Galling Test Rig (up to 300 °C): Case Study
Designing a temperature-controlled tribology rig that bolts onto an existing Instron® load frame for repeatable, publishable results.
Background
A research team needed to study galling (adhesive wear) under user-defined conditions, including temperatures up to 300 °C and controlled contact stress. They already owned an Instron® universal testing machine for force/displacement control and asked CNR to design a rig that integrates with their Instron, adds precise temperature control, and keeps operation straightforward for different users.
The brief
- Temperature envelope: controllable set-points up to 300 °C, with stable dwells.
- Load application: use the lab’s Instron® for repeatable force and positioning.
- Repeatability: stable contact geometry and quick specimen changeover.
- Safety & usability: guarding, interlocks and a clean, simple HMI.
- Future-proofing: modular fixtures and room for additional instrumentation.
CNR’s approach
1) Concept & risk review
We mapped the method, tolerances and risks (temperature control, alignment, cable routing) and produced an interface design to mount the galling head to the Instron crosshead/table without compromising stiffness or accessibility.
2) Temperature-controlled contact
CNR integrated cartridge heaters and thermal management into the head, with closed-loop control surfaced in the rig’s control-panel UI. Operators can set/hold temperatures, run dwell profiles and confirm stability before loading begins.
- Set-point control to 300 °C with dwell/hold
- Instrumented heating with tidy thermocouple routing
- Insulation and clearances designed for service access
3) Stable mechanics & alignment
Rather than duplicate force control, the galling head bolts directly to the existing Instron®. Alignment features protect tooling and simplify set-up; the interface preserves the machine’s working envelope and safety procedures.
4) Instron® integration
The fixture architecture prioritised rigidity and guided alignment so results reflect material behaviour, not fixture variability. Quick-change specimen holders reduce turnaround between tests.
5) Controls, HMI & data
A simple HMI exposes temperature, dwell, cycle count and motion parameters. Hooks are provided for time-stamped data capture so heating profiles can be logged alongside load/displacement from the Instron.
Development & reviews
The team ran a staged build with design reviews to confirm requirements and safety (PUWER-ready). Section models validated heater placement and cable paths; prototype trials checked warm-up time, stability and operator workflow before final assembly.
Outcomes
- Deeper datasets: controlled runs to 300 °C reveal temperature-dependent galling behaviour.
- Repeatability: rigid mechanics, guided alignment and instrumented control reduce test-to-test variation.
- Faster set-up: quick-change holders and the Instron interface cut changeover time.
- Operator focus: a clean HMI and reliable interlocks let researchers concentrate on analysis.
- Modularity: fixtures and sensors can be swapped or added as methods evolve.
What’s next?
The modular design leaves room for additional channels (e.g., friction torque, displacement, vibration) and alternative heating strategies if future studies require higher rates or different temperature profiles.
About CNR
Since 1989, CNR has delivered bespoke test rigs and special-purpose machines for aerospace, automotive, energy and universities/research. We integrate control systems & instrumentation, closed-loop control, data capture and safety from concept to commissioning.
