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Impact Testing SolutionsFor Component Applications
ImpactTestingSolutionsBrochure
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You have selected your material, finalized your design and fabricated your
prototypes. The next step is to test your component to ensure that it will perform
under all anticipated field conditions. You know that your component will be
exposed to routine collisions, accidental drops or repeated impacts in the field, but
how can you simulate these conditions in a laboratory environment with
"traditional" impact test equipment? Furthermore, does your impact test setup
provide you with the detailed information you need to fully understand how your
component will respond to these impact events?
An Impact Industry Pioneer
Impact performance can be one of the most important properties for acomponent designer to consider - and also the most difficult to quantify.For over 25 years, Instron Dynatup has maintained an exclusive focusin the materials testing industry, providing instrumented drop-weighttesters that help manufacturers:
g Simulate real-world impact events on their finished components
g Collect detailed technical information about how their components
perform during these impact events
This brochure features examples from the broad array of industries andapplications in which Dynatup solutions are being used to help specify,develop and test finished products and components. As you readfurther, you will get a better sense of how Instron Dynatup can help youwith your particular real world impact challenge.
Beyond Traditional TestingPages 4 - 5
Aerospace and DefensePages 6 - 7
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Sporting GoodsPages 20 - 21
Product PortfolioPages 22 - 23
ElectronicsPages 14 - 15
IndustrialPages 16 - 17
MedicalPages 18 - 19
AutomotivePages 8 - 9
Consumer GoodsPages 12 - 13
3
Ta
bleofContents
ConstructionPages 10 - 11
Test Specification IndexPage 24
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Impact testing was originally developed to determine the fracture
characteristics of raw materials under high strain rates. Standard
test methods designed for pendulums and simple drop weight testers
require specific equipment design, specimen geometry and analysis
of results.
For many materials, the act of processing them into finishedcomponents directly affects their impact performance
characteristics. Standard test methods such as Charpy, Izod and
Gardner are important tools for raw material research and quality
control, but they provide little value to engineers seeking to
understand how their finished components perform in real-world
impact situations.
Many leading manufacturers today are utilizing more sophisticated
techniques for validating the impact performance of their finished
components. To support this trend, test equipment manufacturers
have developed modern drop weight instruments designed to
simulate a wide variety of real-world impact conditions and collect
detailed performance data for R&D or quality control applications.
Impact Simulation:Energy, Geometry and Environment
In many component applications, it is impractical to recreate a realworld impact event in a laboratory setting. Advanced drop weightimpact testers with variable mass, height and velocity configurationssolve this dilemma by enabling engineers to simulate the impactenergyof real-world objects.
With impact energy reproduced, a custom striker is utilized tosimulate the physical profile of the impacting object. A matchingfixture is also developed to reconstruct the support geometry of thecomponent in its application environment.
Real-world impact events may also occur under a variety ofenvironmental conditions. To ensure further accuracy of thetest, product developers have the option of utilizing an integratedenvironmental chamber to condition the component prior to orduring the test.
Additional benefits of drop weight test instruments include:
g Flexibilityfor simulating a wide variety of real-world impactevents to provide a strong return on investment
g Repeatabilityfor consistent testing and analysis of results over
time and across multiple sites
g Suitabilityfor the modern laboratory environment with
integrated safety and ergonomics features
dInstron Dynatup's 9250HV delivers a broad range of impact energies and can be
fitted with a custom base, custom strikers, fixtures and an environmental chamber
for simulating real-world impact events on almost any component.
Finished components can have very
different impact performance
characteristics than raw material
specimens. In the case of molded
plastics, for example, any of the following
variables can affect how the finishedcomponent reacts to impact loading:
g Molded-in stresses
g Parting lines
g Gate areas
g Geometry
g Coloring agents
Testing raw material specimens may
not provide information suitable
or sufficient to solve
component-level problems.
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BeyondTra
ditionalTestingInstrumented Testing:
The Benefits of Information
Instrumented impact testing offers engineers, scientists and quality managers visibility toperformance data that are otherwise unavailable from less sophisticated pass/fail techniques.More importantly, sophisticated plots of these data can help a product manufacturer identifyimportant component-level impact characteristics, such as:
g Initial break point of internal fibers in a composite aerospace component
g
Total deflection of a polymer panel designed for an automotive body applicationg Force required to deform a metal implant tool used in a high-risk surgical procedure
This information can be critical knowledge for a development team trying to debugunknown field failures or validate a new product for launch. Engineers who rely on simplepass/fail testing to solve impact problems can over-design a component, needlessly addingcost or compromising performance in other areas. Without truly understanding impactbehavior, it can also be difficult to gain confidence about a product when safety is a concern.
Detailed, quantifiable information about impact performance at the component levelempowers manufacturers to make better-informed decisions about productdesign to improve quality, safety, performance and cost.
d
ynatup Impulse data acquisition and analysis software.
Instron Dynatup's Impulse data acquisitionand analysis system is specifically designed forimpact testing. The Impulse system utilizes aspecially designed impact force transducer(tup), falling mass velocity detector andsignal conditioning electronics unit to collect
data from a test event. A powerful integratedsoftware package processes this data andpresents detailed graphs and tables reportingforce, energy, velocity and deflection results.
Instrumented testing can have a rapid return
on investment and help manufacturers improve
their bottom line by reducing time and cost
burdens associated with less sophisticated
pass/fail techniques. Trial-and-error impact
experiments can require:
g Large quantities of specimens
g Time-consuming iteration
g Labor-intensive data collection
and analysis
Sophisticated drop weight test instruments can
dramatically improve the efficiency of a test
program by reducing uncertainty andminimizing the amount of time and material
required to obtain meaningful results.d
ynatup ImpulseTM instrumentation kit.
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The ChallengeLow-power, high-resolution liquid crystaldisplay technology is widely used incommercial and military applications tohelp vehicle pilots navigate and controltheir environment. LCDs are thin andlight, making them ideal forinstrumentation in weight-sensitiveaerospace and defense vehicles.
Cockpits and dashboards containing LCDinstrumentation can be struck repeatedly by
boots, knees, elbows or other objects duringharsh operating conditions found inmilitary applications. A damaged LCD canleave crew members without a critical pieceof equipment necessary to pilot or defendthe vehicle. To avoid such complications,manufacturers rely on instrumentationsuppliers to design and test their LCDproducts for superior impact performance.
