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At least 415 records · Page 23

Cloud Ozone Dust Imager (CODI): Investigation and Technical Plan - Volume 1

The Cloud Ozone Dust Imager (CODI) is proposed to investigate the current climatic balance of the Mars atmosphere, with particular emphasis on the important but poorly understood roles which dust and water ice aerosols play in this balance. The large atmospheric heating (20-50 K) resulting from global dust storms around Mars perihelion is well recognized. However, groundbased observations of Mars atmospheric temperatures, water vapor, and clouds since the Viking missions have identified a much colder, cloudier atmosphere around Mars aphelion that may prove as important as global dust storms in determining the interannual and long-term behavior of the Mars climate. The key climate issues CODI is designed to investigate are: 1) the degree to which non-linear interactions between atmospheric dust heating, water vapor saturation, and cloud nucleation influence the seasonal and interannual variability of the Mars atmosphere, and 2) whether the strong orbital forcing of atmospheric dust loading, temperatures and water vapor saturation determines the long-term balance of Mars water, as reflected in the north-south hemispheric asymmetries of atmospheric water vapor and polar water ice abundances. The CODI experiment will measure the daily, seasonal and (potentially) interannual variability of atmospheric dust and cloud opacities, and the key physical properties of these aerosols which determine their role in the climate cycles of Mars. CODI is a small (1.2 kg), fixed pointing camera, in which four wide-angle (+/- 70 deg) lenses illuminate fixed filters and CCD arrays. Simultaneous sky/surface imaging of Mars is obtained at an angular resolution of 0.28 deg/pixel for wavelengths of 255, 336, 502, and 673 nm (similar to Hubble Space Telescope filters). These wavelengths serve to measure atmospheric ozone (255 and 336 nm), discriminate ice and dust aerosols (336 and 673 nm), and construct color images (336, 502, and 673 nm). The CODI images are detected on four 512 x 512 pixel arrays, as partitioned on two 1024 x 1024 CCD's operated in frame transfer mode. The center of the CODI field-of-view is canted 40 deg from the zenith direction to obtain sky brightness measurements and a 20 deg surface field-of-view. Daily image observations will be conducted when the Sun is greater than or equal to 5 deg outside the edge of the CODI field-of-view, and twilight and nighttime imaging will obtained on a weekly basis. The 673 nm channel includes a polarizer wheel to obtain sky/surface polarimetry. A dust cover protects the entire lens assemblies of all four CODI channels. This opaque dust cover, which is normally opened for CODI imaging, includes a small fixed mirror and transparent window positioned above the 673 nm lens, to redirect the 673 nm field-of-view to the surface for descent imaging. Fixed pointing, internal data buffering, low operating power (2-4 W for less than or equal to 30 seconds), selective data transmission, and simple operational characteristics of the CODI experiment place minimum resource and operational demands on the Mars Surveyor 1998 lander. The CODI science goals are optimized for, but not restricted to, a low-latitude landing site (20 deg S-30 deg N). The primary CODI measurement objectives are the opacities, wave forms, particle properties (size, shape, and alignment), and heights of clouds; the opacities, particle properties, and vertical distribution of dust; and the opacity and vertical distribution of ozone. The variability of cloud, ozone, and dust opacities will be determined on diurnal, daily, and seasonal timescales. Wind velocities will be determined from cloud motions and wave characteristics; and the temporal variability of atmospheric water vapor, with limited altitude information, will be inferred from the CODI ozone observations. Secondary measurement objectives include limited descent imaging capability, surface uv-visible photometry and polarimetry, photochemistry, and meteorite infall rates.

