The fatigue testing has been running really well, practice makes perfect as they say! We’ve been busy changing all the joints of the Whiffletree and replacing the engine mount bolts. This is done at approximately 60,000 cycles. We learnt some lessons during the first period when we had rig failures and bits breaking, but this means the second time round, we can monitor things better and avoid this from happening again. In addition, we made a plan with Game Composites to change certain rig components as a matter of course.
We’re currently at 61,500 cycles and we have to get to 71,663. When we run a 24-hour period it gives us 8,640 cycles, so in running another 24-hour period we will be left with only 900 cycles remaining before we reach the finish line and the golden number of 71,633.
Once we’ve reached the 71,633 cycles, this will also us to begin boxing up the airframe in insulation and the week commencing the 21st we will be doing another ultimate load test at 72 degrees Celsius and then a further ultimate load test at a 15% higher load. It will be getting hot in Catcliffe! So keep checking back for exciting news!
Today was a great day! Last Friday, after all the ups and downs, we finished all the fatigue testing after we reached 71 633 cycles.
With this complete it was time for us to move onto the ultimate load test, performed once before, where the aircraft gets boxed in insulation and heated up to a toasty 72 degrees Celsius. This definitely helps take the edge of the February chills we have here in South Yorkshire.
So with the airframe all boxed up as you can see in the picture, we were all ready for the residual strength test to 64.85 kN which the airframe had no trouble getting through.
When this first pre-load test was complete, we moved onto the static ultimate load test which took the Game Bird 1 up to 82.65 kN. This is the highest loading that the airframe has seen to date, so it was a tense time for all involved. The Game Composites team were on site during the testing today, so we were all feeling the pressure!
Fortunately relief spread across us all when the airframe passed with flying colours. There was the odd creak which was expected, although this didn’t help with the tension levels when we were all watching!
It has certainly been a very exciting week for us here at the AMRC and guided by the Civil Aviation Authority (CAA), it is now time for us and the team from Game Composites to decide what’s next when it comes to further testing for the Game Bird 1 aerobatic aircraft!