Confederation of European Environmental Engineering Societies

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Environmental Testing of the Future

Reality in reliability, virtual testing & trends in physical testing

Date: September 27, 2007

Location: ESA/ESTEC space centre Noordwijk, Holland

Organisation: FHI, federation of technology branches / PLOT, Platform Omgevingstechnologie, Dutch Association for Environmental Engineering

Plenary Sessions

The Costs Of Non Testing By D. Gillissen (500 kb) Focus On Reliability Testing By Harry Roossien, (620 kb) BESTPRODUCT - TENEEST By F. Crepain (72 kb) Confederation of European Environmental Engineering Societies

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The costs of Non Testing

D. Gillissen

Stork FDO

(3)

Stork Materials Technology

An operating company within

(4)

Core activities

• Material testing

• Non destructive

testing

• Calibration

• Consultancy

(5)

Materials testing

• Mechanical testing ( -80ºCto+ 900ºC)

• Bearing strength

• Poisson's ratio

• Tensile, peel and tear

• Bending fatigue

(6)

Consultancy

• Applied mechanics

• Strain and stress measurements

• Failure calculations

• Vibration measurements

• Product testing and evaluations

(7)

Consultancy

• Corrosion • Exposition tests • SSCC tests • Corrosion potential measurements • HIC tests • Etc.

(8)

Consultancy

Failure analyses • Failure mechanism • Failure cause • Repair procedures • Failure prevention

(9)

Experiences of non testing and the

consequences

• Testing after or during production

• Proven knowledge and changing of the

environment

• Designing with stronger materials

• Lighter construction and the role of

fatigue

• Upgrading of components

• Applying new techniques

(10)

Testing after production

• Industrial components short delivery times • Test is frequently done

during production • The results are not

according specification • The manufacturer has a

(11)

Example of a pressure vessel

• HIC test for Hydrogen

induced cracking

• Test failed

• Vessel subjected to

be rejected by the

client

(12)

Designing based on proven

knowledge

• Swimming pools

upgraded to leisure pools • Trent higher

temperatures in in the hall • Higher level of chemicals

for disinfection

• Frequently used materials are subjected to stress

(13)

In 2001, the suspended ceiling of

a municipal swimming pool

collapsed. The reason was the

catastrophic failure of stainless

steel grade 304 fasteners, which

had suffered stress corrosion

cracking (SCC)

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(15)

(16)

Actions and costs

• Inspection of at least 30 swimming pools

with the same construction

• Later on more swimming pools were

inspected

• Most of the ceiling have to be replaced

• New design criteria had to be made

(17)

Designing with stronger materials

• Tension bar in gas handling equipment

• Tension shall be increased to ensure

stiffness

• Material with higher tensile strength

• Result failure during test

• Failure analyses shows hydrogen

induced cracking from a corrosion

process

(18)

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Lesson

• High cost for the failure of a very expensive

piece of equipment

• Material is not suitable for this application

• Searching for new material

• If no material is available design shall be

changed

(20)

Lighter constructions

• Aluminum is one of the favorable

materials to decrease weight

• Lighter construction lower forces

• Fatigue strength is lower

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Example

• Support roll

• Material changed into aluminum

• To improve wear resistance a hard

anodizing coating was applied

• Fracture in short time notice

(22)

(23)

Examination Scanning Electron

Microscope

(24)

Failure cause

• Cracks in the hard

anodized layer

• Reduction of fatigue

strength especially by

high strength

aluminum after hard

anodizing

(25)

Effects of anodizing on fatigue

strength

Alloy

Fatigue strength at E10-6 cycles

Not anodized Anodized

MPa MPA

2024 130 105

6061 105 40

(26)

Lessons

• Although extensive calculations failure

• Hard anodizing caused a lower fatigue

strength as expected

• Testing should have tracked this

abnormality

• All produced and built in supports shall be

replaced

(27)

Upgrading of components

• Upgrading of machinery requires thicker

materials

• Three axial stress conditions can play a

role

• These stress conditions are difficult to

establish even with Finite elements

(28)

Example Fluid Forming Press

Rubber sheet Metal sheet Oil pressure clamp 1500 mm 450 mm

(29)

History of the clamp rings

• First statically

calculated two halves

• Failure in two weeks

• Design adapted

according finite

element analyses

• Key hole design

• Lifetime 3 months

(30)

New design

• Clamp ring built in

segments

• Three axial forces are

lower

• Lifetime over 10 years

(31)

Focus on Reliability Testing

Benchmark of Industry

Development

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Environmental Testing of the Future

(33)

Future = What… if … then … else …

What would happen if:

• SonyEricsson would enter car manufacturing…

– you could select different horn melodies…

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(35)

What would happen if:

• You could predict the future…

– at least:

(36)

Different approaches with same conclusions?

