Gleeble® Welding Simulator

Introducing the All-New Gleeble 540 Welding Simulator

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.




Features include:

  • High-speed, direct resistance heating up to 10,000°C/second
  • Controlled cooling or accelerated cooling with optional quench (air/gas/water/mist)
  • Simulation of multiple welding techniques and materials
  • Ability to test in vacuum, air or inert gas
  • Easy to use controls and software, including DSI’s custom Gleeble Welding Software

Weld HAZ Simulation 400

Above: Weld HAZ simulations can reproduce thermal gradients and characteristics at any location in a weld. The graph shows the thermal profile of two locations during a multi-pass weld.

Adjusted Grips400

Above: Direct resistance heating provides rapid and precise temperature control, creating the desired thermal profile for welding simulations

HAZ GWS Tank closeup400

Above: Water-cooled jaws contribute to very fast cooling rates and enable researchers to simulate steep thermal gradients found in welding applications.

Additional grip models are available to support uniform hot zone and other requirements.

Current Gleeble systems including the Gleeble 3500 and 3800 are very versatile and offer a wide range of simulations and tests. 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.

Below are some of the simulations this new system offers: 

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.

Mechanical Specifications:
The Gleeble 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.

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

Tank Image with Labels820

 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 Welding Simulator 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 Welding Simulator 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 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

Available Options:

  • Vacuum systems – Both roughing pump and diffusion pump options are available
  • Water chillers or heat exchangers are available
  • DSI offers many grips to hold a variety of specimen shapes
  • Quench systems for air/gas/water/mist cooling


Available Thermocouple Types

Type K
Type S
Type R
Type B
Type E

More Information: 
For more information about how the Gleeble Welding Simulator or other Gleeble equipment can help you and your team solve your material and processing challenges, please contact a member of our team at or +1 (518) 283-5350. In the meantime, please download a copy of our electronic brochure by clicking the link below.