Falling Weight Impact Tester
ISO 6603-1 Non‑Instrumented Puncture Impact Tester
Manufacturer: AHP PLASTIK MAKINA
Standard: ISO 6603‑1:2000
Application: Determination of puncture impact behaviour of rigid plastics using falling weight impact method.
As Per the Standard ISO 6603-1
4 Principle
The impact strength of suitably sized test specimens is determined by striking them with a lubricated weighted striker dropped vertically from a known height. The test specimen is impacted at its centre by a striker, perpendicular to the surface of the specimen.
Two methods of adjusting the energy at impact are permitted: altering the mass at constant height and altering the height at constant mass.
NOTE The variable-height procedure is velocity-dependent, and differing results may be observed depending upon the material’s strain rate.
Two statistical methods of test are given:
Method A: staircase method (individual) (preferred).
Method B: group method (optional).
5 Apparatus
5.1 Test device
5.1.1 Essential components
The essential components of the test device (see Figure 4) are:
– an energy carrier (dart system), of the inertial-mass type, which includes:
weights,
a striker (lubrication is required);
– a specimen support (see Figure 4), optionally with a clamping device (Figure 5).
The test device shall permit the test specimen to be punctured at its centre, perpendicular to the specimen surface.
5.1.2 Falling-dart system
The falling-dart system shall be capable of holding and releasing a weighted striker such that it will fall constrained by one or more guides. The fall shall be nominally without friction and losses through windage, or the amount of friction has to be taken into account in the calculations.
5.1.3 Weights (masses)
Appropriate weights are required that can be firmly attached to the striker. The combined mass of the attached weights, and the mass of the striker, shall be known to within 1 %.
5.1.4 Striker
The preferred striker has a polished hemispherical striking surface with a diameter 20 mm +- 0,2 mm. Alternatively, a 10 mm +- 0,1 mm diameter striking surface may be used.
NOTE: The size, dimensions and condition of the surface of the striker will affect the results.
The preferred striker is one made of any material with sufficient resistance to wear and of sufficiently high strength to prevent plastic deformation. In practice, hardened tool steel or similar material with a hardness of 54 HRC has been found acceptable. Harder materials or materials with a lower density (for example titanium) with equivalent hardness are also acceptable. The hemispherical surface of the striker shall be lubricated to reduce any friction between the striker and the test specimen (see annex B of ISO 6603-2:—).
5.1.5 Support ring
The support ring (see Figures 4 and 5) shall be rigidly fixed on a rigid base and shall be designed such that air cannot be trapped under the test specimen, possibly causing a spring effect. Below the support ring, there shall be enough distance for the striker to travel after total penetration of the test specimen. The support ring shall have an inside diameter of either 40 mm+-2 mm or 100 mm+-5 mm and a minimum height of 12 mm.
5.1.6 Striker/support combinations
The following striker/support combinations are permissible:
5.1.7 Base for test device
The test device shall be firmly mounted on a rigid structure of sufficient stiffness to minimize deflection of the specimen support. The mass of the base shall be at least 180 kg.
The test device is generally susceptible to mechanical vibration. The design of the foundation on which the base is mounted shall be such as to minimize the effect of any mechanical vibration in the system. The centre of gravity of the base shall be in line with the trajectory of the impacting striker.
5.1.8 Clamping device (optional)
When it is utilized, a two-piece annular specimen clamp consisting of the support ring and a clamping ring shall be used (see Figure 5).
The clamping device shall have an inside diameter equal to 40 mm+-2 mm or 100 mm+-5 mm. The clamp may work by the application of force on the specimen. A clamping force of >3 kN is recommended.
NOTE: Pneumatically and screw operated clamps have been successfully employed. The results obtained for clamped and unclamped specimens are likely to be different because the edges of an unclamped specimen are free to move under test and specimen vibrations with higher amplitudes may occur (see annex C of ISO 6603-2:—).
5.1.9 Device for catching the dart after impact
This device is designed to prevent multiple impacts on the specimen and damage to the striker.
