How Aerospace Parts Are Tested Without Breaking Them

Author: dr.ir. Alex Van den Bossche

Overview

The aerospace industry requires rigorous testing to ensure safety and reliability, but traditional destructive testing destroys expensive, precision-engineered components—creating a fundamental conflict. Non-destructive testing (NDT) techniques preserve parts while gathering critical performance data.

The Challenge

A single failure can lead to catastrophic consequences in aerospace applications. Every component must meet exacting standards, yet destroying parts for testing is economically prohibitive and statistically limited.

The Solution: Resonance Frequency Analysis

Resonance frequency analysis is one of the leading techniques in this field, providing precise measurements using vibration and sound rather than forceful stress.

The Impulse Excitation Technique uses controlled vibrations to determine mechanical characteristics including:

Young’s modulus: Stiffness under tension/compression
Shear modulus: Resistance to shear deformation
Internal damping: Energy dissipation revealing material condition

These measurements reveal material properties without visible wear or damage.

Key Advantages for Manufacturers

Benefit	Description
Extended lifespan	Parts can be tested repeatedly throughout service life
Cost reduction	Eliminates need for destructive replacement parts
Real-time QC	Enables production adjustments during manufacturing
Compliance	Meets strict aerospace safety standards

Testing Throughout the Lifecycle

Parts undergo testing at three critical stages:

Initial production: Verify manufacturing quality
In-service monitoring: Track material condition over time
Post-maintenance verification: Confirm repair effectiveness

Data is tracked throughout the component’s operational life, building a comprehensive history.

Real-World Application

Jet engine turbine blades can be monitored for material fatigue indicators without removal from service, enabling proactive maintenance and reducing unexpected downtime.

The ability to detect imperfections before they become critical makes NDT invaluable for aviation safety.