Material Testing

Material Testing refers to the technical examination and evaluation of materials and components with regard to their mechanical, chemical, physical and technological properties. As part of EAC Certification and EAC Declaration within the Eurasian Economic Union (EAEU), material testing may be required to demonstrate the suitability of the materials used and compliance with applicable technical safety requirements.

Material testing is particularly important for safety-critical machinery, pressure equipment, pipelines, welded structures and industrial installations.

Depending on the material, product and application, the following properties may be examined:

• mechanical strength, tensile strength and yield strength,
• elongation at break, toughness and hardness,
• chemical composition,
• corrosion and temperature resistance,
• weldability,
• microstructure and metallurgical characteristics,
• other product-specific material properties.

The required material tests depend in particular on the applicable Technical Regulations (TR EAEU / TR CU), relevant standards and Testing Methods, intended operating conditions and the respective Conformity Assessment procedure.

Material testing may be particularly relevant for the following product groups:

• pressure vessels, pipelines and other pressure equipment – Pressure Equipment (EAC PED / EAC DGRL) (TR CU 032),
• machinery and industrial installations – Machinery Safety (TR CU 010),
• explosion-protected equipment – Explosion Protection (TR CU 012),
• valves, fittings and heat exchangers,
• welded structures and safety-critical components.

For pressure equipment in particular, the materials used must be suitable for the intended operating conditions. Pressure, temperature, medium, material properties and design may play a decisive role. For machinery and explosion-protected equipment, additional requirements concerning mechanical strength, operational safety or the prevention of ignition sources may be relevant.

Material testing is primarily intended to:

• demonstrate the suitability of the materials used,
• verify mechanical and chemical properties,
• confirm compliance with specified material requirements,
• verify material specifications and certificates,
• provide the necessary evidence for Conformity Assessment.

Depending on the material and applicable requirements, the following testing methods may be used:

• tensile testing and hardness testing,
• Charpy impact testing,
• chemical material analysis,
• metallographic examination,
• corrosion testing,
• testing of welded joints,
• Non-Destructive Testing (NDT).

Common non-destructive testing methods include:

• Ultrasonic Testing (UT),
• Radiographic Testing (RT),
• Magnetic Particle Testing (MT),
• Penetrant Testing (PT),
• Visual Testing (VT).

Non-destructive testing is used, for example, to examine welds, materials and components for internal or surface defects. The required testing methods and scope of inspection depend on the applicable technical requirements.

Material testing must be distinguished from Pressure Testing, leak testing and functional testing. While material testing primarily examines material properties and possible material defects, pressure testing is intended to demonstrate strength or leak tightness under defined test conditions. Depending on the product, both types of testing may be required.

The results of material testing are documented in a Test Report. Together with an existing Material Certificate and other supporting material records, the test documentation may form part of the Technical Documentation required for EAC Conformity Assessment.

Depending on the product, the test results may also be incorporated into the following documents:

• material inspection certificates and material records,
• welding documentation and strength calculations,
• a Technical Passport, where required,
• a Risk Assessment,
• a Safety Justification, where prescribed,
• other technical evidence required for the respective conformity assessment procedure.

For pressure equipment, correct classification under TR CU 032 is important in addition to material properties. Operating pressure, volume or nominal diameter, and the fluid group are key factors in determining the pressure equipment category and the required conformity assessment procedure. Our Pressure Equipment Category Calculator for TR CU 032 can be used for an initial assessment.

Missing or unsuitable material certificates may lead to additional testing, requests for clarification from a Testing Laboratory or Certification Body, and delays in the Certification Procedure.

Typical problems include:

• missing or incomplete material certificates,
• discrepancies between drawings, parts lists and material records,
• materials that cannot be clearly identified,
• missing documentation for welding consumables,
• unsuitable or insufficiently documented testing procedures,
• missing test reports for safety-critical components.

Properly performed and documented material testing supports the demonstration of material suitability and the assessment of Product Compliance. Whether additional material testing is required depends on the product, applicable regulations and the evidence already available.

We support Manufacturers, plant engineering companies and exporters in assessing the required material tests as part of EAC Certification and EAC Declaration. Our services include reviewing existing material certificates, determining the required scope of testing, coordinating with testing laboratories and certification bodies, and incorporating the results into the Technical Documentation.