FTA ADwin-Gold Assembly instructions

Fracture Technology
Associates
Non-Linear Fracture Toughness Testing and Analysis
Version 3+.16.01
Users’ Reference Manual
January 2016
Keith Donald
Amy Blair
Fracture Technology Associates
2412 Emrick Boulevard
Bethlehem, PA 18020
610-868-3054
www.FractureTech.com

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Table of Contents
1.0 The FTA NLFT Testing and Analysis System.............................................7
1.1 Introduction.................................................................................7
1.2 Software.....................................................................................7
1.2 The ADwin Gold .........................................................................7
1.4 Other Hardware Requirements...................................................9
1.5 License Agreement.....................................................................9
1.6 Manual Layout............................................................................9
2.0 Installation Guide......................................................................................11
2.1 Hardware and Drivers...............................................................11
2.1.1 Analog input and output connections.............................11
2.1.2 Digital input and output connections..............................12
2.2 Connecting the FTA-DCPD Current Supply and Amplifier........13
2.3 PC Setup and Installation of the FTA Software........................15
2.4 Installing the ADWin Drivers on the PC....................................16
2.5 Testing in Simulation................................................................18
2.5 Tuning ......................................................................................18
3.0 Using the NLFT Testing Software.............................................................19
3.1 Understanding Testing Files.....................................................19
3.2 Running a Test Using the FTA NLFT Software ........................20
3.2.1 Setup.............................................................................20
3.2.2 Running The Test..........................................................25
4.0 NLFT Testing Software: Description of Menus and Tabs.........................29
4.1 Splash Screen..........................................................................29
4.2 Main Menu................................................................................30
4.3 File............................................................................................30
4.3.1 Save Analysis File .........................................................30
4.3.2 Exit.................................................................................31
4.4 Config.......................................................................................31
4.4.1 Hardware Configuration.................................................32
4.4.1.1 Calibration (compliance)..................................32
4.4.1.2 Calibration (DCPD)..........................................33
4.4.1.3 Configuration (Compliance and DCPD)...........34
4.4.2 Test Set-up....................................................................36
4.4.2.1 Initialize...........................................................37
4.4.2.2 Calibration.......................................................40
4.4.2.3 Coefficients .....................................................44
4.4.2.4 Dimensions .....................................................46
4.4.2.5 Compliance.....................................................48
4.4.2.6 DCPD..............................................................50
4.4.2.7 Storage............................................................52
4.4.2.8 Limits...............................................................54
4.4.3 General information.......................................................55
4.4.3.1 General ...........................................................56
4.4.3.2 Precrack..........................................................57

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4.5 Control......................................................................................58
4.5.1 Ramp Generator: Compliance and DCPD.....................58
4.6 Display......................................................................................63
4.6.1 Status ............................................................................63
4.6.2 Load-Displacement........................................................64
4.6.3 J –Delta a......................................................................66
4.7 Comments................................................................................67
4.8 Help..........................................................................................67
5.0 Using the FTA Analysis Software.............................................................69
5.1 How the NLFT Analysis Program Works..................................69
5.2 Understanding the Files Used by the Analysis Program...........70
5.3 E1820 Analysis Procedure.......................................................71
5.4 E399 Analysis Procedure.........................................................74
6.0 NLFT Analysis Software: Description of Menus and Tabs........................79
6.1 Splash Screen..........................................................................79
6.2 Main Form: Menu Items............................................................79
6.2.1 File.................................................................................80
6.2.1.1 Open ...............................................................81
6.2.1.2 Save................................................................81
6.2.2 Display...........................................................................81
6.2.3 Help...............................................................................81
6.2.4 Quit................................................................................81
6.3 Main Form: Tabs ......................................................................82
6.3.1 Control...........................................................................82
6.3.2 Coeff[icient]s..................................................................85
6.3.3 General..........................................................................86
6.3.4 Dimensions....................................................................88
6.3.5 Visuals, Etc......................................................................89
6.3.6 Comments .....................................................................91
6.3.7 Data...............................................................................92
6.3.8 Load-Disp Data..............................................................94
6.4 Processing The Data................................................................96
6.4.1 Run Non-Linear Analysis...............................................96
6.4.2 Process Load-Disp Data................................................96
6.5 Display......................................................................................96
6.5.1 J –delta a Display .........................................................97
6.5.2 Output Display...............................................................98
6.5.3 Load-displacement Display............................................99
6.6 Post Processing .....................................................................101
7.0 Analysis Utility ........................................................................................103
7.1. Non-Linear Report..................................................................103
7.1.1 User Input....................................................................105
7.1.2 Reduced Data..............................................................106
7.1.3 J-plot............................................................................107
7.1.4 Cover page..................................................................108
7.1.5 Raw Data.....................................................................110

