Imagine an airplane flying thousands of feet above the earth. It will undoubtedly face several varying conditions there. What if a critical system fails at that moment? The airplane will definitely crash and cause serious life hazards. That’s where the RTCA DO-160 testing standard comes into the scene. This testing standard ensures the safety of airplanes in all types of environmental conditions.
Without RTCA DO-160, an airplane can face severe failure and serious safety hazards. So, whether it is a military or commercial airplane, it must undergo the RTCA DO-160 testing series. But how does this testing standard work? How to perform those tests? Let’s find the answers to all your queries in this detailed guide.
Overview of RTCA DO-160 Testing Standard
RTCA DO-160 is a testing standard that includes a set of several tests. Those tests check the reliability and durability of different airplane components. The Radio Technical Commission for Aeronautics( RTCA) published this standard in 1975. RTCA is a USA-based organization that sets safety standards for aviation. Initially, this standard includes a few tests.
However, with time, several changes and tests were added using advanced technology. Now, RTCA DO-160G is the latest version, updated in 2010. This version provides more precise guidelines for testing procedures and equipment. To perform RTCA DO-160 tests, manufacturers expose different components to real-world conditions.
For example, an airplane flies at high altitude. So, its components are kept in the chamber where low-pressure conditions are applied. If that component withstands low-pressure conditions, it is reliable. After its success, manufacturers apply for approval from aviation authorities (FAA, EASA, etc.). These authorities provide certificates, and then you can legally install those components.
If a component deteriorates, it is declared unsafe and sent for remanufacturing. The aviation industry cannot legally install a component that does not comply with this standard. Remember, each test is specific to a specific component. It depends on the component’s function and where it needs to be installed.
Main Categories of DO-160 Testing
RTCA DO-160 isn’t just a single test—it’s a battlefield for aviation components. It includes many tests. Only the durable part survives in those harsh testing conditions. So, let’s dive in and explore the main categories of DO-160 testing.
1- Temperature and Altitude Tests
As you know, airplanes fly over different regions. Sometimes, they pass through hot deserts. However, sometimes, they face ice-cold conditions in polar areas. At higher altitudes, pressure becomes low, affecting several airplane components. Thus, all these conditions are pre-checked through temperature and altitude tests. But how is this test performed?
For temperature tests, a specialized chamber called a thermal chamber is used. This chamber contains low—and high-temperature conditions. The airplane components, such as batteries and power systems, are placed under this chamber. Operators first apply an above-70 °C temperature. Under this condition, they analyze the expansion or deterioration of batteries.
After that, the components are shifted to -55°C temperature. Here, they check contraction and brittleness. If batteries successfully pass this test, they are placed in a vacuum chamber. This chamber creates a low pressure like high altitudes. This test checks the pressure-sensitive failures, expansions, and stability. If no failure occurs, it is reported as reliable.
2- Humidity Testing
An airplane’s metal parts, connectors, seals, and gaskets are most prone to corrosion. Moisture and humidity cause corrosion, which weakens structural integrity. So, humidity testing inspects the corrosion resistance of those components. During this test, equipment is placed in an environmental chamber containing 95% humidity.
The component is left for several hours to a few days. With time, operators change the temperature from low to high and vice versa. This process condenses the moisture which accumulates on the surface. The condensed moisture can cause short circuits and malfunction. After a definite time, they check cracks, rust, and corrosion effects.
3- Shock and Vibration Testing
Airplanes often face sudden shocks and vibrations during take-off and landing. This test ensures that different gearing components and engines withstand those shocks. So what do they do in this test? A machine known as a vibration test table is available that produces high-frequency vibrations. These vibrations continuously shake the parts for a definite time.
Vibrations check whether fasteners and screws remain intact or become loose. After applying vibrations, operators apply sudden high-force impacts. These impacts ensure the hardness and scratch resistance. The process continues sometimes, and they examine breaking, scratches, and bends. Along with engines, hundreds of other small parts also undergo vibration testing.
4- Sand and Dust Testing
Sand particles seem like tiny factors, but they highly affect airplane parts. These particles damage moving parts, electronic systems, and cooling channels. So, this test analyzes the adequate performance of those parts. Sand and dust testing is performed in three steps. First, a sealed test chamber is used, which blows fine dust particles at low speed.
It checks whether those particles enter cooling channels. After that, coarser or rougher sand particles are blown at high speed. These particles check the abrasion resistance of components. Lastly, operators leave the testing part exposed to sand for a few hours. They check the accumulation of sand particles and the performance of the components.