This flexible test configuration helped an R&Dteam characterize and compare the impactfailure modes of various layers within theirLCD products. For example, curve data fromone series of tests alerted engineers to hiddeninternal delamination that would not beobvious under simple visual inspection.Instron data helped steer future test strategiesto improve impact performance.
Visual Displays
Aerospace and defense vehicles face
unique and intense operating
environments. Materials engineered
for structural applications must be
highly capable of absorbing rapidly
applied forces. During the course of
normal operation, commercial ormilitary aircraft can be hit by runway
debris, hail or maintenance tools. A
minor impact from any of these objects
can cause significant internal damage
to a structural component and lead to
performance failure.
Internal to the vehicle, instrumentation
is also at risk. Crewmembers or loose
objects can strike sensitive navigation
and control equipment during turbulent
operating conditions. Impact testing
early in the R&D phase helps ensurethat proper materials and geometries
are selected to perform during any of
these impact events.
d
Multiple visual displays can be found in the
cockpits of aerospace and defense vehicles.
Our SolutionLCD manufacturers want to experiment withdifferent materials and layer configurations todetermine resistance to common impacts. Forone application, Instron installed a 9250HVdrop tower with an oversized base designedfor mounting a variety of customer-suppliedfixtures. To simulate single impacts deliveredby the heel of a military boot, the machine wasfitted with a 20 mm flat-faced striker andpneumatic rebound brake.
d
A prototype LCD screen with impact damage
pattern caused by a 20 mm flat-faced striker.
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Impulse data acquisition and analysis software revealing hidden incipientdamage on a composite aerospace component during impact.
The Challenge
Designers must keep the weight of aircraftcomponents as low as possible whilemaintaining their structural integrity andsafety. Modern composite materials have high
stiffness and strength-to-weight ratios,making them well suited for use in aerospacecomponent applications.
Fuselage and wing assemblies, however, mustbe resilient to impact events resulting fromhail, flying debris, birds and dropped tools.Inside the passenger and cargo areas, impactforces resulting from dropped luggage,beverage cart bumps and even high-heelshoes can place significant stress oncomponent panels.
While any one of these impacts may not causevisible damage to the component, failure canoccur internal to the composite material -resulting in a permanent structural weaknessthat can propagate under high stressoperating conditions and lead to catastrophicfailure of the component.
Standard tests such as Airbus AITM 1.0010and Boeing 7260 measure the effects of singleimpact events on the strength of smallcomposite specimens. To properly understand
the performance of larger structures andassembly geometries, however, engineersrequire test equipment and instrumentationthat is more flexible and versatile, yet stilleasy-to-use and safe to operate.
Our Solution
Instron Dynatup's 9250 series drop tower isideal for testing composite materials not onlyaccording to industry standards, but also inthe form of finished components such as
structural beams, door assemblies and wingpanels. Standard Airbus, Boeing and othertest fixtures and strikers are easily mountedto the machine. For single-impact testingcommon in aerospace applications, apneumatic rebound brake is also provided.
Structural Composites
7
Aerospa
ceandDefense
d
9250HV test instrument fitted with custom I-beam support table for testing aircraft door and fuselage sections.
To accommodate larger components, Instroncan supply unique I-beam support structuresfor 9250 drop towers, along with integratedsafety features to ensure operator protection.
In all composite material test applications,The Dynatup ImpulseTM instrumentationsystem provides critical design informationabout the specimen, including the incipientdamage point caused by different types ofimpacts. This knowledge helps engineersspecify the proper material, process andassembly geometry for composite-basedaerospace components.
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Advances in materials science have
enabled auto manufacturers to improve
fuel efficiency without sacrificing
performance or safety. As lightweight
alloys, protective coatings and high
performance adhesives become
common in automotive design, thesenew material applications require
creative impact test methods for
research, development and validation.
The automotive industry remains one of
the most common and vulnerable to
impact events. Depending on the
component, impact damage can have a
minor effect on appearance or lead to a
major failure in vehicle safety.
Bumpers and Supports
The Challenge
Automotive bumper assemblies play a criticalrole in vehicle safety. Designed to absorb anddissipate energy from accidental impacts withother automobiles or stationary objects, frontbumper assemblies protect the engine frombeing forced into the passenger compartmentand causing harm to passengers.
In many vehicles, the supports fastening thebumper to the chassis are made from steel.A lower weight material will help improve thefuel efficiency of the vehicle, but may notperform as well during an impact. To compareand qualify alternative materials for bumpercomponents, manufacturers need test equipmentto simulate automotive collisions and measurethe resulting impact performance characteristics.
Our Solution
With an application-specific fixture designedby the customer, Instron delivered ahigh-energy model 8150 drop tower to testboth individual extruded bumper supportsand complete bumper assemblies. The baseplate of the tower was modified toaccommodate the size of the customer'sfixture and included custom clamping wedgesto position the extrusions for testing.
d
Close-up of application-representative fixturing
system for mounting bumpers and supports.
d
Model 8150 drop tower with custom-designed
striker and fixture system for testing full-sizeautomotive bumpers.
For data collection, Instron worked with thecustomer to design a unique load cell (tup)with multiple piezo sensors and a customstriker to replicate the profile of a car bumper.With this complete impact test system, thecustomer was able to accurately simulatebumper-to-bumper collisions and comparethe resulting energy absorbed and deflectionperformance of alternative materials.
d
Bumpers crushed after impact test.
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The Challenge
As automotive design evolves, adhesives arerapidly replacing mechanical fasteners asa conventional solution for joining manymetals, plastics, rubbers and glass.
Specially formulated adhesives used to bondstructural frame assemblies, windshieldsand other components can offer improvedaesthetics, quieter interiors and reducedmanufacturing costs.
With increased use of adhesives, however,automotive and adhesives supplies mustdevelop new test protocols to ensure thestructural integrity of the bonds under allpossible field conditions. Impact forces in acrash may cause bonded areas of the frameor windshield to fail, resulting in serious
injury to vehicle passengers.