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7.1.6 Additional Data ............................................................111
7.1.7 Variables......................................................................112
7.2. Load-Disp and Linear Report .................................................113
7.2.1 Load Disp.....................................................................114
7.2.2 Load Time....................................................................115
7.2.3 User Input....................................................................116
7.2.4 Cover Page..................................................................117
7.2.5 K-Plot...........................................................................118
7.2.6 K-Plot...........................................................................119
7.2.7 Reg Data......................................................................120
7.2.8 Variables......................................................................121
8.0 The NLFT Testing PLAYBACK software ................................................123
8.1 Using the Testing Playback Software.....................................123
8.2 Description of Menus and Tabs..............................................124
8.2.1 Splash Screen .............................................................124
8.2.2 Main Menu...................................................................125
8.2.2.1 File ................................................................125
8.2.2.2 Open .............................................................126
8.2.2.3 Save Analysis File As....................................126
8.2.2.4 Save Metric Load-Displacement ...................126
8.2.3 Input.............................................................................126
8.2.3.1 Data...............................................................127
8.2.3.1.1 Initialize........................................127
8.2.3.1.2 Coefficients..................................128
8.2.3.1.3 Dimensions..................................129
8.2.3.1.4 Calibration ...................................130
8.2.3.2 Options..........................................................131
8.2.4 Display.........................................................................132
8.2.4.1 Load-Displacement .......................................132
8.2.4.2 J –Delta a.....................................................133
8.2.5 Help.............................................................................133
Appendix A: Recovery from System Crash.................................................135
Appendix B: Descriptions of Analysis Files.................................................137
B1: Log file....................................................................................137
B1a: Compliance..................................................................137
B1b: Potential Drop..............................................................139
B2: Compliance .in5 file................................................................141
B2a: Field Descriptors..........................................................142
B2b: Glossary of Variables...................................................142
B3: RAW file .................................................................................146
B4: UNL file...................................................................................147

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1.0 The FTA NLFT Testing and Analysis System
1.1 Introduction
Fracture Technology Associates’ fourth-generation Non-Linear Fracture Toughness
(NLFT) system is an updated hardware and software package designed primarily for
non-linear fracture toughness testing and analysis (ASTM E1820, E1921), ), although
linear elastic testing and analysis is supported (ASTM E399). Each system consists of
an ADwin Gold signal processor and a computer running the FTA NLFT software.
Enhancements to the software include the ability to perform cyclic J and da/dt with a K
profile, desirable for accelerated environmentally assisted cracking tests (KIeac).
Two analysis packages are included with each system: 1) standard analysis and 2)
testing playback software, which allows the user to reprocess unloading slopes that may
have captured non-linear crack measurement data during testing.
FTA’s basic NLFT (ASTM E1820, E1921) testing application is designed to run with the
ADwin Gold and any closed loop servo-hydraulic mechanical test machine and
controller, suitably configured for non-linear fracture toughness testing. It is important to
note that the fourth-generation software requires an ADwin with an integrated USB port:
older Adwins are not supported.
1.2 Software
The basic software application uses either compliance (NLFT-C) or DC potential drop
(NLFT-D) for non-linear fracture toughness testing with a single crack monitor. The
combined application (NLFT-C/D) includes either, independent or simultaneous
compliance unloading and DC potential drop monitor of crack size.
The FTA NLFT analysis program runs independently of the Adwin Gold and has been
upgraded as well. The analysis program can run analysis files created by the new
testing software as well as previous versions.
1.3 The ADwin Gold
The hardware component of FTA’s testing system is the ADwin-Gold signal processor,
manufactured by the German company Jäger. The ADwin takes over from the test
machine controller and performs all function generation, data acquisition, and real-time
data processing, using the ADbasic programming language. ADbasic controls both high
(such as command control and data acquisition) and low priority processes (such as
determination of crack length). The ADwin performs all tasks on a priority basis
regardless of the computer’s workload and time-critical processes run independently of