5.2 Thickness gauge
This device shall enable the thickness of the test specimens to be measured to an accuracy of +-0,01 mm.
6 Test specimens
6.1 Shape and dimensions
The preferred test specimen is 60 mm+-2 mm square or 60 mm+-2 mm in diameter, with a thickness of
2,0 mm+-0,1 mm, and is used with the 40 mm diameter support ring.
For testing brittle fibre-reinforced plastic composites and low failure strain plastics, a test specimen 140+- mm 2 mm square or 140 mm+-2 mm in diameter with a recommended thickness of 4,0 mm+-0,2 mm may be used with the 100 mm diameter support ring.
6.2 Preparation of test specimens
The test specimens shall be prepared in accordance with the relevant material specification. Where none exists, or when not otherwise specified, test specimens shall be prepared in accordance with ISO 293, ISO 294-3, ISO 295 or ISO 1268 as appropriate or machined from plates in accordance with ISO 2818 (see note). The test specimens may also be prepared with a cutting or punching device, since there are no special requirements for the cut edges.
NOTE:The preparation of test specimens 140 mm square or 140 mm in diameter by injection moulding is not yet covered by any International Standard.
Because the larger specimen is used primarily for fibre-reinforced plastic composites, it is recommended that they be made by machining from sheet material.
Test specimens taken from larger sheets or sections of sheet shall be taken from locations that are as uniformly distributed over the surface as possible. Non-homogeneous edge zones shall not be used. The thickness of these test specimens shall be the thickness of the sheet up to a thickness of 4 mm. If the sheet is more than 4 mm thick, the specimens shall be machined to 4 mm.
6.3 Non-homogeneous test specimens
In general, the test is conducted on either side of the specimen, selected at random. However, if there is a reason to believe that the results are dependent on which side of the specimen faces the striker, each side shall be tested separately. This especially holds for test specimens with textured surfaces, specimens lacquered on one side and specimens which are UV-aged. When assessing the influence of a one-sided treatment, the test specimen shall be impacted on the opposite side.
6.4 Checking the specimens
The specimens shall be free of twist and warpage. Both surfaces shall be smooth and free of scratches, pits and sink marks to avoid notching effects.
The specimens shall be checked for conformity with these requirements by visual observation or by measuring with a thickness gauge. Specimens showing any observable departure from one or more of these requirements shall be rejected.
6.5 Number of test specimens
For tests conducted under constant conditions:
Method A: staircase method (individual) (preferred)
At least 30 test specimens shall be used (10 for pretesting to determine the starting energy).
Method B: group method (optional)
At least 40 test specimens shall be used (10 for pretesting and 30 for the main test).
If a large number of test specimens is required, for example to determine the temperature dependence of the parameters measured, the test specimens shall be selected in accordance with statistical principles.
6.6 Conditioning of test specimens
The test specimens shall be conditioned as required by the relevant material specification or as agreed upon by the interested parties. Otherwise, the most appropriate conditions from ISO 291 shall be selected.
7 Procedure
7.1 Test atmosphere
7.1.1 General
Conduct the test in one of the standard atmospheres specified in ISO 291.
7.1.2 Room-temperature testing
If a standard atmosphere from ISO 291 was used for conditioning, conduct the test in the same atmosphere. If not, ensure that the transit time tT (see note) is short enough (i.e. less than 5 s) to prevent changes in the mechanical behaviour (state of material) of the test specimen caused by changes in the temperature of the specimen. For dry polyamides, for instance, a transit time of up to 30 min has been found not to markedly affect the impact behaviour when testing in an atmosphere of 23 °C and 50 % R.H.
NOTE The transit time tT is the total time from the removal of the specimen from the conditioning environment until the specimen is impacted.
7.1.3 Low-temperature testing
When test specimens are conditioned at low temperature and the test equipment is at room temperature, a transit time tT (see note to 7.1.2) short enough to prevent significant changes in the temperature of the test specimen prior to impact is required (i.e. less than 5s). Differences in humidity between the test specimen conditioning atmosphere and the test atmosphere are critical.