Our Solution
Automotive and adhesives supplies commonlyuse ISO 11343 wedge impact method testing tocompare the relative effects of various productand process variables on impact performance.
Instron
has developed standard and customtest configurations based on ISO 11343,including a unique support fixture and strikerarrangement to impact windshield specimensbonded to auto frame components. Packagedwith an Instron SFL environmental chamber,this impact system enabled an adhesives R&Dteam to experiment with different materialcompositions, cure conditions and climatictemperatures to optimize product performanceand comply with government regulations.
Our Solution
Instron configured an instrumented 9250HVdrop tower to perform application-specificimpact tests derived from ASTM D 3763 andGM9904P standards. Round plaques madefrom different automotive plastics weremounted in a pneumatic clamping fixture andtested at several energy levels and velocities toobtain baseline data. Additional plaquescoated with various automotive paints werethen impacted under similar conditions.
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AutomotiveAdhesives
The Challenge
Many of today's exterior automotivecomponents such as doors, fenders andbumpers are made from advanced polymermaterials. Special coatings have beenengineered to improve the performance ofthese plastics in harsh automotiveenvironments where impacts are a commonoccurrence. Bumpers are frequently struck bystones and other road debris, while doors andfenders can be bumped by shopping carts andother vehicles in a parking lot.
Automotive coatings play an important role inresisting these impacts. Because they can alterproperties of the underlying material such asductile-to-brittle transition point, coatingsmust be thoroughly impact tested at ambient
and extreme conditions to identify the mosteffective formulation and application process.An improperly specified automotive paint canpeel, crack and embrittle the base material,weakening the overall impact resistance ofthe component.
d
Plastic specimen coated with automotive paint
clamped in pneumatic fixture for impact testing.
The resulting data helped a productdevelopment team quantify the effects ofdifferent coatings on the brittleness ofunpainted plastics. To supplement thisvaluable R&D information, Instronprovided an integrated environmentalchamber for conditioning specimens tohigh and low temperature extremes priorto and during testing.
d
Automotive windshields are bonded to the frame
with high performance adhesives.
d
Automotive paints face harsh environments where
impacts from road debris are a common occurence.
Paints and Coatings
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Products used in construction
applications face demanding
environments. To maintain proper
visual appeal and structural integrity,
components must be engineered to
withstand a great variety of static
and dynamic loads. Over its lifetime,a construction component may be
impacted by objects such as hail, tree
branches and dropped power tools.
In recent years, manufacturers have
developed innovative construction
materials that combine improved
weather resistance and aesthetics
with reduced maintenance costs.
Consumers pay a premium for such
materials and expect superior
performance. Impact damage can
be visually unappealing, expensiveto repair and even structurally unsafe.
The Challenge
Homeowners looking to remodel the exterior
of their house often turn to vinyl siding for itsnatural beauty, low maintenance, resilience toweather and resistance to insects.Understanding that consumers also valuedesign flexibility, manufacturers must offer aportfolio of styles and colors that is distinctbut commonly impact-resistant.
Vinyl siding must be able to withstandaccidental impacts from tools and roughhandling during installation. Over the lifetimeof the home, the product must then be durable
enough to resist rain, ice and other weather-induced impacts such as falling tree branches.Vinyl siding panels are also likely to receivesudden blows from objects such as lawnfurniture, children's toys, balls and rocksejected from a lawnmower.
Damaged vinyl siding panels are unsightlyand awkward to replace. Unrepaired crackscan propagate allowing penetration of insectsand harmful moisture.
Our Solution
Instron configured a 9250HV drop tower to
perform ASTM D 4226, an industry-specifiedtest for identifying the energy required tofracture a specimen of PVC vinyl sidingmaterial. The ImpulseTM instrumentationpackage collected detailed data plotscomparing the relative performance levels of
vinyl panels with different surface textures and
color additives. While the ASTM standardprescribes a nominal striker and supportgeometry, alternative tooling was developed tobetter simulate and study the effects of balls,rocks and drills impacting the vinyl sidingsamples at various velocities and drop heights.
Vinyl Siding
d
Vinyl siding can improve the beauty of a home,but must be durable to withstand a wide variety
of impacts.
d
9250HV with large base and environmentalchamber for testing construction materials
at temperature.
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The Challenge
Modern architectural roof designs in bothresidential and commercial buildings havedriven the development of new lightweightsynthetic roofing materials. Available in a
wide variety of styles, colors and textures,today's man-made roof tiles are highlydurable and often guaranteed bymanufacturers to last over 50 years.
More than any other exterior building surface,a roof is most vulnerable to impacts fromweather-driven objects such as tree debris andice. Synthetic roof tiles cracked by impactingobjects will allow moisture to penetrate anddecay the underlying structure, with costlyimplications for replacement. Increasing tilethickness arbitrarily can improve impact
performance, but designers must consider theadditional weight and cost of materialinherent in this simplistic approach. Impactperformance needs to be quantified accuratelyin order to optimize design variables.
Our Solution
Instrumented impact testing was performed atvarious energy levels on different synthetic tiledesigns to identify the onset of incipientdamage. Test parameters were set to identify
specific impact conditions that would causeinternal cracking not visible in a finished roofconstruction. To ensure accuracy of theapplication, Instron designed a customsupport fixture made from wood to recreatethe actual tile-to-roof assembly specification.Testing revealed several instances of productfailure that would not have been identified onless sophisticated test equipment.
Our Solution
To simulate a hammer falling from a rooftoponto a deck, Instron mounted a 1-inchhemispherical striker to the crosshead of a9250HV test instrument and performed testingfrom an energy-equivalent height and weight.High velocity hailstone impacts were also
recreated by utilizing a smaller striker andlightweight crosshead together with anincreased drop height. Though a standardfixture was used to test sample compositespecimens in this case, a custom supportstructure could have been developed tosimulate and test actual support geometriesused in deck constructions.
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ConstructionRoofing Tiles
Composite Decks
The Challenge
Outdoor decks are heavy-use structures thatare exposed to harsh environments andfrequent impact events that must be factoredinto product design. To reduce maintenancecosts and improve aesthetics and durability,innovative manufacturers have developed new
composite decking materials comprised ofrecycled plastic and natural wood fibers.
