Life Cycle & Environmental Testing
Contact DTB for the protection and reliability that only product lifecycle testing can provide.
A complete range of environmental factors can be simulated for reliable test results:
Altitude Testing – Combined Environments – Explosive Atmosphere – Explosive Decompression
Fluid Compatibility – Fungus Test – Salt, Fog & Ice – Sand & Dust – Solar Radiation
Temperature – Thermal Vacuum – Wind, Rain and Humidity
Environmental Simulation & Product Life Testing Services
Product success is measured by a predictable performance. Accelerated testing, cycling, aging, exposure, environmental factors, every type of wear and tear, use and abuse can be quantified, measured and analyzed.
- Collected intelligence can prove and improve your product and documenting its performance.
- Design analysis coupled with performance testing in dynamic environments can be a significant predictor of product success.
- DTB’s life cycle testing services can project product life before failure, and uncover opportunities to enhance design and focus improvement efforts only on product vulnerabilities.
Accelerated Testing — Product Life Cycle
DTB has the facilities, expertise and experience to conduct accelerated life cycle testing on a wide variety of products. Accelerated life cycle testing is conducted using aggressive test condition profiles and potential rates of change. Variating conditions include a wide range of vibration levels, temperature, humidity, structural load, altitude, electrical loading and engine loading.
DTB can work with your engineers to develop custom load profiles. Examples of products tested at DTB in this manner include plumbing fixtures, diesel engines, aircraft arresting gear, and electrical components. Field measurements of the actual product environment were used to develop aggressive test parameters that quickly exercised the product, in a realistic manner.
Depending on the type of product and test, DTB facilities can handle large test items and high test levels. From 400,000 lb proof loads to the vacuum of space our facilities can handle extreme test requirements.
MIL-STD-810 is a United States Military Standard that emphasizes tailoring an equipment’s environmental design and test limits to the conditions that it will experience throughout its service life.
MIL-STD-810 test series are approved for use by all United States Department of Defense (DoD) departments and agencies. Although prepared specifically for military applications, the standard is often used for commercial products.
Dayton T. Brown can combine tests and environments to your requirements:
MIL-STD-810 G Method 500.5 Low Pressure Testing (Altitude Testing)
MIL-STD-810 G Method 501.5 High Temperature Testing
MIL-STD-810 G Method 502.5 Low Temperature Testing
MIL-STD-810 G Method 503.5 Temperature Shock
MIL-STD-810 G Method 504.1 Contamination by Fluids
MIL-STD-810 G Method 505.5 Solar Radiation (Sun / UV)
MIL-STD-810 G Method 506.5 Rain Testing
MIL-STD-810 G Method 507.5 Humidity
MIL-STD-810 G Method 508.6 Fungus
MIL-STD-810 G Method 509.5 Salt Fog Testing
MIL-STD-810 G Method 510.5 Sand and Dust Testing
MIL-STD-810 G Method 511.5 Explosive Atmosphere
MIL-STD-810 G Method 512.5 Immersion
MIL-STD-810 G Method 513.6 Acceleration
MIL-STD-810 G Method 514.6 Vibration
MIL-STD-810 G Method 515.6 Acoustic Noise
MIL-STD-810 G Method 516.6 Shock
MIL-STD-810 G Method 517.1 Pyroshock
MIL-STD-810 G Method 518.1 Acidic Atmosphere
MIL-STD-810 G Method 519.6 Gunfire Shock
MIL-STD-810 G Method 520.3 Temp, Humidity, Vibration and Altitude
MIL-STD-810 G Method 521.3 Icing, Freezing Rain Testing
MIL-STD-810 G Method 522.1 Ballistic Shock
MIL-STD-810 G Method 523.3 Vibro-Acoustic/Temperature
MIL-STD-810 G Method 524 Freeze/Thaw
MIL-STD-810 G Method 525 Time Waveform Replication
MIL-STD-810 G Method 526 Rail Impact
MIL-STD-810 G Method 527 Multi-Exciter
Click the following topics for more information —
Life Cycle Testing with Environmental Exposure
AT DTB, environmental exposure testing has been conducted on many types of products, both commercial and military. Even for large systems DTB can develop appropriate regimes of realistically challenging environments to add to life cycle tests.