7.2 Measurement of thickness
For each test specimen, measure the thickness to the nearest 0,02 mm at three points which are equidistant to one another on a circle with a radius of 10 mm centred on the centre of the specimen. Record the average value of the measured thickness (see note). If the thickness of any specimen differs by more than 5 % from the average thickness of the specimens from that sample, discard that specimen and replace it with another specimen.
NOTE When using injection-moulded specimens, it is not necessary to measure the dimensions of each specimen. It is sufficient to measure one specimen from each set.
When using multiple-cavity moulds, measure the thickness of the specimens from each cavity. If the difference in specimen thickness between mould cavities is greater than 5 %, the specimens from each cavity shall be treated as different batches.
7.3 Clamping the test specimen (optional)
The default condition for this test is that the specimen is unclamped.
If the specimen is clamped, however, take care to ensure that the clamping force does not induce bending or torsional forces in the specimen.
7.4 Lubrication
Lubricate the tip of the striker with oil or grease before each test. The viscosity of the lubricant shall be in the range 10 cP < Viscosity< 10000 cP (see annex B of ISO 6603-2:—)
7.5 Puncture test procedure
7.5.1 General
Place the test specimen on the support ring (5.1.5) and clamp in place, if appropriate. When testing machined specimens, impact the specimen on the machined surface. Firmly secure the necessary weights (5.1.3) to the striker (5.1.4). Put the dart (5.1.2) into position at the specified height, according to the method used, and release the dart. If the dart rebounds from the surface of the test specimen, catch the dart after it bounces to prevent
–multiple impacts with the surface of the test specimen;
–any damage to the hemispherical surface of the dart if it impacts with metal parts of the apparatus. Examine the test specimen to determine whether it has or has not failed in accordance with any of the definitions given in 3.2. The failure criteria defined in 3.2 describe definite alterations of the test specimen caused by the falling mass, a failure being defined as any break in the surface of the specimen which is visible to the naked eye. These failure criteria shall be either as specified in the relevant material specification or agreed upon by the interested parties. If other failure criteria (e.g. crazing, indentation, stress whitening, etc.) are deemed to be of importance, these criteria shall be defined by agreement between the interested parties and included in the test report. Each test specimen shall be impacted only once.
7.5.2 Constant height of fall (preferred)
A height of fall of 1 m should preferably be chosen for a variable falling mass. If the specimen cannot be broken by this method, then the alternative constant falling mass approach is recommended.
7.5.3 Constant falling mass (optional)
If a variable height is used, it should be chosen over any range between 0,3 m and 2,0 m, but preferably around 1,0 m.
7.6 Method A: staircase method (preferred)
7.6.1 General
In this method, a uniform energy increment is employed during testing and the energy is adjusted after striking each test specimen. The energy at impact is adjusted either by altering the mass at constant height or altering the height at constant mass (see, however, the note to clause 4).
7.6.2 Pretesting
Use 10 test specimens to estimate the 50 % impact-failure energy E50.
NOTE It is suggested that, during pretesting, the increments used are not uniform. Begin with relatively large increments to find the energies which will cause, with certainty, failure (or no failure). Finish the pretesting with smaller energy increments in order to estimate roughly the energy that causes 50 % of the test specimens to fail.
7.6.3 Test procedure As a starting point, select an energy near the expected impact-failure energy, based on the pretesting.
7.6.4 Expression of results
7.6.4.1 Calculation
Calculate the 50 % impact-failure energy E50, in joules, as follows:
7.7 Method B: group method
7.7.1 General
In this method, successive groups of at least 10 test specimens each are tested. For each group, one impact energy is employed and from group to group the energy is varied in increments. The energy at impact is adjusted either by altering the mass at constant height or altering the height at constant mass (see, however, the note to clause 4)
Testing is carried to a point where there are at least five percentage-failure results: one 0 % failure result, one 100 % failure result and at least three results between the 0 % and 100 % results. The three results between the 0 % and 100 % limits shall not all be lower or higher than 50 %.
