IMA Materialforschung und Anwendungstechnik GmbH. Test before you depart

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Ashlynn Alexander
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1 IMA Materialforschung und Anwendungstechnik GmbH Test before you depart

2 Three test hangars each with more than 5.

materials and structures. Therefore, we provide you with a wide spectrum of customised services and solutions.

As a competent and experienced partner we provide you with a wide range of engineering services for the entire development and certification of railway structures.

We offer an impressive portfolio of services: Structure and component tests to carriage bodies, axle-bearing houses, bogie frames Basic static and dynamic tests Development of test concepts Fatigue

with sophisticated compensation techniques we exactly simulate your desired values in complex, multi-channel tests - using block programs with or without frequency mixing, random signals and measured

3 2 Three test hangars each with more than m test area Climatic chambers for environmental simulation Latest measurement and control units The requirements for engineering are growing, particularly in terms of lifetime verification of new materials and structures. Therefore, we provide you with a wide spectrum of customised services and solutions. seit 2005 From materials to carriage bodies You have the highest technical demands on your product. As a competent and experienced partner we provide you with a wide range of engineering services for the entire development and certification of railway structures. In doing so, all relevant quality standards and requirements of the approving authorities apply. We offer an impressive portfolio of services: Structure and component tests to carriage bodies, axle-bearing houses, bogie frames Basic static and dynamic tests Development of test concepts Fatigue analyses Finite-element analyses Development, manufacture and testing of composites Determination of material characteristics Material databases Technique Thanks to modern digital regulation systems with sophisticated compensation techniques we exactly simulate your desired values in complex, multi-channel tests - using block programs with or without frequency mixing, random signals and measured time lapses in playback. We generate complex control circuits with defined virtual channels. We provide you with synchronised records of the measured data and result dependent switching between different regulation modes. The visualisation of all controlled variables, progression of desired values, cycle numbers, magnitude of errors, et cetera, allows the permanent observation of our tests. Digital measuring technology as well as a multitude of recording types, allow the recording and processing of static and dynamic magnitudes, including force, torque, pressure, path, distension, speed, acceleration, temperature, relative humidity and calculated sizes. We capture quick processes, such as freefall tests, using high speed cameras. We process measured data with commercial software as well as our own software, such as that for rain flow classification (also in real time), envelope curve calculation and for additional algorithms. 3

Component testing Bogie frame Test set up for bogie frame Coupling Whether operating load simulation of braking component, fatigue tests of axel-bearing houses or carriage bodies - in our component

Bogie frame We conduct bogie wagon frame tests for all frame types - whether streetcar, passenger train or freight car or narrow-gauge, broad gauge or standard gauge.

Tests of two-axle and multiaxle frames are possible in normal position and in head location with up to 30 load components. We dimension loads on the basis of the UIC specifications and/or EN 13749.

4 Component testing Bogie frame Test set up for bogie frame Coupling Whether operating load simulation of braking component, fatigue tests of axel-bearing houses or carriage bodies - in our component tests we analyse every detail desired. Bogie frame We conduct bogie wagon frame tests for all frame types - whether streetcar, passenger train or freight car or narrow-gauge, broad gauge or standard gauge. We develop necessary test concepts, special test equipment and elements for load introduction. Tests of two-axle and multiaxle frames are possible in normal position and in head location with up to 30 load components. We dimension loads on the basis of the UIC specifications and/or EN We measure expansion and deformation, both static as well as dynamic load testing. Carriage body and under body structure We implement static tests on carriage bodies in accordance with your specifications and/or according to the EN standard and load the structure servo-hydraulically or with mass elements. We realize longitudinal thrust servohydraulically or with high pressure hydraulic elements at a force of up to 5,000 kn. Since the demand for dynamic testing is becoming ever greater, in particular in the tram sector, we are glad to accept this challenge. We enable tests with 32 servo-hydraulic components and more if demanded. Components Often the devil is in the details. Numerous development-concurrent experiments are necessary to finally verify the stability of the component and to guarantee its safety. We attend to your railway vehicle components with the greatest of care, we examine every necessary detail and offer optimized test scenarios. Your requirements, as well as the existing specifications, are of course decisive. In the past decade, 1082 controlled servo-hydraulic cylinders were used in 185 tests. More than 20 railway construction components per annum pass through our testing laboratories, with an upward trend. From test planning to test report for Axle-bearing houses // axle guides braking components // container folding bars crash-elements // dampers // bogie frames springs // slide support pieces // brackets couplings // longitudinal coupling elements magnetic braking frames // wheel links // tie bars under body structures // carriage bodies cross beams // and others 4

Wheel link Test rig construction Parabolic suspension Based on our long testing experience we develop new test technologies in accordance with customers and market needs.

multi-articulated link, lightweight construction type)?

environment simulation Selection of the critical verification locations Classification of real measuring data for a load collective for the computational evaluation Computational operational

