Accelerated Test Methods for Ground and Aerospace Vehicle Development

Engineers and managers involved with product development are continually challenged to reduce time to market, minimize warranty costs, and increase product quality. This results in less time for testing, which means the need for effective accelerated test procedures has never been greater.

Accelerating your testing program sounds great, but how do you begin? This course starts by taking a look at statistical models for reliability testing. It looks specifically at how sample size and testing timeframe affect what you’re able to do versus what you'd ideally do with more time and money. It also explains the benefits, limitations, processes, and applications of several proven accelerated test methods, including accelerated reliability, step stress, FSLT (Full System Life Test), FMVT® (Failure Mode Verification Testing), HALT (Highly Accelerated Life Testing), and HASS (Highly Accelerated Stress Screening). Throughout the course, you’ll participate in an activity that allows you to identify failure modes, develop hypotheses, and select accelerated test methods for a product of your choice.

It is recommended that you have access to a calculator during this course. Learners will also receive a copy of the instructor's eBook, Accelerated Testing and Validation Management.

What Will You Learn

By participating in this on-demand course, you'll be able to:
  • Choose the accelerated test method for a given application
  • Analyze accelerated testing results
  • Explain how to accelerate your current test methods
  • Explain how to accelerate your validation program
  • Adjust accelerated test programs for business situations
  • Describe how product development cycles can be reduced from 18 to six months

Course Information

COURSE LENGTH
11.00 Hours
ACCESS PERIOD
90 Days

Is This Course For You

This on-demand course is designed for anyone involved in product design, life testing, reliability testing, and validation for passenger cars, light trucks, heavy duty, off-highway or aerospace vehicles, including reliability engineers, validation engineers, design engineers, and their managers. Individuals who need to achieve shorter time to market or higher quality through custom test plans and purchasers or users of testing or engineering services will also find this course valuable. There are no prerequisites, although a technical background is helpful.

Have colleagues who need this course? See Special Offers to the right.

Click on the Requirements tab to make sure you are properly equipped to interact with this course.

Materials Provided

  • 90 days of online single-user access (from date of purchase) to the 10 hour presentation
  • 10 video modules (see Topics/Outline tab)
  • Integrated knowledge checks to reinforce key concepts
  • Online learning assessment (submit to SAE)
  • Course handbook (downloadable, .pdf's)
  • Instructor follow up to your content questions
  • The eBook, Accelerated Testing and Validation Management by Alexander J. Porter
  • 1.1 CEU's*/Certificate of Achievement (with satisfactory learning assessment score)

*SAE International is authorized by IACET to offer CEUs for this course.

Course Requirements

  • Windows 7, 8, 10 (other operating systems and mobile platforms are not supported but may work)
  • Internet Explorer 11, Mozilla Firefox 37, Google Chrome 42 (other browsers are not supported but may work)
  • Broadband-1Mbps minimum

Topics

Module 0: Course Introduction
[Total Run Time: 5 Minutes]

Module I: Statistical Model for Reliability Testing
[Total Run Time: 1 Hour, 20 Minutes]
  • Identify the fundamentals of a statistical reliability test
  • Recognize the limits of statistical analysis and the effects of product types
  • Identify characteristics of an effective sample
  • Describe the purpose of testing to make business and engineering decisions

Module II: Key Accelerated Tests, Terms, and Methods
[Total Run Time: 20 Minutes]
  • Define information goal and explain its importance in selecting test methods
  • Explain the difference between data and information

Module III: Full System Life Test (FSLT)
[Total Run Time: 1 Hour, 35 Minutes]
  • Restate the goal of a full system life test
  • Explain the basic methods of a full system life test
  • Discover how to reduce test time by cycling faster
  • Discover how to reduce test time by eliminating non-damaging conditions
  • Discuss the limitations and assumptions inherent in this method
  • Identify sources of damage

Module IV: Step Stress
[Total Run Time: 40 Minutes]
  • Explain why achieving failure is successful
  • Demonstrate one life in a mandated test while finding failures
  • Examine the limitations and assumptions of the test method
  • Explain why step stress test is an accelerated test

Module V: Accelerated Reliability
[Total Run Time: 1 Hour, 10 Minutes]
  • Describe an accelerated reliability test, including inputs needed, outputs, and limitations
  • Distinguish the stress vs. life vs. probability relationship
  • Determine when to use the accelerated reliability technique

Module VI: Highly Accelerated Life Test (HALT)
[Total Run Time: 1 Hour, 15 Minutes]
  • Identify differences between statistics-based and failure-based testing
  • Describe HALT, including inputs needed, outputs, and limitations
  • Relate the importance of vibration
  • State the importance of vibration frequency range on strain

Module VII: Failure Mode Verification Test (FMVT®)
[Total Run Time: 3 Hours, 30 Minutes]
  • Describe an FMVT® test, including inputs needed, outputs, and limitations
  • Describe examples of conducting FMVT® tests
  • Explain the difference between design maturity and reliability

Module VIII: Test Acceleration vs. Program Acceleration
[Total Run Time: 10 Minutes]
  • Explain why program acceleration is critical to improving time

Module IX: Hybrid Acceleration Methods
[Total Run Time: 10 Minutes]
  • Explain how outputs of one test can be used by other tests
  • Combine two or more tests based on the strengths and weaknesses of the tests

Module X: Decision and Selection Process
[Total Run Time: 1 Hour]
  • Choose accelerated test methods for a given business application
  • Use a hypothesis matrix to organize stresses and failure modes, and to validate the test selection