High Pressure Proof, Burst and Cyclic Testing Services up to 50,000 psi

Independent Pressure Testing for Hydraulic Hoses, Tubing and Fluid System Components

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

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 Pressure Testing

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.

Cyclic Pressure Testing

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 vs Pressure Pulse Testing

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.

High Pressure Testing up to 50,000 psi

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:

Testing can be conducted using hydraulic fluids, water-based media or customer-specified fluids where appropriate.

Aerospace Pressure Testing

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 Pressure Testing

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

Instrumentation and Data Acquisition

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

Why Choose Resonate Testing?

• 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

Discuss Your Pressure Testing Requirements

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.