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the PC operating system. Thus, if the computer running the FTA software crashes, the
ADwin continues to maintain control and collect data. When the computer is rebooted, it
can access the ADwin process and tests continue uninterrupted.
The ADwin has a dedicated Analog Devices SHARC DSP processor; local memory; and
high-speed 16-bit resolution analog input and output. It provides real-time response
within one microsecond. Further documentation can be found in the ADwin manuals
provided with FTA systems.

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1.4 Other Hardware Requirements
Required hardware for the FTA testing package includes the ADwin Gold and a
computer running the FTA software. A computer (either 32-bit or 64-bit) with a Pentium
3 processor and 256M memory (or better) and a CD/DVD drive is recommended.
Windows versions 98 thru 7 are supported, although ADwin drivers will differ according
to the OS used (see section 2.4 of this manual for further details).
For potential drop methods of crack measurement, FTA supplies its own high-quality,
DC potential drop instrumentation (FTA-DCPD). The FTA-DCPD was specifically
designed for the precise current and amplifier stability necessary for the reversing DC
potential drop method of monitoring crack length and consists of two units: a
programmable linear DC power supply with built-in solid-state polarity-reversing relays
and a two channel precision differential DC amplifier
Please consult FTA for additional details regarding system requirements.
1.5 License Agreement
Familiarization with the background and theory of fracture toughness testing as well as
the American Society for Testing and Materials (ASTM) standards for fracture
toughness testing (E1820, E1921, E399) is strongly recommended. Fracture
Technology Associates (FTA) assumes no liability for inappropriate use of this software
and hardware system. It is the user’s responsibility to provide back-up verification of the
performance and accuracy of this software package (i.e., visual checking of crack
length, independent monitoring of the applied loads, and redundant checking of the
analysis).
Each test system requires a software license for each of the two required testing
applications. Permission is granted to make copies of the software for back-up
purposes. The analysis software does not require a license for multiple copies and may
be loaded on additional computers for convenience of use. All rights and title to the
application software shall remain the sole and exclusive property of FTA. Distribution of
this software to another party is prohibited.
1.6 Manual Layout
This manual is intended as a beginning reference for new users of the FTA testing and
analysis software. The following section describes setup and installation of the ADwin
Gold; FTA-DCPD current supply and amplifier; and FTA software. Section 3.2 provides
step-by-step instructions to guide new users through the running of a room temperature
E1820 test, including the option of DCPD crack measurement. Section 4 provides
detailed descriptions of each of the testing software menus and displays in the order in

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which they are typically opened by the user. Sections 5 through 8 detail use of the
analysis software, including testing playback.
This manual includes discussion of the E399 and E1820 standards only. Please contact
FTA for more details on using the NLFT software for E1921 testing and analysis.
Operation and troubleshooting of laboratory controllers and test frames are outside the
scope of this document: for guidance, users are encouraged to contact their equipment
manufacturers.

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2.0 Installation Guide
2.1 Connecting the ADwin to the Controller and FTA-DCPD
The ADwin-Gold is factory-calibrated and configured for differential inputs, although
FTA can provide a calibration procedure upon request. The ADwin must be grounded
for use in conjunction with a test machine: it should be grounded to the system console
or the common ground of the controller (refer to the ADwin hardware manual Start Up
section for details).
2.1.1 ANALOG INPUT AND OUTPUT CONNECTIONS
For fracture toughness applications, the following analog BNC connections are required
(refer to ADwin hardware manual Connector section for details). Note that these
connections are different than those required by FTA’s previous testing applications.
load cell signal from the test controller: connects to the IN 1 connector on the
ADwin
external function generator input on the test machine controller: connects to the
OUT 1 connector on the ADwin
[for compliance] the displacement signal from the test controller or auxiliary
instrumentation: connects to the IN 2 connector on the ADwin.
[for DC potential drop] active probe amplifier output: connects to the IN 5
connector on the ADwin.
[for DC potential drop] reference probe amplifier output (if required): connects to
the IN 6 connector on the ADwin.
in addition, the ADwin’s IN3 and IN4 connectors may be used as auxiliary
channels for display and/or data logging
The software is configured for a 10 volt range. It is therefore recommended that only
active inputs be connected to the ADwin, since an unused displacement or DC potential
drop signal may have an off-scale output (greater than 10 volts). This condition
influences the analog input multiplexer settling time and may affect the readings of the
other channels.