7.7.2 Pretesting
Test a minimum of 10 test specimens to estimate the approximate limits at which 0 % and 100 % failure occurs.
7.7.3 Test procedure
Select the mass (or height) increments such that, between the “0 %” and “100 %” limits, based on the pretesting, a minimum of three points is determined, at each of which at least 10 test specimens are tested.
Record the failure mass (or height) and the percentage of failures for each point.
At this stage, if the minimum five results described in 7.7.1 have been obtained, testing is complete.
7.7.4 Expression of results
7.7.4.1 Calculation
Plot the data on linear probability graph paper (see Figure 8) with mass (or height) along the linear axis and percent failure along the probability axis, omitting the 0 % and 100 % failure points.
Fit the best straight line through the points and read M50 (or H50) from the graph at the falling mass (or height of fall) corresponding to the intersection of the straight line with the 50 % probability line.
1. Introduction
The ISO 6603‑1 Falling Weight Impact Tester is designed to determine the puncture impact resistance of rigid plastics using a free‑falling dart system. The equipment measures the impact failure energy of plastic sheets, molded parts, laminates, and composite materials.
The machine is suitable for:
- Rigid thermoplastics
- Thermoset plastics
- Reinforced composites
- Plastic sheets and molded products
- Research laboratory testing
- Quality control applications
The equipment operates according to ISO 6603‑1 non‑instrumented impact testing procedures.
2. Main Features
- Touch screen control panel
- Automatic height adjustment system
- Pneumatic sample clamping system
- Anti‑rebound safety mechanism
- Adjustable striker mass system
- Interchangeable striker heads
- Support rings for different specimen sizes
- Heavy rigid base construction
- Guided falling dart system
- Emergency stop protection
3. Technical Specifications
| Parameter | Specification |
|---|---|
| Standard | ISO 6603‑1 |
| Test Method | Falling Weight / Non‑Instrumented |
| Drop Height | Up to 2 meters (model dependent) |
| Striker Diameter | 20 mm hemispherical |
| Optional Striker | 10 mm hemispherical |
| Striker Hardness | >54 HRC |
| Support Ring Diameter | 40 mm and 100 mm |
| Sample Size (Small) | 60 mm square or circular |
| Sample Size (Large) | 140 mm square or circular |
| Clamping Type | Pneumatic |
| Clamping Force | >3 kN |
| Base Weight | >180 kg |
| Power Supply | 220 VAC / 50‑60 Hz |
| Air Supply | 6–8 bar clean dry air |
4. Principle of Operation
The tester determines puncture impact strength by dropping a weighted striker vertically onto the center of a test specimen.
Impact energy can be adjusted by:
- Changing striker mass
- Changing drop height
The specimen is supported on a rigid support ring and may be clamped pneumatically before impact.
The anti‑rebound mechanism prevents multiple impacts after penetration.
5. Machine Components
5.1 Main Frame
The rigid frame supports the drop tower and ensures vertical striker movement.
When you receive the packing of the order, it is in two separate part. “Falling Weight Tower” and the “Test Sample Cabin”. The bolts and nuts needed for connection of these two parts is already in place. just put the tower on the sample cabin, tighten the bolts and nuts and connect the tower the the main frame using a standard electrical connector in the backside. After connection of inlet compressed air, set the pressure to about 6 bars.
5.2 Guided Dart System
The striker assembly moves vertically through guide rails with minimal friction.
You can select the proper weight based on your test scenario and according to above sub-weights list you can catch the requested weight for test.
5.3 Striker Assembly
The striker consists of:
- Hemispherical impact head
- Weight carrier
- Additional removable masses
- Bronze guide for the striker
Select the proper striker type and weights according to above table and assemble the added weights on the striker. Loosen bronze guide bolts in one side and assemble the striker inside the chrome coated guid shafts.
put the added weights on the screw under the striker like above picture. In any weight selection scenario you need to use 7 pieces of added masses.