Salt fog, SO2 (acid rain) exposure, dust, sand or ground metallic dust are all examples of contaminants that we have used to provide aggressive environments for testing.
On large components this testing can be broken out by testing smaller coupons with the results applied to the larger system through the use of “knockdown factors”. This can reduce testing time and expense by allowing large components to be tested under laboratory conditions while maintaining confidence of system performance, overall, under specific adverse environments.
Life Cycle Testing Sample Applications
SEAT BELT CERTIFICATION TESTING
Dayton T. Brown, Inc. performs certification testing on automotive safety restraint systems to Federal Motor Vehicle Safety Standard No. 209, Federal Motor Vehicle Safety Standard No. 213 and Canadian Motor Vehicle Safety Standard No. 209 specifications. These include Seat Belt Retractor, Seat Belt Assembly and Webbing Testing. Retractor testing includes Retraction Force, Acceleration Performance and Life Cycle tests. Assembly testing comprises of Pelvic Loop Load and Elongation, Torso Loop Load and Elongation and Buckle Strength Tests. The Webbing testing involves Strength, Elongation, Abrasion and Ultraviolet Light Exposure.
Electrical components that DTB conducts many types of accelerated life tests on each year include environmental stress screening tests on electrical circuit boards, aircraft radio receivers and other electrical equipment. DTB can provide a wide variety of power sources, high current levels, large wattage load banks and cooling supplies to operate items under test. A typical environmental stress screening test is shown here —>
DTB has a long history of service to the plumbing industry. We are one of only a handful of Independent Test Labs certified to the CSA (Canadian Standards Association) for plumbing fixtures and components as well as the IAPMO in the US for multiple tests. We have dedicated facilities that provide automated life cycle testing under real world conditions. When reliability and product image count for your company, you can count on DTB to design a test that will deliver the results that you expect. Commercial and residential applications, as well as industrial components, all require their own unique levels of reliability and performance. Whether its ambient cycling, pressure or water hammer tests, or even temperature affects that you need to evaluate, we have the expertise to assist you with a test design that is appropriate for you.
AIR BAG SENSORS
DTB uses our large facilities and the 24/7 operation of the laboratory to provide DV and PV testing in the shortest amount of time possible. Using our high powered vibration facilities we are able to vibrate 12 to 24 driver or passenger airbags, at the desired environment. These vibration facilities also handle 4 to 8 full IPs at a time. Our drive-in environmental chambers are used to test entire lot samples at one time, further reducing testing time. We use our Solar Radiation array of lights to test the materials of these IPs to provide ample confidence of proper deployment in the vehicle, simulating many years of service.
Our environmental altitude testing facilities simulate altitudes from Death Valley at -14.1 meters (-282 feet), to outer space at 24,300 meters (80,000 feet).
An altitude test is performed in our (6) environmental altitude testing chambers that are all connected to a group of vacuum pumps, which can all be applied to any one chamber.
The result is that a rapid rate of change in altitude can be performed, as well as the standard type of altitude change.
We own six such environmental simulation testing facilities, combining temperature/humidity chambers with electro-dynamic vibration facilities.
The environmental simulation chambers have rapid rates of temperature change and the vibration facilities can handle 18,000 force-pound loads, with frequencies up to 2000 Hz.
Environmental Testing Equipment and Facilities — Forty two environmental testing chambers covering a wide variety of environments from 8 cu. ft to 4500 cu ft in a spacious laboratory of 300,000 square ft. Six walk-in environmental testing chambers with temperature transitions to 9ºF(5ºC) per minute. Three salt fog environmental testing chambers from 40cu ft to 3000 cu ft.
We carry an inventory of portable heating and cooling equipment with a variety of controls and instrumentation, which we use to construct chambers to meet your specific environmental testing requirements.
This environmental testing assures the safety of a component exposed to explosive vapors or to other dangerous environments.
