The last certification test for the horizontal tailplane of the Embraer ERJ190-300/400 E2 was recently completed. This final static residual resistance test completes the campaign for validation of the behaviour of this aeronautical component for Aernnova.
During this campaign initiated in November 2015, a test bench was designed and manufactured with the aim of reproducing the real conditions this structure undergoes, applying fatigue cycles (3 DSG) to check its behaviour.
The testing phase over the course of February 2017 involved use of 8 hydraulic actuators and 13 force transducers to apply and monitor the test loads. 12 displacement transducers and a total of more than 600 instrumentation channels were used to measure deformations at specific points of the structure.
In total, the different tests and their corresponding inspection phases have taken three years to complete, including fatigue campaigns and static tests in different configurations.
The test specimens satisfactorily completed the entire campaign.
At CTA, we are committed to the prevention and safety of all and due to the current COVID-19 outbreak that is spreading rapidly across the country, CTA management has decided to adopt some preventive measures.
According to the instructions and recommendations given by the Spainsh Government and Health Authorities, the activity of our teams has been reorganized increasing to the maximum teleworking, hygienic measures and avoiding face-to-face interaction but minimizing the impact on CTA activity in order to ensure the same efficient response requested by our customers.
We hope that we quickly overcome this challenge.
CTA is working together with Lortek on the Flowcaash project under the European Commission’s Clean Sky II Initiative. The aim of this project during 2018-2020 is to manufacture and validate titanium-aluminium flow control actuators made using additive manufacturing techniques (SLM) to increase lift in aircraft to be installed with next-generation low-emission engines.
CTA is focusing on the aerodynamic tests to validate the production process, along with tests in aggressive environments (vibration, ice, rain, dust and sand, etc.).
Project website: https://www.flowcaash.eu/
As part of the certification programme for the H160 manufactured by Airbus Helicopters, CTA has developed an innovative test bench to perform drop tests of helicopter fuel tanks. This test bench allows these types of tests to be carried out in accordance with the specifications set out in CS27.952(a).
The test bench allows the specimen to be guided during the drop while a pneumatic system attached to the tank releases it, causing it to drop against a concrete block on the laboratory floor. The entire test is recorded on four high-speed cameras allowing precise measurement of both the angle and speed at the moment of impact.
Last March, CTA completed the vibration testing campaign for IRS EQM (Infrared Sounder Engineering Qualification Model) Mirror Assembly under the MTG programme developed by LIDAX.
During this campaign, CTA tested 4 models which were subjected to random vibration levels ranging from 20 to 2,000 Hz. Due to the cleanliness requirements of these types of space specimens, the tests were carried out in an ISO 5 clean room installed on a vibration bench.
This campaign is a continuation of the STM tests begun in 2018 and it is expected to continue in May of this year with tests for the PFM models
The final test for certification of the rudder of the KC-390 was completed in September 2018. This load test completed the series of tests of the flight control surfaces of this aircraft marketed by Embraer: the flaps, ailerons and tailplane. All three components were developed by Aernnova.
This campaign which has been active since October 2015 involved the use of 20 actuators and force transducers to apply test loads, displacement transducers, multiaxial transducers to measure reactions and a total of more than 1,800 instrumentation channels to measure deformations at specific points of the different structures.
In total, the campaign consisted of nearly 3 years of different tests, including fatigue tests and static tests in different configurations.
The test specimens satisfactorily completed the entire campaign.
STAR3 Technology Alliance, the space alliance formed by CTA, CATEC and TECNALIA will develop novel structural components for launchers and satellites using additive manufacturing technologies.
This project, the first one contracted for ESA within GSTP programme, will allow CTA to show the space industry the test capacities and capabilities achieved in the past.
CTA will validate the components at Miñano facilities where is able to perform tests in vibration, structural, pyroshock and vacuum domain to fulfil the testing requirements for aerospace industry.
CTA’s Miñano facilities have been carrying out the fatigue tests for Aernnova on the horizontal tailplane of the ERJ190-E2 / ERJ195-E2 aircraft marketed by the Brazilian company Embraer.
These tests involve application of more than 3 million load cycles using 6 actuators with 48 application points to simulate the aerodynamic loads the component would undergo when in use.
The monitoring of these tests required use of over 600 strain gauges distributed across the specimen and 11 load cells to control the loads applied by each actuator and measure the reactions at certain points, along with 12 displacement sensors.
Following completion of the fatigue tests, static tests of residual loads will be performed using two additional actuators and the corresponding load cells.
During the months of March and April 2017 the Limit Load and Ultimate Load test campaign was carried out for certification of Flap Track 1 and Flap Track 3 of the Embraer E2 aircraft.
This campaign involved testing of two specimens, with each one corresponding to different Flap elements. During these tests, each of the two elements tested were subjected to different limit load and ultimate load cases.
A total of 6 actuators were used to apply the loads to each specimen. The tests also involved use of displacement sensors, strain gauges, 6-axis force sensors and the PONTOS contactless displacement measurement system in order to meet all the customer’s measurement and data requirements.
During the second week of January 2017 the shock tests were carried out on the APP mechanism for Airbus Defence & Space.
The tests were successfully performed using the pyroshock test bench developed by CTA, located on its premises in Miñano (Álava).
The tests consisted of the application of three shocks on each of the three axes of the specimen with an SRS profile of 100-10,000 Hz and levels of more than 1000g.