I am designing a ground air-conditioning duct out of .035 inch wall, 5 inch I.D. 6061-T4.  Operating pressure is 13 psig.  Per 14 CFR 25.1438, I need to proof test to 1.5X and burst test to 2X normal operating pressure.  I have looked but can't find an AMS, ANSI, or other specification that covers pressure testing of thin walled aluminum tubing.

Design it, build 2, cap both ends.  Pressurize with 26 psi and see if it pops.  If it hold, pressurize the other to 20 psi and see if it distorts.  If it held it's shape, it passed proof testing.  Proof each one you make as part of the manufacture/QC process before you tag it and deliver it.

I stand corrected... although flexible hose might still be an option to consider... especially when insulation jacketing of the duct is needed [like a metal AC duct].

For giggles... are You designing this installation with the following specs in mind ??? NOTE: these docs have lots of embeded design references.

SAE ARP85(E) Air Conditioning Systems For Subsonic Airplanes.

SAE ARP217(D) Testing of Airplane Installed Environmental Control Systems (ECS)

or... very harsh design criteria of bleed air systems...

ARP1796(A) Engine Bleed Air Systems for Aircraft

Info...

AIR5378 Aircraft Tube Bending Methods, Techniques and Tooling.

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