Materialerprobung & Werkstoffanalyse
Durability under real-world conditions
From individual components to complex assemblies – we develop test systems that precisely validate and document the behavior of your materials under extreme physical conditions.
Product safety begins with material integrity. WSK Elektronik develops test benches for material testing that go far beyond standard tensile tests. We develop test systems for component and assembly testing that simulate the interaction of mechanical loads, thermal stress and exposure to various media – to identify weaknesses before market launch. With over 30 years of expertise in special-purpose machinery, we provide the technological foundation you need to rely on the durability of your innovations.
Reliable test data as the basis for your series approval
During material selection and component qualification, material testing is a critical step. An unforeseen failure in the field can lead to costly recalls and increase your product liability risks.
WSK Elektronik combines robust testing mechanics with measurement precision: We design systems that simulate defined loads and, through continuous monitoring of the measurement chain, ensure that every measured characteristic is documented reproducibly. This provides a reliable foundation for your conformity assessments and approval decisions.
Defined load profiles instead of generic endurance tests
To reproduce the actual service life of materials efficiently, load cycles must be simulated with precision. Our test benches are based on established profiles to provide reproducible evidence of material fatigue:
- Mechanical cyclic loading: Simulation of millions of movement sequences or switching cycles under defined force conditions using highly precise servo drives or pneumatic systems.
- Climatic & thermal stress: Testing in integrated climate chambers to analyze material behavior under extreme temperature changes from -40 °C to +180 °C.
- Media-related influences: Integration of water, gas, oil or salt spray to test resistance under real-world operating conditions, including pressure, flow and leak measurements.
High-precision analysis for reproducible characteristic values
In long-term test series, the stability of the measurement chain determines the reliability of the data. We address typical risks – such as drift, data loss and undefined system states – with a fully integrated architecture:
- Autonomous process monitoring: The system operates fully automatically and features intelligent shutdown routines when limit values are exceeded, proactively protecting both the test system and the prototypes.
- Low-drift measurement electronics: Hardware with a low temperature coefficient ensures a stable measurement chain over periods of several months. Calibration is carried out at defined maintenance intervals.
- Complete SQL data archiving: All measured values are stored in a central database. This enables trend analyses over the entire test duration and provides audit-ready documentation of component characteristics.
Your roadmap to complete component validation
Developing a system for material testing is an investment in the long-term quality of your products. To ensure that this investment delivers reliable results, we rely on our proven project management approach. As part of our 6-step process for customized test systems, we place particular emphasis on three critical pillars in material testing projects:
1. Definition of load profiles
We support you in translating complex real-world load data into deterministic test sequences to ensure maximum comparability.
2. Development of the test environment
We provide the complete integration of all required media supply systems as well as precise thermal conditioning of the test environment.
3. Detection of early failure indicators
Depending on the testing requirements, we integrate suitable indicators such as resistance measurement, acoustic emission, force-displacement hysteresis or temperature rise. We work with you in advance to determine which detection method provides the required resolution.
Do you already have a testing concept for your materials?
Send us your load profiles and geometries for a technical feasibility assessment and cost calculation.
Need advice on material simulation?
We support you in designing test cycles and selecting the appropriate sensor technology.
Planning reliability through technological expertise
A material test bench from WSK Elektronik is an integral part of your approval process and the assurance behind your product claims. By combining robust mechanics, long-term stable measurement electronics and a control system tailored to the WSK Framework (LabVIEW, TwinCAT, C# / C++), we minimize the risk of measurement errors during critical test phases. We support you from the initial definition of load profiles through to the statistical analysis of your data and consistently align the system architecture with your approval and audit requirements. Contact us for an initial technical consultation.
Frequently asked questions about our material testing systems
We use a redundant storage strategy: measurement data is buffered locally and simultaneously archived in a central SQL database. An uninterruptible power supply preserves the system status in the event of a power failure, allowing the test to resume in a defined manner once power is restored. We minimize drift risks in the measurement chain through low-drift hardware and automated verification cycles against internal references during operation.
The system continuously monitors critical supply media such as compressed air, water, hydraulics and power, as well as the plausibility of the measurement signals. In the event of an interruption or plausibility error, the test specimen is brought into a defined safe state, an alarm is triggered and the system status is logged.
The choice of model always depends on the specific application. For temperature-driven ageing, we use the Arrhenius equation; for thermomechanical fatigue, the Coffin-Manson model; and for purely mechanical fatigue strength, the Wöhler/Basquin approach. Before the project begins, we work with you to determine which model is appropriate and which acceleration factors remain statistically reliable based on your field data.
Where appropriate, mechanical fixtures are designed as modular change plate or adapter systems, allowing new geometries to be integrated without modifying the basic frame. On the software side, the WSK Framework allows test parameters, limit values and sequences to be adjusted via the graphical user interface. As a result, adaptations for new variants can generally be made without requiring intervention by our service team.