Automotive Testing - Industry Applications

The Autofrettage Process

The autofrettage process can extend the fatigue life of high pressure components and in some cases add infinite life. Typically, ductile steel components used in high-pressure systems in chemistry, diesel common rail injection technology and internal high-pressure forming are autofrettaged.

Diesel Fuel Injection Components:

• Diesel Common Rails
• Injector Bodies
• Pump Housings
• Fuel Lines
• Pump Heads

Burst Pressure Test

Characteristic applications for our burst pressure test service:

• Fuel Lines
• Brake Lines
• Brake Calipers
• Cooling System Components (Lines, Hoses, Heat Exchangers, etc)
• Water Hoses
• Oil Lines
• Steering Housings
• Airbag Components
• Hydraulic Accumulators
• Fuel Injection Components

More About Burst Pressure Test

Common Rail Testing Service

The so-called common rail system has been used in diesel injection technology since about the mid-1990s. The ultra-high injection pressures (currently up to around 2,000 bar) and the controlled multiple injection per combustion stroke generate low pollutant emissions and an efficient engine running culture.

The injection system accounts for around half of the prime costs of a modern diesel engine. MAXIMATOR supplies the equipment for impulse testing, leak and burst testing, autofrettage, high-pressure cleaning and automated assembly of individual components, with due regard, of course, for the traceability via bar codes, data matrix codes (DMC) etc. required by the automotive industry.

Our test laboratory enables us to provide our customers with effective support in the development phase by performing pilot tests and endurance tests on the various fuel injection components (prototype testing). We also perform autofrettaging of components as well as pressure, burst and leakage tests.

General Testing Services

Leakage Tests

Characteristical applications for our leakage test service:

• Pumps and Pump Housings
• Manifolds
• Castings
• Covers
• Fuel Lines
• Brake Lines
• Brake Calipers
• Cooling System Components (Lines, Hoses, Heat Exchangers, etc)
• Water Hoses
• Oil Lines
• Steering Housings
• Airbag Components

Pressure Fatigue Testing

Our test labs are often used to support manufacturing facilities, R&D labs, prototype labs, and their quality departments with material validation, PPAP, and component or assembly validation testing. We can help your design, manufacturing, production, and quality engineers gather the data to make important decisions regarding your prototype designs or confirm manufactured parts off your assembly line meet the design criteria of your customers.

Maximator Test – Services:

• High frequency testing up to 4,500 bar
• Installing test benches in your company
• Developing custom test benches

Our pulse test bench in our test laboratory allows freely selectable pressure curves, such as sine or trapezoid, to be specified and pressure ranges greater than 4,000 bar with frequencies of 15 Hz to be implemented.

Characteristical applications for our Pressure fatigue testing service:

Diesel Fuel Injection Components:

• Diesel Common Rails
• Injector Bodies
• Pump Housings
• Fuel Lines

Gasoline Fuel Injection Components:

• Gasoline Common Rails
• Injector Bodies
• Pump Housings
• Fuel Lines
• Brake Pumps
• Hydraulic Brake Lines
• Oil Filter Housings
• Pressure Sensors