Clancy, R. Todd↗

Advanced Lightweight Metallic Fuselage Project Manufacturing Trade Study

Recent advances in large-scale flow forming of integrally stiffened cylinders (ISCs) have motivated evaluation of available technologies for rapid manufacturing of metallic fuselages. The current state-of-the-art in flow forming of ISCs produces 10-ft. diameter, 5-ft. long barrels with integral longitudinal blade stiffeners, and these single-piece ISCs are produced in approximately 1.5 hours. While other manufacturing processes are required to incorporate additional structural elements (ASE) such as circumferential ring frames, reinforcements around window and door cut-outs, and floors to the ISCs to complete the fuselage structure, flow forming technology may assist the aerospace industry in meeting manufacturing rate demands. In order to evaluate this technology, a fuselage manufacturing demonstration article (MDA) fabricated from two ISCs is scheduled for fabrication and delivery to NASA Langley Research Center (LaRC) by the end of 2022. In this study, eight manufacturing technologies were assessed to downselect candidate manufacturing processes for adding ASE to complete the MDA. A literature review and evaluation of contractor-produced panels covering a spectrum of welding and additive manufacturing (AM) processes were conducted at NASA LaRC. The analytical hierarchy process (AHP) was used to evaluate figures of merit (FOMs) for selecting manufacturing process(es) to integrate ASE with the ISCs to form a fuselage MDA. The AHP results revealed that scalability, structural performance, and distortion control were the most valued criteria for downselecting the manufacturing process to construct the internal stiffening structures. Based on the FOMs, this study concluded that a welding process is best suited for integrating the majority of the ASE, namely the circumferential ring frames. All of the welding processes received higher scores than AM processes due to higher maturity, higher structural performance, fewer post-processing requirements in machining and heat treating, and faster deposition rates. Among the welding processes, cold metal transfer (CMT) welding was ranked the most favorable process for assembling the MDA, with the other welding processes (laser welding (LW), friction stir welding (FSW), and refill friction stir spot welding (RFSSW)) scoring slightly lower. This was a consequence of the perceived maturity of the CMT welding process and its relatively high structural performance and low distortion resulting from the low heat input. Among the AM processes, CMT AM showed the greatest promise due to benefits derived from its scalability, lower 1st order process complexity, and low distortion. The AM processes may have potential for select applications, such as adding structural reinforcements around window and door cut-outs, but are not considered optimal for integrating the entire MDA.

Manufacturing↗

Civil Tiltrotor Feasibility Study for the New York and Washington Terminal Areas

NASA tasked LMI to assess the potential contributions of a yet-undeveloped Civil Tiltrotor aircraft (CTR) in improving capacity in the National Airspace System in all weather conditions. The CTRs studied have assumed operating parameters beyond current CTR capabilities. LMI analyzed CTRs three ways: in fast-time terminal area modeling simulations of New York and Washington to determine delay and throughput impacts; in the Integrated Noise Model, to determine local environmental impact; and with an economic model, to determine the price viability of a CTR. The fast-time models encompassed a 250 nmi range and included traffic interactions from local airports. Both the fast-time simulation and the noise model assessed impacts from traffic levels projected for 1999, 2007, and 2017. Results: CTRs can reduce terminal area delays due to concrete congestion in all time frames. The maximum effect, the ratio of CTRs to jets and turboprop aircraft at a subject airport should be optimized. The economic model considered US traffic only and forecasted CTR sales beginning in 2010.

Stouffer, Virginia↗

A Cognitive Systems Engineering Approach to Developing HMI Requirements for New Technologies