5- Waterproofness
Waterproofness is essential for several critical parts of airplanes. Those parts include screens, avionics, and electrical components. A small water droplet can result in serious hazards like short circuits. So, electronic parts are sprayed with water splashes from different angles. After that, the large mechanical parts are placed in the submersion tanks for a long time.
Lastly, jets spray large quantities of water with high pressure, similar to rain storms. As a last step, they increase the humidity level and lower the temperature. Rain droplets condense, which is common, and deteriorate and corrode several metal parts. Engineers observe the waterproofness and malfunction of each component through all these methods.
6- Fluids Susceptibility
Airplanes are often susceptible to hydraulic, de-icing, and cleaning agents. So, this test checks the leakage of fuel tanks and chemical damage to plastic parts. But how to perform this test? First, place those components in fluid immersion tanks for several hours. These tanks contain aircraft-related fluids.
After that, inspect whether plastic parts change shape or remain the same. In the second step, several chemicals are sprayed on avionics and electrical connectors. The temperature changes from low to high and vice versa. This temperature variation causes a chemical reaction that affects plastic parts. Finally, physical damage and breakdown is checked.
7- Electromagnetic Interference (EMI) and Radio Frequency Interference (RFI)
This is the most critical test to ensure flight safety. EMI and RFI interference refers to a disturbance in the normal functioning of electronic parts of an airplane. Often, electromagnetic and radio waves come from lightning and ground radars. These waves collapse with the GSP system and disturb the signals. Hence, it can affect the communication between pilots and cause misunderstandings.
This test ensures that all those components work efficiently. Engineers place the electrical and communication components in EMC Test Chambers for this test. This chamber produces different frequencies of electromagnetic and radio waves. The components are exposed to these waves for some hours. After that, they examine changes in GPS, radars, and radio.
8- Power Input Testing
All the electronic components in an airplane work on a stable power voltage. However, during take-off, voltage fluctuations occur due to engine startup. Thus, the power input test ensures that all those parts remain unaffected. For this test, Transient Generators generate different voltage fluctuations. First, voltage suddenly drops and then increases above the normal value.
Operators ensure that electronic parts do not lose connection during this sudden fluctuation. If the electronic system passes this test, it undergoes a power interruption test. During this test, the power supply is stopped for a short time. It checks how long the critical system, such as the cockpit display, remains functional.
9- Lightning and Surge Testing
As you know, airplanes fly at high altitudes. Most likely, they are attacked by lightning. This lightning can affect the electronic, communication, and safety systems. Therefore, this test ensures the durability of those components in varying weather conditions. You can perform this test in two ways. First is the indirect lightning test.
This test applies high-voltage pulses to electrical circuits for a few minutes. After that, observe whether this system remains unaffected. The second method is the direct lightning test. During this test, place the components in high-voltage test chambers. This chamber generates an artificial lighting effect. Examine the damage and failure.
10- Icing and Freezing Rain
Snow accumulates on the surface when an airplane flies over a polar region. This ice can block sensors, add weight, and reduce lift. Moreover, it can also freeze moving parts and engines. Thus, this test is carried out to check the performance of the anti-freezing system. But how do engineers perform this test? Basically, they use icing wind tunnels.
These tunnels produce artificial snow that mimics freezing rain. So, first place, the engine, sensors, and wings in this tunnel for a few hours. After that, examine the ice buildup and moisture. Make sure that the sensor and electrical system work effectively. Moreover, it also ensures that ice does not block the engine.
Frequently Asked Questions
What is a DO-160 fungus test?
Rubber and plastic components are more prone to mold and fungi attacks. Thus, DO-160 fungus testing ensures that those parts can withstand fungi. For this purpose, engineers place the components in a chamber containing fungi spores. After some time, the effect of the fungi and the functionality of the part are noticed.
What happens if a component fails a test?
If a component fails the test, it is sent for remanufacturing with a detailed summary that describes the issue. Manufacturers then review the design and make changes for more durability.
How long does RTCA DO-160 testing take?
The duration of RTCA DO-160 testing depends on the nature of the different tests. Some tests give quick results, and some take hours to days. So, overall, a complete series of RTCA DO-160 takes a few weeks to a month.
Conclusion
The RTCA DO-160 testing standard is critical to ensuring the safety of airplanes. This standard ensures that all the airplane’s parts are safe to install. It includes several testing categories. In this article, I have discussed those testing series. For example, the shock test checks the vibration endurance of some components.
Moisture and humidity tests examine the corrosion resistance of metal parts. Together, these ten testing categories ensure the safety of every part of an aircraft. An airplane can cause serious problems and life hazards if not tested. So, in the aerospace industry, manufacturers must follow the RTCA DO-160 testing standard.