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The Importance of
Subscale Jet Engine Testing
 The Importance of Subscale Jet Engine Testing 2

The Importance of
Subscale Jet Engine Testing

Aerospace engineers are rapidly advancing the state of technology by pushing the
envelopes of both performance and efficiency in jet engine manufacturing. As increased
levels of competition add pressure to accelerate the pace of development, engineers are
also faced with the task of adhering to strict safety and environmental emissions standards.
During the development of advanced aerospace structures and materials, access to
relevant test data that can be used to validate numerical models significantly improves
engineers’ chances of both first article success and overall confidence in their designs.

During the course of jet engine development, different engineering tests with varying
degrees of “realism”, are employed by engineers to study and generate that necessary
design data. The most commonly known and used testing methods are the Gas Burner &
Torch testing and Full Scale Jet Engine testing – both of which have limitations.

However, pursuing a full-scale engine test as a means of collecting all

required engineering data is an impractical, uneconomical, and frankly,
impossible exercise.
Ultimately, the truest validation of a design will come from the data accumulated by flying jet
engines. But engineers need to be as close to 100% sure as mathematically possible about
their designs before they ever make it to the sky. The next best data compared to flight
data, will come from a full engine test. That being said, full engine tests are very expensive,
complex and time consuming to prepare. Full engine tests are also typically not available
in the design and development phase of a new engine project. The more accessible gas
burner & torch methods can provide some data, but cannot produce a true engine-like
environment. Subscale Jet Engine Testing rigs are built to eliminate those limitations.”

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 The Importance of Subscale Jet Engine Testing 3

The Challenges of Full Scale Jet Engine Testing

It is true that a full-scale engine test is the only way to capture the exact operating conditions the
components face in real-life operation. However, pursuing a full-scale engine test as a means of
collecting all required engineering data is an impractical, uneconomical, and frankly, impossible
exercise.

Preparing a test engine requires careful modification to the engine to allow for instrumentation, the
fitting of test parts, and the use of non-standard operating protocols within the testing (ex. overriding
the built-in safety features). The complexity of the project, estimated timelines, and costs pile up
quickly. The number of tests is also limited to the number of component copies that are available.

When it comes to a totally new engine in the design and development stage, a full-scale engine test
is simply not an option – the physical engine does not exist. In the very best case scenario, testing
would be performed by a surrogate engine, which would contain varying degrees of difference from
the engine in development.

Full-scale jet engine testing facilities are often privately owned, which can present various issues
and inconveniences for engineers who are seeking to test on the small-scale. Below are two of the
most common issues:

Schedule & Timing — Waitlist times

• 
for full-scale testing facilities can be
months — or even years — long.
Priority is often given to the products
and components that are further along
in the engineering process, and closer
to full launch. Components that have
gone through proof-of-concept testing
are not considered as high-priority.

Costs — Depending on the initial

• 
setup, the overall complexity of the
tests, and the number of tests required,
full-scale engine testing costs can
vary significantly. Costs can increase
throughout the testing process as
adjustments are made to the rig, and
additional tests become necessary.

571 Main Street / Hudson, MA 01749-3035 / testdevices.com / Phone: 978-562-6017

 The Importance of Subscale Jet Engine Testing 4

The Challenges of Gas Burner and Torch Testing

Gas Burner and Torch testing methods are a viable testing alternative. However, the scope of what
gas burner and torch setups can actually test is very limited. Burners are only able to test one
aspect of engine environment — the temperature and combustion environment.

Many burner and torch type test rigs require compressed air, which will necessitate higher costs and
limit the duration of sustained test. Burners are also typically limited to a small unit, resulting in a
limited flow rate.

Depending on the specific application – for example, when testing sensors for engine hot sections –
burners and torches can only achieve limited effect. Simulating the combustion section of an engine
require both relevant temperature, pressure and combustion process. Sub scale jet engine rigs are
not bound to these constraints, and offer a higher flow rate in terms of both quality and quantity.

