HALT is a rigorous methodology designed to push aerospace products beyond their operational limits, identifying potential weaknesses and failure modes that traditional testing methods might miss. By subjecting aerospace products to extreme stress conditions—far beyond what they would encounter in their normal life span—HALT provides invaluable insights into the inherent durability and reliability of aerospace components.

The beauty of HALT lies in its ability to reveal the unknown. It accelerates the aging process, simulating years of wear and tear in a fraction of the time, thereby uncovering latent defects and vulnerabilities. This preemptive identification allows for critical design modifications and enhancements, significantly reducing the risk of costly failures and recalls post-launch.

For aerospace manufacturers, the implications of HALT are profound. It signifies a commitment to excellence and represents a strategic investment in the product’s lifecycle. By integrating HALT into the development process, aerospace companies can confidently navigate the complex landscape of product reliability, ensuring that their products are not just fit for purpose but are built to last.

Aerospace Testing Laboratory: Advancing Product Reliability with HALT

In the quest for unparalleled aerospace product reliability, our aerospace testing laboratory offers organizations the use of Highly Accelerated Life Testing (HALT) methodologies. HALT represents a commitment to excellence and a testament to our dedication to advancing aerospace technology.

The HALT process within our aerospace testing laboratory involves a series of accelerated stress tests, including rapid temperature cycling, 6 degrees of freedom random vibration tests at varying frequencies, and combined environment tests. These tests are designed to expose products to conditions far more severe than they would ever encounter in service. By doing so, Delserro Engineering Solutions can identify potential failure points and address them long before they become real-world issues.

Key Advantages of HALT in Our Aerospace Testing Laboratory:

• Early Detection of Design Flaws: By applying stressors that exceed the normal operational limits, HALT helps uncover hidden weaknesses in product designs.
• Cost-Efficiency: Identifying and rectifying potential failures before products hit the market significantly reduces the risk of costly recalls and brand damage.
• Reduced Time to Market: Accelerated testing means faster validation of product robustness, enabling quicker transitions from design to production.
• Customized Testing Strategies: Our aerospace testing laboratory tailors HALT protocols to match the specific requirements and challenges of each aerospace product.

Through the strategic application of HALT, our aerospace testing laboratory supports the industry’s continuous drive toward innovation and reliability. We help our clients achieve the highest standards of performance and dependability in their aerospace endeavors.

Embrace the future of aerospace product testing with us. Discover how our HALT methodologies can elevate your products’ reliability to new heights.

The Impact of HALT on Aerospace Testing and Product Integrity

Highly Accelerated Life Testing (HALT) has significantly influenced aerospace testing practices, leading to more resilient and reliable aerospace products. HALT extends beyond traditional testing methods by focusing on identifying potential failure modes early in the product development cycle.

The practical benefits of integrating HALT into aerospace testing include:

• Early Detection and Rectification of Flaws: By pushing components beyond their operational limits, HALT helps uncover hidden weaknesses in the design and materials, allowing for early modifications.
• Comprehensive Stress Testing: HALT subjects aerospace products to a variety of stressors, including extreme temperatures and vibrations, to ensure they can withstand a broad range of operational environments.
• Support for Innovation: The rigorous demands of HALT encourage the exploration of new materials, designs, and manufacturing techniques, driving innovation in aerospace technology.
• Risk Mitigation: Identifying potential issues before products reach the market minimizes the risk of costly recalls and enhances the overall safety of aerospace missions.
• Streamlined Product Development: HALT can reduce the time required for product testing and validation.
• Stakeholder Confidence: Demonstrating a commitment to thorough testing and product reliability helps build trust among manufacturers, regulatory agencies, and users.

HALT’s role in aerospace testing is to provide a practical, systematic approach to improving product reliability and integrity. It’s about making informed decisions based on comprehensive data. Through the application of HALT, the aerospace industry can achieve a balance between innovation and reliability.

Improve Your Aerospace Products with HALT

Adopting Highly Accelerated Life Testing (HALT) for your aerospace products is a strategic move toward securing a competitive edge in the aerospace industry. By incorporating HALT into your product development process, you’re committing to the highest standards of safety, durability, and performance.

Our aerospace testing laboratory is equipped with state-of-the-art HALT technology and a team of experienced engineers dedicated to helping you achieve excellence in product development. Our aerospace testing laboratory’s ISO/IEC 17025 and ISTA accreditation are a testament to our capability to execute tests that are both precise and reliable. We understand the unique challenges of the aerospace sector and are committed to providing tailored testing solutions that meet your specific needs.

In the dynamic field of aerospace, staying ahead means continually pushing the boundaries of what’s possible. Partner with Delserro Engineering Solutions to harness the power of HALT and take your aerospace products to new heights.

Contact us today to learn more about how we can support your journey toward unparalleled reliability and success in the aerospace industry.

