Quartz Lamp Thermal Fatigue Testing Machine

Customers do not need a single heating device; they require a thermal fatigue testing system capable of performing a "heat-cool-reatt" cycle. The equipment should simulate the operating conditions of metal sheets or similar materials undergoing repeated heating and rapid cooling during service, inducing alternating thermal stresses on the specimen surface to observe material damage evolution under thermal cycling.

This solution uses quartz lamp radiation as the primary heat source. Quartz lamps offer non-contact heating, fast response, customizable heating zones, and minimal sample contamination, making them ideal for rapid localized heating of plate specimens. Combined with a water-cooled cooling zone and an automatic lifting mechanism, they enable stable and repeatable thermal cycling.

1. Design Basis and Scope of Application

This design references the structural logic of thermal fatigue testing machines outlined in HB 6660—2011 "Test Method for Thermal Fatigue of Metal Sheets," retaining core functions such as heating, cooling, specimen clamping, lifting mechanisms, temperature-control thermocouples, water inlet/outlet piping, frames, and control systems. The key distinction is that this方案 replaces traditional electric furnace heating with quartz lamp radiant heating. Based on actual specimen dimensions, target temperatures, and cycle requirements provided by customers, the heating zone size, cooling method, clamp structure, and control system can be customized accordingly.

This equipment is designed for thermal fatigue testing of rectangular plate specimens and similar structures. Typical applications include hot-section materials in aircraft engines, high-temperature alloy sheets, thermal protection structural materials, welded or coated specimens, as well as material selection and process validation under thermal cycling conditions. For non-standard or irregularly shaped specimens, the system can be extended by swapping in dedicated fixtures and localized heating modules.

2. Device Implementation and Test Results

III. Overall Equipment Solution

The equipment features a vertical frame structure. Once the specimen is mounted in a dedicated fixture, a lifting mechanism moves it between the heating and cooling zones. During the heating phase, quartz lamps radiate heat to the specimen's local or specified area. In the cooling phase, a water-cooling tank rapidly cools the specimen.

The control system uses a PLC and touchscreen as the core to manage quartz lamp output, lifting/lowering actions, cooling circulation, temperature acquisition, and cycle counting. The equipment supports both manual debugging mode for initial process parameter tuning and automatic test mode for stable long-term operation during formal trials.

IV. Key Technical Specifications

5. Key Components and Functional Overview

5.1 Quartz Lamp Radiation Heating Module

The quartz lamp heating module provides non-contact radiative heating to a specified area of the sample. The number and power of the quartz lamps can be configured based on sample width, target heating zone, and desired temperature. Heating performance is further optimized by adjusting lamp spacing, reflective/insulating structures, and sample positioning. Compared to conventional electric furnaces that enclose the entire sample, the quartz lamp system offers faster response times and is ideal for establishing pronounced heating-cooling thermal cycles.

5.2 Specimen Clamping and Automatic Lifting Mechanism

The specimen fixture holds rectangular plate specimens and exposes the heated zone. An automatic lifting mechanism moves the specimen back and forth between the quartz lamp heating zone and the water-cooling zone. Lift position, dwell time, and cycle count are configurable via the touchscreen. During operation, upper/lower limit switches and position sensors ensure reliable movement.

5.3 Water-cooled cooling system

The cooling system consists of a water trough, inlet pipe, drain pipe, water level adjustment mechanism, and circulation water interface. After heating, the specimen enters the cooling zone for rapid temperature reduction via water cooling. For applications requiring high consistency in cooling conditions, a circulating water tank or constant-temperature cooling unit can be configured to ensure stable cooling across different test batches.

5.4 Temperature Measurement and Data Acquisition System

The device supports temperature measurement via thermocouples, with optional infrared sensors based on sample conditions. Thermocouples are ideal for standardized temperature control and process logging, while infrared sensors enable non-contact monitoring of the sample surface. The system records key parameters such as sample temperature, heating duration, cooling time, and cycle count to generate temperature-time curves and support test process traceability.