Both during and after the installation process,the composite deck boards must be able towithstand a wide variety of impacts fromweather, human use, and falling objects suchas tools and furniture. If a composite board isdamaged by an impact, the structural integrity
and safe use of the deck may be compromised.
d
Simply increasing the thickness of roof tiles to improve impact performance can result in unnecessary
weight and cost.
d
Composite deck specimens with impact damage causedby 1-inch hemispherical strikers.
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Many consumer products are
manufactured in high volume for sale
worldwide. From the factory floor to
retail store shelves, these products
(and their packaging) must withstand a
variety of impacts during the
transportation and handling process ontrucks and in warehouses. Once in the
home, consumer products can
experience accidental drops, kicks or
bumps in the course of normal use.
At stake for a manufacturer is brand
image. In a highly competitive
marketplace, products burdened with
a reputation for poor quality are less
likely to survive. When safety issues
are involved, a large recall prompted
by impact failures can also erode
brand image and sink profitability.
The Challenge
To package beef, chicken and other meats forretail sale, butchers utilize foam trays that are
lightweight and inexpensive to produce.Rough handling of the meat packages bygrocery store clerks or customers, however,can easily cause bends or cracks in the cornersof the trays. Packages of perishable foods thathave been damaged by an impact are avoidedby customers, resulting in unsold and wastedinventory for retailers.
In the home, reusable plastic containers soldin a wide range of shapes, sizes and colors arepopular for preparing and storing food.Designed for use in refrigerators, freezers,
microwave ovens and dishwashers, theseversatile containers must withstand harshtemperature extremes without deterioration.Cold containers can easily crack or split whendropped. Hot containers can become too softand easily separate from a lid. In either case,the resulting food spills or contaminationleads to customer frustration.
Our Solution
Instron Dynatup teamed to develop aversatile fixture designed to grip foam trays in
various orientations beneath a custom striker.This flexible setup enabled an R&D team tosimulate impacts at different angles on themost vulnerable design feature of the trays -the corner. Instrumentation helped the teamdetermine the maximum load and deflectionvalues of different tray materials, thicknessesand designs.
Food Packaging and Storage
For reproducing conditions in a freezer ormicrowave oven, a Dynatup EC 8250
Environmental Chamber was installed to helpengineers measure the effects of temperatureon the ductility of plastic food containers.Products can be mounted and impacteddirectly inside the chamber to test for energyabsorption characteristics and material failurein vulnerable areas such as corners, edges andmold gates.
d
Plastic and foam food containers must endure temperature extremes and accidental drops.
d
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Impact testing simulates the effects of
dropping a razor in the bathroom or shower.
Our Solution
Engineers seeking todevelop a baseline of impactperformance data, such asmaximum load, energy, anddeflection, can utilize Instron Dynatup'sMini-Tower configured with the Impulse dataacquisition and analysis system.
To simulate the impact event resulting froman accidental drop, Instron fabricated aunique fixture designed to position the razorassembly perpendicular to a custom 10 mmflat-faced striker. This setup enabled impacttesting of (a) connected blade/handleassemblies to determine separation force and(b) exposed docking features on the handle toquantify forces required to deform and breakthe plastic.
13
C
onsumerGoods
The Challenge
Powdered detergent tablets designed for homeuse in washing machines and dishwashers arepopular with consumers who value the smallsize and convenience of premeasured
quantities. For manufacturers and retailers,the advantages of tablets over traditional boxesof loose detergent include more efficientpackaging size, transportation and storage.
Detergent tablets are vulnerable to impactsexperienced during the shipping and handlingprocess. Broken tablets discovered by aconsumer or retailer can burden amanufacturer with costly product returns anda poor reputation for quality. While amanufacturer can modify chemicalcompositions to improve powder adhesion, the
resulting product may be over-designed andfail to dissolve properly in water. R&D labsneed detailed impact performance data tooptimize these chemical compositions.
Our Solution
Impact testing was performed on severaldifferent detergent tablets using the Dynatup
MiniTowerTM fitted with an ImpulseTM dataacquisition and analysis system. To simulate
rough handling conditions while packaged inbulk, the tablets were placed on a fixtureplate and impacted with a flat 1 1/2-inchdiameter striker specially designedfor the application.
Instrumentation revealed performancecharacteristics not identified in previousR&D efforts employing more simplego/no-go drop testing. Tablets demonstrateddifferent deflection, energy absorption andload-time profiles that were easily visualizedand compared for consistency using Impulse's
advanced plotting features. With a morerepeatable test process, visual inspection offailure modes, such as cracking and
Powdered Soap Tablets
Razors
The Challenge
Today's most advanced razor designs featuredisposable blade assemblies that are fastenedto reusable handles. The mechanical dockingfeatures on the handle and blade consist ofthin and flexible plastic geometries. When arazor assembly is dropped onto a hard surfacein the bathroom or shower, this latchingmechanism can release or become
permanently damaged, leaving a consumerunable to finish shaving. Consumer productsthat routinely fail in the course of normal usequickly gain a poor reputation. Razormanufacturers seeking to maintain brandimage need instrumented R&D equipment toquantify impact forces that cause undesireddisassembly or cracking.
d
Powdered soap tablets with and without packaging
are impact tested to simulate rough conditions
during transportation and handling.
disintegration, also became more valuable.Variables such as product shape, size andpackaging method can also be investigated forinfluence on impact performance.
Instron has alsoworked with consumer
product manufacturers
and third party
suppliers to engineer
completely custom
instrumented impact
test equipment.
For more information,
see the Electronics
section on pages
14 and 15.
d
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Electronic products in a variety of
industries continue to become
smaller in size with a growing
number of features and capabilities.
As more and more components are
assembled to smaller printed circuit
boards, the interconnectionsbetween these components must
also become miniaturized.
In many applications, these same
electronic devices must be
designed to withstand mechanical
shocks encountered during their
use. Sudden impacts can dislodge
electronic components assembled
with tiny solder joints, crack entire
circuit boards or damage the
external casing of a product.
The Challenge
Solder joints have become more vulnerableto impact failure with the miniaturization ofportable electronic devices. The impactshock resulting from an accidental drop cancause a solder joint on the circuit board to
crack or split, resulting in intermittent orpermanent product failure. This can haveserious consequences in military oraerospace applications that demand highreliability and performance.
