Thanks Don.
So my takeaways are that:
A. we are well into "audible" territory with very common measures (based on
@amirm 's reviews). This is audible generally when a system is pushed hard (initially for transients/other high dynamics moments), but that is enough to be noticeable, isn't it?
B. Clearly, speakers are the biggest contributor.
C. Once you're in "audible" territory, the cumulative contribution of the source, amps, and anything else in the chain will have the *potential* to make it worse.
D. We need better tools to self-test audibility of distortion during peaks; steady tones are not the most likely use case.
@pkane, can your tool help us with that?
I don't know about (A). And I mean that literally; I am not sure just how much distortion is really audible. When you push a system hard, speakers are most likely to be the main distortion source unless your amplifier is severely clipping, and again that may be only on very loud peaks. For sine waves, if I flip back and forth I can hear 1% pretty readily, 0.1% barely better than guessing, at low levels via headphones that may or may not be contributing. Listening to music 1% is almost impossible to tell (by me), except in special cases where I know the music and what to listen for, and even then is tough. Certainly (well, maybe not "certainly", but pretty certain for me) 1% distortion at the peak of a cymbal hit, drum strike, or gun shot/explosion seems unlikely to be audible. If I inject 1% into a two-tone or multitone test I can hear it due to IMD products thus a little easier to pick out than for single tones.
For (C), it depends upon the relative levels of distortion. Ideally your sources, preamp, amp, and speakers all clip together to maximize dynamic range (at least at the upper end). Electronics, at least SS, tend to quickly go from completely inaudible to audible distortion (due to feedback keeping it low until that point) -- look at any amp THD chart and notice how quickly THD rises when you approach and exceed its power limits.
I also do not know the integration period of the ear/brain system. Can we really hear clipping if it is just on a peak for a fraction of a second? How large a fraction? Not something I know.
I am not sure we need better tools. You can use any AWG to generate tone bursts to listen for clipping. That is what I used to do, anyway, back when I was playing around with this stuff in the primordial past. Since we know the low-level stuff is unlikely to be a problem, you could just adjust the signal into the amp, but the problem is going to be tolerating high SPLs -- both your ears and the speaker's drivers. A test to destruction when it's my ears or speakers being destroyed is not a practical methodology, at least for me.
If I do basic sweeps or single-tone tests to perhaps 100~110 dB, assuming within the capabilities of my amp and speakers, and the distortion is about 1% or even a few percent, then I'm good.
For that matter, when I was piddling with subwoofers, I found 10% or more distortion was actually pleasing to some folk -- it made the bass/sub "richer" or fuller. Why? My conjecture is that at say 60 Hz the fundamental is hard to hear, so when you add a 120 Hz component, there is "more bass" so people like it.