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What is the best way to select a test method for a structural component?

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Structural components are essential for the safety and performance of aerospace systems, such as aircraft, rockets, satellites, and spacecraft. They must withstand various loads and stresses, such as aerodynamic forces, thermal expansion, vibration, shock, and fatigue. To ensure that the structural components meet the design requirements and specifications, they need to be tested and validated using appropriate methods and tools. But how do you select the best test method for a structural component? In this article, you will learn about some key factors and steps that can help you make an informed decision.

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Sabrina Nicacio

Mechanical and Aerospace Engineering @ Princeton University ‘25 | AIAA, Coca-Cola, Funda??o Estudar, and Jack Kent…
Kishore Brahma

Consultant & F&DT Trainer! Ex-Scientist & Ex-Academia, 35 years of experience covering R&D Organization, Engineering…

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?a?r? Do?al Gül

Mechanical Engineering in BSc Expert Ballistic Weapon Designer Rocket Scientist (SRM)

1 Factor 1: Objective

The first factor to consider is the objective of the test. What are you trying to achieve or measure with the test? For example, are you testing the strength, stiffness, durability, or reliability of the component? Are you testing the component under static or dynamic conditions? Are you testing the component in isolation or in interaction with other components or systems? The objective of the test will determine the type and level of loading, the environmental conditions, the measurement techniques, and the data analysis methods that you need to apply.

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?a?r? Do?al Gül

Mechanical Engineering in BSc Expert Ballistic Weapon Designer Rocket Scientist (SRM)
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Well, we can consider it is one of the engineering problems which we faced in the past. First thing that you should start with the function of the structural component in the total system. The nature of acting forces and other loading factors will help to selecting the test method; compression, tension, fluctuating loads, mechanical vibration, penetration, explosion, blast, etc. You have to predict the mechanical behaviour in the body of the component. It is a very good start basically.

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Steve M.

Large Account Manager @ ESI Group | Key Account Management
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The component or system being tested: What is it? What is its function? The context of the test: Is it for quality control, research, product development, etc.? Any specific concerns or areas of interest: Are you focusing on specific properties like strength, stiffness, or durability? The intended use of the test results: How will the information be used to make decisions or inform further actions? And a very important loading decision is the safety factor.

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2 Factor 2: Standards

The second factor to consider is the standards that apply to the test. Standards are guidelines or specifications that define the procedures, methods, criteria, and requirements for testing and validating structural components. Standards can be issued by regulatory authorities, industry associations, or professional organizations. For example, in aerospace engineering, some common standards are the Federal Aviation Regulations (FAR), the European Aviation Safety Agency (EASA) regulations, the International Organization for Standardization (ISO) standards, and the American Society for Testing and Materials (ASTM) standards. Standards can help you ensure the quality, consistency, and compliance of your test.

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Kishore Brahma

Consultant & F&DT Trainer! Ex-Scientist & Ex-Academia, 35 years of experience covering R&D Organization, Engineering Services, Academia & Skill Sector
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Usually, there are no standards available to carry out tests on structural components, the way they are available for coupon level tests. ASTM gives A to Z for carrying out different tests for coupon level. It may not be possible to come up with such details for component level tests as the size, shape, loadings etc. vary. It is left to the respective design office/engineers of OEM to develop their own methods to achieve the overall objectives as required by regulatory authority. However, it is required to follow the standards when it comes to different components used for the component test. Calibration of sensors like Load cell, LVDT, electronic equipment, test rig (stiffness requirements), etc. should follow the respective standards.

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Jo?o Victor Alves

Space Systems Engineering | Visiona Space Technology
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Regulatory authorities often mandate specific standards for testing structural components to ensure safety, performance, and compliance with legal requirements. For example, in the aerospace industry, regulatory bodies like the Federal Aviation Administration (FAA) in the United States or the European Aviation Safety Agency (EASA) in Europe establish standards that manufacturers must adhere to for certification. These standards dictate the acceptable test methods and procedures for verifying the structural integrity of aircraft components.

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Steve M.

Large Account Manager @ ESI Group | Key Account Management
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Sometimes engineers will perform tests which are not required. A good example is ditching. Federal Aviation Administration (FAA): For commercial aircraft in the US, the FAA regulations don't mandate a water landing test. However, they require specific design features and procedures for ditching (emergency water landing) scenarios. European Union Aviation Safety Agency (EASA): Similar to the FAA, EASA regulations don't require a water landing test but mandate specific ditching procedures and design features for commercial aircraft.

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3 Factor 3: Resources

The third factor to consider is the resources that are available for the test. Resources include the time, budget, personnel, equipment, facilities, and materials that you need to conduct the test. Depending on the complexity and scope of the test, you may need to allocate more or less resources. For example, a simple tensile test of a metal rod may require only a few hours, a small budget, one or two technicians, a standard testing machine, a laboratory, and a few samples. However, a full-scale fatigue test of a wing may require several months, a large budget, a team of engineers, a custom-built testing rig, a hangar, and a prototype. You need to assess the availability and feasibility of the resources that you need for the test.