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2.1.2 DIGITAL INPUT AND OUTPUT CONNECTIONS
With each system, FTA supplies a 25-pin run-stop cable, which connects to CONN 2
(digital out) of the ADwin. Pins 5 and 13 of this connector (short red and black wires)
monitor the run state of the controller (pin 5 connects to ‘high’ and pin 13 to ‘low/ground’
of a digital-in logic signal –else, the wires are interchangeable). The nine-pin connector
goes to the back of the FTA-DCPD power supply if required. See Section 2.2 for FTA-
DCPD hook-up.
An ADwin connection diagram appears below:
EXTERNAL FUNCTION GENERATION INPUT (OUT 1)
DISPLACEMENT SIGNAL (IN2)
LOAD CELL SIGNAL FROM TEST CONTROLLER (IN1)
ACTIVE DCPD (IN5)
REFERENCE DCPD (IN6)
CONTROLLER RUN STOP,
FTA-DCPD
POWER SUPPLY
CONTROLLER GROUND
PC USB

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2.2 Connecting the FTA-DCPD Current Supply and Amplifier
The figure below shows the front panel of the power supply. Programming functions are
activated by the keypad (see the DCPD options described in the test procedure in
Section 3.2 of this manual for details). The voltage/current output on the lower left side
has been disabled.
On the back of the unit, the current output is located on the left side beneath the 120
volt AC power cord. Use the FTA-provided current wire from the Current Out connector
to the test specimen or terminal strip. A cable-tie strain relief is recommended. On the
upper right side of the unit is a 9-pin connector labeled DCPD control, which is
connected to the nine-pin connector from the 25-pin CONN 2 connector on the cabling
to the ADwin-Gold. Note that pin 25 of CONN 2 goes to pin 1 of DCPD control; pin 1 of
CONN 2 goes to pin 3 of DCPD control, and pin 14 of CONN 2 goes to pin 2 of DCPD
control. Do not use the voltage/current outputs on the right side below the DCPD
control connector. Grounding of the unit is provided through the AC power cord.
However, an additional chassis ground terminal is provided next to the power cord and
use of that additional ground is recommended. FTA provides ground cabling in all
shipments.

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On the FTA DCPD amplifier, gain selection and auto zero are provided using the panel
controls on the Ectron modules. The two shielded Input connectors above the toggle
switches (left and right) connect to the active and reference probes. The active probe
senses the voltage drop across the crack while the reference probe senses the voltage
drop at a location not significantly affected by crack growth. The left-side Ectron module
is linked to the left-side connector and the right-hand module is linked to the right-side
connector. Active/reference assignment is at the discretion of the user.
The two BNC Output connectors below the toggle switches are the amplified and
conditioned voltage outputs for the active and reference probes respectively. They are
each paired with the shielded connector above. The channel designated ‘active’ by the
user connects with IN5on the ADwin-Gold. The channel designated ‘reference’ by the
user connects with IN6on the ADwin-Gold.
The toggle switch between the Input and BNC Output connectors is the Filter Switch
for each channel. Filter ‘out’ is the down position, filter ‘in’ is the up position.