• Reliability Roadmap.

– current developments in reliability testing.

• Benchmark with Industry Developments.

– developments in Industry related to approaches in reliability.

• Conclusion

– Reliability Maturity Model.

new old

(37)

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1. Reliability Roadmap

Single Simulation Simulation Programs Combined Testing Single Robustness Robustness Programs HALT HASS production testing Simulation Robustness Acceleration

? Virtual?? ROSE ESS

Q

$

t

R

p

PoF? HVS, HASS, HAST Test filosophy Mmt focus

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?

• Failure Hotel

Test only on the known failure mechanisms.

• Life Cycle Analysis

Base the test(criteria) on the real world conditions the product will face. Eventually with a safety margin.

• Fix all

No base quality levels, but intention to fix all failures. Trade off and impact analysis per observed failure.

• Virtual testing / Zero verification

Based on simulation and modelling confidence on end quality

• Quality Supply Chain

Base the end result on the sum of all part verifications. Determine the quality erosion

(40)

Today Tomorrow Yesterday is history Tomorrow is mystery Yesterday

Tendency

(41)

2. Benchmark of Industry Developments

A paperless office has about as much chance as

a paperless bathroom

(42)

Developments in organisation structures

• Formalisation, rational approaches

– Weber (bureacratics)

– Fayol (management activities) – Taylor (scientific management)

• Human relations approach

– individuals in organisation

• System approaches

– Lawrence and Lorch (contingency approach) – Galbraith (information model)

– influence environment (Porter 5S)

• Organisation culture approach

– organisation structure and culture

• Lean and mean

– flexibility, core business

(43)

Benchmark industry development

Weber: Bureacratism Fayol: Mmt activities Taylor: Scientific Mmt Socio/technical Human Relations Porter: Environment/Contingency System Approach CLASSIC MODERN Informal Orga-nisation Culture Flexibility–Core Lean and Mean

Utmost dynamic Rafting organisation Development of orga

nisation structures

Development of testing Virtual Testing Tailored Testing Life Cycle Analysis HALT/ HASS ROSE commitment tailoring analysis prediction

Development of regular education

TUE FMECA standarisation Simulation Tests Simulation Programs integration PLOT © www.reliability-test.nl

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Utmost dynamic environments

RAFTING ORGANISATIONS

• flat structure – minimum mmt layers

• structure organised around core processes* (not line or function)

• 3 to 5 core processess*

• outsourcing of non-core processes*

• multifunctional and multi employable teams • simple directive structure with clear

tasks, responsibilities and targets

• orderly, manoeuvrable (flexible), sober unit, but extremely good organised for task

(45)

s ing le S IM S IM . p ro gr . c o m b. tes ti ng s ing le. RO SE RO SE . p ro gr . H A LT . p ro gr . HA SS . p ro gr . P oF & RCA . VIRTUAL FMECA MTBF LCA physics theo re ti cs … … .

3. Reliability Maturity Model

…

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VIRTUAL FMECA MTBF LCA … …

Reliability Maturity Model

re

ti

(47)

DEVELOPERS CONSERVATIVES INNOVATORS

PIONEERS

s ing le S IM S IM . p ro gr . c o mb . tes ti ng s ing le. RO SE RO SE . p ro gr . H A LT . p ro gr . HA SS . p ro gr . P oF & RCA . VIRTUAL FMECA MTBF LCA physics theo re ti cs … … .