Our environmental testing facility can be used to test the most complex flight electronics system or a shop vacuum used in a gas station, in order to verify proper operation in the explosive atmosphere environment.
Using our 10 ft diameter by 20 ft long altitude environmental testing chamber as the accumulator, we can obtain a wide range of rapid decompression requirements.
That large volume of the chamber combined with the (8) vacuum pumps permits a large array of possibilities when the decompression occurs.
Subjecting test item or material samples to various types of fluids as required by either the Mil-Std environmental testing requirements or the test item’s actual Life Cycle.
In hot and humid environments, fungus can cause equipment damage and create a health liability.
We’ll simulate these ill effects in a controlled environmental test. DTB has a dedicated fungus chamber to subject either a test item or items to the Mil-Std fungus spores.
This environmental testing requires 24/7 oversight to insure that the proper fungus test conditions are maintained.
Control samples are included in all environmental tests to ensure that proper conditions have been maintained to grow the fungus spores.
Salt, Fog & Ice
The second facility employs our 21 ft salt fog chamber and permits wind and rain environmental testing to be performed indoors; therefore this particular environmental test will not be delayed due to weather conditions. We’ll give you a spring drizzle, torrential wind-driven rain, or anything else, including freezing rain and ice. Using our large drive-in and walk-in environmental testing chambers we can produce inches of ice on very large or small test items.
Accelerated corrosion atmospheres can be produced for the effects of salt and sea mist.
Here at DTB, salt spray and salt fog corrosion are applied to items as large as a pick-up truck.
Other contaminants, like SO2, can be added to our salt fog testing chambers according to desired environmental testing conditions.
Testing is performed in accordance with MIL-STD-810G, ASTM B117 and ASTM G85 Annex A4.
Sand & Dust
We can recreate a desert storm or the air blast from an aircraft with the wind-driven abrasion and erosion of sand and dust, combined with actual temperatures.
Mil-Std environmental testing is performed in our facility that is located outside our main building. The winds for this environmental test are developed using a large electric motor blower assembly.
Two environmental testing facilities can be used for dust testing. The 13ft standard facility is used for smaller systems with an effective work area of 64 cu ft. The second facility is a large drive-in chamber for large environmental test items.
Solar Radiation Testing — DTB has multiple solar array facilities throughout the laboratory. Our largest, which conforms to MIL-STD-810G can test an item 8 Ft x 12 ft. Additionally, we have two (2) smaller facilities for test items that can fit within a 60 in and 24 in. diameter test area. The combination of the three (3) solar light arrays and the number of chambers we can place them in, permits meeting the most demanding environmental testing schedules.
Our environmental testing chambers vary from 2.1 to 3500 cubic feet. Our standard facilities simulate temperatures from -80°F to +350°F and our enhanced facilities go from -150°F to+450°F.
Relative humidity can range from 2% to 100% RH.
We have over 30 high/low temperature environmental testing chambers, the largest being our new 25ft deep by 15ft wide by 12ft tall drive-in environmental test chamber that is coupled with over 240 Hp of refrigeration, 240,000 KVA of heat and a 42 KVA Steam Generator for humidity test requirements.
Our thermal vacuum environmental testing chamber is 4ft in diameter and 6ft deep, with heating and cooling that can be accomplish by two methods.
The first is by direct contact through the use of a chill plate; the second is through the use of the thermal vacuum chamber’s shroud.
Wind, Rain and Humidity
DTB’s main wind and rain environmental testing facility is located outside, near our remote facility and employs an adjustable aircraft prop that is coupled to a high power marine engine.
Our wind and rain exposure facility can provide a sprinkle of rain to a downpour and winds up to 75 MPH.
This combination permits DTB to meet Mil-Std-810 as well as other environmental testing requirements that you may have.
DTB humidity test chambers range in size from our large drive-in environmental testing facility that is 25ft deep by 15ft wide by 12ft tall, to our standard humidity test chamber, which is 64 cu ft in volume.
All such humidity test chambers meet the requirement of Mil-Std-810. They can reach temperatures to 185ºF(85ºC) and Relative humidity of 100%.