What is Gravel Flame Jet Test Apparatus?

The Sand and Gravel Flame Jet Test Equipment is a specialized testing instrument designed to evaluate the combustion behavior and impact resistance of battery enclosure materials under simulated battery thermal runaway conditions. By simultaneously applying high-temperature flames and high-velocity sand and gravel jets, it replicates the extreme thermo-mechanical coupled environment that may occur during battery thermal runaway events.This article will introduce the equipment from the following aspects, and we hope it will be helpful to you.

Technical Features of the Sand and Gravel Flame Jet Test Equipment

The Sand and Gravel Flame Jet Test Equipment is a comprehensive testing system that integrates high-speed particle impact with a high-temperature flame environment. It is primarily used to evaluate the durability of materials such as automotive coatings, battery enclosures, and aerospace components under severe operating conditions. Its key technical features are as follows:

1. Highly adjustable test parameters

The system allows precise control of particle type, impact velocity, flow rate, impact angle (e.g., 45° or 90°), and exposure time. Some multifunctional models also integrate temperature and humidity control modules, enabling simulation of complex environments such as high-temperature desert conditions.

2. Excellent operational stability and repeatability

The equipment adopts precision-machined air gun systems and stable airflow control technology to minimize fluctuations in gas flow, ensuring high consistency of test results. Key components are typically sourced from well-known brands to support long-term, high-intensity, and high-frequency testing requirements.

3. Modular and highly compatible design

The system is mainly assembled using standardized components. Key parts such as the spray gun assembly, impact chamber, and specimen holder are designed for easy installation and removal. The nozzle tube size can be customized or quickly replaced according to customer requirements, allowing compatibility with different testing standards and specimen dimensions.

4. High automation and safety protection

The control system is typically based on a microcomputer-programmable logic controller (PLC), enabling fully automated test execution and parameter configuration. The equipment is equipped with multiple safety mechanisms, including emergency shutdown, automatic air pressure control, and door interlock power-off protection.

5. Comprehensive auxiliary and environmental design

The system is often equipped with an external sand collection box and dust removal functionality to facilitate maintenance and reduce environmental contamination. The electrical system is independently configured and designed in compliance with grounding safety standards.

Overall, the Sand and Gravel Flame Jet Test Equipment combines flexibility, precision, automation, and safety, making it a highly reliable solution for simulating extreme thermo-mechanical environments and evaluating material performance under harsh conditions.

Functions and Applications of the Sand and Gravel Flame Jet Test Equipment

The Sand and Gravel Flame Jet Test Equipment is a testing device used to evaluate material performance under combined conditions of thermal runaway exposure and high-speed particulate impact. It is mainly applied in the fields of new energy battery safety and high-risk environmental material testing.

Functions

Simulation of battery thermal runaway scenarios:

The system simultaneously applies a high-temperature flame (up to 3 kW) and high-velocity sand and gravel flow (1.5 g/s) onto the material surface, replicating the extreme conditions that may occur during battery thermal runaway events.

Precise control of combustion and sand-jet parameters:

Mass flow controllers are used to accurately regulate methane (0–10 L/min), oxygen (0–50 L/min), and air flow rates. The flame temperature can be calibrated, and the sand injection rate is stable and precisely controlled. An electric spark igniter ensures automatic ignition and synchronized control of flame and sand jet activation.

Multi-channel temperature monitoring:

The system is equipped with four K-type thermocouples (including flame calibration point, rear surface of the sample, and a position 25 mm from the sample). It records real-time temperature–time curves for detailed thermal analysis.

Automated testing process:

Supports both manual and automatic operation modes. The integrated Windows-based control software enables data acquisition, report generation, and data export.

Safety and structural design:

Features a steel integrated open-frame platform to reduce heat accumulation. A stainless-steel exhaust hood with adjustable airflow is installed on the top for smoke collection. An automatic flame shield opening system enhances operational safety.

Applications

Battery enclosure material evaluation:

Primarily used to test the flame retardancy, impact resistance, and structural integrity of lithium-ion battery enclosures under thermal runaway conditions, in compliance with standards such as UL 2596.

Reduction of R&D cost and time:

By testing materials independently rather than full battery packs, it significantly shortens development cycles and reduces experimental costs.

