Testing Solutions
Delivering comprehensive testing solutions that add value
We provide precise, tailored testing services to meet your validation needs, ensuring real performance data that drives value at
every stage of development. Our solutions enhance efficiency, optimize design, and support the highest standards in component testing.
Capabilities & State-of-the-Art Testing Facilities
Compressor Test
Gain valuable insights into your compressor development programme with comprehensive component testing. We deliver a complete compressor map, including surge and choke limits, using high-resolution measurement technology for detailed stage-by-stage performance analysis. Our tests provide critical data for mechanical integrity, support the optimisation of bleed and VGV schedules, and establish a solid foundation for improving numerical algorithms.
General capabilities
- Electric drive system providing up to 18,000 kW (24,000 HP)
- 11 controllable pipe measuring sections for bleed air extraction
- Control of up to 5 (extendable to 7) variable guide vane stages driven by hydraulic jacks
- Versatile rig oil system for roller/ball or journal bearings
- Secondary air supply system, e.g. for buffer seal air or instrumentation cooling
- Versatile and programmable compressor & facility control system with built-in safety concept
Intermediate Pressure Compressor (IP) test facility
- Various gear sets, speeds of up to 15,200 RPM
- Split flow test facility with maximum mass flow of 200 kg/s at the inlet, 150 kg/s at the bypass and 65 kg/s at the core
- Reduction of inlet pressure down to 0.2 bar
- Maximum compressor outlet conditions of T=400 °C and P=11.0 bar in the bypass section (or as single flow)
- Axial thrust piston to compensate maximum axial force of 80 kN
High Pressure Compressor (HP) test facility
- Various gear sets, speeds of up to 58.000 RPM
- Primary single flow test facility with maximum mass flow of 50 kg/s (extension to split flow possible)
- Reduction of inlet pressure down to 0.2 bar
- Maximum compressor outlet conditions of T=640 °C and P=21.4 bar
- Inlet air can be heated up by up to 100 °C above ambient
Measurement system
Permanent facility measurements:
- Ambient pressure, temperature and relative humidity at the facility inlet
- Pressure in the inlet Venturi
- Temperature at several points in the test facilities including the anechoic chamber
- Mass flow in the inlet Venturi/ flare (HP, IP and Anechoic), in the bleed lines (HP and IP) and in the core exhaust lines in the IP and Anechoic testbed
- Speed and torque at the drive shaft
- Compressor thrust compensation force of the balance piston (part of the torquemeter) – IP and Anechoic testbeds only
- Oil and air supply parameter for the compressor bearings
- Valve positions
- Health & safety measurements on all systems (vibrations, temperatures, pressures,etc.)
Steady state/ transient measurement system
- Pressure:
- 1418 HP & IP test facility
- 1184 Noise test facility
- Temperature:
- 480 thermocouple (type E, J,K,N,T) HP & IP facility
- 300 thermocouple (type E, J,K,N,T) Noise test facility
- 32 RTD channels
- Analogue voltages: >150
- Frequency inputs:16
- Vibration channels:
- 20 HP & IP test facility
- 26 Noise test facility
- DC strain: 8
- Various:
- Tip timing on Noise test facility
- Tip clearance measurement on HP & IP test facilty
Dynamic Data System
- 384 channels @ 250 kHz maximum sampling rate (configurable), fully synchronized
- Used for high frequency inputs, e.g.
- vibration measurements (strain gauges)
- noise measurements
- fast pressure transducers
- Real-time monitoring and limit checking of all input channels at a time
- Monitoring of up to 32 modal limits per channel
- Real-time displays, including Campbell, Z-Mod, Oscilloscopes, FFT
Fan Performance and Noise Test
We operate Europe’s largest anechoic chamber as a powerful tool for experimental validation during fan system development. Noise reflections from test facility walls are fully suppressed in the frequency range of interest, thus acoustically simulating free-field conditions, e.g. like on an airfield. At the same time, testing is not limited by adverse weather conditions or environmental limitations.
General capabilities
- Electric drive system providing up to 18,000 kW (24,000 HP)
- Primary split flow test facility, maximum mass flow 118 kg/s at the inlet, 103 kg/s at the bypass and 24.2 kg/s in the core
- Anechoic chamber footprint of 1,000 m² and 10 m height
- Noise reflection from test facility walls <1% in the frequency range 200 Hz – 40 kHz
Universal Fan Facility for Acoustic (UFFA )
- To complement the noise test facility UFFA has been designed as a versatile and adaptable modular test vehicle to easily accommodate customer specific fan system hardware configurations in an existing test environment. Using a common hardware platform minimises the initial efforts required to design a test vehicle.
- We offer the complete package from concept, design and production of the test hardware up to testing. Modularity of the UFFA test vehicle allows for quick change of multiple test configurations in the test cell speeding up a specific test campaign significantly.
- The UFFA test vehicle is used for validation of hardware development (fan, OGV, liner, struts, nacelles, etc.), but also provides a realistic test case to improve calculation models (fan noise, propagation of noise in the bypass duct, noise insulation from liners, effect of noise on aerodynamics, effects of acoustic hardware on flutter).
UFFA test vehicle
- Nominal fan diameter of 869mm (34,2’) with a maximum rotational speed of 10,000 RPM.
- Bypass ratio is largely variable, depending on the layout of the fan module as specified by the customer
- Noise emission measured in various locations upstream & downstream of fan by circumferential and axial microphone arrays,
- 2 circumferential traversing positions for aero/ acoustic probes
- Up to 500 microphone locations
- Fan efficiency measurement by mass flow, pressure, temperature/ torque
Flow Lab
Our flow lab features an open wind tunnel for calibrating flow probes, investigating flow characteristics of components, and researching airflow effects, enabling the transfer of results from scaled models to real conditions.
