Used to improve the safety and reliability of testing, Element’s spin testing services help solve the greatest challenges facing the aerospace industry today.

As technology continues to advance, new, lighter materials have to withstand higher loads and longer service life without impacting safety. In our spin testing facilities, we can examine nearly every kind of rotating components of aero engines, turbine compressors, turbochargers and blowers under realistic conditions using highly sophisticated spin test rigs. Our spin testing services ensure that aircraft components will continue to function safely and effectively throughout their service lives.

For aerospace components, spin testing is an integral part of safety testing programs. A burst failure (uncontained engine failure) can result in hazardous or even catastrophic effects on the aircraft and its passengers. We test components such as disks, blisks, shafts, seals, bearings, spools, and impellers, at speeds up to 200,000 rpm, with the ability to test large components in highly specialized conditions. 

Whether testing to RTCA DO-160, EUROCAE ED14, JAR, or to a custom project that requires unique set-ups, our aerospace qualification services and global network of high-capacity labs support you from start to finish with reliable results and on-time delivery.

For more information about our spin testing services, or to request a quote, contact an expert today.

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Dynamic Spin Testing

Analyzing the interaction of blades and disks at certain vibration conditions during rotation is important to understand their affect on service behavior, especially in HCF conditions at resonant frequencies.

To reproduce resonant conditions, Element uses special spin testing technologies to excite a bladed rotor using either air or oil jets. Highly sophisticated measurement and multichannel telemetry technologies enable determination of the damping parameters for individual blades during testing. 

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Low Cycle Fatigue (LCF) Spin Testing and Burst Testing

Providing the most realistic test environments considering operating conditions as specified by the customer is our key objective. 

We have an unparalleled range of spin testing facilities, monitoring systems and support technology in place to enable LCF conditions, so that we truly understand the components´ behavior throughout the testing process. Our experts have developed “Online” detection methods to identify crack initiation and growth during test operation, enabling us to shut down the facility in time to prevent the specimen from bursting. This controlled shutdown process enables Element to subsequently complete in-depth metallurgic and fracture mechanic investigations. 

For intended burst tests, our spin testing facilities can also be equipped with special equipment that can contain even the smallest fragments to enable further metallurgic examinations. Exceptional routines in cyclical spin tests and low cycle fatigue (LCF), as well as cyclic thermal spin tests, are established to determine the Wöhler curve of the component.

Key facts
  • Number of facilities: 3
  • Speed range: up to 65.000rpm
  • Test article temperature: - 40°C up to + 1000°C
  • Test chamber pressure: < 3="">
  • Test chamber dimensions: D 1600mm, L 1000mm
  • Test article max. weight: 2500 kg
 
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Partial Air Spin Testing

Spin tests are normally performed under vacuum for practical and safety related reasons. However, to achieve even more realistic results, a small portion of atmospheric oxygen is required for so called “partial air” conditions during cyclic spin testing at high temperatures, which leads to oxidation of the test body.

The inclusion of essential environmental influences delivers results which are closer to the reality, enabling clients to extend safe component cycle times and inspection intervals for maintenance, and allows for better service life prediction. Partial spin testing allows for a substantial increase of in-service time for engine components. 

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Small Spin Testing - High Speed Spin Testing/Turbo Charger Testing

Element uses small spin testing (or high-speed spin testing) to evaluate rotating components with higher RPM speeds in our Aerospace Rotating Components Center of Technical Excellence in Berlin.

Our small spin testing range typically covers small turbo charger wheels that will see high rotation speeds in the final operation. Our lab can also test scaled components where rotational speeds have been increased by simulation in order to maintain the stress level to the material as it will occur in the nominal component. Our scaled component spin testing contributes to lower manufacturing cost and significantly shorter prototype manufacturing lead times. 

For all spin testing services offered, full adaptation of specimens to the facilities, rotor dynamical analysis and balancing of the test assembly is included. On request special monitoring systems can be set up.

Key facts

  • Number of facilities: 3
  • Speed range: up to 200.000rpm (research for 300.000rpm ongoing)
  • Test article temperature: up to + 800°C
  • Test chamber pressure: < 3="">
  • Test chamber dimensions: D 400mm, L 500mm
  • Test article max. weight: 50 kg
 
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Rub Testing

Due to aerodynamic losses, minimized tip clearance is one of the key success factors of modern fuel efficient engines. A tight tip clearance involves the risk of rotor-vibration if the blade touches the abradable coating of the stator castings. We help mitigate this risk with rub testing services.

To evaluate the effects of rotor vibration on a components' service life, Element developed an outstanding horizontal spin rig which can reproduce and simulate these conditions accurately. Any vibrations and deteriorations that occur during testing can be monitored online through the use of state-of-the-art telemetry systems. Used especially for HPT shrouds made of CMCs, this interaction is an important research area where we can support you with our expertise and experience.

Key facts

  • 1 Horizontal test facility
  • Speed range: up to 24.000rpm
  • Test article temperature: up to + 700°C
  • Test chamber pressure: < 3="">
  • Test chamber dimensions: D 800mm, L 500mm
  • Test article max. weight: 200 kg
 
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Pre-Spin Testing

Tailored spin procedures for material improvement up to the yield range of the material can also be offered for the Power Generation and Oil & Gas sectors.

The main intention of pre-spin testing is to improve the material properties after raw machining, or to apply a controlled rotational pre-growth of a component before installation into the final assembly.

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State-of-the-Art Measurement Technology

Element's state-of-the-art measurement technology enables real-time monitoring of your testing, so you can have the highest level of confidence in your results.

Using telemetry and up-to-the-minute measuring equipment, we monitor spin testing around the clock to make sure that results are precise and accurate. Our test procedures incorporate a variety of measurement devices, including: 

  • Generation of 3D temperature gradients by special oven technologies
  • Contact-free measurement of temperature
  • Contact-free measurement of radial expansion on continuous and interrupted surfaces
  • Multi-channel telemetry systems
  • Permanent vibration monitoring
  • Crack detection and crack growth monitoring at rotating specimens
  • High speed cameras
 

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