Due to size alone, subscale engine tests require significantly lower

costs and less labor to prepare for a test than a full-scale testing.

What is a Subscale Jet Engine Testing?

Subscale jet engines (also known as micro/mini-turbines), designed for use in model airplanes, are
becoming more ubiquitous and affordable. Redesigning and modifying these off-the-shelf engines to
create subscale test rigs has created an opportunity to bridge the information gap that currently exists
within the testing capabilities available to jet engine designers and engineers.

With the use of an actual engine, these subscale jet engine facilities can reliably and economically
simulate the relevant environment of a full-scale jet engine facility. Due to size alone, subscale engine
tests require significantly lower costs and less labor to prepare for a test than a full-scale testing. They
also allow greater flexibility and access for engineers to instrument for data, change configurations,
iterate, and learn from the test in a “trial-and-error” manner before investing in full-scale jet engine
testing operations.

Testing capabilities will vary depending on the specific small testing rig being utilized, but all of these
scaled-down facilities allow engineers to gather valuable data to tune their numerical models and
measure the number of data needed for studying the probability of failure.

The data and learning from the test would boost the confidence in the designs and engineering
decisions made in the earlier part of the jet engine development – ultimately resulting in significant
time and cost savings down the line.

571 Main Street / Hudson, MA 01749-3035 / testdevices.com / Phone: 978-562-6017

 The Importance of Subscale Jet Engine Testing 5

Case Study: Small Rigs for Coating Durability Testing

At Test Devices, we recently worked with a client who needed to do subscale testing that required
an engine. They were looking to determine how engine exhaust would affect materials being placed
in the exhaust stream, and needed to conduct a coating durability test. The client designed a test
in which coated tile-specimen would be placed in the exhaust stream to see how quickly particles
accumulated on the tile, ultimately allowing the team to see how the coating quality was affected.

Even if a full-scale jet engine facility was available, and money was not an issue, a full-scale jet
engine testing would have been impractical for this test. To implement the test, the team would have
needed to construct a new purpose-designed test rig in which the test specimen (matched to the
size of a full-size engine) would require a crane to handle. Doing so would not only take a much
longer time to assemble, but would also incur extremely high costs.

As a solution, a subscale engine test rig was developed and set up by Test Devices, the rig allowed
for the use of smaller tile specimen that could be handled and installed by hand. During the
course of the test, the client reviewed the data and observed something new and unexpected. The
observations led to a need for an additional set of tests with new instrumentation as well as some
rig settings adjustments. The subscale jet engine rig allowed for quick adjustments, and the new
tests were set up and implemented in a matter of hours. The subscale engine rig offers the clients
superb convenience and a significantly more economical testing solution.

571 Main Street / Hudson, MA 01749-3035 / testdevices.com / Phone: 978-562-6017

 The Importance of Subscale Jet Engine Testing 6

The Benefits of Small Rig Testing

Subscale engine tests rig can be customized to allow engineers to test to their specific needs
more affordably and conveniently than a full-size engine test would allow. Below are some of
the benefits of subscale engine testing:

• Easy customization - Because subscale engine rigs are subject to far fewer constraints
than full-scale testing, a unique test setups can be built quickly and adjusted as needed. In
typical testing, the needs for in-situ changes often rises – Subscale engine rigs allow for great
operational flexibility. With full-scale engine tests, on the other hand, layouts often allow very
limited changes and engineers operates under stricter timing constraints.

• Fuller test data - Unlike full-scale testing, subscale jet engine testing is not constrained by the
established test method and data from the past. This allows engineers and designers a greater
freedom to test and measure data as they needed - enhancing fullness of the experiment and
the measured data set.

• Fuller understanding - Due to the purpose designed boundary conditions, the data from
the subscale test are easier to compare with the model and gain critical understanding of the
phenomenon of interest. In a full-scale test, defining the boundary conditions and interpreting the
data would be a much more challenging task. Subscale engine test data allow engineers to build
confidence in their models and design decisions from ground up.

