Aerospace Component Testing: Types and Environmental Testing

All the products and materials we use in our daily lives must undergo a rigorous series of tests to ensure our safety, but there are sectors where this is more crucial than others. The aerospace industry is one of them, for two reasons.

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First, because the environmental conditions that vehicles and their components must endure are extreme to say the least. And second, because a malfunction in this area can have very serious consequences.

In the aerospace industry, safety and reliability are paramount, and today we're focusing oncomponent testing.

Tests for aerospace components are of various nature and concern all the components, mostly electronic, used in spacecraft, satellites and aircraft.

Today we will discover the main tests for aerospace components, with particular attention to environmental ones.

Types of Testing for Aerospace Components

There are dozens and dozens of tests for aerospace components, each with a specific purpose. However, they can be divided into three main categories: Environmental Testing, Structural Integrity Testing, Electrical and Functional Testing.

Let's see them in detail:

• Environmental testing: Reproduces extreme conditions of temperature, humidity, and pressure. For example, thermal cycling simulate rapid temperature changes to test the expansion and contraction of materials.
• Structural integrity tests: These tests verify resistance to mechanical stress. For example, static load testing evaluates how a component withstands forces greater than those expected during a mission.
• Electrical and functional tests: These check the correct functioning of electronic systems. Among these, the continuity test verifies the integrity of connections, while the insulation test detects any electrical leaks.

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Aerospace Component Testing: Environmental

Among the tests for aerospace components, environmental tests are particularly important because the environments that vehicles and their components will face are extreme. 

The tests simulate these conditions, such as those that occur during launch, at high altitude or in space.

Among the most important is, for example, theHigh-Temperature Performance Test, aimed at evaluating the behavior of components at high temperatures. 

The test is performed using a laboratory instrument called an environmental chamber. 

The environmental chamber is part of the family of climatic chambers, that is, hermetically sealed chambers within which it is possible to alter and monitor temperature and relative humidity. We call environmental chambers the types of chambers specialized in extreme tests, that is, those that reach very high values ​​​​in descent or ascent.

In fact, among the High-Temperature Performance Test protocols there are thermal cycles that reach 150° and are used to verify that the expansion and contraction of the component materials is within acceptable ranges.

These and other environmental tests are regulated by internationally recognized bodies that produce standards outlining the procedures. 

Among the most common we find:

• MIL-STD-810: Military standard for environmental testing.
• RTCA DO-160: Standard for High Altitude Environmental Conditions
• ECSS-E-ST-10-03C: European Standard for Aerospace Environmental Testing.

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The FDM Environmental Chamber for Aerospace Component Testing

For over 70 years, FDM – Environment Makers has been a leader in the climate testing sector.

FDM environmental chambers are the ideal solution for environmental testing of aerospace components. Designed for maximum precision, they simulate a wide range of extreme conditions and can be easily programmed for rapid thermal cycling thanks to our innovative revoFACE , which guides the operator through every phase of the process.

For further information, please do not hesitate to contact us.

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Reference Standards

• RTCA DO-160G — Environmental Conditions and Test Procedures for Airborne Equipment
• MIL-STD-810H — Environmental Engineering Considerations for defense/aerospace components
• ECSS-E-ST-10-03C — European Cooperation for Space Standardization — testing branch
• NASA-STD-7002B — Payload Test Requirements
• ISO 15864 — Space systems — General test methods for spacecraft
• EASA CS-25 — Certification Specifications for Large Airplanes
• MIL-STD-1540E — Test Requirements for Launch, Upper-Stage and Space Vehicles

Authoritative Sources

• ECSS — European Cooperation for Space Standardization
• NASA Technical Standards
• ESA — European Space Agency
• EASA — European Union Aviation Safety Agency

Frequently Asked Questions About Aerospace Component Testing

What environmental tests are mandatory for aerospace components?

For civil avionics: RTCA DO-160G (sections 4-26) required for FAA/EASA certification. For military components: MIL-STD-810H (Methods 500-520 climatic, 521-525 rain/sand/dust). For space components: ECSS-E-ST-10-03C (thermal vacuum, vibration, pyro shock, outgassing). Each test level depends on the operating altitude, mission class, and component criticality.

What is the difference between ground qualification and flight qualification?

Ground qualification ( QM — Qualification Model) uses a flight-identical model for extreme destructive testing (+25% margin over specification). Flight qualification (FM — Flight Model) uses the actual flown model, subjected to reduced acceptance testing (specification +10%). For space missions, a Proto-Flight Model (PFM) is added, combining qualification and acceptance in a single piece of hardware.

Typical temperature ranges for avionics components?

DO-160G Standard: Category A1 (-55°C/+70°C) pressurized cabin, Category B1 (-55°C/+85°C) unpressurized bay, Category C1 (-55°C/+55°C) mild environment. For engine nacelle: up to +175°C in operation, +225°C soak. For space components LEO: -120°C/+120°C in thermal cycle; GEO: up to -180°C/+150°C.

Outgassing test: when is it mandatory?

Always mandatory for space components (ECSS-Q-ST-70-02C, ASTM E595). Limits: TML ≤ 1.0% (Total Mass Loss), CVCM ≤ 0.1% (Collected Volatile Condensable Materials). Non-compliant materials release molecules that contaminate optics, sensors, and vacuum solar panels. Not required for ground-based avionics but recommended for components in sealed or cryogenic compartments.