5.5 Electrical Control and Safety Protection

The control system is built around a PLC and HMI to handle parameter setup, automatic cycling, process visualization, data logging, and alarm interlocks. Safety protections include over-temperature, low water level/empty tank, lift limit, emergency stop, and ground fault protection, ensuring safety and stability during continuous cyclic testing.

VI. Typical Test Process

• Specimen Preparation: Prepare rectangular plate specimens according to test requirements. Clean the specimen surfaces to remove oil, scale, and obvious burrs. Based on the test objective, mark observation areas on the specimen surface in advance to facilitate subsequent recording of crack initiation sites, crack length, and propagation direction.
• Sample Installation: Secure the sample in a dedicated fixture, ensuring it is centered within the quartz lamp heating module. Ensure the sample is held firmly and positioned vertically to prevent shifting or vibration during vertical movement cycles. Position the temperature control thermocouple near the heating zone or at a designated spot on the sample surface for real-time temperature feedback.
• Parameter Settings: Configure test parameters on the touchscreen interface, including target heating temperature, dwell time, cooling duration, lift speed, cycle count, and temperature safety limit. Based on material type and test requirements, adjust quartz lamp power output, lift stroke, and cooling water level to maintain a close distance between the heating zone and the cooling water surface.
• Heating Phase: Upon test initiation, the lifting mechanism moves the specimen into the quartz lamp heating zone. Once activated, the quartz lamps rapidly radiate heat to the designated area of the specimen, causing its temperature to rise over time. The system continuously monitors the specimen temperature via thermocouples. When the target temperature is reached or the preset heating duration expires, the process proceeds to the next step.
• Rapid Transfer Phase: Immediately after heating completes, the lifting mechanism activates to move the specimen from the heating zone down to a nearby water-cooled zone. With the cooling tank positioned directly beneath the quartz lamp heating module at close proximity, this design minimizes the transition time from high temperature to cooling, thereby enhancing thermal cycling shock performance.
• Water Cooling Stage: Upon entering the water-cooling zone, the specimen contacts cooling water and cools rapidly. During this phase, the system maintains the set cooling duration while water is replenished or circulated via inlet and outlet pipes to ensure stable water levels and consistent cooling performance. After cooling, the lifting mechanism returns the specimen to the quartz lamp heating zone.
• Cycle Test: The equipment automatically cycles through the sequence "heating → cooling → water cooling → rising." Upon completion of each heating and cooling cycle, the system automatically records the cycle count along with temperature changes, heating duration, cooling duration, and other relevant data. The cycling continues until the preset number of cycles is reached or termination conditions—such as specified cracking or fracture in the specimen—are met.
• Test Observation and Recording: During the test, you can pause at set cycle intervals to inspect the specimen surface. Record whether cracks appear, their initiation location, length, and propagation direction. Use a magnifying glass, microscope, or image capture device as needed for closer inspection.
• Test End: The equipment automatically stops once the set number of cycles is reached or the specimen reaches a defined failure state. Turn off the quartz lamp heating module and cooling system. Once the specimen temperature drops to a safe range, remove it for subsequent crack measurement, fracture analysis, or performance evaluation.
• Data Organization: Upon completion of the test, organize the temperature–time curve, cycle count, cycles to crack initiation, crack propagation details, and final failure status. These data are used to evaluate the material's thermal fatigue life, resistance, and crack propagation characteristics under thermal cycling conditions.

VII. Configuration List

VIII. Solution Summary

This solution utilizes quartz lamp radiation heating, water-cooled rapid cooling, and an automatic lifting-cycling structure to address key challenges in thermal fatigue testing: ensuring stable, repeatable heating–cooling cycles; accurately recording cycle data; and obtaining reliable material thermal fatigue evaluation results. With its clear equipment design and intuitive test workflow, it is well-suited for standard thermal fatigue tests, comparative material process trials, and R&D-stage thermal cycling damage assessments.