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    Spin Testing Capabilities: Test Devices Rigs

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    xmlbiox
    Test Devices provides spin testing services and equipment to manufacturers in demanding industries like aerospace and aviation. They operate highly accurate test rigs to evaluate critical components under realistic operating conditions. Services include overspeed testing to failure, low cycle fatigue testing to determine safe life, and dynamic response testing using jet excitation or aerodynamic pulses to evaluate resonance response at high temperatures. In-situ measurements of radial growth, strains, and high-speed video capture provide valuable data to validate designs and failure modes.

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    Spin Testing Capabilities: Test Devices Rigs

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    xmlbiox
    38 views4 pages
    Test Devices provides spin testing services and equipment to manufacturers in demanding industries like aerospace and aviation. They operate highly accurate test rigs to evaluate critical components under realistic operating conditions. Services include overspeed testing to failure, low cycle fatigue testing to determine safe life, and dynamic response testing using jet excitation or aerodynamic pulses to evaluate resonance response at high temperatures. In-situ measurements of radial growth, strains, and high-speed video capture provide valuable data to validate designs and failure modes.

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    TestDevices_Services

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    TestDevices_Services

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    Test Devices provides spin testing services and equipment to manufacturers in demanding industries like aerospace and aviation. They operate highly accurate test rigs to evaluate critical components under realistic operating conditions. Services include overspeed testing to failure, low cycle fatigue testing to determine safe life, and dynamic response testing using jet excitation or aerodynamic pulses to evaluate resonance response at high temperatures. In-situ measurements of radial growth, strains, and high-speed video capture provide valuable data to validate designs and failure modes.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    38 views4 pages

    Spin Testing Capabilities: Test Devices Rigs

    Uploaded by

    xmlbiox
    Test Devices provides spin testing services and equipment to manufacturers in demanding industries like aerospace and aviation. They operate highly accurate test rigs to evaluate critical components under realistic operating conditions. Services include overspeed testing to failure, low cycle fatigue testing to determine safe life, and dynamic response testing using jet excitation or aerodynamic pulses to evaluate resonance response at high temperatures. In-situ measurements of radial growth, strains, and high-speed video capture provide valuable data to validate designs and failure modes.

    Copyright:

    © All Rights Reserved
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    Download as pdf or txt
    of 4

    Test Devices Services

    When the world’s most advanced manufacturers


    of rotating equipment need the world’s most
    Spin Testing Capabilities
    accurate spin testing systems and services
    to evaluate the critical components they’re Test Devices Rigs
    designing and fabricating, they turn to Test Spin Test Machines
    Devices. • 54” (1372 mm) diameter x 48” (1219 mm) axial depth
    Test Devices provides rotational and other testing • 42” (1067 mm) diameter x 36” (914 mm) axial depth
    services and equipment to demanding markets • 36” (914 mm) diameter x 36” (914 mm) axial depth
    with exacting applications and requirements. • 24” (610 mm) diameter x 24” (610 mm) axial depth
    For aerospace, aviation and power generation • 20” (508 mm) diameter x 20” (508 mm) axial depth
    clients, Test Devices offers rotational testing Drive Options
    services and equipment that most closely • Air Turbines & Electric Motors
    represent operational engine environments. Test • Speed accuracy:
    Devices has developed the world’s most precise, +/- .01% maximum speed for overspeed testing
    accurate and efficient test equipment because +/- 1 rpm for dynamic spin testing (HCF)
    we operate a contract test laboratory serving
    these demanding industries. For over 40 years
    Test Devices has developed and advanced the R&D Testing Offerings
    science of centrifugal, vibratory and thermal Overspeed & Burst Testing
    stress testing – critical solutions engineers need Overspeed centrifugal stress testing to the point of burst offers
    to evaluate the integrity and validate the life of manufacturers valuable information about the ultimate strength of a
    component parts. We support our customers part or material. Rigorous strain surveys and temperature control can
    as they research and develop the safest, most provide critical data right up to the point of failure that helps improve the
    reliable, best-performing products in the world. predictability of life and the modes of failure.

