Destructive Testing Strategies

Some products can only be tested by destroying them — a tension test, a burst test, a fatigue test. Because every test consumes a unit, destructive testing relies on statistical sampling and careful test design.

Common destructive tests

Test type	Measurement	Industry
Tensile test	Ultimate tensile strength, yield strength, elongation	Metals, polymers
Burst test	Pressure at failure	Hydraulics, pressure vessels
Fatigue test	Cycles to failure at a given stress level	Aerospace, automotive
Peel test	Bond strength (N/mm)	Adhesives, labels, medical devices
Charpy impact test	Energy absorbed (J) at fracture	Metals, weld qualification

Sampling considerations

Because units are consumed, sample sizes for destructive tests are typically smaller than for non-destructive inspection. Variables sampling plans (ANSI/ASQ Z1.9) are often preferred because fewer units yield equivalent statistical information compared to attributes plans.

Zero-failure demonstration testing

For a one-sided confidence C with zero failures observed: n ≥ ln(1 − C) / ln(R_demo) Example: demonstrate R = 0.95 with C = 0.90 and zero failures: n ≥ ln(1 − 0.90) / ln(0.95) = ln(0.10) / ln(0.95) = −2.303 / −0.05129 ≈ 45 units

CQE exam tips

Destructive test lot sampling: use variables plans when possible; smaller n gives the same risk protection.
If even one failure occurs in a zero-failure demonstration test, the reliability goal is not demonstrated at that confidence level.

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