There are many variables that affect theimpact strength of solder connections,including alloy composition, solder padsurface finish and thermal cycling history.For R&D teams, the JEDEC drop impact teststandard can require high material and
labor investment and only provides data forqualitative rankings. Solder manufacturersand circuit board designers can furtherbenefit from impact test equipment designedto collect quantitative performance datadirectly from individual solder connections.
Our Solution
Instron's new MicroImpact test system isdesigned to deliver consistent and repeatablelow-energy impacts to individualmicroelectronics structures such as solderjoints. Featuring a highly sensitive load cell
and displacement transducer, this uniquetest instrument is integrated with aDynatup ImpulseTM data acquisition andanalysis system to characterize impactperformance in full detail.
Solder Joints
14
d
Instron's MicroImpact test system.
For R&D purposes, the MicroImpact systemprovides a wealth of data not available from astandard JEDEC test setup, enablingmanufacturers to reproduce drop impactshocks on individual solder joints and analyze
their effects. Experiments can be performedto determine impact shear failure modes andquantify measures of joint quality such aspeak load, time to peak load and total energyabsorbed. With simple specimen preparationand user-friendly operating procedures, theMicroImpact system is also well suited forprocess quality control applications.
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The Challenge
Personal electronic devices such as mobilephones, PDAs and notebook computers havebecome indispensable tools for businessprofessionals. Designed to be lightweight and
stylish, these products must also be ruggedand durable to withstand numerous impactsthroughout their lifetime.
Accidental drops resulting in cracked plasticare the most common impact experienced byportable electronic products. In such anevent, electronic components andinterconnections on the circuit board insidethe device can also become damaged, causingintermittent function or complete failure ofthe device. Engineers need test equipmentthat can simulate and quantify the impact
forces required to damage casing materials orcircuitry and wiring inside their products.
Personal Electronic Devices
15
Electronics
Our Solution
Instron Dynatup has delivered severalimpact test solutions for personal electronicdevices, with designs ranging from modifieddrop weight instruments to completely
customized configurations.
d
Unique "Drop-the-Product" impact test system.
Drop Table Impact System
For testing the electrical performance ofcircuit boards during a mechanical shock perJEDEC test specifications, Instron Dynatupmodified a 9250HV drop tower to include aunique crosshead fixture and inverted tup.Circuit boards mounted to the fixture weredropped from different heights onto a flat-faced striker to deliver impact shocks. Thetest system also included an integratedaccelerometer, pneumatic rebound brake andImpulseTM instrumentation kit to measuremaximum load and acceleration.
d
Dynatup 9250 instrument modified for JEDEC drop
impact testing.
Horizontal Impact System
As an alternative configuration, InstronDynatup engineered an impact test instrumentto strike small electronic products and circuitboards along a horizontal axis. Designed forlow-energy impacts, the system featuredcustom fixturing, adjustable impact speedsand full Impulse instrumentation and softwareto collect, analyze and report impactperformance data.
d
Custom-designed horizontal impact tester.
"Drop-the-Product" Impact System
Working in partnership with a customer andthird party instrumentation supplier, InstronDynatup developed a unique instrumentfocused exclusively on simulating accidentaldrops of finished products. Well-suited fortesting portable electronics and otherconsumer goods, the system was equippedwith pneumatic grips to release an object at
various drop heights and angles above aninstrumented platen. This test instrumentenables product designers to methodicallyexperiment with different impact energies andmeasure the resulting impact forces on theouter casing of a product.
d
Mobile phones are especially vulnerable to
accidental drops that can damage the outer casing
or internal circuitry.
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Many industrial products are purposefully
designed to receive or deliver impacts in
their application - tools used in
manufacturing and maintenance
operations, for example, or heavy-duty
mining and construction equipment.
These components need to be extremelyhard and tough, so manufacturers utilize
high strength steels, coatings and even
diamond-based materials to ensure a
long impact service life. Failure to
perform can compromise the economics
or safety of a project, therefore impact
performance is often a critical measure
of product quality.
Our Solution
Instron configured a 9250HV test instrumentwith a 50,000 lb (222 kN) tup to capture thehigh-impact loads expected during tool
strikes. A standard 2-inch spherical insert(to simulate the head of a hammer) was usedto strike the various products, which were allmounted in a custom fixture to ensure directaxial loading. A rebound brake preventedsecond strikes on the specimen.
The ImpulseTM instrumentation packageprovided a wealth of performance datapreviously not available using a more basic
free-fall test technique. Analysissoftware was used to develop a
thorough databaseof impactenergiesrequired toinitiate damagein several handtool designs.
Hand Tools
The Challenge
Simple hand tools made from steel can befound in private residences, manufacturingfacilities, construction sites and service
garages. Many of these tools, such as chiselsand pin punches, are purposefully designedto be struck with a hammer. Others,including screwdrivers and wrenches, havea different purpose but are often used asimpact tools as well.
Improperly designed tools can bend or crackduring a hammer strike. The resulting debrisor hammer deflection can injure the user orcause damage to surrounding objects. Whilethe effects of impact failure are rarely severe,
a manufacturer can earn a reputation forpoor quality that is difficult to overcome. Toavoid this problem, tool designers need toverify the mechanical design of steel shaftsand integrated plastic handles with anappropriate impact test system.
d
Custom vertical fixture used to position
hand tools for impact testing.
The 9250HV also enabled repeat testing atdefined energy levels to quantify the servicelife of the tools.
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Industrial
The Challenge
Automatic band saws used to cut metals,plastics and wood are a basic piece ofequipment found in machine shops. Bandsaw blades are made from various steels and
geometric designs to optimize performance fordifferent specimen materials and types of cut.
The most important feature of a band sawblade is the cutting edge. Band saws operateat high speeds and the cutting teeth must bedesigned for long fatigue life, good thermalconductivity and minimal vibration and noise.Each tooth must also be highly resistant toimpact shock. A band saw tooth may strike aspecimen at high velocity many thousands oftimes during its service life.