Research and certification support:

Widely used in universities, research institutes, and industrial laboratories to support safety certification and technical studies in electric vehicles, energy storage systems, and related fields.

Simulation of combined hazard environments:

Provides reliable data on material behavior under real-world accident scenarios, such as collision-induced thermal runaway combined with debris or particle impact.

Industries Applicable to the Sand and Gravel Flame Jet Test Equipment

The Sand and Gravel Flame Jet Test Equipment is a comprehensive testing system that combines high-speed sand/gravel impact with high-temperature flame exposure. It is primarily used to evaluate the durability, impact resistance, and thermal stability of materials under extreme operating conditions. According to the latest publicly available information, its main application industries include:

1. New Energy Battery Industry

Used to evaluate the performance of battery enclosure materials under thermal runaway conditions, simulating the extreme environment of high-temperature flames and fragment impacts during battery fire or explosion events. It supports compliance with safety standards such as UL 2596.

2. Automotive Manufacturing and Materials R&D

Applied to assess the resistance of automotive coatings, plastics, glass, and metal materials to high-speed sand and gravel impact (e.g., gravel or steel shots) combined with high-temperature flame exposure. Key properties evaluated include wear resistance, adhesion, corrosion resistance, and impact resistance, in accordance with standards such as SAE, ISO, and ASTM.

3. Aerospace Industry

Used to test structural integrity and protective performance of aerospace materials under combined conditions such as high-altitude high-speed particle impact (ice crystals, sand, debris) and high-temperature airflow, simulating complex flight environments.

4. Rail Transit Equipment

Evaluates the durability of train body structures, braking systems, and external coatings under conditions involving ballast (track gravel) impact and high-temperature braking environments.

5. Industrial Protective Materials Development

Applied in the development and validation of high-temperature resistant and abrasion-resistant protective coatings or composite materials, especially for surface protection technologies used in chemical, energy, and heavy industrial equipment.

Overall, the Sand and Gravel Flame Jet Test Equipment plays a critical role in industries that require extreme-condition safety validation, providing essential experimental support for material selection, structural optimization, and safety certification.

Operating Procedure of the Sand and Gravel Flame Jet Test Equipment

The Sand and Gravel Flame Jet Test Equipment is a specialized system used to evaluate the high-temperature resistance, impact resistance, and flame retardant performance of battery enclosure materials under simulated battery thermal runaway conditions. The standard operating procedure is as follows:

1. Pre-Test Preparation

Environment and equipment inspection

Ensure the laboratory temperature is maintained between 10°C and 35°C. Check that the main equipment structure, stainless-steel exhaust hood, specimen holder, control cabinet, and data acquisition system are in proper working condition. Confirm that the power supply is 220V and that the compressed air pressure is stable at 6 bar.

Gas and consumables preparation

Prepare bottled methane and oxygen and connect them to the corresponding gas inlets. Check all pipelines for airtightness. Ensure sufficient sand and gravel abrasive media are available and meet test requirements.

Specimen preparation

Prepare flat battery enclosure material samples according to the specified standard dimensions. Securely mount the specimen onto the designated position of the stainless-steel specimen holder.

System power-on and software startup

Turn on the main power supply. Launch the Windows-based control software and enter the main interface.

Safety verification

Operators must wear appropriate personal protective equipment. Ensure safety devices such as the flame shield and exhaust system are functioning properly.

2. Parameter Setting and Calibration

Operating mode selection

Select either “Manual mode” for setup and debugging or “Automatic mode” for standardized test execution within the software.

Gas flow configuration

Set methane, oxygen, and air flow rates via the mass flow controllers. Typical ranges are:

Methane: 0–10 L/min

Oxygen: 0–50 L/min

with accuracy better than ±2% F.S.

Exact values must follow relevant testing standards.

Flame temperature calibration

Move the specimen holder to the calibration position.

Install a flame temperature calibration thermocouple in front of the burner.

Start flame operation without sand injection and allow stabilization.

The system automatically records and calibrates flame temperature to achieve the required 3 kW heat output or corresponding temperature level.

After calibration, turn off the flame and remove the thermocouple.

3. Test Execution

Specimen positioning

Move the mounted specimen holder from the calibration position to the test position. The holder is automatically inserted into the test chamber.

Start test sequence

After confirming all parameters, initiate the automatic test program.

Automatic test operation

The flame shield automatically opens.

