Engineering

Material Testing

Optimal Inc. Material Testing Services utilize some of the industry’s most recognized equipment and software tools to provide our customers with high quality analysis that they need to evaluate competitive products or optimized their own product designs.  Aside from a complete suite of CAE evaluation analysis, Optimal offers the following physical material testing services:

 

Positive Material Identification (PMI)
  • Identification & analysis of various metal alloys
  • Chemical composition analysis
  • Searching 4 million records for over 200,000 metal grades
  • Covered Metal Alloys include:
    • Fe alloys, cast-iron alloys
    • Al: alloys, cast alloys, etc.
    • Cu: bronze, brass, Cu-Ni, etc.
    • Ni: hastelloy, inconel, monel, etc.
    • Ti: pure Ti, Ti.6-4 ~ Ti.8-Mn, etc.
    • Mg-, Zn- alloys
Material Identification Equipment
Material Identification
Micro-Structure Analysis
  • Differential scanning calorimetry (DSC, TA-Q200)
  • Microscope (Nikon Digital Insight DS-L2, up to x100 objective lens)
  • Scanning electron microscope with focused ion beam & (SEM, Quanta 200, NOVA)
  • Energy dispersive X-ray spectroscopy attached to SEM (EDAX)
  • X-ray diffraction (XRD, Rigaku)
  • Other software: MTEX for inverse pole figures & orientation density function

Microstructure Analysis

Material Hardness Evaluation
  • Testing ability of superficial Rockwell scales
  • 15N, 30N, 45N, 15T, 30T, & 45T scales

Material Hardness Tester

Tensile & Stress Strain Curve
  • Tensile/compressive test for both metal and polymers
  • Force: 50 kN (11,250 lbf) for metal; 89 kN (200 lbf) for polymers
  • Load accuracy: +/- 0.5 % for metals; +/- 0.001 % for polymers
  • 1 kHz data acquisition rate
  • Sensors include:
    • Instron wired extensometer
    • Laser extensometer
    • 3 dimensional digital image correlation (DIC, Correlated Solutions Inc.)
    • High speed cameras (Photron Fastcam SA2)
    • Infrared camera (FLIR SC5000)

Tensil Compressive Test

Coupon Test – Material Preparation
  • MTI Diamond cut-off saw
    • Cut small samples under 20 mm length
  • Leco MSX205M
    • Precise sectioning of samples
    • Up to 8 in. (200 mm) blade
    • 2.04 HP (1.5 kW)
    • 4.2 gallon recirculating system
  • Buehler SimpliMet XPS1
    • Mounting samples with 1.25 in. mold
    • Automatic electro-hydraulic compression mounting system
      with intelligent cooling and simple closure
  • Buehler EcoMet AutoMet 250
    • 8 in. Grinder/polisher

Coupon Test – Material Preparation

Coupon Test – Metal
  • Electromechanical Universal Test Machine
    • Tensile/compressive test
    • Force: 50 kN (11,250 lbf)
    • Load accuracy: +/- 0.5 %
    • 1 kHz data acquisition rate
  • Other sensors
    • Instron wired extensometer
    • Laser extensometer
    • 3 dimensional digital image correlation (DIC)
    • High speed & resolution cameras
    • Infrared camera

Material Testing Coupon Test – Metal

Coupon Test – Polymer
  • United SMART1 Electromechanical Test Machine
    • Tensile/compressive test
    • Force: 0.89 kN (200 lbf)
    • Load accuracy: +/- 0.001 %
    • 1 kHz data acquisition rate
  • Other sensors
    • Instron wired extensometer
    • Laser extensometer
    • 3 dimensional digital image correlation (DIC)
    • High speed/resolution cameras
    • Infrared camera

Material Testing Coupon Test – Polymer United SMART1

Electrical Vehicle Powertrain Testing

Optimal EV Powertrain Testing Services utilize some of the industry’s most recognized equipment and software tools to provide our customers with high quality analysis that they need to evaluate competitive products or optimized their own product designs. We offer the following EV powertrain testing services:

  • EV powertrain performance benchmarking
  • EV drive performance testing (battery, motor, inverter)
  • EV battery pack CAE validation of performance, crash, NVH, safety, thermal management
  • EV powertrain CAE structural and CFD thermal management validation
  • EV powertrain performance simulation and physical testing

 

Full Vehicle Testing & Validation

Optimal Full Vehicle Testing Services utilize some of the industry’s most recognized equipment and software tools to provide our customers with high quality analysis that they need to evaluate competitive products or optimized their own product designs. Optimal offers the following full vehicle testing services:

  • Full vehicle simulation models
  • CAE/CFD validation including aerodynamics, durability, impact and NVH
  • On-Dyno or On-Road performance testing

 

 

Accurate Predictive CAE NVH Models Accurate Predictive Crash Safety CAE Model Vehicle Performance Assessment

 

 

 

 

 

 

Award Winning Quality Service & Value

Through the application of the latest technology coupled with a highly experienced, trained and efficient staff, Optimal is the Engineering Services provider of choice for many companies. Optimal is the recipient of the Ford Motor Company Technical Silver Partner Award for their CAE Services.

Optimal maintains its ISO-9001:2008, ISO-14001:2004, is a certified Minority Supplier, and is a member of the Michigan Minority Business Development Council (MMBDC). Optimal was the recipient of the Ford Motor Company Technical Silver Partner Award for their CAE Services.