Component-level testing in aviation

A safe aircraft is made up of millions of reliable components.

A flight can span thousands of kilometers, traversing diverse climates and operating continuously for hours. Throughout that journey, millions of mechanical, electrical, electronic, and composite components work together to ensure the aircraft operates smoothly.

Just one malfunctioning pressure sensor, a loose electrical connector, or a control board losing signal can affect the entire system. Therefore, in the aviation industry, testing each component before assembly is always considered a fundamental step in the product development process.

That is the goal of Component Level Testing.

What is Component Level Testing?

Component Level Testing is the process of evaluating individual components or sub-assemblies to confirm that they meet functional, durability, reliability, and performance requirements under real-world operating conditions.

In the V-Model product development model , this is the first level of testing before components are integrated into a system and then into the entire aircraft.

Detecting errors at the component level significantly reduces rework costs in later stages and minimizes the risk of errors occurring when systems are integrated.

Why is Component Level Testing particularly important in the aviation industry?

Aircraft operate in extremely demanding environments. Components must not only perform their functions correctly but also maintain performance over many years, under the influence of constantly changing temperatures, vibrations, pressures, and loads.

If a defect is only discovered after the system has been assembled or when the aircraft enters a higher level of testing, the cost of fixing it can increase many times over. Not only does this waste time on disassembly and re-testing, but the manufacturer also risks delays in certification or disruptions to production plans.

Component-level testing helps engineers verify that each detail meets requirements before moving on to the integration phase, thereby improving the quality and reliability of the entire product.

These components are typically tested.

Sensors and measuring devices

Modern aircraft use a multitude of sensors to monitor the operational status of engines, flight control systems, hydraulics, and fuel.

These components are tested for:

• Accuracy.
• The repeatability of the measurement.
• Stability over time.
• Ability to operate under varying temperature and pressure conditions.

Electronic circuit boards and electrical devices

Electronic control units (ECUs), power modules, and signal processing boards need to undergo various tests, such as:

• Functional testing.
• EMC testing.
• Try the vibrations.
• Thermal cycle.
• Aging is accelerating.
• Reliability testing.

Connectors and cables

Electrical connectors and wiring systems are crucial components that are often overlooked.

The tests typically include:

• Tensile strength.
• Plug/unplug cycle.
• Anti-vibration capability.
• Corrosion resistance.
• Contact resistance.
• Ability to work in high-temperature environments.

Mechanical equipment

Many mechanical components such as hinges, joints, bearings, drive mechanisms, or brackets are inspected for evaluation:

• Mechanical strength.
• Hardness.
• Fatigue.
• Load capacity.
• Abrasion resistance.

Aerospace materials

Besides components, materials also need to be carefully evaluated before being used in production.

Typical tests include:

• Tensile strength.
• Compressive strength.
• Flexural strength.
• Fire resistance.
• Corrosion resistance.
• Fatigue strength.

For composite materials, the tests also evaluate delamination ability and stability after multiple loading cycles.

Common tests in Component Level Testing

Depending on the type of component, the testing laboratory will select the appropriate testing methods.

Environmental testing

Components are placed in a test chamber to simulate conditions such as:

• High temperature.
• Low temperature.
• Thermal cycle.
• Humidity.
• Salt spray.
• Dust.
• Low pressure.

The objective is to assess the ability to operate stably in a real-world mining environment.

Vibration and mechanical shock testing

During takeoff, landing, and cruise flight, the components are constantly subjected to vibrations.

Vibrating tables and shock devices help simulate these conditions for testing:

• Vibration resistance.
• Structural durability.
• Risk of fracture.
• The connector is loose.

EMC testing

Electrical and electronic components must meet the following requirements:

• No electromagnetic interference is emitted beyond the limits.
• Unaffected by ambient noise sources.

This is a mandatory requirement for many modern aviation electronic devices.

Durability and lifespan testing

Many components are operated continuously for extended periods or subjected to millions of load cycles for evaluation:

• Lifespan.
• Fatigue resistance.
• Performance stability.
• Probability of failure.

Functional testing

After completing environmental and mechanical tests, the component is further tested to confirm that all functions still meet the design requirements.

Equipment commonly used in Component Level Testing

An aerospace component testing lab is typically equipped with a variety of specialized measurement and simulation systems, such as:

• Temperature and humidity test chamber.
• Heat shock chamber.
• Electrodynamic Shaker System.
• Mechanical shock testing device.
• Material tensile, compression, and fatigue testing machine.
• EMC measuring device.
• High-speed data acquisition system (DAQ).
• Force, acceleration, pressure, and temperature sensors.
• High-speed cameras are used for motion analysis.

The choice of equipment depends on the type of component, the applicable standards, and the testing objectives of each development program.

Commonly applied standards

Component testing in the aerospace industry often references numerous international standards, such as:

• RTCA DO-160 – Environmental conditions and test methods for aircraft equipment.
• MIL-STD-810 – Environmental testing.
• ASTM – Standards for Testing Materials.
• ISO 6892 – Tensile testing of metallic materials.
• ISO 17025 – Competence of testing and calibration laboratories.
• Specific requirements from the FAA , EASA , or aircraft manufacturer.

Component Level Testing – The first step towards a reliable system.

Every aircraft development program aims at the ultimate goal of ensuring safety and reliability throughout its operational lifecycle. To achieve this, quality must be built from the smallest components.

Component-Level Testing not only helps detect component weaknesses early but also lays the foundation for system integration and full aircraft testing. When each component is validated according to standards, subsequent stages in the V-Model will be more efficient, reducing risks and significantly saving product development time.

Effective implementation of Component Level Testing requires a well-equipped laboratory with appropriate procedures and adherence to international standards. This also forms the foundation for improving product quality from the very early stages of development.

GPower Vietnam provides testing solutions for the aerospace industry, ranging from environmental testing equipment, vibration testing, EMC testing, material testing machines, measurement and data acquisition systems to consulting on building customized testing laboratories. We partner with businesses, research institutes, and universities in developing testing capabilities according to international standards.