How Do Extreme Shock Environments Impact Aerospace Components?

Have you ever wondered how aerospace components are designed to survive the extreme forces they face during space missions? Whether it’s enduring the immense pressure of a rocket launch or withstanding the violent jolt of stage separation, aerospace components are regularly subjected to some of the harshest conditions imaginable.

In the aerospace industry, failure is not an option. A single malfunction in a critical component can spell disaster for an entire mission, leading to enormous financial losses or even endangering lives. This is why aerospace engineers must take into account the extreme shock environments their components will face and ensure they are built to withstand these intense forces.

At Delserro Engineering Solutions (DES), we specialize in protecting aerospace components from the destructive impact of these shock environments. With over 30 years of experience in advanced shock and vibration testing, our team knows exactly what it takes to ensure that aerospace components thrive in the most challenging conditions.

Reach out to us today to learn more about how we can help ensure your aerospace components perform reliably, even in the most extreme shock environments.

Understanding Extreme Shock Environments in Aerospace

Extreme shock environments are one of the most challenging aspects that aerospace components must endure. These environments expose components to sudden, high-intensity forces that can cause immediate or long-term damage. Without thorough preparation and testing, critical aerospace systems may fail.

Aerospace shock events can occur during multiple phases of a mission, including:

Rocket launches: During liftoff, components face immense G-forces as the rocket accelerates. These forces can test the limits of structural integrity and function.
Stage separations: When a rocket’s stages disengage mid-flight, the explosive force of separation can create a sudden shock wave that impacts all connected components.
Ballistic impacts: Collisions in space, whether intentional or due to debris, generate shock waves that can damage mechanical and electronic parts.
Reentry forces: As spacecraft reenter the Earth’s atmosphere, rapid deceleration and high-intensity vibrations place extreme strain on their components.

Each of these events creates stress in the form of acceleration (measured in G-forces) and vibration frequencies. Although these forces last for mere milliseconds, they can lead to significant wear or immediate failure.

Why Shock Environments Matter

For aerospace engineers, these extreme shock environments present a critical challenge. Without the proper design and testing, components are vulnerable to:

Systemic failures: Sensitive electronics or mechanical parts may malfunction due to shock stress.
Structural damage: High G-forces can result in material fatigue, cracks, or deformation, threatening the overall integrity of the spacecraft.
Shortened lifespan: Continuous exposure to extreme shocks, without sufficient testing or design improvements, can reduce the functional lifespan of vital aerospace components.

Contact Delserro Engineering Solutions today to learn more about how we can help you understand and mitigate the effects of extreme shock environments on your aerospace components.

How DES Provides Comprehensive Shock Testing Solutions for Aerospace Components

At Delserro Engineering Solutions (DES), we specialize in delivering comprehensive shock testing solutions designed to meet the demanding needs of aerospace components. Our services are built on a foundation of precision, experience, and industry-recognized standards. This ensures that your components are ready to endure the harshest conditions they might face in real-world environments.

Here’s what sets our shock testing services apart:

Comprehensive Testing Capabilities: We conduct both mechanical shock and pyroshock testing to simulate real-world conditions, including rocket launches, missile stage separations, and more. Our tests cover a wide range of shock environments, from high G-force impact to rapid acceleration and deceleration events.
Accredited Facilities: DES operates an ISO/IEC 17025 accredited lab, certified by A2LA. This ensures that our testing methods and processes are not only rigorous but also compliant with internationally recognized standards, including MIL-STD-810G/H, RTCA DO-160, and ISO 19683.
Customized Test Plans: We develop tailored testing plans that are specific to your product’s design and intended operational environment. Our team takes the time to understand the unique demands of each project, creating solutions that are as unique as your aerospace component.
State-of-the-Art Equipment: Our advanced testing facilities are equipped with the latest in data acquisition and shock simulation technology, enabling us to offer high-precision testing for both large-scale aerospace assemblies and intricate microelectronic components.
Experienced Team: Our team has worked with industry leaders like Boeing, Lockheed Martin, and NASA, we bring a wealth of expertise to every project. Our testing experts ensure that every aspect of the testing process is handled with precision and care, from setup to final reporting.
Detailed Reporting and Analysis: After testing, we provide thorough reports that not only document compliance with the necessary standards but also offer actionable insights into areas of improvement for your products. This empowers you to make design adjustments that can enhance product longevity and performance.