General capabilities
- Free flow tunnel with a jet outlet diameter of 80 mm
- Mach numbers from 0.1 to almost 1
- Mass flow up to 2.2 kg/s
- Pressures up to 9.6 bar
- Reference: example of massflow measurement by use of an orifice plate according to DIN EN ISO 5167, Mach-number related calibration
- Mass flows of up to 70 kg/s: Mach number and/or Reynolds number related calibration in reference to an orifice plate or a supersonic nozzle
- Mass flows > 70 kg/s: measurement and analysis of the interface profiles, and applicability of the BS1042 standard
- Consideration of the specific flow geometries and various operating conditions: measurement and analysis of boundary layer profiles and application of the BS1042 standard
- Traversing system with 1 translational and 2 rotational degrees of freedom
- Available measurement technology:
- Mass flow
- Pressures
- Temperatures
Combustor Test
Combustor tests are carried out at external test facilities with certified partner organisations or at the customer site. We have gathered special experience at the test facilities of the German Aerospace Centre (DLR) in Cologne where more than 100 tests have been carried out at various test facilities (HBK2, HBK3 and HBK5). Additionally, tests are also conducted at the external test facilities of the Sesta Lab in Italy.
General capabilities
Technical data of DLR Köln facility
- Emission test, rumble test and optical exhaust gas measurement
- EDS: optical admission, main air supply max. 1 kg/s, max. 20 bar, max 850 K
- HBK1: main air supply – max. 2.2 kg/s, max. 20 bar, max.900 K
- HBK2: main air supply – max. 30 kg/s, max. 40 bar, max. 920 K
- HBK3: main air supply – max. 7 kg/s, max. 40 bar, max. 920 K
- HBK4: main air supply – max. 45 kg/s, max. 40 bar, max. 920 K
- Further details are available on German Aerospace Centre (DLR).
Technical data of Sesta Lab
- 3 Test Cells for combustion tests
- Test Cell 1and 2: up to 100MWth, P3 up to 28 bar, T3 up to 520°C
- Test Cell 3, up to 5MWth, P3 up to 30 bar, T3 up to 600°C
- Ultra fuel flexibility:
- Syngas with on demand composition
- Jet Fuel and SAF
- Diesel and HVO
- Natural Gas
- Hydrogen
- Ammonia
- Ethane, LPG and CO
Turbine Test
Turbine tests are carried out at certified test facilities with partner organisations as well as at the customer site. We have gained particular experience within the turbine test facilities of the Institute of Aircraft Propulsion Systems (ILA) at the University of Stuttgart and at the German Aerospace Centre (DLR) in Göttingen.
General capabilities
Technical data of ILA Stuttgart facility
- Air supply up to 140 kg/s
- Inlet air conditions -60 °C to 170 °C, inlet pressure 0,05 bis 2,5 bar
- shaft break power 10 000 kW
- Conditioning of cooling water 160 m³/h at 3.5 bar, max. Tin 50 °C / min. T-out 10 °C (e.g. for water brake)
- Oil system 2 x 15l/min and 1 x 10l/min at a maximum of 8 bar and the maximum flow temperature of 70 °C (e.g. for test vehicle)
- Secondary air supply system 2.6 kg/s @ 6 bar and 4.6 kg/s @ 22 bar
- Air dehumidification in the main air supply up to a dew point of at least 7 °C
Technical data of DLR Göttingen facility
- Air supply up to 10 kg/s
- Inlet air conditions 20 °C to 320 °C, inlet pressure 0,1 bis 2,0 bar
- shaft break power 1,5 MW (HDT) and 1,0 MW (NDT)
- Rig oil system, secondary air supply system
- We will accommodate individual customer-specific test requirements with the installation and supply of external additional units, such as air dehumidifiers, power generators, heaters, water coolers and apparatus for mass flow and pressure control in secondary air supplies.
Whole Engine Test
From engine components through core engines to complete aircraft engines. We are flexible and ready to support test campaigns from Start to End.
General capabilities
- Support in selecting of suitable test facilities
- Consulting services for the development of test schedules/test campaigns
- Instrumentation design and application for full engine test
- Provide data acquisition solutions for a specific test campaign
- Flexible test crew that can be deployed worldwide
- Support in commissioning of test facilities
Capabilities & State-of-the-Art Testing Facilities
Compressor Test
Hier steht ein kurzer Einleitungstext
Fan Performance and Noise Test
We operate Europe’s largest anechoic chamber as a powerful tool for experimental validation during fan system development. Noise reflections from test facility walls are fully suppressed in the frequency range of interest, thus acoustically simulating free-field conditions, e.g. like on an airfield. At the same time, testing is not limited by adverse weather conditions or environmental limitations.
Flow Lab
Our flow lab features an open wind tunnel for calibrating flow probes, investigating flow characteristics of components, and researching airflow effects, enabling the transfer of results from scaled models to real conditions.
Combustor Test
Combustor tests are carried out at external test facilities with certified partner organisations or at the customer site.
Turbine Test
Turbine tests are carried out at certified test facilities with partner organisations as well as at the customer site. We have gained particular experience within the turbine test facilities of the Institute of Aircraft Propulsion Systems (ILA) at the University of Stuttgart and at the German Aerospace Centre (DLR) in Göttingen.
Whole Engine Test
Hier steht ein kurzer Einleitungstext