5.4 Pneumatic Clamp
The clamp securely holds the specimen during testing.
5.5 Support Ring
Two support rings are available:
- 40 mm inner diameter
- 100 mm inner diameter
After you put the sample piece between collars and gripped the sample using pneumatic cylinders, now you need to set proper distance of downface of striker to the second impact preventor fingers in zero point.
This distance in starting point will be 20-30mm for proper working of second impact preventor system.
Up and down keys on the control panel could be used for setting the proper place for sample table assembly.
After the sample table heigh adjustment, now is the time to bring the pneumatic holder of the striker down, for the sensor of it to touch the striker. this is needed to set the zero point position of the striker to set proper heigh of impact. Above picture shows how to do this.
When the sensor reaches to the vicinity of the barrier on the striker it will be activated and Led on the sensor will be ON like the above picture. After you get this point and Led is activated now is the time to make the heigh counter zero from the touch screen. For this, click of RESET button on the touch screen as below picture.
Then set the proper heigh of impact as below picture and hold the up key for the strider holder to get to set heigh. After it gets to that heigh will be stopped automatically and you can release the up key on the touch scree.
There are two limit switches for movement of sample table up and down. operator can change the position of these switches in case of need.
5.6 Touch Screen Controller
The touch display controls:
- Height positioning
- Test start
- Safety functions
- Parameter settings
Height S.P (cm): Set heigh for the striker release
Height (cm): Current height of the striker from zero point
RESET: to reset he heigh counter for setting the zero point of the striker
Impact S.P: Set the automatic number of impacts in case of need for multi impact test
Impact Num: Current number of impact
Single test: to do only one impact on sample piece
MULTI TEST: To do multiple impacts on the sample piece
CAL. FAC. : is the calibration factor that converts the pulse counter value to the real heigh
COUNT: is the counter value of the encoder for the heigh
POS.: the value of the heigh that is calculated based on the counter of the height and the “CAL. FAC.”
Dart Release Delay: The delay time that striker will be released from the pneumatic gripper after being gripped by it
Second Impact Prevent Time: is the time that pneumatic elevator will remain activated after first impact is done on the sample piece
General parameters of the test setup will be input on this page. These values will be input into the report on EXCEL file when exporting to the report file in flash disk.
Second page of parameters for general test setup. these data also will go to the EXCEL file when exporting to MS EXCEL file in flash disk.
There are keys here to bring calibration page, sample test page, sample general info input page up.
Above two page is related to the test result information according to the norm ISO 6603-1. for detailed learning of how to fill this table of results, please refer to the standard and video presentation of how to works in the company YouYube channel.
5.7 Anti‑Rebound Device
Prevents secondary impacts after specimen first impact by the striker.
6. Safety Instructions
WARNING
Improper operation may cause injury. Always follow these safety instructions:
- Only trained personnel may operate the machine.
- Keep hands away from the impact area.
- Never stand below the raised striker.
- Ensure safety guards are installed.
- Disconnect power before maintenance.
- Use emergency stop in unsafe situations.
- Wear safety glasses during testing.
- Ensure pneumatic connections are secure.
Emergency Stop
Press the emergency stop button immediately if:
- Abnormal noise occurs
- Striker movement becomes uncontrolled
- Air leakage is detected
- Electrical malfunction occurs
7. Installation
7.1 Location Requirements
Install the machine on:
- Flat rigid floor
- Vibration‑free area
- Dry indoor environment
- Adequate ventilation space
7.2 Electrical Connection
- Verify voltage before connection.
- Connect to grounded outlet.
- Use stable power supply.
7.3 Pneumatic Connection
- Connect clean dry compressed air.
- Recommended pressure: 6–8 bar.
- Check for leaks before operation.
7.4 Leveling
Level the machine properly to ensure accurate striker alignment.
8. Specimen Preparation
Standard Specimens
Small Specimens
- 60 mm square or circular
- Thickness: 2.0 ±0.1 mm
- Used with 40 mm support ring
Large Specimens
- 140 mm square or circular
- Thickness: 4.0 ±0.2 mm
- Used with 100 mm support ring
Conditioning
Condition specimens according to applicable ISO material standards before testing.