    • Rotor burst tests (bladed & un-bladed)


    • Blade liberation tests
    • FAA certification tests
    • Customized validation testing
    • High-speed video recording
    • Containment effectiveness testing
    • High “G” field testing of electrical components
    • Cryogenic tests of rocket motor fuel pumps

    Low Cycle Fatigue (LCF) Testing


    Establishing the fatigue life of a rotating component is critical to determining
    safe working life criteria. Test Devices offers LCF spin testing services with
    rapid cycling capability to accelerate fatigue testing programs, providing
    Figure 1 – Overspeed & Burst Testing customers with life-assessment data earlier. Optional crack detection can
    monitor component integrity in real time, enabling a test to be stopped prior
    to catastrophic failure.
    Spin Testing Capabilities cont.
    • Lifing for new platforms or life-extension In-Situ (Real Time) Radial Growth
    • 24 hour unattended operation
    • Component testing & material evaluation (mini-disk) Test Devices often measures elastic and plastic growth of a
    • Heated capability (isothermal & gradient) component using stationary probes. Most programs call for
    • Monitoring with patented crack detection to prevent rotor radial growth profiles as a function of speed, but axial growth
    failure can be logged as well.

    Blade Excitation (Dynamic Response) • Eddy current and optical (laser) probes used
    Under certain conditions of operation, blades vibrate in • Growth probes installed for measurement during spin testing
    response to pulsing flow from upstream stages. When the • Bore & rim most measured for validation of stress models
    vibration matches the natural frequency of the component, • Growth characteristics are measured in “real time” and can
    the blades can resonate and fracture from High Cycle Fatigue be recorded up until a burst event
    (HCF). Repair of integrally bladed rotors (IBR’s and Blisks) • Measurements can be performed at representative engine
    often results in changes to the tuning of these components. temperatures using laser probes
    HCF testing offers a means of validating the repair as well as
    retuning the component for further service. Strain Survey Testing
    Test Devices has two different methods for exciting resonant Also an In-Situ instrumentation technique, information
    frequencies of blades during rotation (Dynamic Spin Testing): gathered in Test Devices’ comprehensive strain surveys can
    be used to gain detailed understanding of local stresses and to
    • Liquid Jet Excitation
    validate stress models used for design under realistic loading
    • Aerodynamic Pulse Generation (APG)
    conditions.
    These methods are used to excite blades under different
    •S train gauges are attached at specific points on rotating assembly
    conditions, evaluating their resonance response in a rotational
    • Slip rings are used to transfer the signals with multiple
    frame. A benefit of APG is that it can be performed in high
    channels
    temperature environments.
    • Advanced data acquisition systems
    Heated Dynamic Response Testing • Actual measurements used to validate computer models
    Test Devices can employ its unique APG technique to perform • Highly cost effective – typically costing substantially less than
    HCF tests in elevated temperature conditions. This allows a a complete FEA
    more realistic way for OEMs to evaluate the durability and
    behavior of the rotating airfoils. The APG method: High-Speed Video Testing
    • Uses the pumping action of the blades in partial atmosphere Test Devices can provide a high-speed video recording of the
    • Can be employed with additional external heating to allow failure event in a burst test. These videos can provide visual
    testing in an elevated temperature condition data that is critically important to designers in determining
    • Provides a method for evaluating new high-temperature what failed first in the rotating assembly. Often, during the first
    blade designs and coatings in complex engine-like conditions slow motion playback of the burst event, customers are able to
    • Evaluates damper effectiveness determine if the rim or bore section of the test rotor triggered
    • Characterizes the dynamic response of the assembled the burst event. Test Devices’ high-speed video testing provides:
    hardware and coatings
    • Cutting-edge high-speed video technology to provide
    exceptional image clarity
    • System captures and saves the trigger event as well as the
    visual history leading to the event
    • Support for the failure analysis process that follows a burst test
    • Ability for metallurgical engineers to quickly hone in on
    the critical pieces of the burst fragments to direct their
    examination

    Figure 2 – Heated Testing Figure 3 – In-Situ (Real Time) Radial Growth

    2 | Test Devices Inc.