Impact failure of a saw tooth can haveeconomic or safety-related consequences. Adamaged saw blade causes machine downtimeand reduces shop efficiency. More seriously, asaw tooth that chips off at high velocity cancause injury to a bystander.
Our Solution
The Instron Dynatup MiniTowerTM is wellsuited for testing the impact performance ofsaw blade teeth. During operation, the tipof each tooth faces the greatest impact load
as it strikes the specimen. To accuratelyrepresent this event, an Izod-style tup insertmade from hardened tool steel is positionedin line with the cutting edge of a saw bladespecimen. The specimen itself is heldvertically in a custom fixture.
With this configuration, engineers canperform tests to understand the impactforce and energy limits of the saw bladeteeth. Understanding how each tooth failscan help lead to improvements in the
geometry of the cutting edge orspecification of better steels, coatingmaterials or manufacturing processes.
Band Saw Blades
The Challenge
For oil, natural gas and other miningapplications, ultra-hard drill materials arenecessary to penetrate underground rockformations. Drill bits made from industrialdiamond are manufactured under extremetemperature and pressure conditions toobtain maximum hardness and durability.Both are key measures of performance in thishigh-speed, abrasive environment.
Drilling companies strive to maximize rate ofpenetration into the rock. Prematurely wornor damaged drill bits can slow down theprogress of the operation. To reduce costlymaintenance and improve drilling efficiency,component manufacturers invest heavily inmaterials and equipment R&D labs.Instrumented impact testers are among thetools found in these labs for comparing drillbit material compositions, cutting structuresand manufacturing processes.
Our Solution
A special application-specific fixture andstriker system was mounted to a 9250HV droptower to perform impact testing on variousmining drill bit designs. Industry-standardfixturing supplied by the customer positionedthe drill bit beneath the striker at an angle tosimulate field-use conditions. A custom tupinsert was also provided. This component wasmounted to a high-capacity tup and designedto hold single-use strikers that represented a
hard rock formation being drilled.
Several drill material development labs -previously using crude drop weighttechniques to analyze impact performance -benefited from the repeatability andinstrumentation provided by the 9250HV. Anew level of information regarding impactforce and energy became available to providefurther visibility and new insight into drill bitfailure modes.
Mining Drill Bits
d
Close-up of Izod striker used to impact saw blade
tooth for determining impact force and energy
performance limits.
d
Ultra-hard drill bits used in mining applications
are specially designed for impact performance.
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Medical products is a fast-growing,
global industry driven by innovative
manufacturers. Surgeons, doctors,
nurses and consumers all place great
trust in the quality, safety and reliability
of the medical devices they use. Some
products, such as surgical and dentaltools, are purposefully designed to
receive impacts. Others, like medical
durables and disposables, can face
accidental impacts during field use.
In many applications, the consequences
of a medical product failure can be
severe for both the patient and
manufacturer. A patient can suffer
serious injury or death, damaging the
manufacturer's reputation in the
marketplace and exposing the company
to product liability lawsuits.
18
The Challenge
The successful completion of certain surgicalprocedures, such as vertebrae fusions and hipreplacements, requires the use of high-performance implant delivery tools. Duringthe course of the procedure, these tools aresubjected to repeated impacts from thesurgeon's hammer and must performflawlessly. A tool failure can lead tocomplications during surgery such asunwanted debris in the wound field or
excessive time under anesthesia.
It is critical for manufacturers of implantdelivery tools to earn the confidence andrespect of surgeons by providing a productthat has been thoroughly tested under end-use conditions. Without sophisticated testequipment, manufacturers may not be able toaccurately simulate forces, geometries andother impact characteristics that their toolswill experience in the operating room.
Our Solution
To identify design features of the implant toolmost likely to fail, Instron developed a testsetup on a 9250HV instrumented drop towerto simulate surgical impact conditions.Custom fixturing was assembled to grip theimpact tool and a striker head was selected toreplicate the face of a surgical hammer. Arebound brake was also installed to preventsecondary impacts on the tool.
Once the relevant geometries were recreated,a simple modification to the ImpulseTM
software enabled the drop tower to performautomatic cyclic testing - effectivelyreproducing the motions of a surgeonrepeatedly striking the tool. By methodicallyand consistently simulating the energy level,frequency, quantity and geometry of impacts,Instron was able to improve quality controltesting of the implant tool. A previouslyundetected failure mode was identifiedduring analysis of the data.
Surgical Tools
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Test setup for surgical tools includes custom fixture
for vertical positioning, rebound brakes for single
impact, and software module for cyclic testing.
For more information about Instron in the medical community, ask about our
"Solutions for Biomedical Testing" brochure or visit us on the web at:
www.instron.com/wa/applications/biomedical
BIOPULSTMTM
BIOPULS
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Our Solution
For this low-energy application, Instronworked with a customer to configure aninstrumented Dynatup Mini-Tower tosimulate various types of impact on thedisposable glass insulin cartridge. V-grooveand cantilever support fixtures were createdto represent different injector pen designs inthe customer's product family. Utilizing theMini-Tower as an R&D tool, Instron'scustomer tested the cartridges in many
different support configurations and energylevels. The resulting data provided an impactresistance profile that revealed sensitivedesign features and confirmed a specific fieldfailure mode, helping the manufacturer tomake decisions about product design andprocess quality control.
The Challenge
A significant percentage of the world'spopulation wears some form of corrective orprotective eyewear such as reading glasses,
sunglasses or sports goggles. The primarypurpose of eyewear is to improve vision, butthe lenses must also withstand impact forcesresulting from unintentional drops and hits.
To the eyewear consumer, the potentialconsequences of impact failure - a shatteringlens and serious injury to the eye - areimmediate and severe. Governmentregulations set minimum impact performancestandards for eyewear products. Lensmanufacturers need a flexible test instrument
to research materials and demonstrate productcompliance to government specifications.
Our Solution
Instron created a support fixture to simulatehuman facial geometry and test the impactperformance of eyeglass lenses. A thin
neoprene gasket bonded to a 11/4-inchdiameter steel ring was fastened to the baseof an instrumented Dynatup Mini-TowerTM.Sample lenses of different mineral andorganic compositions were placedunrestrained on the fixture and impacted bya 5/8-inch hemispherical striker at variousweights and drop heights. The resulting arrayof data provided detailed information aboutthe relative deflection, maximum load andenergy absorption of the different materials -
information that was used to steer
product development and todemonstrate product compliance.
