controlled cooling and any shell formation desired on the cast material. The ends of the specimen are retained in water-cooled grips, preventing the melting from occurring beyond the end of the crucible. The crucible is mounted under the specimen with two retractable arms that provide support for the crucible during the casting process. To ensure efficient melting and to control segregation, the system is designed to provide electromagnetic stirring of the melt pool. Melt superheat may be limited due to the open top of the crucible.

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The fragile liquid specimen, with its thin, solidified shell, requires that any deformation be balanced. The specimen should not move in the direction of deformation force while being deformed. To ensure any specimen moment does not occur, two opposing vertical, servo-hydraulic, rams are used. One ram in mounted in the top crosshead of the machine and the other ram is mounted in the bottom crosshead. The rams are synchronized to start and finish deforming the specimen at the same time and velocity.

When the specimen mid-span melts, the level of liquid at the top of the specimen is depressed. The liquid level is brought back to the original height by compressing the specimen. The amount of compression can be programmed into a test manually or automatically. This compression returns the specimen to its original thickness prior to solidification. During solidification the specimen is further compressed to accommodate any shrinkage which may occur as the specimen solidifies.

Characteristic	Specification
Heating System Type and Control	Direct resistance with closed-loop control
Temperature Controller	Digital closed-loop control using 18-bit ADC and 32-bit digital processor
Temperature Range	Room Temperature to 1,550°C (2,822°F)
Temperature Monitoring Source	Thermocouple
Thermocouple Sampling Rate	Twice the Power Supply Frequency (100 - 120 Hz)
Resolution	±1°C or°F
Maximum Number of Simultaneous Thermal Channels	4 thermocouple channels
Accuracy of Control	±1°C or°F (in steady state)
Accuracy of Measurement	±1°C or°F or ±1 % of temperature (whichever is greater) plus the accuracy of the thermocouple wire (in steady state)

11.1.2.1. Heating Rates

Heating rates are based on using a 480 V / 200 A power supply and 1018 carbon steel specimens.

Specimen	Orientation	Drawing Number	Maximum Heating Rate
			°C/s (°F/s)
10 mm dia x 50 mm wide x 165 mm long	Lengthwise	SMF005B	5 (9)
10 mm dia x 15 mm long		SMC203B	1 (1.8)

Note

As the specimen size, diameter, length, or cross-sectional area increases the effective heating rate will decrease.

11.1.2.2. 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.

Quenching after specimen melting, prior to complete solidification, can result in undesirable specimen surface conditions. Care should be taken to ensure that the specimen has solidified enough to withstand surface contact with the desired quenching media.

Surface Cooling Rate During Water Quenching

Cooling rates are achieved with a 1018 carbon steel specimen.

Specimen	Free Span	Drawing Number	Temperature Range	Cooling Rate
			°C (°F)	°C/s (°F/s)
10 mm thick x 50 mm wide x 165 mm long - undeformed		SMF005	Max Solid Temp - 800 (Max Solid Temp - 1,472)	50 (90)

Surface Cooling Rate During Gas Quenching

Cooling rates are achieved with a 1018 carbon steel specimen.

Specimen	Free Span	Drawing Number	Temperature Range	Cooling Rate
			°C (°F)	°C/s (°F/s)
10 mm thick x 50 mm wide x 165 mm long - undeformed		SMF005	800 - 500 (1,472 - 932)	5 (9)

Surface Cooling Rate During Gas Quenching for Uniaxial Compression

Cooling rates are achieved with a 1018 carbon steel specimen and Uniaxial Compression Anvil set and quench spray heads.

Specimen	Free Span	Drawing Number	Temperature Range	Cooling Rate
			°C (°F)	°C/s (°F/s)
27 mm long x 15 mm dia		SMC209	800 - 500 (1,472 - 932)	5 (9)

11.1.3. 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.

11.1.3.1. 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.

11.1.4. Measurement Gauges and Kits - HDS-V40

11.1.4.1. HDS-V40 Lengthwise Extensometer - Range: ±50.8 mm

The HDS-V40 is supplied with a Lengthwise Strain Gauge Assembly. The L-Strain gauges mounted on the anvil attachment points to provide precise measurement of the anvil movements.

Characteristic	Specification
Type	LVDT
Linear Range	±50.8 mm (2.0 in)
Accuracy	±0.25 % of full scale
Resolution	0.0027 mm (1.063x10-4 in)
Response Time	0.5 msec
Gauge Length	0 - 31 mm (0 - 1.22 in)
Maximum Usable Stroke Rate	1, 700 mm/s (66.92 in/s)

Part Number	Description	Sold As
3V924	L-Strain Gauge Assembly - HDS-V40	Kit

11.1.4.2. HDS-V40 Uniaxial Compression Anvil Assembly

Fig. 11.3 HDS-V40 Uniaxial Compression Anvil Assembly as installed.

The model 3V968 Uniaxial Compression Anvil Assembly is used for uniaxial compression tests. An alternative load cell is included to allow more precise measurements of the forces encountered in uniaxial compression tests. The anvil face size is 25 mm (0.984 in ) diameter and uses the ISO-T design developed by DSI to provide uniform temperatures and minimum barreling of the specimen during compression tests.

Fig. 11.4 Uniaxial specimen quench spray heads are included with this option.

Part Number	Description	Sold As
3V968	Uniaxial Compression Anvil Assembly - HDS-V40	Kit

11.1.4.3. HDS-V40 Plane Strain Anvil Assembly

Fig. 11.5 HDS-V40 Plane Strain Heated Mk II Anvil Assembly.

