Autofrettage Systems up to 15 000 bar. Autofrettage systems enable manufacturers to extend the fatigue strength and service life of components such as common rails, pump heads, (diesel) injection lines and many other components in research and development as well as in series production.
up to 15 000 bar
Autofrettage is a method for increasing the fatigue strength of components for use at high and pulsating pressures. Consequently, Autofrettage compresses a container’s inner surface, making better use of the material’s structural properties. The process can reduce fatigue concerns in pulsating pressure applications and lets engineers reduce tubing thickness in high-pressure applications without sacrificing strength, life, or safety.
The autofrettage method is based on the reciprocal relationship between the plasticized inner zone and the elastically deformed outer zone. For that reason, the components are placed under so much pressure that their interiors become plastically deformed. After relaxing, pressure stresses are created in these areas, which prevent the outer areas from reforming to their original shape. Instead, it remains stretched. This prevents crack formation in operation, increases the service life of the components, and therefore offers cost reduction potentials.
Typical applications are liners and jackets for high-pressure pumps, pump housings, automotive common-rail injection components for cars and trucks, but also cannon and gun barrels. We at Poppe + Potthoff Maschinenbau GmbH are the leading manufacturer of Autofrettage systems.
Due to its high variability, the Universal Autofrettage is ideal for research and development purposes as well as for smaller series production. It increases the fatigue strength of high-pressure components such as pipes, lines, valves, rails, pump heads, sensors and other pressure vessels.
For variable geometries
Components with different geometries can be flexibly autofrettaged on this system. The conversion is carried out by changing the device. The Autofrettage parameters are freely programmable and editable.
The pressure intensifier consists of a drive and a high-pressure part. The hydraulically-driven pressure converter also acts as a mediator.
Common Rail Serial Production Autofrettage
The autofrettage system consists of two subassemblies that are combined into a single compact rig. The pressure generation system (hydraulic intensifier) and the electric control cabinet are installed on one side of the rig. The other side is designed as a test chamber. An automatic door is installed in front of the chamber, while a safety lens in the protective door allows for an observation of the component. The protective door is secured and is programmed to not be opened during the autofrettage process; making it a very safe rig.
Autofrettage for Injection Lines
With this system, high-pressure lines for diesel injection are automatically prepared for use with pulsating pressure in series. Different components can be autofrettaged with the system. The changeover is carried out by changing the device.
In a series of ten
A protective door opens on the front for manual insertion and removal of up to ten lines. The control panel is on the right. Among other things, the autofrettage pressure can be freely programmed here. All other relevant data is also displayed there for the operator.
Upgradable Autofrettage Rig for Lines
The diesel injection line autofrettage system is an independent unit for the autofrettage of diesel injection lines up to 8,000 bar. Most Poppe + Potthoff Autofrettage rigs can be upgraded to a 10000 bar and 12000 bar autofrettage systems, as well as extended to a multi-chamber system. If your production ramps up, the system can be equivalently adapted. This uniquely developed autofrettage unit is a great starter system as it can be gradually increased from one chamber, to two chambers and all the way to or even 6 chambers in some cases.
Autofrettage for Prototypes and Development
The Autofrettage system is ideal for research and development purposes. The rig allows high flexibility in terms of components that can be autofrettaged. Although limited for autofrettage on high quantities the rig is ideally placed in labs working on improving fatigue strength and material composition of new components. The Autofrettage pressure is freely programmable to fit customers’ requirements per each DUT. The control panel is located at an ergonomic height for operators and all relevant data is displayed to the operator and can be quickly edited at any time.
For example, it is possible to convert the system from a rail device to a pump head device. The system thus allows the autofrettage of various components and can be integrated into research and development as flexibly as possible. Even a small production can be supported with the system.
Testing as a Service
At Poppe + Potthoff we offer autofrettage in various pressure ranges and for many components as a service. Whether for research and development or serial production, please contact us with your testing requirements for a non-binding offer.
Test RIGS and Applications–
Accurate and reliable
As a specialist in pressure testing technology and test rigs, Poppe + Potthoff Maschinenbau supports the development and production of extremely resilient components made of various materials – especially for automotive, shipbuilding and mechanical engineering as well as fluid and the medical industry. We offer individually designed test benches such as burst pressure test rigs, pressure cycle test benches, leak test systems, functional test rigs and autofrettage systems.
Pressure cycle test stand with vacuum test
Pressure cycle test cooling systems of ECUs, PTC heaters, high-voltage coolant heaters, ACDC and DCDC converters and other media-carrying components while controlling the ambient and media temperature of e.g. water-glycol at temperatures from -40 °C to 140 °C .
Function test bench: Battery simulation under the influence of temperature
A temperature-controlled volume flow (e.g. 50 l/min) can be generated with the Poppe + Potthoff test stands for functional testing of media-carrying components. In addition, a component from e-mobility can be energized if required and pressure cycles applied.
Leak Test Stands
With the leak test rigs from Poppe + Potthoff, various components and assemblies can be tested for leaks by means of a drop in pressure. Depending on the test requirements, our systems including a vacuum unit and low-pressure or high-pressure module can be designed for optimal leak testing. In addition, Poppe + Potthoff offers e.g. bubble tests in a water bath / underwater tests with air and gas.
Compressed Air Boosters
Poppe + Potthoff Maschinenbau GmbH supplies compressor units and pressure control systems up to 400 bar. We offer you ready-to-connect units to increase the existing pressure for pneumatic and hydraulic applications. This allows the performance of existing systems to be expanded flexibly and efficiently.
1050 bar helium / nitrogen / hydrogen
A leak test bench equipped with a pressure module up to 1050 bar, an optionally integrated climatic chamber and a gas sniffer (e.g. Inficon) to detect leaks in H2 components such as on-tank valves, hoses, pipes, fittings, regulators, valves and fuel cell components.
Household appliance manufacturers are aware of the importance that their media-carrying components must be leakproof from day one, and components must be able to withstand a higher pressure load than the operating pressure. Poppe + Potthoff Maschinenbau supports the industry with various pressure testing systems.
Test benches for medical technology components from Poppe + Potthoff Maschinenbau put a wide variety of components to the test. Reliable, repeatable and accurate pressure tests and verification processes ensure the quality of a component during research and development, and production.
Marine engines are made up of components that are exposed to extremly high pressures and require pressure testing. Among many others, cooling systems, pumps and valves in ship engines are subjected to pressure and tested for their resilience using pressure test benches from Poppe + Potthoff.
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