Reliability Maturity Model

(48)

Reliability Maturity Model

• Insight current position

– SWOT

– focus areas, analysis or testing

• Benchmark your position

– with suppliers/test houses – with competitors

• Strategy development

– current and wanted position

– vision (how to develop, which direction)

(49)

Summary and focus points

• 2 different visions (old and new)

– fit in one model: Reliability Maturity Model

• You cannot be good in all segments of the model

– specialisations, organisation type

• Understanding is key for future testing

– ROSE, PoF, analysis

• Focussed and Fast Testing

– Tailored testing, virtual testing

– Not only products testing (components, analysis, virtual simulation)

• Power of suppliers and customers

(50)

Testing remains popular

Thais Rush To Condom Test

August 23, 2007

Some 1,000 amorous Thais volunteered to test condoms for

customer satisfaction Wednesday. At least 500

positions were available as part of a campaign to promote safe sex in the region. According to Durex, a Thai

marketing firm for condoms, "We are surprised to see huge interest in our campaign with almost 1,000 applicants wanting to take part. "

(51)

Thank you!

Let’s enjoy the future together

Can we predict future?

• Where are you?

• Where are your suppliers? • Where are your competitors?

(52)

More information via: www.plot.nl

(53)

BestProduct

-

Teneest

E! 3517

September 2007 September 2007

www.eneest.eu

(54)

Presentation overview

1. CEEES

2. EUREKA Project E! 3517

BESTPRODUCT

3. Other Project Proposals

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Confederation of European

Environmental Engineering

Societies - CEEES

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Member Societies

• ASTE France • BSMEE Belgium • AITPA Italy • GUS Germany • KOTEL Finland

• Nacei Czech Republic • ÖGUS Austria

• PLOT The Netherlands • SEE United Kingdom

(57)

CEEES

Aims and Objectives

• Exchange of Information and Experience • Advancement of EE science & Technology • Achieving Recognition as an Expert Pool

• Arranging International Symposia and Workshops • Participation in Standardization and Best Practices

Elaboration

(58)

BestProduct

-

Teneest

E! 3517

September 2007 September 2007

www.eneest.eu

(59)

ORGANISATION

•

• Conference of Ministers: coordinating bodyConference of Ministers: coordinating body •

• High Representatives of participating countries: to High Representatives of participating countries: to prepare and to assist the Conference of Ministers

prepare and to assist the Conference of Ministers

•

• SecretariatSecretariat

•

• National Project Coordinators of participating countries: National Project Coordinators of participating countries:

to help establishing EUREKA projects (finding partners,

defining the project, access funding,..)

(60)

EUREKA Project (criteria)

• Proposed ,defined & managed by its

partners (bottom-up approach)

• International partners from at least 2

EUREKA members

• Led by industry

• Developing hi-tech

(61)

BESTPRODUCT

•

• Good

Good

product

•

• Better

Better

product

•

• BEST

BEST

PRODUCT:

is a product in a optimized is a product in a optimized

harmony with its environment, it serves market needs as

well as ecological requirements.

(62)

How BESTPRODUCT?

•

• Urgent need to merge in a network the

Urgent need to merge in a network the

knowledge of highly qualified EE specialists and

to make an inventory of the existing EE technical

capabilities all over Europe

•

• To use that experience for designing and

To use that experience for designing and

producing a best product.

•

(63)

BESTPRODUCT

-

TENEEST

•

• BESTPRODUCT BESTPRODUCT -- TThrough a Ehrough a European uropean NNetwork on etwork on

E

Environmental Environmental Engineering Sngineering Sciences and ciences and TTechnologiesechnologies

•

• EUREKA Project (Factory) Nr. EUREKA Project (Factory) Nr. ΣΣ! 3517 (June 2005)! 3517 (June 2005)

•

(64)

Σ

! 3517

OBJECTIVES

•

• To create a networkTo create a network in order to merge the EE expertise in order to merge the EE expertise

of highly qualified specialists and the EE technical

capabilities all over Europe.

•

• This network is :This network is :

–

– aiming on a durable integration of experts’ knowledgeaiming on a durable integration of experts’ knowledge –

– a platform of excellence for solving on a concrete manner a platform of excellence for solving on a concrete manner relevant problems in EE

(65)

Project Tasks

•

• Assessment of all existing EE activities, survey of

Assessment of all existing EE activities, survey of

research and test centres,...

•

• Establishment of an international network as

Establishment of an international network as

preparation for the creation of a

preparation for the creation of a virtual EE

virtual EE

competence centre

.

•

• Determination of the gaps where facilities and

Determination of the gaps where facilities and

activities are missing.

•

• Creation of possibilities for international co

Creation of possibilities for international co

-

-operation

operation

•

• Detection of possible research topics and

Detection of possible research topics and

stimulation of EUREKA

(66)

European Skills directory for

product testing

•

• First initiative: the set up of an electronic

First initiative: the set up of an electronic

European skills directory for product testing.