5 Wheel link Test rig construction Parabolic suspension Based on our long testing experience we develop new test technologies in accordance with customers and market needs. seit 2005 Fatigue analysis verification Are you satisfied with applicable directives in order to ensure operational durability even in case of increasing demands on your product (low floor, multi-articulated link, lightweight construction type)? We offer you decisive expertise, repeatedly proven in the development of different streetcar types: Service packages Development of components of fibre reinforced plastics Vibration test with environment simulation Selection of the critical verification locations Classification of real measuring data for a load collective for the computational evaluation Computational operational durability verification (according to FKM Directive and IIW) Consultation regarding material selection and structuring of new compounds Transformation of measurement loads to test loads (loading time lapse, safety concept) Experimental tests of individual component parts, up to the optimized car body Sensorbased condition monitoring (e.g. early damage detection) Mobile measurements, long-term monitoring, remote diagnostics Investigation of component parts of metal and plastics Research, e.g. operating load simulation and new joining connections Consulting to technology, material employment, material databases Study Test Engineer (TestIng -Bachelor/Master) in cooperation with DVM and Steinbeis-Hochschule Berlin 5

Materials Magnetic particle testing Sample preparation for tensile test Dye penetrant testing Our basic tests provide a perfect basis for expanding knowledge and strengthen your confidence in variant

We determine s/n-curves (Wöhler curves) and life curves, test materials under extreme temperature and climatic conditions and investigate the influence of media.

Flexible accredition by DAP allows us to inspect materials in accordance with diverse standards and to develop new testing procedures.

6 Materials Magnetic particle testing Sample preparation for tensile test Dye penetrant testing Our basic tests provide a perfect basis for expanding knowledge and strengthen your confidence in variant assessments. The results of numerous tests have been extended our material database WIAM since decades. Materials and connections In the beginning, there is the question for the material. We determine s/n-curves (Wöhler curves) and life curves, test materials under extreme temperature and climatic conditions and investigate the influence of media. Finally, we offer you acceptance and approval tests for materials and monitor your manufacture. Flexible accredition by DAP allows us to inspect materials in accordance with diverse standards and to develop new testing procedures. Material database Our company has been developing databases since decades, including WIAM METALLINFO, in which significant material properties are systematically integrated. At present, you can comfortably research more than materials, modifications and more than four millions of entries - including high-alloy steels, aluminium, magnesium, nickel, titan, plastics and fibrereinforced plastics. We advise you on materials application and develop customer-specific solutions upon request - just ask us. Non-destructive tests In our laboratories as well as at your facility we can make statements about the quality of your test specimen. Our test engineers are qualified in accordance with the standards EN 473 and EN 4179 and they provide you with these methods of non-destructive testing: Ultrasound testing (contact-, immersion- and phased-arraytechnique) Magnetic powder testing (including flourescent) Penetration testing (including flourescent) Eddy current testing (conductivity measurement, layer thickness measurement, surface crack detection, multifrequency technology) Electronic knocking testing Endoscopy Visual inspection Optical measurement (ARAMIS, PONTOS) 6

Engineering FEM simulation train roof of GFRP Test rig development Construction / Modification carriage body The verification of operational stability is indispensable for warranty and improvement of

seit 2005 Calculation and simulation By means of application measurements, measurement runs and longtime monitoring we acquire mechanical stresses during real operation.

During the stage of development we make statements of dimensioning of components and we offer you the opportunity to compare different construction versions.

What dimensioning achieves the best stability values? How does the natural vibration and resonance behaviour influence the structural strength?

7 Engineering FEM simulation train roof of GFRP Test rig development Construction / Modification carriage body The verification of operational stability is indispensable for warranty and improvement of safety and reliablity of components. Essential basis are the analysis of strains, the simulation of dynamic loads and the numerical operational stability of components. seit 2005 Calculation and simulation By means of application measurements, measurement runs and longtime monitoring we acquire mechanical stresses during real operation. Load assumptions are created and are basis for calculation from finite-elements method (FEM) and for the various tests performed in our company. During the stage of development we make statements of dimensioning of components and we offer you the opportunity to compare different construction versions. In examining the stress, deformation and stability we can evaluate the component s strength and safety. How many dynamic loads does your construction bear? What dimensioning achieves the best stability values? How does the natural vibration and resonance behaviour influence the structural strength? These and many other questions we will answer by means of calculation and experimental verification of operational and fatigue strength. We calculate and evaluate the lifetime. Our results will support you to optimise your products from the stage of development. Calculated operational stability - the FKM guideline The FKM (stability verification) guideline is for numerical strength verification of mechanical parts made of aluminium, steel and cast iron materials. This textbook, published in German and English by VDMA, was developed by a renowned team of scientists under the leadership of our company. Subject of this guideline is the static strength verification as well as the verification of fatigue strength (operational and fatigue strength). By now, nearly 800 industrial companies and customers make use of it. Distribution density strain measuring load work load strength population q-te specimen at test (depending on failure rate) Logarithmic equivalent stress amplitude X=lg Safety concept of the stability verification according to FKM guideline 7

System DFF 21. Highly elastic rail fastening for conventional rail and metro the optimum single support point for slab track

System DFF 21. Highly elastic rail fastening for conventional rail and metro the optimum single support point for slab track System DFF 21 Highly elastic rail fastening for conventional rail and metro the optimum single support point for slab track System DFF 21 Highly elastic rail fastening for conventional rail and metro the