Part Number	Description	Sold As
3V890	Plane Strain Heated Mk II Anvil Assembly - 10 x 70 mm (0.393 x 2.755 in) - HDS-V40	Kit

11.1.4.4. HDS-V40 Melting Crucible Retractors and Control Unit

Fig. 11.6 HDS-V40 HDS-V40 Melting Crucible as installed.

Part Number	Description	Sold As
3V905	Melting Crucible Retractors and Control Unit - HDS-V40	Kit

11.1.4.5. Non-Contact LED Optical Micrometer - Ranges: ±60 mm ±6 mm ±0.6 mm

Fig. 11.7 Non-Contact Optical Dilatometer & Extensometer - DSI# 59032.

The 59032 Non-Contact LED Optical Micrometer uses a high-intensity GaN long-life LED combined with an HL-CCD sensor to provide high-speed measurements with no moving parts. Easy-to-use menu-driven setup software is included with the unit to allow configuration of predefined measurement ranges via the Gleeble HMI. Settings can be stored, recalled, and easily changed for a variety of test conditions. The 59032 Non-Contact LED Optical Micrometer can be used to measure in either a crosswise configuration or a lengthwise configuration.

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Fig. 11.8 Optical Measurement Comparison.

Green LED Technology

The green LED light is distributed as a uniform parallel light beam, and is applied to a target. The edge between the bright and dark areas on the HL-CCD sensor is detected and translated into a measured value, such as a specimen’s outer diameter.

Traditional Laser Technology

In a conventional laser optical measuring device, the laser beam is projected onto a rotating polygonal mirror. The reflected light scans the measurement range, then reaches the receiving element. To improve speed and accuracy of this laser measuring device, the mirror’s rotating motor would need to operate at a faster rate, sacrificing durability and reliability.

Characteristic	Specification
Range	±60 mm (±2.36 in)	±6 mm (±0.236 in)	±0.6 mm (±0.0236 in)
Resolution	12 μm (4.72 x 10-4 in)	1.2 μm (4.72 x 10-5 in)	0.3 μm (1.18 x 10-5 in)
Accuracy	±68 μm (±2.67 x 10-3 in)	±14 μm (±5.51 x 10-4 in)	±8.6 μm (±3.33 x 10-4 in)
Sampling Rate	16 kHz
LED Type	InGaN Green
Ambient Luminescence	3,000 Lux or lower
Smallest Detectable Object	0.8 mm (0.031 in)
Serial Communication	RS-232, parity:none, baud:9600
Analog	Output ±10 VDC
Output Impedance	~100 ohms
Supply Power	24 VDC
Maximum Power Consumption	1.2 amps
Operating Temperature	0 - 50°C (32 - 122°F)
Operating Humidity	20 - 85 % RH
Mounting	Crosswise or Lengthwise

Note

Measuring range may be limited by vacuum chamber window size.

Danger

Never look directly into the scanning optical system LED transmitting head. Never point the transmitting head away from the vacuum tank while the power is on.

Part Number	Description	Sold As
59032	Non-Contact Optical LED Dilatometer and Extensometer	Ea

11.1.5. Additional Features

Vacuum System

Gleeble vacuum pumping systems are designed to perform as an integral part of the HDS-V40 system. The vacuum pumping system consists of the complete pumping system and its electronic controls. The entire unit is powered and controlled from the HDS-V40 control console. It provides vacuum pressures of 5 x 10^-4 Torr. The system is equipped with a 350 L/min (92.5 gal/min) roughing pump and a 1,250 L/min (330 gal/min) diffusion pump.

Operation of the Vacuum Pumping Systems is fully automatic. The system status is monitored by the control software and pressure readings are available on the VPM monitor. The system can be used as a roughing pump alone for experiments that do not require extreme vacuum. The tank may be rough pumped and then backfilled with an inert gas such as argon or nitrogen.

Characteristic	Specification
Voltage Rating	380/400 VAC
	460/480 VAC
Roughing Pump	350 L/min (92.5 gal/min)
Diffusion Pump	1,250 L/min (330 gal/min)
Diffusion Pump Size	102 mm (4 in) diameter
Diffusion Pump Cooling	Gleeble chilled process fluid
Lowest Achievable Diffusion Pump Vacuum Pressure	5 x 10-4 Torr

Note

The achievable vacuum pressure of the HDS-V40 vacuum tank, 5 x 10^-4 Torr is only possible in a dry atmosphere (relative humidity less than 60 %) with a clean, dry, and properly sealed vacuum tank.

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

Gleeble HDS-V40 systems are equipped with an independent 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 Gleeble system configuration.

Fig. 11.9 Gleeble Hydraulic Power Unit.

Typical configurations allow the user to choose between a high and a low output pressure. These pressures can be manually selected with a button on the HMI or through the programming of a Gleeble test. Special configurations of the Gleeble will limit the pressures available for testing.

The Gleeble HPU uses one branch of the process fluid chiller for automatic computer control of the hydraulic oil temperature. 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 sensor, a high oil level sensor, and a low oil level sensor.

Characteristic		Specification
Pump Motor		40 hp
Variable Pressure Output	Low Pressure	68.94 bar (1000 psi)
	High Pressure	206.84 bar (3000 psi)
Hydraulic Oil Reservoir		568 L (150 gal)

11.1.6. HDS-V40 Physical Dimensions

Equipment	Height	Depth	Width	Weight
Control Console	180 cm (71 in)	66 cm (26 in)	61 cm (24 in)	195 kg (430 lb)
Hydraulic Power Unit	63.5 cm (25 in)	121.92 cm (48 in)	91.44 cm (36 in)