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On the back panel of the amplifer may be found the illuminated power switch; a fuse
holder with a 2-amp fuse; and a 12-volt DC power cord. A 120-volt AC to 12-volt DC
power supply is provided with the system.
To the left of the DC power cord is a ground terminal. The unit must be connected to
ground to function properly: FTA provides ground cabling in all shipments.
Note that the unit is ready for operation only after all the cables have been installed.
This includes attaching the potential drop and current wires to the specimen. In addition,
the FTA DCPD testing software must be open and all test parameters entered before
the system’s power is turned on. Activation of the FTA software sends a logic signal to
the DC power supply enabling the polarity switching relays to start in the forward
position. Detailed instructions for use of the FTA-DCPD system are included in the test
procedure provided in Section 3.2 of this manual.
2.3 PC Setup and Installation of the FTA Software
1. Deactivate the computer’s power saving modes, including standby and
hibernation. The settings of the Windows display should be high color, 800 by
600 pixels (small fonts) or 1024 by 768 (large fonts). The Theme/Appearance
should be set to Windows Classic, regardless of the computer’s OS.
2. From the FTA CD, execute the three setup files for Testing, Analysis, and
Testing Playback from their respective folders. It is recommended the software
be permitted to create the default directories of c:\Program Files\NLFT Testing
and c:\Program Files\NLFT Analysis.
3. Each program can now be launched from the Start Programs menu. To launch
the applications from the desktop, right click on their filename in the Start
Programs menu and Send them to the desktop (create shortcut). Icon files
FTAlogo3.bmp or FTAlogo4.bmp may be used for customization. These icons
can be found in the NLFT Testing folder in the Programs directory.

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2.4 Installing the ADWin Drivers on the PC
Use the ADwin drivers contained on the FTA-provided CD rather than the gold-colored
CD provided with the ADwin. Version 3.20.1200 should be used for 32-bit systems with
Windows 98 through Windows XP; for Windows 7 use version 5.00.10.00. Users of
older Adwins with ISA-link-to-USB adaptors must use the ADwin driver version
3.00.2332. Adwin drivers for 64-bit systems can be provided by FTA or found on the
web at www.adwin-downloads.de.
Copy the entire ADwin folder onto the PC desktop and carry out installation from there.
Before installing the drivers, connect the ADwin (powered off) to the computer.
1. Run the installation program in the ADWin folder. From the ADWin splash
screen, execute the complete Driver and ADbasic setup.
2. V. 3.20.1200 users will be prompted to restart the computer at this point. Do not
do so. Return to the splash screen, choose Developer-Software setup, and
repeat installation. Exit the installation program.
3. Restart the computer with the ADwin powered off.
4. Power up the ADwin. When prompted by the ‘new hardware wizard’, choose to
find the drivers from a specific location. Go the ADwin folder on the desktop and
choose to search. Ignore warnings about Windows logo testing and finish the
installation.
5. The installation window will reappear when this first stage of installation is
complete. Click ‘next’, choose not to search the internet, and continue with all
defaults.
6. Next, go to Start\Programs\ADwin\ADconfig. For v. 3.20.1200, remove the two
default ‘Link’ type connections. Add USB from the drop-down menu and click OK
to exit the form.

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For v. 5.00.10.00, on the ADconfig screen choose ‘Add USB’ from the menu
across the top. Choose Device #150 [hex] and USB Serial #0.
7. Double click on the Adbasic icon on the computer desktop. Leave the license key
blank and click ‘OK’ twice to open the ADbasic program. For v. 3.20.1200, go
straight to step 8. For v. 5.00.10.00, go to the ‘options’ tab at the top of the
window and choose ‘compiler’. Make sure ‘System’ = ADwin Gold; ‘Processor’ =
T9; and ‘Device No.’ = 150 Hex. Close the window.
8. Press the red ‘B’ button on the Adbasic screen to boot the ADWin.
9. A flashing green LED on the ADwin-Gold unit means a successful connection
has been established. Unless the hardware is changed, booting the system from
this point forward will be done automatically when the FTA testing software is
opened.
10.The final installation may be confirmed by viewing the following form in the
Windows’ Device Manager.

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2.5 Testing in Simulation
Note that it is possible to disconnect the ADwin from the test machine and operate the
NLFT program in simulation mode. Thus, users may familiarize themselves with the
FTA software and evaluate operation of the system without endangering the test
machine or expensive specimens. See Section 3.2 of this manual for sample test
procedures.
To simulate a compliance test, use BNC cables to jumper the ADwin’s OUT 1 to IN 1
and IN 2. To simulate a DCPD test, jumper OUT 1 to IN 1 and connect PIN 1 of
connector 2 to both of the center posts only of [PD active] IN 5 and [PD reference] IN 6.
Run the program as normal: new users may benefit from experimenting with the sample
test procedures provided in Section 3.2 of this manual.
2.6 Tuning
Make sure the machine controller is in displacement (actuator) control. Tune the system
as you normally would for a displacement controlled test. Since loading is static, some
dither might be required.

