Pressure testing is a critical validation method used to demonstrate the safety, integrity and durability of hydraulic hoses, fittings, manifolds, valves, actuators, accumulators and fluid system assemblies. At Resonate Testing, we provide high-pressure proof, burst and cyclic pressure testing up to 50,000 psi (3,450 bar) for aerospace, defence, industrial, motorsport and specialist engineering applications.
Our pressure testing capabilities support product development, certification, qualification, production verification and failure investigations, helping manufacturers confirm that components can safely withstand operating and extreme pressure conditions.
Proof pressure testing verifies that a component can withstand a specified pressure level without leakage, permanent deformation, structural damage or loss of performance.
The test typically involves:
Filling the test article with hydraulic fluid or another suitable test medium
Gradually increasing pressure to a predetermined proof level
Holding pressure for a specified duration
Monitoring for leakage, dimensional changes or performance degradation
Conducting post-test inspections where required
Proof testing is commonly specified as a percentage of the component’s rated working pressure (i.e. 1.5 or 3) and is frequently required during:
Aerospace qualification programmes
Flight hardware acceptance testing
Production quality verification
Defence equipment validation
Hydraulic component certification
Typical test articles include:
Hydraulic hoses
Tube assemblies
Flexible hose assemblies
Valves
Pumps
Actuators
Manifolds
Pressure vessels
Aerospace fluid system components
Burst testing determines the maximum pressure a component can withstand before structural failure occurs usually required to be a least 2 to 4 times normal working pressure at normal rated temperature.
This test provides critical data on:
Ultimate pressure capability
Failure modes
Design safety margins
Manufacturing consistency
Regulatory compliance
During testing, pressure is increased under controlled conditions until rupture, leakage or catastrophic failure occurs.
Burst testing can identify:
Hose reinforcement failures
End fitting separation
Tube wall rupture
Seal extrusion
Cracking of machined components
Weld failures
Manifold fracture points
Actual margin vs calculated margin
Comprehensive instrumentation allows accurate recording of burst pressure, pressure rise rate and failure characteristics, providing valuable engineering data for design verification and root cause investigations.
Pressure cycling evaluates a component’s ability to withstand repeated pressure loading throughout its expected service life.
Unlike proof or burst testing, cyclic testing subjects a component to thousands or even millions of pressure cycles between defined pressure limits.
Cyclic testing can reveal:
Fatigue cracking
Hose reinforcement degradation
Seal wear
Connection loosening
Progressive leakage
Material fatigue failures
Long-term durability concerns
Typical test parameters include:
Minimum pressure
Maximum pressure
Pressure differential
Cycle frequency
Number of cycles
Fluid temperature
Environmental conditions
Pressure cycling is widely used for:
Aerospace hydraulic systems
Aircraft brake systems
Landing gear hydraulics
Industrial hydraulic equipment
Mobile machinery
Defence vehicle systems
Offshore hydraulic equipment
Pressure cycling and pressure pulse testing are often confused but serve different purposes.
Pressure cycling generally involves controlled repetitive loading between pressure limits to evaluate fatigue life and durability under representative service conditions.
Pressure pulse testing uses rapid pressure transients and shock loading profiles designed to simulate severe hydraulic pressure spikes encountered during operation.
At Resonate Testing, we provide cyclic pressure testing focused on durability and fatigue performance, allowing manufacturers to assess long-term reliability and component wear and performance over life, under realistic operating conditions.
Many modern hydraulic systems operate at increasingly high pressures to improve power density and reduce system weight. This places greater demands on hoses, fittings and components.
Our high-pressure capability supports testing of products operating across a broad pressure range, including:
| Pressure Range | Typical Applications |
|---|---|
| Up to 5,000 psi | Industrial hydraulics |
| Up to 10,000 psi | Mobile equipment |
| Up to 15,000 psi | Heavy-duty hydraulic systems |
| Up to 20,000 psi | Aerospace hydraulic applications |
| Up to 30,000 psi | Specialist defence systems |
| Up to 50,000 psi | Ultra-high-pressure and research applications |
Testing can be conducted using hydraulic fluids, water-based media or customer-specified fluids where appropriate.
Aerospace hydraulic systems operate in safety-critical environments where component reliability is essential.
We support qualification and verification testing for:
Hydraulic hoses
Metallic tubing assemblies
Quick disconnect couplings
Actuators
Servo valves
Engine-mounted components
Landing gear systems
Brake system components
Flight control hydraulic equipment
Testing can be developed to meet the requirements of customer specifications and major aerospace standards.
Relevant standards may include:
SAE aerospace specifications
AS standards
MIL specifications
RTCA environmental programmes
Customer qualification requirements
OEM proprietary standards
Industrial hydraulic equipment is often exposed to demanding operating conditions including high pressures, temperature extremes and continuous duty cycles.
We support testing for:
Hydraulic cylinders
Pumps
Valves
Hose assemblies
Connectors
Pressure vessels
Energy sector equipment
Oil and gas components
Process industry equipment
Testing programmes can demonstrate:
Compliance with industry requirements
Product durability
Design verification
Safety margin validation
Production quality assurance
Accurate measurement is critical during high-pressure testing.
Our systems can provide:
High-accuracy pressure measurement
Continuous pressure recording
Leak monitoring
Cycle counting
Temperature measurement
Failure event capture
Automated data logging
Detailed test reporting
Clients receive comprehensive test reports documenting:
Test procedures
Pressure profiles
Hold times
Cycle counts
Acceptance criteria
Results
Observations
Non-conformances where applicable
Pressure testing up to 50,000 psi
Proof pressure testing
Burst pressure testing
Cyclic pressure fatigue testing
Aerospace, defence and industrial expertise
Independent third-party testing
Bespoke test rig development
Detailed engineering reporting
Qualification, certification and investigation support
Rapid project turnaround
Whether you are qualifying a new aerospace hydraulic hose, validating a high-pressure manifold design or investigating a component failure, Resonate Testing can develop a tailored proof, burst or cyclic pressure testing programme to meet your requirements.
Contact our engineering team to discuss your testing objectives, applicable standards and pressure requirements. We will work with you to design a test programme that delivers reliable, defensible engineering data and confidence in product performance.
Use the contact route to share the requirement, test profile, drawings or specification for review.
Whether you’re looking to contact us for the first time or have another testing requirement, we’d love to hear from you.
