Aerospace Qualification Testing - Senior Aerospace BWT

PRODUCT TESTING

FROM START
TO FINISH

AEROSPACE QUALIFICATION TESTING

BWT is in a unique position as a company. We design and manufacture all our tools and products, yet thanks to our Aerospace Qualification Testing capabilities, we also have the ability to test them to qualifying standards.

Our facilities exceed 10,000m2 in total size. BWT has two locations in Macclesfield, UK. One is dedicated to product manufacturing, the other for building test rigs (aircraft simulations) where our components or system of components go through a series of tests that examine and determine their functional performance. Once approved, our products are ready for shipment and use in an aircraft.

BWT has a vast physical infrastructure where our qualified engineers ensure that all our products receive the required qualification for flight.

We build an aircraft simulation in the form of a test rig and then start the testing procedures.

At BWT’s testing facilities, we make sure that when we put the full test on, everything – from the connection to the interfaces – works perfectly.

Test Rig Development for Aerospace Components

BWT’s team of engineers build the test rig primarily to carry out flow balancing, back pressure testing and balance testing.

The rig is of a size approximate to the actual aircraft for which the BWT components are being tested. To simulate the aircraft, BWT engineers use brackets that hold the components in place. Each bracket has specific coordinates, which also need to be of an approximate size to the actual aircraft.

The test rig helps to stabilise the ducting, balance the air that goes through it while ensuring that it goes through the right areas. At the same time, it helps examine how air circulation can differ from cabin to cockpit.

BWT’s engineers achieve this is by ensuring that all parts are absolutely secure, that no matter the conditions, all the low pressure ducting systems stay in place, remain balanced and airflow circulates smoothly.

Verification, Validation and Certification Processes

BWT offer a variety of testing programmes such as materials testing, flow testing, acoustics intensity and temperature tests, among others. These tests produce data, validation and information that is crucial to aircraft manufacturers. Moreover, our products are tested to RTCA DO-160 (DO-160) Environmental Conditions and Test Procedures for Airborne Equipment - a standard for the environmental testing.

The qualification stage refers to a system validation in regards to: temperature, vibration, humidity, environment, aging, and more. As an aircraft goes through thousands of cycles, BWT’s Qualification Testing engineers will test a part to tolerate as many cycles of use.

BWT is unique in the fact that it offers this level of testing to its customers. We are proud to say that we are one of a few companies that can design, manufacture and qualify all its products in-house.

Below are some of BWT’s testing facilities:

Temperature testing – Cold/Hot: In recent years, BWT made an investment in the purchase of a thermal test chamber giving us the ability to test high and low temperature, which allows us to test our products from -55⁰ C to +180⁰
Pressure cycling: To complete the testing cycle, we also place products in the pressure jig, which pressurises and depressurises a product for +80,000 hrs continuously.
Displacement testing: We perform displacement testing on bellows, a large component in the Environmental Control System (ECS) as it supplies all the air to the aircraft. Bellows take a lot of force, pressure and vibration and receive more displacement flux. In our facilities, BWT’s engineers test bellows individually. Testing starts at minimum stress and goes up to maximum stress, a process that’s repeated for +80,000 cycles.
And more: At BWT, every part goes through operating testing three cycles, to ensure clear outlets throughout the aircraft. Every process is monitored, measured and tracked and all products are qualified to ensure they are compliant with BSI standards and regulations.

We offer a lot more testing on our facilities, such as materials, humidity and fixture design for vibration testing, therefore, if you do not see it included on here, please contact us for more information.