Contact Delserro Engineering Solutions today to learn more about how our shock testing services can help safeguard the success of your aerospace project.

Trust DES for Your Aerospace Component Testing Needs

At Delserro Engineering Solutions (DES), we understand that every aerospace project presents its own set of unique challenges. That’s why we go beyond standard testing by customizing our approach to fit your specific component needs and mission requirements. Our team works closely with you to ensure that no detail is overlooked, from initial testing strategies to actionable insights that help improve your designs.

Get in touch with us today to discuss how our expert testing solutions can protect your aerospace components and enhance your project’s success.

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IEC 60068 Vibration Testing

IEC 60068 Explained: A Deep Dive into Vibration Testing Standards

What is IEC 60068 Vibration Testing?

IEC 60068-2 is a subset of the broader IEC 60068 series, which sets out international test standards for various environmental tests on products, equipment, and components. Included within the IEC 60068-2 series are the vibration test standards:

IEC 60068-2-6 Environmental testing Part 2-6: Test Fc: Vibration (sinusoidal)
IEC 60068-2-64 Environmental testing Part 2-64: Test Fh: Vibration, Broadband Random, and Guidance

DES has extensive experience performing many vibration tests to IEC 60068-2-6 and IEC 60068-2-64. We are A2LA accredited to those standards.

Why perform IEC 60068 Vibration Testing?

All products will likely experience some vibration during their lifetime from shipping and transportation. Thus, some level of vibration testing is valuable.
For items being sold outside of the USA, the results from vibration testing to IEC 60068-2-6 and IEC 60068-2-64 are accepted worldwide.
IEC 60068-2-6 and IEC 60068-2-64 can be used to evaluate the reliability and performance of products that will be exposed to vibration environments.
They are useful to assess the durability and performance of connectors exposed to harsh conditions such as military, automotive, and space environments. During the vibration, the connectors are monitored for intermittent electrical contact with specialized equipment provided by DES.
Manufacturers can validate the structural integrity of items and identify possible degradation under different vibration conditions.
Automotive and aerospace suppliers can evaluate the reliability, durability, and performance of their components that are subjected to intense vibration during their lifetime.
IEC 60068-2-6 and IEC 60068-2-64 can be used to investigate structural dynamic characteristics for items used in spacecraft programs.
Testing to these standards can simulate the stresses that occur during the life of a product giving confidence in its performance and longevity.
Products can be developed to function and withstand vibration exposures encountered during their life cycle.
Companies can evaluate the durability and performance of components, equipment, and articles during transportation and service vibration.

IEC 60068-2-6: Sinusoidal Vibration Test Standard

IEC 60068-2-6 is a test standard for Sinusoidal Vibration Testing. It defines a procedure for testing specimens to sinusoidal vibrations over a specified frequency range for a given duration. It is applicable (but not limited) to products or components that are subjected to harmonic vibrations such as rotating, pulsating, or oscillating forces that occur in ships, aircraft, land vehicles, rotorcraft, machinery, space applications, and seismic events.

Much of the IEC 60068-2-6 specification deals with controlling the test parameters. Other parts cover various test severities such as the vibration amplitude, frequency ranges, and durations. It is up to the user to choose which test severities are applicable to their products. Annex A in IEC 60068-2-6 gives some guidance on testing. Annexes B and C provide examples of severities based on different applications. The user must also specify whether the specimen shall be functional during the vibration test or whether it can be functionally tested before and after.

IEC 60068-2-6 endurance testing can be accomplished either by endurance by sweeping or endurance at fixed frequencies. Endurance by sweeping is performed by continuously sweeping or varying the sinusoidal vibrations from the lowest to the highest to the lowest frequencies for a chosen number of sweep cycles. Endurance at fixed frequencies is completed by subjecting the specimens to a sine dwell at the product resonances for a fixed duration and vibration amplitude.