This document examines the challenges inherent in designing and regulating to support human-automation interaction for new technologies that will deployed into complex systems. A key question for new technologies, is how work will be accomplished by the human and machine agents. This question has traditionally been framed as how functions should be allocated between humans and machines. Such framing misses the coordination and synchronization that is needed for the different human and machine roles in the system to accomplish their goals. Coordination and synchronization demands are driven by the underlying human-automation architecture of the new technology, which are typically not specified explicitly by the designers. The human machine interface (HMI) which is intended to facilitate human-machine interaction and cooperation, however, typically is defined explicitly and therefore serves as a proxy for human-automation cooperation requirements with respect to technical standards for technologies. Unfortunately, mismatches between the HMI and the coordination and synchronization demands of the underlying human-automation architecture, can lead to system breakdowns. A methodology is needed that both designers and regulators can utilize to evaluate the expected performance of a new technology given potential human-automation architectures. Three experiments were conducted to inform the minimum HMI requirements a detect and avoid system for unmanned aircraft systems (UAS). The results of the experiments provided empirical input to specific minimum operational performance standards that UAS manufacturers will have to meet in order to operate UAS in the National Airspace System (NAS). These studies represent a success story for how to objectively and systematically evaluate prototype technologies as part of the process for developing regulatory requirements. They also provide an opportunity to reflect on the lessons learned from a recent research effort in order to improve the methodology for defining technology requirements for regulators in the future. The biggest shortcoming of the presented research program was the absence of the explicit definition, generation and analysis of potential human-automation architectures. Failure to execute this step in the research process resulted in less efficient evaluation of the candidate prototypes technologies in addition to the complete absence of different approaches to human-automation cooperation. For example, all of the prototype technologies that were evaluated in the research program assumed a human-automation architecture that relied on serial processing from the automation to the human. While this type of human-automation architecture is typical across many different technologies and in many different domains, it ignores different architectures where humans and automation work in parallel. Defining potential human-automation architectures a priori also allows regulators to develop scenarios that will stress the performance boundaries of the technology during the evaluation phase. The importance of adding this step of generating and evaluating candidate human-automation architectures prior to formal empirical evaluation is discussed.

human systems integration↗

Structural Analysis of Load-Bearing Components in Mars Science Helicopter

The successful demonstration of powered flight on Mars by Ingenuity has led to the development of next generation Martian rotorcraft. As technology advances from a technology demonstrator to possible expanded planetary science investigations, the potential to fly a high payload carrying rotorcraft relies on the capability to analyze and validate the structural integrity of the vehicle in addition to the rotor aerodynamic performance. The Mars Science Helicopter (MSH), a next generation hexacopter concept, is one example of a proposed vehicle that would perform science independently of a land-based vehicle. To ensure the feasibility and viability of MSH mission performance, it is critical to mature the structural design for these vehicle concepts to bridge the gap between the best practices of the spacecraft and aircraft communities. MSH was analyzed under operational and 26G quasi-static launch loads with different rotor arm and fuselage designs. Structural analysis results showed that rotor arms could be stiffened for significantly improved structural performance with minimal mass penalty, while the rotorcraft frame exhibited a more complex relationship between mass and launch load stresses due to the mass-dependent launch loads.

Load-Bearing↗

Group Capability Model

The Group Capability Model (GCM) is a software tool that allows an organization, from first line management to senior executive, to monitor and track the health (capability) of various groups in performing their contractual obligations. GCM calculates a Group Capability Index (GCI) by comparing actual head counts, certifications, and/or skills within a group. The model can also be used to simulate the effects of employee usage, training, and attrition on the GCI. A universal tool and common method was required due to the high risk of losing skills necessary to complete the Space Shuttle Program and meet the needs of the Constellation Program. During this transition from one space vehicle to another, the uncertainty among the critical skilled workforce is high and attrition has the potential to be unmanageable. GCM allows managers to establish requirements for their group in the form of head counts, certification requirements, or skills requirements. GCM then calculates a Group Capability Index (GCI), where a score of 1 indicates that the group is at the appropriate level; anything less than 1 indicates a potential for improvement. This shows the health of a group, both currently and over time. GCM accepts as input head count, certification needs, critical needs, competency needs, and competency critical needs. In addition, team members are categorized by years of experience, percentage of contribution, ex-members and their skills, availability, function, and in-work requirements. Outputs are several reports, including actual vs. required head count, actual vs. required certificates, CGI change over time (by month), and more. The program stores historical data for summary and historical reporting, which is done via an Excel spreadsheet that is color-coded to show health statistics at a glance. GCM has provided the Shuttle Ground Processing team with a quantifiable, repeatable approach to assessing and managing the skills in their organization. They now have a common frame of reference across NASA/contractor lines to communicate and mitigate any critical skills concerns.

