MIL-A-8867C, MILITARY SPECIFICATION: AIRCRAFT
STRENGTH AND RIGIDITY GROUND TESTS (23 MAR 1987).,
This specification contains the requirements which, in
combination with other applicable specifications, define the
ground tests required for structural evaluation of fixed wing
piloted airplanes.
Types of Ground Tests
1. Structural Testing: This includes load tests to evaluate the
aircraft's ability to withstand extreme stresses, such as
turbulence and hard landings. Engineers simulate flight
loads to assess the structural integrity of the aircraft.
2. System Testing: Critical systems such as electrical,
hydraulic, and fuel systems are tested to ensure they
operate efficiently under various conditions. This phase
verifies the functionality of avionics, navigation, and
communication systems.
3. Ground Vibration Testing (GVT): GVT is performed to
obtain experimental vibration data for the aircraft structure.
This data helps validate and improve structural dynamic
models, which are crucial for predicting flutter behavior and
ensuring safety during flight tests.
4. Acoustic Testing: This involves assessing the noise levels
produced by the aircraft and its impact on the environment
and passenger comfort. It includes measuring airborne and
structure-borne acoustic transmission paths.
Process of Ground Testing
The ground testing process is complex and involves several steps:
Preparation: Specialized facilities are set up, and the
aircraft is transported to these locations.
Connection: Aircraft systems are connected to test
equipment through extensive wiring.
Execution: Tests are conducted according to established
protocols, with specialized personnel overseeing the
process.
Analysis: Results are analyzed to ensure compliance with
safety and performance standards.
Innovations in Ground Testing
Recent advancements, such as portable testing devices like the
MMIBS, have revolutionized ground testing by allowing tests to be
conducted in various locations without the need for extensive
facilities. This innovation reduces costs and accelerates the
testing process, making it more efficient.
In summary, aircraft ground testing is a vital component of the
aviation industry, ensuring that aircraft are safe and ready for
flight through rigorous evaluation of their structures and systems.
Ground Testing 101
Ground testing is the barrage of tests that aircraft must undergo before first flight. It’s mandatory
for any new aircraft design or for an aircraft that has undergone significant structural modification.
All new commercial aircraft undergo testing on the ground before first flight. It’s often a years-
long process that’s part of earning an airworthiness certificate from the Federal Aviation
Administration (FAA) or other international regulatory body. In the case of Overture, for example,
the Boom team is already working with the FAA to develop the certification program for the
supersonic airliner. (Click here to learn more about the Overture program.)
That airworthiness certificate? It’s essential to operate an aircraft. You can’t leave the ground
without it.
Swing. Run. Test.
Ground testing includes flight loads simulation, material static and fatigue, structural dynamics,
modal analysis, airborne and structure borne acoustics, and much more. Some common tests
involve:
“swinging” the landing gear on the ground (to simulate use in the air)
testing all systems for electromagnetic interference with each other
running the engines to ensure adequate performance
testing the functionality of all systems in a manner that reproduces flight
Commercial versus demonstrator
The requirements for commercial certification — as opposed to demonstrator aircraft —
are very different. Commercial aircraft programs are designed to meet the requirements
of a regulatory agency, such as the FAA. Those requirements are very extensive, given
that airlines will fly the aircraft for decades. (Click here for more about certification and
safety.)
In the case of demonstrator aircraft — flown under very strict conditions and usually
without civilian passengers — the requirements must convince the designers and the
FAA that the aircraft will function as intended.
Taking aircraft to the breaking point — or not
Structural testing requirements are a good illustration of the differences between
commercial and demonstrator aircraft.
In both cases (commercial and demonstrator), engineers will “load” the aircraft structure
to some level beyond what it’s expected to see in flight. Structural loads include
aerodynamic forces, inertia, ground reactions and thrust. It’s the measure of the stress
that the aircraft structure will experience.
For commercial aircraft, the applied load will exceed what the aircraft will experience
during flight. In a typical commercial certification program, there are multiple test aircraft,
each dedicated to a different type of testing. Very often, one of these aircraft will be
“sacrificed” to endure load structural testing to the breaking point. Manufacturers load the
aircraft to its breaking point, or even until it breaks.
When it comes to a one-of-its-kind demonstrator, breaking the aircraft is obviously not
feasible. It’s also not necessary. The demonstrator is not intended to carry passengers.
Rather, it carries test pilots and flies under very controlled conditions. In the case of a
demonstrator like Boom’s XB-1, the applied load is some level above the normal
expected flight loads.
Going from isolation to assembly
For a demonstrator aircraft such as XB-1, engineers often begin by testing all new aircraft
systems in isolation before completing full assembly and systems integration. For example, they
may test the flight control system while it’s powered by an external hydraulic mule before
installing it into the aircraft.
After completing the full assembly, engineers test all systems on the aircraft. In the case
of XB-1, this involves powering up the three engines (two of which operate the aircraft’s
flight and utility hydraulic systems) to power the flight controls (which are powered by an
external source during earlier tests).
Additional ground tests include examining backup modes of operation. For flight controls,
this includes both hydraulic systems as well as a backup DC electrical pump that can
power the hydraulic system. Another example would be running the engines on both the
primary and secondary fuel pumps to ensure that they can continue operating in all
conditions.
When all of the subsystems come together in a completed aircraft, it’s critical to analyze
interactions between these systems to identify undesirable performance. Engineers watch for
any electromagnetic interference issues between aircraft systems, and will sometimes address
problems with better shielding, grounding, or even relocating wires on the aircraft.
After systems, engineers move into even more physical tests. One of the more interesting tests is
ground vibration testing or GVT. It’s a unique test during which the aircraft is isolated (either by
hanging or putting it on large airbags). It’s then “excited” by placing different electromechanical
sensors on the aircraft, or by sweeping the control surfaces at different rates. This excites
different modes of vibration in the aircraft, and allows designers to confirm that it matches their
analysis. The test also gathers important data that informs flutter testing, which is accomplished
later during flight test.
Shifting from Ground to Taxi Testing
Following ground tests, new aircraft are ready for the runway. In the case of XB-1, Boom will
conduct all of the initial ground testing at Centennial airport, outside Denver, Colorado. Boom is
located near the airport, and we have a hangar on the airfield. It’s an ideal location because we
have our manufacturing team nearby in case support is needed.
Commercial or demonstrator: safety comes first
Regardless of whether an aircraft is commercial or demonstrator, engineers prioritize safety
above all else. Each ground and flight test is unique, and custom-built to match the purpose of
the aircraft.
For any aircraft design, risks can be more closely controlled on the ground versus in the air.
That’s why engineers and test pilots conduct as many tests as possible before flight. It’s always
better to uncover an issue during ground tests than while airborne.
By the time that any aircraft takes flight, engineers are confident that the extensive series of tests
will result in a safe and successful first flight.
