Autofrettage

by Poppe + Potthoff

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Autofrettage Machines up to 15,0000 bar

What is Autofrettage? Increase Components Fatigue Strength in Pulsating Pressures

Autofrettage  is a method for increasing fatigue strength of components for use at high and pulsating pressures.
In short, Autofrettage compresses a container’s inner surface, making better use of the material’s structural properties. The process can reduce fatigue concerns in pulsating applications and lets engineers reduce tubing thickness in high-pressure applications without sacrificing strength, life, or safety.

The autofrettage method is based on the reciprocal relationship of the plasticized inner zone and the elastically deformed outer zone. The components are placed under so much pressure that their interiors become plastically deformed. After relaxing, pressure stresses are created in these areas, which prevent the outer areas from reforming to their original shape. Instead, it remains stretched. This prevents crack formation in the later application, increases the service life of the components, and thus offers the corresponding cost reduction potentials.
Typical applications are: liners and jackets for high-pressure pumps, automotive common-rail injection components for cars and trucks, but also cannon and gun barrels. That being said our company policy does not engage in cannon nor gun Autofrettage projects.

Contact us to learn more and discuss potential ideas and machines you may require. The image attached is an Autofrettage  machine capable of creating pressure up to 15,000 bar / 220,000 psi. Poppe + Potthoff Maschinenbau GmbH in Germany is the leading manufacturer for Autofrettage systems.

Of course, our systems are UL or CE compliant as required. In addition, we offer you direct on-site service and support.

Compact Serial Production Autofrettage Machine for Serial Production

Serial Autofrettage for rails

Autofrettage Machine for Prototypes and Research and Development up to 16000 Bar

Autofrettage prototypes and development

Autofrettage machine to increase fatigue strength of metal components

Universal-Autofrettage

Autofrettage for Diesel Injection and Common Rail up to 9000 bar

Autofrettage plant for diesel injection lines

For High-pressure Components

Poppe + Potthoff Maschinenbau offer equipment for the precisely defined Autofrettage of prototypes and standard components, which are subject to a constant change of high and low pressures.

Applications

  • Components for high-pressure hydraulic and diesel injection systems
  • Pressure vessels, gas cylinders and components for water-jet cutting systems
  • Pipes for chemical plant construction, plant and power station construction
  • Pressure sensors and transmitters

Service
In general, we also offer autofrettage in the relevant pressure areas as a service. Whether for research and development or for one-time prototypes, please contact us with your test requirements for a non-binding offer.

For various autofrettage machines, please click on the following applications:

With these systems, the durability of common rails can be increased in series. Autofrettage is performed automatically after the rails are inserted, with several radial and axial sealing points provided.

The test system consists of two subassemblies that are combined into a single compact unit. The pressure generation system and the electric control cabinet are installed on the left side. The right side was designed as a test chamber. An automatic door is installed in front of the chamber. A safety lens in the protective door allows for a good observation of the test object. The protective door cannot be opened during the auto-frettage, since a mechanical interlock occurs via the safety switch. On the left side, the pressure converter is installed in a horizontal position.

Performance data:

  • Auto-frettage-Pressure up to 12,000 bar
  • High Product variability, individual auto-frettage-program
  • Automatic tensioning of different rail types from 200 mm to 1,300 mm length

The Autofrettage system is a research and development facility. Due to the high product variability, various components or prototypes can be autofretted on the system. The Autofrettage pressure is freely programmable. The control panel is located at ergonomic height on the right side. All relevant data is displayed to the operator and can be quickly edited at any time.

Performance data:

  • 16,000 bar Autofrettage pressure
  • High product variability
  • Plant for research and development as well as prototype Autofrettage

Autofrettage schedule

  • Inserting the assembly into a device
  • Close the protective door, close the sealing tips of the clamping device with minimum pressure
  • Filling-up the system
  • Position the pressure converter
  • Autofrettage pressure build-up with proportional clamping pressure increase
  • Pressure-holding time and auto-frettage
  • Pressure reduction
  • Sealing tips and protective door
  • Remove component

Because of its high variability, Universal Autofrettage is ideal for research and development purposes as well as for smaller series. It increases the fatigue strength of high-pressure components such as pipelines, valves, rails, pump heads and pressure vessels.

For variable geometries
components with different geometries can be flexibly auto-fretted on this system. The conversion is carried out by changing the device. The Autofrettage parameters are freely programmable and editable.

Pressure converter
The pressure converter consists of a drive and a high-pressure part. The hydraulically-driven pressure converter also acts as a mediator.

Drive part
The actuator is driven by the linear drive part. It is designed as a hydraulic cylinder. The components are a piston rod with piston as well as a cylinder tube with cylinder bottom and cylinder cover. A displacement measuring system is connected to the piston. The displacement transducer indicates the position of the pressure converter. The hydraulic pressure is fed into the cylinder bottom.

High-pressure part
High pressure is created in the high-pressure part of the pressure converter. The actual pressure of up to 16,000 bar is measured in the high-pressure circuit. The control takes place via a proportional valve. The piston position of the pressure converter is detected by a remote measuring system. The stroke length and the lifting speed are monitored during the pressure build-up.

Performance data:

  • Autofrettage pressure up to 16,000 bar
  • change devices and proportional jig for round and cubic component geometries
  • Freely programmable pressure increase and electronic measuring data acquisition

High pressurelines for diesel injection are automatically prepared with this system for continuous use at pulsating pressure in series. Different components can be auto-fretted with the system. The conversion is carried out by changing the device.

In-tens series
For manual insertion and removal of up to ten lines, a protective disc opens in front. The control panel is on the right. Here, The Autofrettage pressure can be programmed. All other relevant data is also displayed to the operator.

Performance data:

  • Autofrettage pressure up to 9,000 bar
  • Tensioning pressure proportional
  • Five different line types
  • 10-way station

Your request

Contact us

Stefan Dreyer

CEO

Johannes Montag

CEO / Head of Sales

Frank Baudler

CTO

+49 3631 46221022
salesppm@poppe-potthoff.com

Philip-Claussen

Philip Claussen

Poppe + Potthoff Maschinenbau America

+1 617 250 7668
philip.claussen@poppe-potthoff.com

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