Olejarski, Michael↗

Selected contribution: a three-dimensional model for assessment of in vitro toxicity in balaena mysticetus renal tissue

This study established two- and three-dimensional renal proximal tubular cell cultures of the endangered species bowhead whale (Balaena mysticetus), developed SV40-transfected cultures, and cloned the 61-amino acid open reading frame for the metallothionein protein, the primary binding site for heavy metal contamination in mammals. Microgravity research, modulations in mechanical culture conditions (modeled microgravity), and shear stress have spawned innovative approaches to understanding the dynamics of cellular interactions, gene expression, and differentiation in several cellular systems. These investigations have led to the creation of ex vivo tissue models capable of serving as physiological research analogs for three-dimensional cellular interactions. These models are enabling studies in immune function, tissue modeling for basic research, and neoplasia. Three-dimensional cellular models emulate aspects of in vivo cellular architecture and physiology and may facilitate environmental toxicological studies aimed at elucidating biological functions and responses at the cellular level. Marine mammals occupy a significant ecological niche (72% of the Earth's surface is water) in terms of the potential for information on bioaccumulation and transport of terrestrial and marine environmental toxins in high-order vertebrates. Few ex vivo models of marine mammal physiology exist in vitro to accomplish the aforementioned studies. Techniques developed in this investigation, based on previous tissue modeling successes, may serve to facilitate similar research in other marine mammals.

Whales/genetics/physiology↗

Cellular Responses to Mechanical Stress Selected Contribution: A Three-Dimensional Model for Assessment of in Vitro Toxicity in Balaena Mysticetus Renal Tissue

This study established two- and three-dimensional renal proximal tubular cell cultures of the endangered species bowhead whale (Balaena mysticetus), developed SV40-transfected cultures, and cloned the 61-amino acid open reading frame for the metallothionein protein, the primary binding site for heavy metal contamination in mammals. Microgravity research, modulations in mechanical culture conditions (modeled microgravity), and shear stress have spawned innovative approaches to understanding the dynamics of cellular interactions, gene expression, and differentiation in several cellular systems. These investigations have led to the creation of ex vivo tissue models capable of serving as physiological research analogs for three-dimensional cellular interactions. These models are enabling studies in immune function, tissue modeling for basic research, and neoplasia. Three-dimensional cellular models emulate aspects of in vivo cellular architecture and physiology and may facilitate environmental toxicological studies aimed at elucidating biological functions and responses at the cellular level. Marine mammals occupy a significant ecological niche (72% of the Earth's surface is water) in terms of the potential for information on bioaccumulation and transport of terrestrial and marine environmental toxins in high-order vertebrates. Few ex vivo models of marine mammal physiology exist in vitro to accomplish the aforementioned studies. Techniques developed in this investigation, based on previous tissue modeling successes, may serve to facilitate similar research in other marine mammals.

Goodwin, T. J.↗

Hybrid Wing-Body (HWB) Pressurized Fuselage Modeling, Analysis, and Design for Weight Reduction

This paper describes the interim progress for an in-house study that is directed toward innovative structural analysis and design of next-generation advanced aircraft concepts, such as the Hybrid Wing-Body (HWB) and the Advanced Mobility Concept-X flight vehicles, for structural weight reduction and associated performance enhancement. Unlike the conventional, skin-stringer-frame construction for a cylindrical fuselage, the box-type pressurized fuselage panels in the HWB undergo significant deformation of the outer aerodynamic surfaces, which must be minimized without significant structural weight penalty. Simple beam and orthotropic plate theory is first considered for sizing, analytical verification, and possible equivalent-plate analysis with appropriate simplification. By designing advanced composite stiffened-shell configurations, significant weight reduction may be possible compared with the sandwich and ribbed-shell structural concepts that have been studied previously. The study involves independent analysis of the advanced composite structural concepts that are presently being developed by The Boeing Company for pressurized HWB flight vehicles. High-fidelity parametric finite-element models of test coupons, panels, and multibay fuselage sections, were developed for conducting design studies and identifying critical areas of potential failure. Interim results are discussed to assess the overall weight/strength advantages.