19
Medical
Consumer DurablesEyeglass Lenses
The Challenge
Diabetes sufferers today can choose from awide variety of insulin-delivery products tomanage their blood glucose levels.Manufacturers have developed innovativeinjector pens with disposable, pre-filled glassinsulin cartridges designed for convenientself-treatment. Consumers expect theseinjector pen and cartridge systems to be robustagainst accidental impacts. The disposablecartridges must also be packaged effectively to
resist impact strikes commonly experiencedduring shipment.
A glass cartridge broken during shipping or inuse can cause injury and prevent the patientfrom receiving necessary medication. For themanufacturer, the patient's resulting loss ofconfidence in the product can be the mostharmful effect of an impact failure. Theproduct must be thoroughly tested for impactperformance prior to launch into theconsumer marketplace.
Consumer DisposablesInsulin Delivery Systems
d
Glass insulin cartridge positioned in a V-groove
fixture for impact testing.
d
Eyeglass lens tested on
instrumented Mini-Tower to
measure deflection, load and
energy absorption performance.
BIOPULSTMTM
BIOPULS
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Designers of sporting goods used by
recreational and professional athletes
compete to provide superior fit,
durability and performance. Products
are often made from lightweight
materials including composites,
plastics, rubbers and foams that areselected to perform under specific
impact conditions. Racquet designs
are optimized for striking game balls,
for example, while helmets must
protect athletes from impact injuries.
For many of these products, the
amount of energy returned or energy
absorbed during an impact is an
important performance feature.
The Challenge
The design of tennis racquets has evolveddramatically over the past 20 years. Fiber-reinforced, composite materials have enabledmanufacturers to develop racquets that arelighter and better performing than theirwooden predecessors.
Tennis racquets must withstand frequent,high-speed impacts with tennis balls andfixed objects such as playing surfaces, netsupports and fences or walls. Under suchreal-world impact conditions, compositematerials can have complex and hiddenfailure modes with resulting effects on theperformance of the racquet. Instrumentedimpact testing is a valuable tool to helpidentify and improve product durability.
Tennis Racquets
After incipient damage points were identifiedand recorded, further testing was performedon both strung and unstrung racquets tomeasure the effects of string tension on impactperformance. Finally, the rebound response ofstrings was compared between damagedframes and undamaged frames to characterize
the reduction in overall product performance.
Our Solution
A unique fixture was created to firmlygrip and support a series of tennis racquetdesigns. The fixture/racquet assembly wasmounted beneath a high-velocity drop towerfitted with single impact rebound brakes toreproduce common tennis impacts. Using acustom flat-faced striker, Instrons equipment
delivered application-representative impacts tothe top surface and front face of the racquet'scomposite frame.
d
A composite tennis racquet frame can fracture when striking a hard court surface.
d
Energy absorbed or returned during an impact can be a critical performance factor for athletic equipment.
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SportingGoods
The Challenge
Many golf ball manufacturers offer a range ofproducts for amateur and professional playerswith different levels of swing speed and clubcontrol. In golf ball design, multiple layers of
material are molded around a core together toachieve specific performance characteristicssuch as spin, distance and lift.
The outer cover is often made from a soft,dimpled urethane material that must bedurable and resist cuts during launch andlanding impacts. Poor material selection anddesign can lead to permanent deformation ofthe ball during a swing impact, resulting inpoor flight performance. Understanding theimpact energy return characteristics of a
coating material or treatment can be animportant measure of performance forproduct R&D teams.
Our Solution
Instrumented impact testing is an effectivesolution for collecting, analyzing andcomparing rebound characteristics ofprototype golf ball designs. To simulate
application conditions, Instron can design acustom flat-faced tup insert and matchingfixture for installation on a 9250HV droptower. The ImpulseTM instrumentation systemhelps engineers quantify the amount of energyabsorbed and returned under different impactconditions, as well as deflection experiencedby the coating material. A Dynatup
pneumatic rebound brake is alsorecommended to prevent second strikes andimprove the quality of data.
Golf Balls
The Challenge
The soles and inserts of athletic shoes aremade from engineered layers of foam andrubber that must endure a high cycle life ofrunning, pivoting and jumping. Eachmaterial in the structure is designed forspecific performance characteristics. Somecompress to provide shock absorbency andcushion impacts, while others maintain
stiffness to provide stability and control.
In the case of running shoes, heel impactperformance is especially important to theathlete. Improper shoe design combined withrepetitive impacts can lead to fatigue, painand long-term injury to the athlete. Materialdeflection during a heel impact, total forceand energy absorbed can all be importantmeasures of performance to help designersoptimize layer configuration.
Athletic Shoes
Our Solution
Dynatup drop towers can be used to performsimulated heel strike tests on individual layersof material or complete assemblies inside a
shoe structure. Instron configured aMini-TowerTMwith Impulse
instrumentation and a 3,500 lb (15.6 kN) tupto characterize different layer configurations.A custom rounded striker was included to
simulate the impact geometry delivered by theheel of a runner's foot. Instron also provideda steel fixture for supporting the test
specimens under study. Together, thisimpact test package enabled engineers to
quantify and compare important energyabsorption, force and deflection vs. time
data for numerous prototype designs.
d
Dynatup Impulse software displaying typical impact force and energy rebound characteristics of materials
used in golf balls and athletic shoes.
d
Golf ball coating materials must be designed for
impact performance.
d
Material deflection during heel impact, total force and energy absorbedcan all be important measures of performance in athletic shoe design.
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For over 25 years, Instron Dynatup has provided high-quality impact test solutions to academic institutions, R&D labs and
manufacturing plants around the world. Instron Dynatup serves a broad range of industries with a family of instrumented
testers and data acquisition systems that are repeatable, reliable, safe and easy to operate.
For applications that require low energy andvelocity, Instron offers two economical dropweight test instruments. The compact andportable Mini-Tower is used for penetrationtesting of film, packaging materials and lightplastics. Thin or brittle plastics, composites andmetals can be tested on the larger Model 8200.Both instruments have a manual crossheadrelease mechanism, interchangeable dropweights and large work area for testing bothspecimens and components. The DynatupImpulseTM data acquisition system can also beintegrated to collect and analyze impactperformance data.