    Unique Testing Techniques
    Test Devices provides some of the most advanced testing services available in the world. Measurement of elastic/plastic growth,
    strain survey testing, high temperature (thermal gradient, extreme temperature and thermal mechanical fatigue testing), and HCF
    spin testing exemplify our highly sophisticated techniques. Following are several of our most important unique approaches.

    Blade Excitation and Response


    Excitation of blade resonant vibrations in fully assembled jet
    engine stages during rotational testing at operational speeds
    and/or temperatures.

    • Excite and control the vibrations of rotating blades at desired


    modes
    • Measure, capture and store blade strain test data
    • Provide graphic display of vibration for individual blades
    • Validate Campbell diagrams
    • Assess the impact of strain amplitudes on the HCF life of the
    component Figure 4 – Blade Excitation and Response

    • Measure amplification factor (Q) at different modes

    Thermal Mechanical Fatigue (TMF) Testing


    TMF testing, which synchronizes the temperature gradient
    with engine speed in real time. Compared to constant gradient
    testing, TMF creates a more realistic test environment by
    simulating operating conditions to a much higher degree.

    • Prototyped on DOD flight hardware


    • High-response heating elements
    • Active cooling
    • Thermal gradient
    • Program objective to demonstrate control

    Aerodynamic Pulse Generation (APG)


    The APG test method utilizes special hardware in a partial
    Figure 5 – Thermal Mechanical Fatigue (TMF) Testing
    atmosphere test chamber to excite the rotating blades. The
    method is used to excite blades at different conditions,
    evaluating their resonance response in a rotational frame. One
    unique benefit of APG is that it can be performed in high-
    temperature environments.

    • Partial atmospheric test


    • Local Aero Impulse from static hardware
    • Controlled rig pressure
    • High engine order (54+)
    • Aerodynamic heating; additional heating possible (1250F+) Figure 6 – Aerodynamic Pulse Generation (APG)
    • Blade response depends on multiple factors:
    • Drive power
    • Blade set/drag
    • Heat limitations

    Test Devices Services | 3


    Specialty Equipment to Address Customer Challenges
    Test Devices provides turnkey solutions for specialty testing needs including non-rotational. We leverage our unparalleled systems
    engineering capabilities to provide testing solutions that our customers need and cannot obtain anywhere else.

    Test Devices’ test equipment is ready to meet your most difficult


    testing challenges. We provide:
    • Safest & most robust equipment in the industry
    • Air turbine and electric drive systems
    • Systems incorporate numerous innovations derived from Test
    Devices’ testing experience
    • Continual upgrades assure you get the best results
    - We adjust to evolving testing needs
    - Continually incorporating new technology

    Test Devices can address customers’ targeted applications, with:


    • Industrial equipment design
    • System integration
    Figure 7 – Bird-Strike
    • Design for extreme thermal conditions
    • Damping and stability
    • Containment and safety
    • Controls and user interface
    • Structural analysis FEA
    • Rotational drive systems
    • High-speed bearing assemblies
    • Vacuum systems
    • Pressure vessels
    • Precision components
    • Tooling & fixtures
    • Air flow delivery & control (e.g. heat exchangers)
    • Blade erosion
    • Aeromechanical
    Figure 8 – Tip Rub Testing

    Figure 9 – High Temperature Thin Wall Test Rig Figure 10 – Test Chamber

    571 Main Street | Hudson MA, 01749-3035


    Tel: 978-562-6017 | Fax: 978-562-7939 | www.testdevices.com

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