Welding consumables for wear protection, repair and demanding material joints.
Development and production of electrodes to meet specific material and application requirements.
Technical selection aids and calculation tools for safe material decisions.
When data is missing or components fail, we create the foundation for reproduction and optimisation.
Analysis of materials, wear patterns and causes of damage. The goal is to derive appropriate measures for long-lasting solutions.
Our in-house laboratory for material and component analysis. Reliable results without long waiting times.
Hands-on training and presentations on welding consumables, wear protection and material selection – on site at your company.
Targeted build-up and optimisation of components using laser technology. For applications that cannot be realised using conventional methods.
Optimised components for heavily stressed applications. For reduced wear and minimised downtime.
Typical applications and solutions from industrial practice. From wear protection to component optimisation.
Application examples for joint and hardfacing welding. From manual applications to automated processes.
Application examples for soft and hard brazing. From delicate joints to industrial series processes.
Application examples for functional and protective surface coatings. From wear protection to finishing of complex components.
When components wear or fail, the cause often lies in the interaction of material, loading and operating conditions. Component and material testing provides clarity about why components reach their limits and which measures are technically sensible. capilla uses hardness testing, corrosion testing and wear testing for this purpose among others, combining them into a thorough material testing of the component.
We examine components systematically and assess both the material and real operating conditions. Depending on the component and the question, we combine various tests – from material analysis through hardness and corrosion measurements to damage analysis.
Material testing examines the composition, microstructure and properties of a material and shows whether it is suitable for the application. We use spectral analysis, EDX analysis at the scanning electron microscope and light microscopy for microstructure and carbide assessment, among other methods. From the results, alternatives and optimisations can be derived – for example when an existing material is not sufficient for the actual loading.
Material hardness is a key characteristic for wear resistance and load-bearing capacity. We carry out hardness testing according to the standard methods HB, HRC and HV, providing the numerical value that shows whether a component can withstand the requirements in service.
In corrosion testing, we examine how a material reacts to its operating environment – for example to moisture, chemicals or aggressive bulk solids. The results show whether a material is resistant in the specific application area or requires a protection concept.
Wear testing measures how a material wears under actual loading. We carry out both standardised tests to ASTM G65-A, ASTM G75 Miller Test and ASTM B611 and in-house, application-oriented methods such as the wear pot for mixer parts and technical knives or the impact wheel to ASTM G65-A. This enables materials to be specifically selected for their actual application.
After a component failure, damage analysis clarifies the cause. Cracks, fractures and material failure are investigated and traced back to their origin – whether material fatigue, overloading or an unsuitable material selection. The results feed into measures that prevent recurring failures.
We advise you on selecting the appropriate material testing and align it with your application.
In the following video you can see our wear testing in practical use. The system simulates real loads and makes visible how different materials behave under abrasion and stress. This allows wear behaviour, service life and the suitability of a material for later use to be assessed directly.
Well-founded component and material analysis saves costs, prevents failures and forms the basis for longer-lasting solutions. With capiLab, our own certified testing laboratory is available directly in-house.
Short throughput times through the in-house testing laboratory – without external commissioning and unnecessary waiting times.
Certified testing methods and experienced specialists deliver well-founded, documented results.
Material, microstructure, loading and operating conditions are assessed together, not in isolation.
Based on the material analysis, we specifically develop welding consumables, coatings or component optimisations.
Targeted material optimisation measurably reduces wear on components and extends the service life of parts.
All processes are certified to DIN EN ISO 9001:2015 for consistent quality in every testing assignment.
A material test must reliably show why a component fails, whether a material suits the loading and what the next sensible step is. In the capiLab we test along the entire chain – from raw material through the material in use to the finished component – and bring the results together in a concrete recommendation.
At the outset, we clarify together which question is paramount: damage analysis, material optimisation or the suitability of a material or component for service. On this basis, suitable samples or components are provided for testing.
In the in-house capiLab, the relevant parameters are determined – including hardness, microstructure, composition and wear behaviour. Which testing methods are used is matched to the respective question.
The measured values are evaluated and assessed in the context of the real operating conditions. The result is a structured findings report with clear statements on the cause, the severity of the findings and the possible courses of action.
Based on the component and material analysis, we recommend concrete measures – such as switching to a more suitable welding consumable, a wear protection coating or a design-based component optimisation. On request, we also accompany implementation.
All relevant testing methods are combined in the capiLab directly in-house. This saves time, reduces coordination effort and enables fast, well-founded results.
Material testing, hardness analyses and damage assessments interlock and provide a reliable basis for decisions.
Do you have recurring damage, high wear or unclear material problems?
We analyse your components and show you which measures are technically and economically sensible.
Please feel free to contact us.
Material testing examines the properties of a material – its composition, microstructure, hardness, wear and corrosion behaviour. It shows whether a material is suitable for its loading or where its limits lie.
Component testing examines a specific component, usually in connection with its application case. While material testing assesses the material, component testing considers the entire component with its geometry, material and loading.
Hardness testing measures how resistant a material is to the penetration of a test body. Depending on the method (HB, HRC, HV), a ball or diamond cone is pressed against the surface with a defined force and the resulting indentation is measured.
We combine several methods depending on the question, including spectral analysis and EDX analysis for material composition, light microscopy for microstructure, hardness testing to HB, HRC and HV as well as corrosion and wear testing. Which methods are used is matched to the specific assignment.
We offer both standardised wear tests to ASTM G65, ASTM G75 Miller Test and ASTM B611 and in-house methods – such as the wear pot for mixer parts and technical knives and an impact wheel method. This enables materials to be compared and selected specifically for the respective application.
A damage analysis is useful when a component has failed unexpectedly, fails recurrently or shows unusual wear patterns. It clarifies the cause – whether material fatigue, overloading, incorrect material or a manufacturing defect.
We derive from the findings the measures that prevent recurring failures.
The duration depends on the scope of the testing and the condition of the component. Since the tests take place in the in-house capiLab, the waiting times of external laboratories are eliminated, which shortens throughput time.
We support customers from numerous industries in which materials and components are subject to high loading, including apparatus and valve manufacturing, building materials and cement industry, conveying technology, foundries, glass industry, ceramics and refractory industry, recycling and processing, forging, tooling, agriculture as well as rail track and railway technology. Which tests and welding consumables are suitable for an application is matched to the respective industry and specific application case.
You receive a structured findings report with the measured values, an assessment in the context of the operating conditions and a concrete recommendation for the next steps.
Based on the findings, we implement the recommended measures directly – for example through a precisely matched welding consumable, a wear protection coating, a design-based component optimisation or additive new manufacturing. Since testing and implementation are both in-house, the knowledge from the capiLab goes into manufacturing without detours.