•

• A short questionnaire (registration process) is

A short questionnaire (registration process) is

given on the EE website:

given on the EE website: www.eneest.eu

www.eneest.eu

•

• Companies interested in EE, either as users

Companies interested in EE, either as users

or as service providers, are asked to express

their interest in this initiative.

(67)

SUPPORTING COUNTRIES

•

• Countries supporting the project:

Countries supporting the project:

– – BelgiumBelgium – – FinlandFinland – – GermanyGermany – – SpainSpain – – SwedenSweden – – SwitzerlandSwitzerland –

– The Czech RepublicThe Czech Republic –

– TurkeyTurkey –

– CEEES as international body is the main participantCEEES as international body is the main participant

•

(68)

What has been realised?

•

• Kick

Kick

-

off meeting (Brussels 15 Feb 2006)

•

• Consortium agreement signed in Sept 2006

Consortium agreement signed in Sept 2006

•

• The technical Steering Committee met 4 times

The technical Steering Committee met 4 times

•

• 4 international workshops took place

4 international workshops took place

•

• Registration Process (January 2007)

Registration Process (January 2007)

•

• Web site www.eneest.eu

Web site

www.eneest.eu

operational (April 2007)

•

(69)

3. Eureka Project Proposals

• Creation of an artificial climate

• Ageing and life prediction

• VPET

(70)

Creation of an artificial climate

in closed environments

•

• Creating an artificial climate in a fixed or mobile closed Creating an artificial climate in a fixed or mobile closed environment.

environment. ModelisationModelisation of a laminar airflow in a high of a laminar airflow in a high care facility for burn patients.

care facility for burn patients.

•

• Study of all relevant parameters in creating an artificial Study of all relevant parameters in creating an artificial climate in a building, active facade, shelter, cockpit,

climate in a building, active facade, shelter, cockpit,

cabin, etc.

•

• Relevant parameters are moisture, radiation, Relevant parameters are moisture, radiation,

temperature (wet and dry bulb), air movement and air

(71)

Ageing and life time prediction

in automotive engineering

•

• Ageing and life time prediction of light materials used in Ageing and life time prediction of light materials used in automotive

automotive engineering.(enginsengineering.(engins) and the caused ) and the caused environmental degradation

environmental degradation •

• Chalmers University, Sweden.Chalmers University, Sweden. •

• Prof. Lars Prof. Lars NyborgNyborgand Ass. Prof Janand Ass. Prof Jan--Erik Erik SvenssonSvensson..

•

• KanthalKanthal AS, AS, SandvikSandvikMaterials Technology AB, AB Materials Technology AB, AB Volvo (Volvo

Volvo (Volvo PowertrainPowertrain), Volvo Car Corporation, Audi, ), Volvo Car Corporation, Audi, Sweden.

Sweden.

•

• Institute de Institute de IaIa Corrosion, University Pierre and Marie Corrosion, University Pierre and Marie

Curie, France.

(72)

VPET

•

• Virtual and Physical Environmental Testing.Virtual and Physical Environmental Testing.

•

• The goal of virtual testing is to avoid development testing The goal of virtual testing is to avoid development testing of test set

of test set--ups, test fixtures, etc. and to use physical ups, test fixtures, etc. and to use physical testing for validation and verification only.

testing for validation and verification only.

•

• More limited proposal:More limited proposal:synthesis of test profiles used in synthesis of test profiles used in environmental vibration tests.

environmental vibration tests.

•

• SemconSemcon, Sweden. , Sweden.

•

• LMS International, Belgium.LMS International, Belgium.

•

• RMA BelgiumRMA Belgium

•

(73)

Methods for acceleration of

ageing and corrosion tests

•

• Methods for simulation of ageing and corrosion caused Methods for simulation of ageing and corrosion caused by internal chemical environment in e.g. contaminated

by internal chemical environment in e.g. contaminated

products especially in electronics.

•

• Methods for acceleration of ageing and corrosion caused Methods for acceleration of ageing and corrosion caused by internal chemical

by internal chemical environment(e.genvironment(e.g. in electronics).. in electronics).

•

• BodycoteBodycoteMaterials Testing AB, Materials Testing AB, DeLavalDeLavalInternational International