Strength Testing of New Cladding Material for Aero-Engines
This case analyzes a material strength test conducted in December 2022 for a research institute. The project focused on evaluating the compressive strength of a new composite material intended for aero-engine casings. Using a combination of strain gauges and displacement sensors, the test successfully measured the material's deformation under controlled pressure, providing critical data for material qualification. The case highlights the application of a compact, high-precision data acquisition system for reliable static structural testing.
1. Project Background & Overview
Client & Objective: A research institute needed to characterize the mechanical properties of a newly developed composite material. The primary objective was to understand the material's compressive strength and deformation behavior by applying specific pressure and measuring its response.
Application Context: The material is designed for use in aero-engine casings, where containing debris in case of engine failure is critical. Therefore, verifying its ability to withstand pressure is a key safety requirement.
Testing Method: The test involved applying incremental pressure to a material sample. The resulting strain (micro-deformation) and displacement (macro-deformation) were simultaneously measured to create a complete picture of its structural behavior.
2. Core Solution & Technical Highlights
The solution centered on a precise and electrically isolated measurement system to ensure data accuracy.
1. Targeted Sensor Configuration:
Strain Measurement (32 channels): 32 strain gauges were bonded at various points on the material sample. These gauges provided high-fidelity data on the local micro-deformations (strain) across the surface, revealing stress concentrations and overall material elasticity.
Displacement Measurement (4 channels): 4 displacement sensors (likely LVDTs or similar) were installed to measure the absolute deflection or compression of the material under load. This macro-level data complemented the localized strain measurements.
2. Integrated and Isolated Data Acquisition:
System Configuration: The acquisition system comprised a DE-916 and a DE-918 Isolated Dynamic Signal Test and Analysis System. This combination provided the necessary number of channels (exceeding 36) for all sensors.
Electrical Isolation: The use of isolated systems is crucial for preventing ground loops and electrical noise, which is essential for capturing the small-magnitude signals from strain gauges with high accuracy and stability.
Unified Software Platform: The Dynatronic basic platform software provided a unified interface for configuring all channels, real-time monitoring, and data recording, ensuring a streamlined workflow.
3. Analysis of Key Success Factors
High-Precision Measurement: The isolated acquisition systems guaranteed the integrity of low-level analog signals from the strain gauges, which was fundamental for obtaining reliable stress-strain curves.
Simplicity and Effectiveness: The solution was perfectly scaled to the task—neither overly complex nor insufficient. It effectively captured all necessary data points (strain and displacement) under a well-defined load (pressure).
Proven Reliability: The use of established DE-916/918 hardware and Dynatronic software demonstrated a low-risk, dependable approach that met the institute's requirement for trustworthy validation data.
4. Project Significance & Value
Value for the Client (Research Institute): The test provided definitive quantitative data on the new material's performance under compressive load. This data is essential for:
Material Qualification: Determining if the material meets design specifications for engine casing applications.
Design Improvement: Informing engineers how to optimize the material composition or casing design based on its observed mechanical behavior.
Supporting Certification: Generating evidence required for future airworthiness certification processes.
Value for Our Company: This project serves as an excellent example of our capability in advanced materials testing. It demonstrates the suitability of our systems for precise, benchtop-scale structural tests in R&D environments, a key market segment alongside large-scale testing.
5. Conclusion & Outlook
The successful completion of this materials test underscores the versatility of our data acquisition solutions, which are effective for both large-scale full-vehicle tests and focused component/material-level R&D.
Looking forward, this case suggests strategic opportunities:
Target the Materials Science Sector: Actively promote these proven solutions to universities, material science research institutes, and composite material manufacturers.
Develop Standard Material Test Packages: Bundle the DE-916/918 systems with appropriate sensors and pre-configured software settings for common material tests (tensile, compression, flexural), creating an off-the-shelf solution.
Highlight Benchtop Testing Capabilities: Use this case to showcase expertise in "small but critical" validation tests that are fundamental to aerospace innovation.