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DES president Gary Delserro is featured in an article published in Assembly Magazine on July 9, 2021.  Titled “Accelerated Life Testing,” the article discusses different types of manufacturing life testing and quotes Gary with reference to highly accelerated life testing (HALT):

“Companies have reported savings in the millions after using HALT,” claims Delserro. “The test can accelerate a product’s aging process from actual months into test minutes, and it can help you discover weaknesses in your product during the design stage. Combined vibration, temperature and electrical stress variables, as well as internal fluid pressure, are typically used during HALT to induce failures and uncover fault points. By using combinations of loads, we can uncover design or manufacturing process flaws before they reach your customer.”

The entire article can be found on Assembly’s website. 

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A customer contacted DES, seeking to create a reliability test plan for their product based on customer usage, new features and design limits.  One of the concerns identified by the customer was the need for an accelerated life test which tested whether their “door assembly” product met the design specification for usage.  In other words, the goal was to create an automated test solution which opened and closed cabinet doors to the estimated amount they would see during a lifetime in the field.

Results

DES created a custom test set up, shown in the video above, which utilized control software, sensors and a motor to simulate the open and close motion seen in the field.  A goal was determined by the customer which represented the number of cycles the product was expected to see in the field.  The control software allowed DES to control and automate the movement, delays and speed of the motor.  In doing so, DES was able to condense the product lifespan into a week-long test.

The product withstood the grunt of testing with little to no observable damage.  The customer was very pleased with the results of the test and confident moving forward with the product design.  This was one of many rigorous customized reliability test solutions DES designed for this customer and product line.  DES has over 20 years of experience designing customized test solutions to fulfill your product and testing needs.  Contact us or call 610.253.6637 to find out what DES can do for you!

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Customer Goal

A customer approached DES looking to perform Highly Accelerated Life Testing (HALT) on a new circuit board design.  DES and the customer agreed to test the circuit boards using DES’s traditional HALT test procedure which calls for hot/cold temperature steps followed by rapid temperature ramping, vibration steps and combined temperature and vibration stresses.  HALT testing on electrical componentry is quite common across industry to expose design weaknesses; both mechanical and electrical (What is HALT and Why Perform HALT?).  Typical failures include poor solder connections, overheating, component failure, etc. (What Kind Of Failures Occur During HALT?)

Results

The hot/cold temperature steps exposed soft failures such as power resets and lack of communication for the circuit boards.  One hard failure was also exposed during this stage which proved to be a recurring problem and thus an area of weakness in the product design.  The units functioned properly during the vibration steps and rapid thermal ramping stages.  The combined temperature and vibration stage, however, revealed the same issue as seen in the first stage on two other units.

The circuit board featured potted componentry for purposes exclusive to the customer.  This potted feature cracked on multiple units throughout testing and caused all sorts of communication issues for the units.  In 3 days the customer was able to expose a product design weakness that would most likely have caused a number of warranty and reliability issues.  In the words of the customer:

“The results from this testing have identified strong and
more importantly weak areas in our design.”

– Customer

HALT testing is a necessity for products with electrical circuity in terms of preventing field failures and high product return rates.  Problems such as these can be really damaging to a company’s bottom line if not addressed early in the design process.  Fortunately this customer has had experience with HALT in the past and chose to perform HALT before finalizing the product design.  DES has over 20 years of experience performing HALT testing on a variety of medical, commercial, industrial and military products.  Schedule your next HALT test with us by contacting us or call us at 610.253.6637.

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• What is HALT Highly Accelerated Life Testing and why perform HALT?
• What is a typical HALT procedure?

A Rapid HALT is an abbreviated HALT, typically one day of tests, making it a great cost-effective solution for those seeking faster qualitative results.  Exposing a product to a Rapid HALT early in the design process can help reduce product development time and cost by enabling manufacturers to identify flaws or areas of improvement before it’s too late.

Rapid HALT’s are a good tool for assessing the reliability of different suppliers of components but can also be used to assess the reliability of less complicated products.  For example, DES has performed Rapid HALT’s to evaluate the reliability of different suppliers of power supplies, cooling fans, and LED’s.  DES has also performed a Rapid HALT to study different fastening methods in order to determine which was more robust.

Rapid HALT profiles may vary slightly depending on the product.  Figure 1 illustrates DES’s standard Rapid HALT profile.  Vibration levels are ramped up concurrently with hot and cold temperature cycles.  The stresses are increased until the practical limits of products have been reached.  Examples of practical limits include the melting temperature of solder joints or excessive softening of plastics.  These stress levels are obviously well beyond the scope of most product designs and that is ok.  The purposes of any HALT is time compression by applying higher-than-normal stress levels.  The user should not necessarily focus on what level of stress caused the problem, but should focus on improving the weak points in their product.

Many times our customers are surprised with the Rapid HALT results because the less expensive components perform better.  Thus our customers are able to apply a significant cost reduction to their products.  This results in increased profits and reduced warranty costs.

For more information on HALT or other testing services, contact DES or call 610.253.6637.

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A customer approached DES looking to find an accelerated test solution for an AC powered cooling fan used in one of their products.  The product had been established in the marketplace and the company was now looking for ways to reduce cost by looking at different cooling fan suppliers.  Most fans, however, have a mean life rated for over 20,000 hours, so a typical accelerated life test would require a significant amount of time and money. 