Contact DES today to discuss your IEC 60068-2-6 vibration testing requirements with one of our experts.

The Random Vibration Test: An In-depth Look at IEC 60068-2-64

IEC 60068-2-64 is a procedure for Random Vibration Testing of components, products and equipment. Random vibration occurs in transportation environments, vehicles, aircraft, aerospace, military environments, etc. Random vibration tests can also be useful for evaluating the general robustness and durability of products and components. IEC 60068-2-64 defines requirements for subjecting specimens to broadband random vibration tests over a specified frequency range for a given duration. It is primarily intended for specimens that are unpackaged, however, a packaged product can be tested using transportation vibrations.

The first part of IEC 60068-2-64 covers controlling the test parameters. Subsequent parts of IEC 60068-2-64 list various test severities such as the Grms value of acceleration, the frequency range, and the duration of testing. Similar to IEC 60068-2-6, the user chooses what test severities to apply to their products and if the specimen shall be functional during the vibration test or whether it should be functionally tested before and after. Annex A in IEC 60068-2-64 provides examples of severities based on different applications. Annexes B and C provide information and guidance.

An optional low-level vibration response investigation (sometimes called a resonance scan or modal survey) can be performed before and after the random vibration in each axis. The vibration response investigation can be either a sinusoidal vibration sweep or random vibration applied for a short duration. In either case, the vibrations should be low level to avoid damaging the test specimen but high enough to excite resonances.

Completing the Vibration Test

Once all the severities are chosen in either IEC 60068-2-6 or IEC 60068-2-64, the testing is performed along three perpendicular axes, one at a time. Upon completion of the vibration test, DES will promptly deliver a detailed test report that includes the customer’s name and address, the test dates, a summary of the test procedure, chosen severities, equipment & measuring system calibration information, operational test data, test observations & results, color pictures of the vibration test setup and color pictures of any failures.

Secure your product’s market success with DES’s comprehensive random vibration testing services. Contact us now and let’s get started.

DES Your Go-To for IEC 60068 Compliant Vibration Testing

Choosing the right partner for your vibration testing needs is crucial. At Delserro Engineering Solutions, we offer a comprehensive suite of services designed to ensure your products meet the stringent IEC 60068 standards. Here’s why DES should be your first choice:

Customized Solutions: We design and fabricate your vibration test fixtures tailored to your specific needs.
Precision and Care: Our test setup process is meticulous, incorporating control and response accelerometer placement, correct bolt torque application, and organized cable routing.
Quality Assurance: As an accredited laboratory, we adhere to IEC 60068-2-6 and IEC 60068-2-64 test standards, ensuring quality and compliance.
Advanced Facilities: With our state-of-the-art testing facilities and equipment, we are equipped to handle a wide range of vibration test requirements.
Extensive Experience: Our team has a broad range of experience in vibration testing, including products used in outer space, rockets, missiles, automotive and truck environments, military environments, and medical environments.

Contact DES today to discuss your vibration testing requirements with one of our experts.

If you want to learn more about different types of vibration testing, please read these related blog articles:

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ISTA Series 1 Package Testing Standards

ISTA 1 tests are Non-Simulation Integrity Performance Tests meant to evaluate the strength and robustness of the product and package combination. Each of the ISTA 1 test procedures (1A, 1B, 1C, 1D, 1E, 1G, and 1H) include a combination of tests to assess the ability of packaging to withstand different transportation hazards. These tests help manufacturers and distributors identify weaknesses in their packaging and product designs, and ultimately make improvements to ensure products arrive at their destinations in good condition. All ISTA 1 tests share the common goal of minimizing potential shipping issues and product damage during transportation.

