Endurance testing
What is endurance testing and why is it important
Endurance testing is testing aimed at assessing the ability of a component, material, or product to maintain its performance over time, even when subjected to prolonged or cyclic stresses. The main objective is to identify wear phenomena, mechanical fatigue, functional degradation, or possible failures that could compromise the reliability of the product under real-world conditions of use. Unlike destructive testing, which brings the specimen to failure to analyze its endurance limits, endurance tests are conducted in a controlled manner directly on the component to monitor its behavior over the long term, simulating real-use conditions without immediately compromising its integrity. Performing these tests prior to market release is essential to ensure product quality and safety, reduce the risk of premature failure, and support research and development activities in designing more durable solutions and selecting the most reliable materials.
Types of endurance testing
There are different types of endurance tests, each aimed at evaluating specific aspects of component strength and durability.
A macro-distinction is between: cyclic tests, which simulate repeated use conditions over time by subjecting the specimen to mechanical, thermal or chemical stresses to check for fatigue; and constant-load tests, which involve the prolonged application of a force or pressure to analyze the material’s ability to maintain its performance without deformation or failure.
As part of endurance testing, pressurization and fluid dynamic tests can be performed, which measure the component’s resistance to high internal pressures and/or repeated pulses.
Standards and regulations for endurance testing
Endurance testing for product validation purposes, prior to entry into production, must be performed in accordance with specific international and industry standards, which establish test methodologies, acceptance criteria and safety requirements. Key reference standards include:
- Aerospace sector:
- MIL-STD-810 – Defines environmental testing for aerospace equipment and components.
- RTCA DO-160 – Regulates endurance testing for aircraft electronic equipment.
- Automotive sector:
- ISO 16750 – Specifies durability and strength tests for electrical and electronic components in road vehicles.
- SAE J1455 – Standard for durability testing in harsh operating environments.
- Oil & gas and piping industry:
- ASME BPVC Section VIII – Regulates the design and testing of pressure vessels.
- API 6A – Standards for qualification of wellhead valves and equipment.
- ISO 10423 – Standard for drilling and production equipment.
- Industrial and manufacturing sector:
- ISO 9001 – Defines general quality requirements, including testing and validation procedures.
- IEC 60068 – Standard for environmental resistance testing on electrical and electronic equipment.
- Biomedical sector:
- ISO 10993-5 – Specifies strength and biocompatibility tests for materials intended for medical devices.
- ASTM F1980 – Guidelines for accelerated aging simulation of medical devices.
Adherence to these standards is essential to ensure that endurance tests are performed according to internationally recognized parameters, ensuring quality, safety, and conformity of products before they are placed on the market.
In R&D or after-sales failure analysis, on the other hand, customized endurance tests designed on the specific need of the customer become necessary.
In this case there may not be a suitable reference standard.
TEC Eurolab can also support the customer in designing and conducting custom tests that allow specific functionality of the components or assemblies under test to be investigated, replicating the conditions and stresses they would encounter during operation.
This approach benefits the customer in several ways:
- Quickly detect abnormal behavior or to identify any defects or critical issues not found in the design phase.
- Improve the overall quality of the product
- Accelerating the design phase by collecting experimental data useful for fine-tuning computer calculations
- Identification of potentially critical stresses or operating conditions
- Etc.
How an endurance test works
1. Definition of test parameters
Test conditions, such as applied loads, stress cycles, durability and acceptance criteria, are established in accordance with industry standards and design requirements.
2. Design and development of the test system
3. Sample preparation.
4. Performance of the test
5. Monitoring and data collection
6. Analysis of results
7. Reporting and validation
The results are documented in a technical report that may include recommendations for improving the design or optimizing the product life cycle.
Test methods vary depending on the industry and the nature of the material: for example, a mechanical component may be subjected to repeated load cycles, while a polymeric material may be exposed to prolonged thermal changes. Similarly, test conditions for aerospace devices differ from those for biomedical or industrial products, depending on the stresses to which they will be subjected in operation.
Tools and methodologies
Performing an endurance test requires the use of specific equipment and methodologies capable of simulating the actual or accelerated operating conditions to which a component, material or system will be subjected during its life cycle. The choice of technology depends on the type of test, the area of application, and the characteristics of the product being tested.
Among the main equipment, required for an endurance test:
- Modular test benches – Used to design customized test solutions based on customer need, type of test to be performed and type of component
- Climatic and environmental chambers – Allow samples to be exposed to extreme temperatures, humidity, UV radiation or thermal cycling to simulate real operating conditions during durability testing.
- Pressure systems and fluid dynamics-Imployed for tests such as pressure cycling, hydrostatic testing, leak testing or burst testing, they verify the strength of components subjected to high internal pressures and/or repeated pulses.
- Fatigue testing machines-Tools that apply alternating loads to evaluate material resistance to fatigue and fracture phenomena.
- Electrical and Electronic Test Equipment – Analyze the durability and reliability of circuits, and electronic devices subjected to prolonged thermal, mechanical, or electrical stress.
To ensure reliable test results and accurate reports, advanced methodologies and technologies are used to perform endurance tests
- Sensor monitoring and predictive diagnostics-The use of temperature, strain, vibration, and pressure sensors enables real-time data collection, improving performance analysis.
- CAD design of the fixtures and test system using FEM simulations – To ensure the strength of the fixtures and a test design that accurately simulates the conditions of real use of the component
- Testing in controlled environments – In some cases, endurance tests are performed in simulated environments (temperature, humidity…) to evaluate the behavior of the product under real operating conditions.
Application areas of endurance testing
Endurance testing finds application in many industries, where component durability and reliability are critical to ensure safety, optimal performance and compliance with industry regulations.
Major areas of application include the Aerospace sector, where components must withstand extreme temperature and pressure conditions; vibration tests are performed on avionics components, pressure tests on fuel tanks and hydraulic circuits. Another extremely important area for endurance testing is Automotive. The automotive industry uses these tests to ensure the durability and safety of vehicles and components under extended use. In this application area, tests are performed, for example, on suspension and brakes, tanks, and cooling and air conditioning systems. In Oil & Gas, components must withstand high pressures, corrosive environments and intense mechanical stress. Fundamental are hydrostatic and pneumatic tests on pipes and valves and burst tests on pressure vessels.
Can your component withstand prolonged stress over time?
The endurance testing service in TEC Eurolab
Relying on TEC Eurolab to perform endurance testing means being able to count on a qualified technical partner capable of offering a complete and customized service. Thanks to our experience in test engineering, we support customers in the design and execution of customized test circuits, designed to accurately replicate the real operating conditions of the component or system and developed according to the customer’s technical and regulatory requirements. This approach allows us to obtain more representative data, reduce validation time, and optimize the product development process.
Our customized approach and the availability of tests in various areas, such as fluid-dynamic, pneumatic, hydraulic, thermal, and mechanical-dynamic, allow us to provide a complete view of the performance of the component under test.
Our goal is to offer comprehensive support, ranging from test design to analysis of results, to help companies ensure the compliance of their products, improving their quality and safety before they are released to the market.
Validation test on rotary switch located on the dashboard
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Functional validation of aircraft valve
The DUT is a 5-way aviation bypass valve. One section of the valve is completely dedicated to the passage of a fluid called “control” that laps its internal active material. A separate section, on the other hand, is dedicated to the passage of aeronautical lubricant.
Through a deformation of the materials inside the valve, made possible by the change in temperature of the control fluid, the DUT directs the lubricating fluid either to the main circuit or to an exchanger: if affected by high temperatures, it allows the lubricating fluid to flow to a heat exchanger to allow the correct operating temperatures to be restored.
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