Surface Requirements
- Clean surface
- No visible damage
- Uniform thickness
9. Operating Procedure
9.1 Power ON
- Switch ON main power.
- Release emergency stop.
- Wait for controller initialization.
- Verify pneumatic pressure.
9.2 Select Test Parameters
Set:
- Drop height
- Striker mass
- Specimen type
- Support ring type
9.3 Install Specimen
- Place specimen centrally on support ring.
- Activate pneumatic clamp.
- Verify secure positioning.
9.4 Raise Striker
- Use touch screen controls.
- Move striker to required height.
- Confirm locking condition.
9.5 Start Test
- Ensure test area is clear.
- Press START button.
- Striker releases automatically.
- Observe specimen failure.
9.6 After Test
- Remove broken specimen.
- Inspect striker head.
- Record test results.
- Prepare next sample.
10. Test Methods
Method A — Staircase Method
- Preferred ISO method
- Impact energy adjusted after each test
- Energy increased or decreased depending on failure result
Method B — Group Method
- Optional method
- Multiple specimens tested at fixed energy levels
- Statistical analysis used for evaluation
11. Calculation of Impact Energy
Impact energy is determined using:
E = m × g × h
Where:
- E = Impact energy (J)
- m = Total striker mass (kg)
- g = Gravity acceleration (9.81 m/s²)
- h = Drop height (m)
12. Maintenance
Daily Maintenance
- Clean machine surfaces
- Remove specimen debris
- Inspect striker head
- Check air pressure
Weekly Maintenance
- Lubricate guide rails lightly
- Check pneumatic hoses
- Verify clamp operation
- Inspect electrical connections
Monthly Maintenance
- Verify height calibration
- Inspect anti‑rebound mechanism
- Check fasteners and bolts
- Clean touch screen panel
13. Calibration
Calibration should be performed periodically.
Verify:
- Drop height accuracy
- Striker mass
- Support ring dimensions
- Vertical alignment
- Pneumatic clamping force
Recommended calibration interval:
- Every 12 months
- After major maintenance
- After machine relocation
14. Troubleshooting
| Problem | Possible Cause | Solution |
| Striker does not release | Emergency stop active | Release emergency stop |
| No pneumatic clamping | Low air pressure | Check compressor supply |
| Incorrect height movement | Sensor or motor issue | Inspect height system |
| Multiple impacts occur | Anti‑rebound malfunction | Inspect rebound system |
| Specimen slips | Low clamping force | Increase air pressure |
| Touch screen inactive | Power issue | Check electrical supply |
15. Cleaning
- Disconnect power before cleaning.
- Use dry or slightly damp cloth.
- Do not use aggressive solvents.
- Keep pneumatic and electrical components dry.
16. Storage
If machine will not be used for extended periods:
- Disconnect power
- Disconnect air supply
- Clean all surfaces
- Apply anti‑corrosion protection if necessary
- Cover machine to prevent dust accumulation
17. Spare Parts
Recommended spare parts:
- Striker heads
- Pneumatic seals
- Guide bushings
- Air hoses
- Sensors
- Fuses
Use only original or approved spare parts.
18. Environmental Conditions
| Condition | Requirement |
| Operating Temperature | 15–35 °C |
| Relative Humidity | <80% |
| Installation Area | Indoor only |
| Vibration | Minimal |
19. Disposal
Dispose of electrical and pneumatic components according to local regulations.
Metal parts may be recycled.
20. Manufacturer Information
AHP PLASTIK MAKINA
Website: https://ahp-makina.com
Application Standard: ISO 6603‑1 Non‑Instrumented Impact Testing
21. Notes
- Always follow ISO 6603‑1 procedures during testing.
- Record all test conditions for traceability.
- Use calibrated masses and verified specimen dimensions.
- Ensure striker lubrication when required by the standard.