What are the benefits of ISTA Series 1 Package Tests? They can:

Evaluate the durability of individually packaged products
Compare the performance of various package and product design alternatives
Test that your products will arrive unharmed at their destination
Provide a cost-effective screening test to evaluate potential shipping issues or product damage
Shorten package development time and gain confidence before launching products

The ISTA 1 tests are divided into the following procedures:

ISTA 1A, Integrity Testing for Packaged-Products weighing 150 lb. (68 kg) or Less
ISTA 1B, Integrity Testing Packaged-Products weighing Over 150 lb. (68 kg)
ISTA 1C, Extended Integrity Testing for Individual Packaged-Products weighing 150 lb. (68 kg) or Less
ISTA 1D, Extended Integrity Testing for Individual Packaged-Products weighing Over 150 lb. (68 kg)
ISTA 1E, Integrity Testing for Unitized Loads
ISTA 1G, Packaged-Products weighing 150 lb. (68 kg) or Less utilizing Random Vibration
ISTA 1H, Integrity Testing for Packaged-Products weighing Over 150 lb. (68 kg) utilizing Random Vibration

ISTA 1A to ISTA 1E: Packaging Up to 150 Pounds and above (1B, 1D, 1E)

ISTA 1A Package Testing

ISTA 1A is a package test procedure for individually packaged products weighing up to 150 pounds. The table below provides the test sequence required for ISTA 1A. ISTA 1A is the same as ISTA 1G except for the vibration. ISTA 1A uses fixed displacement vibration while ISTA 1G specifies random vibration.

Sequence	Test Category	Test Type	For ISTA Certification
1	Atmospheric Preconditioning	Laboratory ambient temperature and humidity	Required
2	Vibration	Fixed Displacement	Required
3	Shock (alternative methods allowed-select one test type)	Package Drop Test or Inclined Impact or Horizontal Impact	Required

ISTA 1B Package Testing

ISTA 1B is a protocol for individually packaged products weighing more than 150 pounds. ISTA 1B is the same as ISTA 1H except that ISTA 1B specifies fixed displacement vibration whereas 1H uses random vibration. The table below provides the test sequence required for ISTA 1B.

Sequence	Test Category	Test Type	For ISTA Certification
1	Atmospheric Preconditioning	Laboratory ambient temperature and humidity	Required
2	Vibration	Fixed Displacement	Required
3	Shock (alternative methods allowed-select one test type)	Package Drop Test (6 in) or Inclined Impact (69 in/sec) or Horizontal Impact (69 in/sec)	Required
4	Shock	Rotational Edge Drop (8 in)	Required when not testing face 1

ISTA 1C Package Testing

ISTA 1C is an extended package test procedure designed for individually packaged products weighing 150 pounds or less. ISTA 1C adds compression testing vs. 1A or 1G and gives alternative choices for vibration. The test sequence is listed below.

Sequence	Test Category	Test Type	For ISTA Certification
1	Atmospheric Preconditioning	Laboratory ambient temperature and humidity	Required
2	Compression Testing (alternative methods allowed-select one test type)	Compression Tester, apply and release Compression Tester, apply and hold Weight and Load Spreader	Required
3	Vibration (alternative methods allowed-select one test type)	Fixed Displacement or Random Vibration	Required
4	Shock (alternative methods allowed-select one test type)	Package Drop Test or Inclined Impact or Horizontal Impact	Required

ISTA 1D Package Testing

ISTA 1D is an extended test protocol for individually packaged products weighing more than 150 pounds. ISTA 1D is the same as 1B or 1H with the addition of compression testing and alternative choices for vibration. The test sequence is shown below.

Sequence	Test Category	Test Type	For ISTA Certification
1	Atmospheric Preconditioning	Laboratory ambient temperature and humidity	Required
2	Compression Testing (alternative methods allowed-select one test type)	Compression Tester, apply and release Compression Tester, apply and hold Weight and Load Spreader	Required
3	Vibration (alternative methods allowed-select one test type)	Fixed Displacement or Random Vibration	Required
4	Shock (alternative methods allowed-select one test type)	Package Drop Test (6 in) or Inclined Impact (69 in/sec) or Horizontal Impact (69 in/sec)	Required
5	Shock	Rotational Edge Drop (8 in)	Required when not testing face 1

ISTA 1E Package Testing

ISTA 1E is for testing unitized (palletized) loads made up of either single or multiple products or packages of the same products. The test sequence is shown below.

