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Gleeble 540:  Welding Simulator

 Gleeble 540 System with test chamber and control console


Gleeble Specimen being heated in copper jaws with steep thermal gradient

Built on over 60 years of experience designing and manufacturing welding simulators, the Gleeble Welding Simulator provides a complete platform for a wide range of welding simulations and testing capabilities including weld HAZ simulation, hot tensile testing, nil-strength determination and much more. 

This new system is tailored to provide a compact, low cost solution while retaining world-class capabilities that have made Gleeble systems the industry standard.

The new Gleeble Welding Simulator has been designed from the ground up with the needs of welding researchers in mind. The capabilities of this system are customized to meet those needs.

Material Testing Simulations:
  • Weld HAZ Simulation
  • Nil Strength Testing
  • Charpy Specimen Heat Treatment
  • Hot Ductility and Tensile Testing
  • Melting and Solidification
  • Study of Local Brittle Zones
  • Embrittlement and Crack susceptibility
  • Strain Induced Crack Opening (SICO)
  • Post-Weld Heat Treating


Process Simulations:
  • GMAW - Gas Metal Arc Welding
  • GTAW - Gas Tungsten Arc Welding
  • SAW - Submerged Arc Welding
  • ESW - Electroslag Welding
  • Welding of Ferrous and Non-Ferrous Materials
  • Diffusion Bonding
  • Laser Welding
  • Upset Welding
  • Post Weld Heat Treatment
  • Stress Relieving
  • Aging Characterization
  • Annealing

HAZ Simulation:

One of the most popular types of welding research conducted on the Gleeble is HAZ Simulation. The Gleeble recreates specific sections of the HAZ based on the programmed thermal and mechanical cycle. The microstructural gradients and residual stresses created by the rapid heating and cooling found in welding can be reproduced in a controlled laboratory setting.  The Gleeble can be used to create large enough sections of HAZ material for subsequent mechanical properties testing.

 Vacuum Tank Closeup: 

Gleeble 540 vacuum tank with specimen in grips and descriptions of various components The vacuum tank of the Gleeble 540: Welding Simulator contains a water-cooled jaw carrier
which delivers electric current to copper grips, enabling very fast heating and cooling of specimens.

Mechanical Specifications:

The Gleeble 540 Welding Simulator offers a high speed mechanical system with unmatched performance in its class. The innovative hydraulic system results in a servo system capable of 200 millimeters per second stroke rate with precise control and measurement accuracy.  

 Mechanical System
  •  Horizontal frame, closed-loop hydraulic control
 Maximum Dynamic Force
  •  30 kN (~3000kgf,  ~3 Tons)
 Maximum Stroke Rate
  •  200 mm/second in tension or compression (with no load) 
 Minimum Stroke Rate 
  •  0.01 mm/second in tension or compression 


Thermal Specifications:

The Gleeble 540  offers a high speed thermal system with heating rates up to 10,000°C/second. The ability to reproduce a wide variety of thermal profiles and gradients that materials undergo in actual processes is critical to the success of physical simulation. The Gleeble 540 accomplishes this by offering both high heating rates and high cooling rates with a variety of specimen types and materials.

 Heating System
  • Direct resistance with closed-loop control
 Temperature Controller
  • Digital closed-loop control using 18 bit analog-to-digital converter and 32 bit control processor
  • Controller response rate: 10,000°C/second
  • Resolution: One degree (C or F)
  • Up to 8 Thermocouple channels (2 channels supplied standard)
Temperature Measurement 
  • A variety of thermocouple types are available depending on the material being tested and the desired temperature range. Thermocouple types include: 

Type K      Type S       Type R       Type B       Type E      Type J

 Temperature Range
  • Room Temperature to 1700°C (Based on choice of  thermocouples) 
 Maximum Heating Rate
  • Heating rates up to 10,000°C/second (6 mm diameter specimen)
  • Heating rates are dependent on sample size and material conductivity
 Controlled Cooling Rates
  • Controlled cooling rates of up to 200°C/second from 800°C to 500°C for a 10 mm plain carbon steel bar with 10 mm free span reduced to 6 mm diameter for 6 mm long at midspan
 Maximum Quench Rates
  • More than 10,000°C/second at 550°C at the specimen surface for 1 mm thick x 10 mm wide sheet of plain carbon steel with 25 mm free span
More Information:

For more information about how Gleeble Systems can help you and your team solve material and processing challenges, please contact a member of our team at info@gleeble.com or +1 (518) 283-5350. In the meantime, please download a copy of our electronic brochure by clicking here

Gleeble systems have been trusted by leading industry, universities, and research institutions for over 60 years:
  • University of Wollongong Logo
  • Wits
  • Waterloo
  • University West
  • Magdeburg
  • UConn
  • UBC
  • TU Delft
  • TU Wien
  • TU Graz
  • The Ohio State U
  • Tata
  • Swerea Kimab
  • Politecnico di Bari
  • Swansea
  • SAIL
  • Portland State
  • Atilim University
  • Oulu
  • Ostrava
  • Colorado School of Mines
  • Chemnitz University
  • Mississippi State
  • EPFL
  • ETS
  • FAU
  • Freiberg
  • Imperial
  • Iowa State University
  • Lehigh
  • LNLS
  • Lulea
  • University of Kentucky

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