What Is Space Structure Testing?
Space structure testing is a critical part for our space testing services, ensuring that the components and complete systems used in launch vehicles and spacecraft meet the highest standards of strength, durability, and reliability.
We simulate real-world conditions such as extreme temperatures, vacuum environments, and heavy mechanical loads, and verify that these structures can withstand the stresses encountered during lift-off, flight, orbital operations, and re-entry.
Space structure testing helps manufacturers, space agencies, and integrators ensure mission success, protect valuable payloads, and maintain crew safety.
What Space Structure Testing Services Do We Offer?
At Applus+ Laboratories, we specialise in testing a wide range of structures used in launch vehicles and other spacecraft. Our end-to-end services encompass the development of customised test rigs, loading systems, measurement and control technology, as well as the execution of complex test programs.
We rigorously follow industry standards, guidelines, and customer-specific requirements to assess structural integrity and performance under realistic conditions.
Test on Large Space Structures
To ensure large space structures are flight-ready, their strength and stiffness must be tested under realistic load scenarios.
- Bespoke Test Sites: Our team designs custom test sites that simulate stiffness-equivalent boundary conditions while preventing unwanted load concentration. This includes a multi-disciplinary approach including structural analysis, both numerical and analytical, design and manufacturing capabilities. Outcome is a cost-efficient test rig, that meets the requirements to perform a successful test.
- Dummy Structures: Dummy structures are required to provide reasonable boundary conditions for the specimen. We can rely on a wide experience base for developing dummy structures for ever changing requirements regarding size, precision, strength and stiffness.
- Reliable Load Introduction: Applying required loads correctly, not only in terms of a measured value, is key to a reliable test result. We have the capability to design and implement loading systems for complex loading conditions, like superposition of forces in a single point, forces and moments at a larger structures and/or pressurization of tanks.
- State-of-the-Art Instrumentation: We apply state of the art instrumentation to specimen and rig to ensure reliable data acquisition. Applied sensing techniques include strain gauges, displacement transducers, high-speed video and 3D digital image correlation. The latter can also be applied to high-speed events, such as a collapse of a structure.
- Remote Testing: Destructive tests are safely controlled using live data visualisation and advanced monitoring systems.
- Advanced Technology: Our state-of-the-art measurement and control systems ensure precise load application, delivering valuable data for certification and/or improvement.
Space Structural Tests on Interstages
To ensure the structural integrity of interstage structures, we design and implement complete loading systems capable of simulating real-world conditions.
- Axial Forces and Bending Moments: Our systems handle very large axial forces combined with complex bending moments to replicate realistic scenarios.
- Advanced Analysis: Engineers perform linear and non-linear analyses to protect structural elements from premature failure.
- State-of-the-Art Instrumentation: Projects like the Interstage 1/2 of the Vega-C launcher included over 450 strain gauges, 200 displacement transducers, high-speed cameras, and 3D optical measurement systems.
Space Structural Tests on Thrust Frames
Thrust frames play a critical role in anchoring rocket engines and propelling launch vehicles into orbit. To ensure their reliability, we subject these components to rigorous testing.
- Custom Test Rigs: We design and build specialised rigs to apply loads until the components reach their ultimate failure point.
- Advanced Technology: Our state-of-the-art measurement and control systems ensure precise load application, delivering valuable data for improvement.
- Notable Projects: For the Ariane 6 launcher, we tested the Vinci Thrust Frame under highly complex load scenarios, validating its structural integrity and performance.
Tests on Intertank Space Structures (ITS)
Intertank structures are essential for the stability and performance of launch vehicles. Our tests ensure these structures meet rigorous performance standards.
- Static: We introduce forces, internal pressure, and temperature to simulate real-world conditions.
- Adaptable Systems: Our scalable testing systems are tailored to your specific requirements.
- Proven Expertise: With extensive experience in ITS testing, such as the upper and lower Ariane 6 intertank structures, we ensure precise load application, accurate data capture, and robust evaluations of structural integrity.
Space Structural Tests on Tanks
Tanks are critical components for storing propellants, requiring rigorous testing to ensure they withstand significant internal pressures.
- Complete Test Sites: We build comprehensive facilities with refuelling and pressurisation systems to push tanks to their breaking points.
- Precision Instrumentation: Strain gauges and other measurement devices are carefully installed to avoid damaging delicate tank walls.
- Remote Testing: Destructive tests are safely controlled using live data visualisation and advanced monitoring systems.
- Proven Results: This approach was instrumental in testing the tanks of the Ariane 6 launcher, providing essential data for design optimisation.
Examples of Notable Tests
The following examples describe test campaigns that relied on the methods and tools from above to be performed successfully:
- Vega-C Interstage 1/2: It included over 450 strain gauges, 200 displacement transducers, high-speed cameras, and 3D optical measurement systems.
- Ariane 6 Vinci Thrust Frame: We tested the Vinci Thrust Frame under highly complex load scenarios, validating its structural integrity and performance.
- Ariane 6 Lower Intertank Structure: A set of 28 hydraulic actuators, with one focus on booster loads of up to 5 MN to be applied.
- Ariane 6 Upper Intertank Structure: A set of 20 hydraulic actuators, with one specific dummy simulating an attached tank structure and distributing the load of 8 actuators to the structure.
- Ariane 6 LH2 Tank Pressure Test: Test up to rupture of an LH2 tank.
- Ariane 6 Tank Structure Buckling Test: Buckling test of a thin-walled tank structure with a special focus on predictable, even load distribution.
What Are the Benefits of Space Structure Testing?
Space structure testing provides numerous advantages for manufacturers, space agencies, and integrators. It ensures that space systems meet the necessary performance and safety standards for successful missions.
- Ensuring Safety and Reliability: Rigorous testing validates that structures can withstand extreme loads and conditions, safeguarding missions, payloads, and crew.
- Verifying Design Principles: Experimental data from testing compares material use, construction methods, and calculation models to refine designs and improve performance.
- Reducing Risk and Costs: Identifying potential points of failure early in development allows for necessary design modifications, reducing the risk of costly on-orbit failures.
- Optimising Performance and Efficiency: Understanding how structures behave under various load conditions helps engineers refine their designs for lighter, more efficient, and more reliable components.
- Supporting Certification and Compliance: Testing demonstrates compliance with industry standards, customer specifications, and regulatory requirements, streamlining the path to qualification and approval.
Why Choose Applus+ Laboratories for Space Structure Testing?
Applus+ Laboratories has a proven track record as a trusted partner in major European launcher programs. Our engineering teams have successfully managed, developed, and executed tests to failure on large space structures, interstages, intertanks, thrust frames, and tank structures for vehicles like Vega-C and Ariane 6. Our expertise includes:
- Comprehensive Solutions: We handle the entire testing process, from concept development and finite element analysis (FEA) through to the design and construction of test rigs, instrumentation, and execution.
- Cutting-Edge Technology: State-of-the-art measurement, control systems, and advanced optical diagnostics ensure precise, reliable, and detailed test data.
- Extensive Experience: Decades of hands-on experience and involvement in high-profile space programs empower us to deliver high-quality processes and outcomes.
- Tailored Test Programs: We adapt to your specific requirements, creating customised load conditions, test rigs, and test methodologies for accurate and realistic assessments.
- End-to-End Support: From the initial development of space structures and components to final series production approval, our team works seamlessly with you to ensure that your products meet all strength, safety, and performance objectives.
By choosing Applus+ Laboratories, you align with a dedicated partner who understands the complexities of space structure testing and delivers reliable, data-driven insights to support your mission’s success.