DES Solution

Performing a quantitative accelerated life test on cooling fans presents challenges because they have such a long lifespan.  Reasonably speaking, the shortest quantitative solution for determining the lifespan of a fan could take as long as a couple months.  DES proposed a qualitative solution, a Rapid HALT.  A Rapid HALT (Highly Accelerated Life Test) is designed to apply a variety of stresses, concurrently, to a product in order to significantly time compress a product’s lifespan.  A typical Rapid HALT lasts only one day which is extremely convenient for companies that need results quickly.

Results

A sample size of 3 cooling fans were tested for 4 different fan suppliers.  We will refer to these suppliers as Supplier A, B, C and D.  All 12 fans were placed in the chamber together and a Rapid HALT was conducted.  None of the four suppliers survived testing without some issues but the results were still differentiating.  Supplier A had no electrical issues in any of its samples but the fan blades on all 3 samples vibrated off the armature.  Fans of Supplier B, all experienced sputtering of the fan blade and eventually saw two of its fans current levels drop to 0.  By the time testing was completed, none of the fans were functioning.  Supplier C fared slightly better than A and B.  One of Supplier C’s fans lost current at the most extreme step and never recovered.  The other two however, experienced fan blade sputtering but were functioning normally upon final inspection.  Supplier D performed the best out of the four suppliers and thus would be considered the most durable of the suppliers tested.  Only one of the fans experienced any issues, in which it lost current at the most extreme step.  Upon final inspection all of the fans were functioning normally.

There are other factors to consider such as price and accessibility but these results were able to successfully assist our customer in differentiating between the reliability of the four fan suppliers.  While a HALT is qualitative and will not produce an actual estimated fan lifetime, it is a great comparison tool to evaluate the reliability of different suppliers faster and less expensive than traditional testing techniques.

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A leading medical technology company contracted DES to perform Product Reliability Testing of a carrying handle. A sample of the test can be seen below and in our video library. The carrying handle had to be pulled, released, rotated and subjected to a sizable lifting force, approximately 20,000 times during its life time. 

DES has considerable capability to complete product reliability testing. The main challenge for this project was that each cycle consisted of complex motion. The motion included pulling/releasing the handle to unlatch/latch a pin while rotating the handle. In order to achieve this, DES had to design fixtures and mechanisms that would reposition the carrying handle into each of the designated positions. The number of cycles was automatically counted until failure or 20,000 cycles were completed. During the test, the force to pull the handle was measured at various intervals. The Accelerated Life Testing was completed successfully demonstrating a high reliability.

Please visit our video library to see more examples of DES’s capabilities.

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DES has considerable capability to complete push pull reliability testing.  The main challenge for this project was that one third of the cycles had to be completed at -7 °C and one third had to be completed at +49 °C.  This was difficult because DES did not want to expose a precision actuator to extreme hot/cold temperatures because it could be damaged.  Therefore the case was placed inside of a large temperature chamber while the actuator was located outside of the chamber.  The chamber had to be large because the case was big and the handle extended 18 inches.  DES made a special link to connect between the case handle and actuator.  The link moved through a sealed chamber access port.  A frame was built around the case to hold it in place while the handle was pulled opened and pushed closed.

The push/pull cycling motion was performed using a special actuator.  The actuator travel, velocity and acceleration were programmed into a controller.  The number of cycles was automatically counted until failure or thousands of cycles were completed.  During the test, the force to open and close the handle was measured at various intervals.

The Accelerated Life Cycle Test was completed successfully providing highly useful results to the customer.  This was a unique challenge to perform push pull reliability testing at extreme hot and cold temperatures.  Please visit our video library to see more examples of DES’s capabilities.

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The Arrhenius Equation that relates reaction rates to temperature is:

The Acceleration Factor (AF) can be obtained by the ratio of the reaction rates at two different temperatures and is given by the following equation:

As an example, consider a product with a normal operating temperature of 50 °C. Testing the product at 100 °C will result in the following acceleration factor, assuming an activation energy of 0.7 eV:

Testing the product for 1,000 hours (≈ 6 weeks) at 100 °C is therefore equivalent to 29,000 hours or 3.3 years of life at the normal operating temperature of 50 °C. Increasing the test temperature will increase the acceleration. For example, if the same sample could be tested at 130 °C, the acceleration factor (AF) would increase to 146 so that the same 1,000 hours of testing would now be equivalent to 16.7 years of life at the normal use temperature. However, care must be taken such that the test temperature is not higher than what the product can withstand. Using too high of a test temperature may result in unrealistic failures that would not occur during normal product operating temperatures. It is therefore always important to evaluate failures obtained during accelerated temperature testing to determine if they are the same type of failure that would be expected to occur at normal operating temperatures.

Using the correct value for the activation energy is also important as a small change in the activation energy will have an effect on the acceleration factor. Activation energy values for various processes have been reported and can be found in the literature or the Internet. It is also possible to experimentally determine the activation energy by performing tests at multiple temperatures and plotting the results.

What sets Delserro Engineering Solutions, Inc. (DES) apart from other labs is our knowledge on how to relate test time to time in the field. So if you do not know what test conditions that you should use, what specification to choose, or how to correlate your test to field life, then we will help you because we are reliability testing experts!

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