Sequence	Test Category	Test Type	For ISTA Certification
1	Atmospheric Preconditioning	Laboratory ambient temperature and humidity	Required
2	Vibration (alternative methods allowed-select one test type)	Fixed Displacement or Random Vibration	Required
3	Shock (alternative methods allowed-select one test type)	Inclined Impact (69 in/sec) or Horizontal Impact (69 in/sec)	Required
4	Shock	Rotational Edge Drop (8 in)	Required

Vibration and Shock Testing for Packages Up to 150 lb (ISTA 1G) & above (ISTA 1H)

ISTA 1G Package Testing

ISTA 1G is a package test procedure applicable to individually packaged products weighing 150 pounds or less. Like ISTA 1A, it evaluates the strength and robustness of the product and package combination without simulating actual environmental conditions. The primary difference between ISTA 1A and ISTA 1G is the vibration testing, with ISTA 1A using fixed displacement vibration and ISTA 1G specifying random vibration.

Sequence	Test Category	Test Type	For ISTA Certification
1	Atmospheric Preconditioning	Laboratory ambient temperature and humidity	Required
2	Vibration	Random Vibration	Required
3	Shock (alternative methods allowed-select one test type)	Package Drop Test or Inclined Impact or Horizontal Impact	Required

ISTA 1H Package Testing

ISTA 1H is a protocol for individually packaged products weighing more than 150 pounds. ISTA 1H is the same as ISTA 1B with the exception that ISTA 1H specifies random vibration. The test sequence is listed below.

Sequence	Test Category	Test Type	For ISTA Certification
1	Atmospheric Preconditioning	Laboratory ambient temperature and humidity	Required
2	Vibration	Random Vibration	Required
3	Shock (alternative methods allowed-select one test type)	Package Drop Test (6 in) or Inclined Impact (69 in/sec) or Horizontal Impact (69 in/sec)	Required
4	Shock	Rotational Edge Drop (8 in)	Required when not testing face 1

ISTA 1 Series: Comprehensive Testing for Optimal Product Shipping and Delivery

ISTA package testing standards play a pivotal role in ensuring that products arrive in optimal condition at their destinations. These tests help manufacturers and distributors evaluate the durability and performance of their packaging and compare different packaging and product design alternatives. To ensure their products meet these standards, companies can rely on professional package testing services from accredited laboratories, delivering a safe and satisfying experience.

DES provides package testing services to the medical device, electronic, automotive, and aerospace industries within their environmentally controlled, accredited laboratory. Please contact an expert if you have any questions.

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Shock Testing: Long Duration Half Sine Shock

Shock testing with long durations can be a challenging endeavor. DES recently had to perform a 35G peak, half sine shock with a 50 millisecond duration. The video below shows this shock test being performed.

This sounds like an easy shock to carry out because a peak of 35G is low compared to many shocks. However, this is a difficult shock to perform because 50 milliseconds is a long duration. Most typical shock durations are less than 20 milliseconds.

A half sine shock impulse has the shape of a half sine wave. More details can be found elsewhere on our blog, in an article titled “Classical Shock Testing“.

Continue reading Shock Testing: Long Duration Half Sine Shock →

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Temperature Cycling Testing: Coffin-Manson Equation

Temperature cycling testing is another method of accelerated life testing for products that are exposed to temperature variations during use in normal operation. The temperature variations can be a result of self heating for products that are repeatedly turned on and off, or can be the result of cyclic environmental changes — such as temperature variations from day to night — or other causes.

These repeated temperature changes can result in thermal fatigue and lead to eventual failure after many thermal cycles. Accelerated life testing can be performed by cycling the product to high and low temperatures that exceed its normal use temperatures.

It should be noted that temperature cycling may also be referred to as thermal cycling or thermal shock testing. However, some test standards, such as MIL-STD-883, make the distinction between temperature cycling being performed as air to air testing and thermal shock being performed with the samples transferred between liquids. This article deals with testing performed using an air to air thermal cycle chamber.

Typical temperature cycling equipment consists of at least one hot chamber and one cold chamber. The test samples are automatically transferred between the two chambers by an elevator-type mechanism. It is also possible to perform temperature cycling in a single compartment chamber where the temperature is ramped between hot and cold. This generally produces a slower rate of temperature change compared to the two chamber method.