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3.0 Using the NLFT Testing Software
The following section of this manual opens with a discussion of the six file-types
associated with the testing program. Section 3.2 contains an illustrative test procedures,
which detail the use of both the compliance and DCPD testing software. Analysis of test
results is covered in sections 5 through 8.
3.1 Understanding Testing Files
It is important to note that six different types of file are associated with the testing
program, each with its own extension. Some of these files are created automatically
during testing, while others must be configured and saved by the user. Several are
required by the FTA analysis software. Procedures for using these files are detailed
throughout this manual, but a summary of the different files is given briefly, for
information, below.
Test Parameter file (.pr5 extension): key information unique and necessary to
the test, such as specimen dimensions and initial test conditions. Although the
information is required, the files themselves are optional, and may be loaded,
modified and saved by the user for ease of use.
General Information file (.gn2 extension): general information not required for
testing, but that may be common across tests (such as test temperature or
material description). These optional files may be loaded, modified and saved by
the user. General information may also be added at analysis time.
Log file (.log extension): details of the test including test parameters and data
that are part of the analysis file (.in5). A log file is appended, rather than
overwritten, every time it is saved. See Appendix B1 for a description of log files.
Analysis file (.in5 extension): data required for the Windows Visual BASIC
analysis software. See Appendix B2.
Unloading Data file (.unl extension): calibration factors and the voltages of the
load-displacement unloading slopes. See Appendix B3.
Raw Data file (.raw extension): load-displacement information including elapse
time; load; displacement; and auxiliary channel information recorded in
engineering units. See Appendix B4.

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3.2 Running a Test Using the FTA NLFT Software
The following is a general outline illustrating use of the FTA software to conduct a non-
linear fracture toughness test (E1820) at room temperature, using both a clip gage and
DC potential drop. These steps are meant as guidelines only in order to demonstrate
use of the FTA testing software. For detailed descriptions of the menus and forms
referred to below, see Section 4 of this manual. For an analysis procedure, see Section
5.3.
Note that when data are entered in a text box on a program menu, the data are not
transferred to the corresponding variable until another text box or command button
(such as Send to DSP) is clicked. If data have been entered in a text box but Send to
DSP has not been clicked, a blinking red reminder message will appear.
The following step-by step guide to test execution applies both to compliance and
DCPD testing. Where the process differs, directions for compliance testing appear in
blue and directions for DCPD testing appear in red. These steps are a guideline only: a
thorough knowledge of governing ASTM standards is essential.
3.2.1 SETUP
1. Turn on power to the ADwin.
2. Power to the FTA-DCPD amplifer and power supplies should be on, but the
power supply’s Output (number 1 on keypad) should be toggled to Off (the
front LED panel on the power supply should display ‘Output Off’). The unit will
start with a default voltage of 5 volts, which is recommended for most
applications. The default current is 1 amp. With Output set to off, the current
may be changed using the keypad. To input a current of 10 amps, for example,
press CURR (number 8 on the keypad) to bring up a new menu. Press the
numbers 1 and 0. Press the blue ENTER key to confirm the new setting.
3. On the FTA-DCPD amplifer, set the desired gain with the black dial on the
appropriate Ectron module (left module for left channel, right module for right
channel). Remember that the actual gain is 10 times that displayed on the
module. Also ensure that the amplifier’s VERN toggle switch is in the OUT
position and the left-hand toggle switch is in the X1 position. Note that the
toggle switch for the excitation has been locked in the 5 volt position. Do not
tamper with this lockout.
4. Open the NLFT testing program. If the program is already open from a previous
test, skip straight to step 7 of this procedure. Ensure the green light on the
Adwin is blinking, which indicates communication with the computer. Reboot
the Adwin to establish communication, if necessary. On the initial Splash
Screen, choose the crack monitor type: Compliance (for clip gage