The ignition system activates the burner, generating the preset flame jet.

The sand injection system simultaneously starts, spraying sand at a controlled rate (e.g., 1.5 g/s) onto the specimen.

The data acquisition system begins real-time recording of flame temperature, rear-surface temperature, ambient temperature 25 mm behind the specimen, and sand injection signals at a 1-second sampling interval.

Process monitoring

Real-time temperature–time and sand injection–time curves are displayed on the software interface for continuous monitoring of the test process.

4. Test Completion and Post-Processing

Automatic shutdown

Once the preset time or conditions are reached, the system automatically shuts off methane, oxygen, and sand supply. The flame is extinguished and sand injection stops.

Specimen withdrawal

After the flame shield closes, the specimen holder automatically returns to the safe position outside the test chamber.

Data storage and report generation

All temperature, time, and sand injection data are automatically saved. The operator can generate a complete test report, including temperature curves, sand injection curves, and key evaluation data.

System shutdown and cleaning

Turn off the software and main power supply. After cooling, clean residual sand and debris inside the chamber. If a water filter cup is installed, drain accumulated water.

5. Safety Operation Requirements

Always ensure proper ventilation before and during testing; the exhaust system must remain active.

Do not open the test chamber or touch high-temperature components during operation.

In case of gas leakage, abnormal flame behavior, or system malfunction, immediately press the emergency stop button and report to responsible personnel.

Regularly inspect gas seals, safety valves, and electrical safety systems to ensure proper functioning.

Importance of the Sand and Gravel Flame Jet Test Equipment

The Sand and Gravel Flame Jet Test Equipment is a critical experimental system designed to evaluate the performance of battery enclosure materials under simulated extreme battery thermal runaway conditions. Its importance is reflected in the following key aspects:

1. Simulation of extreme thermal runaway conditions to ensure battery safety

By precisely controlling the mixing ratio of methane and oxygen, the system can reproduce flame jet and sand-blasting flame conditions defined in safety standards such as UL 2596. It simulates the high-temperature flames and high-velocity particle impacts that may occur during battery thermal runaway, including fragments from casing rupture or electrolyte ejection.

This provides a near-realistic testing environment for evaluating flame resistance, penetration resistance, and structural integrity of materials—making it an essential validation tool for improving the safety level of power batteries and energy storage systems.

2. Improving R&D efficiency and reducing development cost

The equipment enables direct testing of sheet materials without the need to assemble full battery packs. This significantly shortens testing cycles, allows rapid screening and optimization of material formulations, and accelerates product development while effectively reducing R&D costs.

3. Highly controllable parameters and reliable data output

The system integrates high-precision mass flow controllers, multi-channel temperature measurement systems, and automated control software, ensuring excellent repeatability and accuracy of results.

Precise control: Methane and oxygen flow accuracy better than ±2% F.S., enabling stable generation of 3 kW flame and 1.5 g/s sand jet.

Comprehensive monitoring: Multi-point thermocouples simultaneously record flame temperature, rear-surface temperature, and ambient conditions, while also capturing sand injection signals to generate complete temperature–time and sand–time curves.

Automated operation: Includes automatic flame application, specimen positioning, data acquisition, and report generation, minimizing human error and improving efficiency.

4. Compliance with international standards and certification support

The system is designed in strict accordance with internationally recognized standards such as UL 2596. Its burner system is consistent with UL laboratory configurations, ensuring high credibility and comparability of test results.

These results can be directly used to support product safety certification and market access, making the equipment an essential hardware foundation for manufacturers demonstrating compliance.

5. Application value and industry demand

With the rapid development of new energy vehicles and energy storage systems, battery safety has become a global focus. Such equipment is increasingly recognized in government procurement and major research programs as a key testing platform for advanced safety validation.

In addition, its core testing principle—high-speed particle impact under extreme conditions—is also widely applicable in automotive, aerospace, and other industries for evaluating material durability, such as coating resistance to sand, gravel, and debris erosion.

In summary, the Sand and Gravel Flame Jet Test Equipment serves as a critical bridge between material development, safety standards, and real-world applications. Through highly realistic, quantifiable, and standardized testing, it provides indispensable technical support for improving battery system safety and accelerating the application of advanced materials.We sincerely welcome your inquiries or direct contact for more detailed product information and technical support.