by Jay Wesand

Created on: February 09, 2009   Last Updated: February 17, 2009

All types of commercially manufactured aircraft must undergo the Flight Test Process. This procedure is required in order to ascertain that the engineering and design characteristics of an aircraft meet established structural, controllability and safety parameters. It serves to establish compliance with certification requirements for new aircraft as well as major changes to existing aircraft.

This is a very involved process, especially for new aircraft, and typically involves the following:

A. Structural testing of actual aircraft components that have been built to design specifications for the express purpose of stress testing. These components are placed in steel jigs where measurable pressure is exerted on specific areas by hydraulic rams. The pressure is then measured in different areas of the structure by attaching electronic stress devices which give a digital readout for engineering interpretation. Through these tests it can be determined if the actual structure can handle the stress loading that the actual aircraft will experience during takeoff/landing and in-flight maneuvers. These tests continue with the electronic stress devices during the initial and subsequent actual test flights so airborne operational measurements can be taken and compared to the static test readings taken on the ground.

B. Ground testing of the actual engine/power-plant selected for the aircraft. This testing program determines if the actual power/thrust output is adequate for the operational weight and design characteristics of the aircraft. Reliability, fuel consumption and noise levels of the power-plant are also of concern. Takeoff, landing, climb and cruise performance of the engines are also monitored during the initial and subsequent test flights.

C. Aircraft reaction to flight control input that indicates a high level of controllability is a desirable outcome of the in-flight checks accomplished during the initial and subsequent test flights. Any problems encountered in this area must be solved ASAP. In order to preclude initial flight problems, multiple ground checks and reliability and engineering studies are done prior to flight.

D. Avionics (aviation electronics) encompasses a number of critical systems that are calibrated and tested numerous times prior to and during the initial flight and on subsequent test flights. These systems include communication systems,

navigation systems, various monitoring systems, the auto-functions of flight control systems, collision avoidance

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