Mini-TowerTM and
Model 8200Instron's most versatile and popular impacttest system is the Dynatup 9200 series.Designed to deliver a wide range of impactenergies, this instrument is ideal for testingplastics, composites, metals and finishedcomponents in most any industry.Fully-instrumented with the Impulse dataacquisition and control system, the 9250 canbe configured for high-velocity testing andcomes standard withcomplete softwarecontrol of test setupand operation.Economical and fullyautomated systems arealso part of the Model9200 family.
Model 9200 Series
Model 8100 SeriesEnergy Range
2.4-27.8 kJ (37.2-20,536 ft-lbs)Max Velocity
7.0 m/s (23 ft/sec)Impulse System
OptionalDimensions
4880 x 1320 x 1120 mm(192 x 52 x 44 in)(Model 8150)
The Model 8100 series instruments aredesigned to perform high-energy impacttesting of large metal and compositespecimens and structures. Three versions areavailable to meet a broad range of dropweights and impact energies. The Model 8100can be configured for drop weight tear, three-point bend or full component testing. Impulseinstrumentation and customized fixtures arealso available toserve uniqueautomotive,aerospaceand metalsindustryapplications.
Model 8100 Series
Model 9200 SeriesEnergy Range
2.6-1603 J (1.9-1182 ft-lbs)Max Velocity
20 m/s (65.6 ft/sec)Impulse System
StandardDimensions
2558 x 584 x 508 mm*(112.5 x 23 x 20 in)*Standard base
Model 8200
Energy Range
0.5-132.7 J (0.4-97.9 ft-lbs)Max Velocity
4.3 m/s (14 ft/sec)Impulse System
OptionalDimensions
1714 x 406 x 457 mm
(67.5 x 16 x 18 in)
Mini-Tower
Energy Range
0.7-18.0 J (0.5-13.2 ft-lbs)Max Velocity
3.0 m/s (9.7 ft/sec)Impulse System
Optional
Dimensions910 x 381 x 254 mm(36 x 15 x 10 in)
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ProductPortfolio
POE2000e Pendulum
Energy Range
2.7-50 J (2.0-37 ft-lbs)Max Velocity
3.5 m/s (11.5 ft/sec)Impulse System
StandardDimensions
584 x 406 x 305 mm(23 x 16 x 12 in)
The Dynatup POE2000e provides accurateand repeatable Izod and Charpy impact testingof plastics, composites and ceramics.Designed in accordance with ASTM and ISOspecifications, this pendulum instrumentfeatures a rigid arm design with fullyadjustable drop angle and optional weights toobtain a complete range of potential energies.The POE2000e is fitted standard withImpulseTM instrumentation and software toprovide detailed calculations and plots of load,deflection, energy and velocity.
POE2000e Pendulum
For R&D or quality control applications in themicroelectronics industry, Instrons newMicroImpact test system characterizes theshear impact performance of circuit boardinterconnections. Fully-instrumented with theImpulse data acquisition and analysis system,this innovative tool provides a level of detailthat is not available using customary dropimpact test methods. Manufacturers ofelectronics can experiment with differentsolder compositions, pad finishes and otherdesign features to optimize interconnectionstrength for specific applications.
MicroImpact
Test SystemThe Dynatup Impulse system consists ofinstrumentation, electronics and software foracquiring, analyzing and storing high-qualityimpact performance data. During an impactevent, signals collected from an instrumentedtup and velocity detector pass through a highperformance signal conditioning unit and areprocessed into valuable data plots and resultstables. The powerful software interface alsofeatures a customizable library of standard testmethods, profiles and calculations. Impulsecan be fitted to any Dynatup impact testinstrument and on test frames from mostother manufacturers.
ImpulseTM Data
Acquisition System
IST Hydropuls catapult testing systems areused for high speed vehicle crash simulationtesting and passenger protection research.
Hydropuls Crash
Simulation System
Instrons VHS Series servohydraulic impactsystems feature closed-loop, high strain ratetesting with speeds up to 25 m/s.
VHS Series
As the world leader in impact testing solutions, Instron offers additional products to complement the Dynatup family.
For more information, visit us on the web at www.instron.com.
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Test Specification Index
Mini-Tower TM Model 8200 9200 Series 8100 Series POE2000e
AITM 1.0010 - Compression/Impact X X
ASTM D 256 - Izod (Plastics) X X X
ASTM D 950 - Adhesive Bonds X
ASTM D 1709 - Plastic Film Penetration X X
ASTM D 1822 - Tensile Impact X X
ASTM D 2444 - Thermoplastic Pipe X
ASTM D 3029/ASTM D 5420 - Gardner X
ASTM D 3763 - Puncture (Plastics) X(film) X X
ASTM D 4508 - Chip Impact Strength X
ASTM D 4812 - Unnotched Cantilever X
ASTM D 6110 - Charpy (Plastics) X X X
ASTM E 23 - Charpy/Izod (Metals) X
ASTM E 208 - Nil Ductility X
ASTM E 436 - Drop Weight Tear X
ASTM E 604 - Dynamic Tear X
BOEING 7260 - Compression/Impact X
DIN 53 373 - Plastic Film Penetration X
ISO 179 - Charpy (Plastics) X X X
ISO 180 - Izod (Plastics) X X X
ISO R 148 - Charpy (Steel) X X
ISO 6603-2 - Puncture (Plastics) X(film) X X
ISO 7765-2 - Plastics Film and Sheeting X X
JIS K 7111 - Charpy (Plastics) X X X
NASA ST-1 - Compression/Impact X X
Corporate HeadquartersInstron Corporation
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Tel: +1 800 564 8378
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Tel: +49 6151 3917-0
Fax:+49 6151 3917-500
For information on Instron products and services call your local worldwide sales, service and technical support offices:
www.instron.comInstron is a registered trademark of Instron Corporation.
Other names, logos, icons and marks identifying Instron products and services referenced herein are trademarks of Instron Corporation and
may not be used without the prior written permission of Instron.
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