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Sabrina Nicacio

Mechanical and Aerospace Engineering @ Princeton University ‘25 | AIAA, Coca-Cola, Funda??o Estudar, and Jack Kent Cooke Scholar
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In aerospace engineering for space missions, picking the right test method for components leans heavily on having special gear like thermal vacuum chambers. These setups are key for mimicking the harsh space environment, crucial for making sure our components can handle the real deal up there. It's all about making sure we can trust our gear to work flawlessly in space, which directly ties back to having access to this high-tech simulation equipment. So, when we choose how to test, it's really about ensuring we've got what it takes to recreate those extreme space conditions right here on Earth.

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4 Factor 4: Risks

The fourth factor to consider is the risks that are associated with the test. Risks are the potential hazards or uncertainties that may affect the outcome or quality of the test. Risks can be technical, operational, environmental, or human. For example, some technical risks are the failure or malfunction of the component or the testing equipment, the errors or inaccuracies in the data collection or analysis, and the deviations or discrepancies from the design or standards. Some operational risks are the delays or disruptions in the testing schedule or process, the conflicts or miscommunications among the testing team or stakeholders, and the changes or modifications in the testing scope or requirements. Some environmental risks are the variations or disturbances in the temperature, pressure, humidity, or noise that may affect the component or the testing equipment. Some human risks are the injuries or accidents that may occur to the personnel or the public during the test, the lack of skills or training of the personnel, and the ethical or legal issues that may arise from the test. You need to identify, evaluate, and mitigate the risks that you may encounter during the test.

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5 Factor 5: Alternatives

The fifth factor to consider is the alternatives that are available for the test. Alternatives are the different options or choices that you can use to achieve the same or similar objective as the test. Alternatives can be different types or methods of testing, different sources or providers of testing services or equipment, or different ways or approaches of testing. For example, if you want to test the aerodynamic performance of a component, you can use a wind tunnel test, a computational fluid dynamics (CFD) simulation, or a flight test. If you want to test the vibration response of a component, you can use a shaker table, a modal analysis, or a random vibration test. If you want to test the thermal expansion of a component, you can use a thermal chamber, a thermal cycling test, or a thermal stress analysis. You need to compare and contrast the alternatives that you can use for the test, based on their advantages and disadvantages, costs and benefits, and suitability and compatibility.

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Kishore Brahma

Consultant & F&DT Trainer! Ex-Scientist & Ex-Academia, 35 years of experience covering R&D Organization, Engineering Services, Academia & Skill Sector
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While carrying out static or fatigue test of structural components, one must be judicious in planning since it involves complexity and cost in testing. Such testing does not come with readymade facility the way it is available for similar tests in coupon level. It is important to have a prior knowledge, either based on engineering judgement or analysis, the range of load, displacement or strain expected at the different locations of component or full-scale article as a quite number of such items are required at different locations for simulation & monitoring. That will decide the use of right kind of loadcells, LVDT or strain gauges not only to optimize the cost but mostly provide better resolution for either simulation or data acquisition.

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6 Step 6: Decision

The sixth and final step is to make a decision based on the factors that you have considered. A decision is the selection of the best test method for the structural component, based on your objective, standards, resources, risks, and alternatives. A decision should be rational, logical, and evidence-based, as well as aligned with your goals, expectations, and constraints. A decision should also be documented, communicated, and justified, as well as monitored, evaluated, and revised, if necessary. You need to make a decision that is optimal, feasible, and reliable for your test.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Kishore Brahma

Consultant & F&DT Trainer! Ex-Scientist & Ex-Academia, 35 years of experience covering R&D Organization, Engineering Services, Academia & Skill Sector
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The philosophy used to comply with regulation requirements is “analysis supported by tests.” It takes a great deal for an analyst to correlate the test results of one-off case after incorporating a ‘fudge factor.' It is acceptable, if the analysis results differ from the test results by a factor (either under or over prediction at all the points). It becomes a real concern when the same method does not work properly in other load cases. The most probable reason might be that the FE model is not able to capture/simulate the realistic boundary and loading conditions of a built-up structure experienced during the testing. The emphasis should be addressing the correct simulation of both the conditions based on the behaviour of the component.

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What is the best way to select a test method for a structural component?

1

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3

4

5

6

7

1 Factor 1: Objective

2 Factor 2: Standards

3 Factor 3: Resources

4 Factor 4: Risks

5 Factor 5: Alternatives

6 Step 6: Decision

7 Here’s what else to consider

Aerospace Engineering

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What is the best way to select a test method for a structural component?

1

2

3

4

5

6

7

1 Factor 1: Objective

2 Factor 2: Standards

3 Factor 3: Resources

4 Factor 4: Risks

5 Factor 5: Alternatives

6 Step 6: Decision

7 Here’s what else to consider

Aerospace Engineering

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