Continue reading Temperature Cycling Testing: Coffin-Manson Equation →

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What is Pyroshock Testing?

First we should answer, what is a pyroshock or a pyrotechnic shock? Both pyroshocks and pyrotechnic shocks are the same thing. A pyroshock occurs when explosive events are used to separate the stages of rockets or missiles, or from a ballistic impact to a structure by a projectile. When a pyroshock occurs, a stress or shock wave propagates through the structure and into the electronic equipment contained within the structure.

Pyroshocks are unique shocks that have high G-level, high frequency content with very little velocity and displacement change during the shock. The frequency range of a pyroshock is usually 100 Hz to 10,000 Hz or greater. Pyroshocks have a very short duration of usually less than 20 milliseconds. The acceleration time history of a pyroshock approximates a combination of decaying sinusoids as shown in Figure 1.

Continue reading What is Pyroshock Testing? →

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How a HALT Test Shows The Future

Circuit Board HALT — HALT of Circuit Boards

Highly Accelerated Life Testing Procedures

Speeding up the process of device or circuit failure requires extreme inputs, those that are unlikely to occur during real-world use by customers regardless of the environment. Three common testing inputs are high and low temperatures, rapid cycling of the same and vibration along six-axes. In some cases, a highly accelerated life test (HALT) will incorporate combined temperature and vibration stresses. These inputs can result in component failure in the span of days, hours, or even minutes compared to months or years of typical usage.

Benefits of HALT Testing

While the percentages of failure based on the stress applied to a product can vary significantly, highly accelerated life testing can typically expose weaknesses faster than other means of testing. For example, of the above inputs, roughly two-thirds of failures will only come after the introduction of vibration alone or combined vibration and temperature tests. This means that during the product development process, a significant number of potential flaws would not be identified through testing that did not include these two stresses.

Continue reading How a HALT Test Shows The Future →

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Random Vibration Testing

Random Vibration Testing is one of the more common types of vibration testing services performed by vibration test labs. A primer containing a technical explanation on random vibration testing can be found in our blog article Sinusoidal and Random Vibration Testing Primer.

Real world vibrations are usually of the random type. Vibrations from automobiles, aircraft, rockets are all random. A random vibration test can be correlated to a service life if the field vibrations are known. Since random vibration contains all frequencies simultaneously, all product resonances will be excited together which could be worse than exciting them individually as in sine testing. Sometimes random vibrations are mixed with sine vibrations in Sine-on-Random Vibration Testing. Also, a low level of broad band random vibration can be mixed with additional high levels of narrow band random vibrations in Random-on-Random Vibration Testing.

Some common test standards that have specifications for Random Vibration Testing are:

Continue reading Random Vibration Testing →

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Sinusoidal and Random Vibration Testing Primer

The most common types of vibration testing services conducted by vibration test labs are Sinusoidal and Random. This primer is an explanation of the typical requirements found in vibration test specifications and the parameters used to control the vibration tests. Both types of vibration tests are used to evaluate products for ruggedness, durability and to expose vibration defects.

See Sinusoidal Vibration Basics to learn more about vibration fundamentals.

See Sinusoidal Vibration Testing to learn more about the different types of sinusoidal vibration testing.

Examples of vibration test videos can be found on our YouTube page.

Continue reading Sinusoidal and Random Vibration Testing Primer →

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An Informational Guide to HALT and HASS

Product reliability is essential to success in today’s competitive global market. HALT and HASS are intensive methods used to expose and then improve design and process weaknesses. HALT and HASS are faster, less expensive and more accurate than traditional testing techniques. HALT and HASS are proven processes used to lower product development and manufacturing costs, compress time to market, reduce warranty costs, improve customer satisfaction, gain market share and increase profits. Some companies have reported savings in the millions after using HALT and HASS.

HALT and HASS can accelerate a product’s aging process from actual months into test minutes much faster than traditional testing!

Continue reading An Informational Guide to HALT and HASS →

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