• Ability to test to failure — Unlike full-scale jet engine rigs, the subscale engine setups allow
engineers to conduct test to failures. Below are just a few of the various failure mechanisms that
can be tested:

Creep Low-Cycle High-Cycle Thermo- Fracture

Fatigue Fatigue mechanical Mechanics
Fatigue Rotor Burst

• Shorter timelines — While full-scale testing can take years, subscale rig testing can be
completed in just months, keeping down costs and speeding up all related processes. Custom
design usually takes around one or two months, and manufacturing generally requires about
two months. Subscale jet engine tests themselves usually require about two weeks for full
assessments, depending on the number and complexity of the tests required.

571 Main Street / Hudson, MA 01749-3035 / testdevices.com / Phone: 978-562-6017

 The Importance of Subscale Jet Engine Testing 7

Coupon Spin Engine Scaled Engine

Test Conditions
Yes
Thermal Gradients Very Difficult Yes Yes
(Radial gradient on a disk)
Complex Geometry Possible but difficult Yes Yes Yes
Yes
High Pressure Condition Limited Yes Yes
(Up to 1 atm)
Gas Species /
Very Difficult No Yes Yes
Environmental
Failure Mechanisms
Yes
Rotor Burst NA Yes Yes
(Very expensive)
Yes
Low Cycle Fatigue Yes Yes Yes
(Isothermal)
Yes
Fracture Mechanics Yes Yes Yes
(Isothermal)
Yes
Creep Yes Yes Yes
(Isothermal)
Yes Yes
High Cycle Fatigue Yes Yes
(Limited R=-1) (Rm Temp)
Thermomechanical Fatigue Very Difficult Yes Yes Yes
Test Setup & Operation
Instrumentation Access Easily Accessible Easily Accessible Difficult Easily Accessible
Teardown Turn Time Minutes Hours Days-Weeks Minutes-Hours
Test Price Range+
$1000's~10,000's
$1,000's $1000's~$10,000's
Basic Tests >$1,000,000 (Test with existing facility &
(Tensile test) (Simple spin)**
equipment)
$5,000 - $10,000's $10,000's - $100,000's $100,000's
Advanced Eng Tests >>$1,000,000
(Heated cyclic tests*) (Heated test, LCF, HCF)*** (Test requiring design work)
+ For comparison only. Not **Rm temp spin with minimum ***Depending on the
suitable For budget planning *Depending on the test duration. data requirements. complexity of the test and the
purpose. instrumentation requirement.

Types of Small-Rig Jet Engine Tests

• Oxidation/corrosion • Blade HCF • Fuel burn study
• Creep/fatigue • Coating durability

Highly cost- and time-efficient, the realistic engine conditions created in subscale jet engine testing
allow engineers to accurately assess the reliability of turbine and combustion design, as well as the
performance of rotors and other critical components.

To learn more about the benefits of small jet engine testing and how it can help ensure top
performance and longevity, reach out to the expert team at Test Devices.

571 Main Street / Hudson, MA 01749-3035 / testdevices.com / Phone: 978-562-6017

Working With Test Devices
Test Devices has provided aerospace-quality spin testing and balancing services
for nearly 40 years. As a business unit of SCHENCK USA CORP, a member of
the world’s leading mechanical and plant engineering firm, the Dürr Group, Test
Devices can draw on their depth and breadth of both technical prowess, resources
and stable financial backing. We’ve expanded our facility to provide one-stop-
shop convenience with rapid turnarounds, helping achieve the shorter lead times
our OEM clients need to succeed. TD is an AS9100/ISO9001–certified business,
performing spin-testing and balancing services to support a wide range of industry
standards. When you’re ready to improve the accuracy of your models, shorten
testing programs, reduce the risk of engine test cell failures, and lower the cost of
testing, contact us today to request a free quote, and one of our expert TD team
members will be in touch within 48 hours.

Contact Us Learn More

571 Main Street / Hudson, MA 01749-3035 / testdevices.com / Phone: 978-562-6017