Mukhopadhyay, Vivek↗

Measurement realities of current collection in dynamic space plasma environments

Theories which describe currents collected by conducting and non-conducting bodies immersed in plasmas have many of their concepts based upon the fundamentals of sheath-potential distributions and charged-particle behavior in superimposed electric and magnetic fields. Those current-collecting bodies (or electrodes) may be Langmuir probes, electric field detectors, aperture plates on ion mass spectrometers and retarding potential analyzers, or spacecraft and their rigid and tethered appendages. Often the models are incomplete in representing the conditions under which the current-voltage characteristics of the electrode and its system are to be measured. In such cases, the experimenter must carefully take into account magnetic field effects and particle anisotropies, perturbations caused by the current collection process itself and contamination on electrode surfaces, the complexities of non-Maxwellian plasma distributions, and the temporal variability of the local plasma density, temperature, composition and fields. This set of variables is by no means all-inclusive, but it represents a collection of circumstances guaranteed to accompany experiments involving energetic particle beams, plasma discharges, chemical releases, wave injection and various events of controlled and uncontrolled spacecraft charging. Here, an attempt is made to synopsize these diagnostic challenges and frame them within a perspective that focuses on the physics under investigation and the requirements on the parameters to be measured. Examples include laboratory and spaceborne applications, with specific interest in dynamic and unstable plasma environments.

Szuszczewicz, Edward P.↗

Simultaneous in situ Optical Monitoring Techniques during Crystal Growth of ZnSe by Physical Vapor Transport

ZnSe crystals grown in sealed ampoules by the physical vapor transport method were monitored in situ using three techniques, simultaneously. A Michelson interferometer was set-up to observe the growth rate and surface morphological evolution. An interference pattern (interferogram) is formed by the interaction between the reflection of a HeNe laser (632.8 nm wavelength) off the crystal-vapor interface and a reference beam from the same laser. Preliminary results indicate that the rate of growth/thermal-etching can be calculated using analog data acquisition and simple fringe counting techniques. Gross surface features may also be observed using a digital frame grabber and fringe analysis software. The second in situ technique uses optical absorption to determine the partial pressures of the vapor species. The Se2 and Zn vapor species present in the sealed ampoule absorb light at characteristic wavelengths. The optical absorption is determined by monitoring the light intensity difference between the sample and reference beams. The Se2 Partial pressure profile along the length of the ampoule was estimated from the vibronic absorption peaks at 340.5, 350.8, 361.3 and 379.2 nm using the Beer's law constants established in the calibration runs of pure Se. Finally, because the high temperature crystal growth furnace contains windows, in situ visual observation of the growing crystal is also possible. The use of these techniques not only permits in situ investigation of high temperature vapor growth of semiconductors, but also offers the potential for real time feed back on the growing crystal and allows the possibility of actively controlling the growth process.

Su, C.- H.↗

Formation Flying of Tethered and Nontethered Spacecraft

A paper discusses the effect of the dynamic interaction taking place within a formation composed of a rigid and a deformable vehicle, and presents the concept of two or more tethered spacecraft flying in formation with one or more separated free-flying spacecraft. Although progress toward formation flight of nontethered spacecraft has already been achieved, the document cites potential advantages of tethering, including less consumption of fuel to maintain formation, very high dynamic stability of a rotating tethered formation, and intrinsically passive gravity-gradient stabilization. The document presents a theoretical analysis of the dynamics of a system comprising one free-flying spacecraft and two tethered spacecraft in orbit, as a prototype of more complex systems. The spacecraft are modeled as rigid bodies and the tether as a mass-less spring with structural viscous damping. Included in the analysis is a study of the feasibility of a centralized control system for maintaining a required formation in low Earth orbit. A numerical simulation of a retargeting maneuver is reported to show that even if the additional internal dynamics of the system caused by flexibility is considered, high pointing precision can be achieved if a fictitious rigid frame is used to track the tethered system, and it should be possible to position the spacecraft with centimeter accuracy and to orient the formation within arc seconds of the desired direction also in the presence of low Earth orbit environmental perturbations. The results of the study demonstrate that the concept is feasible in Earth orbit and point the way to further study of these hybrid tethered and free-flying systems for related applications in orbit around other Solar System bodies.

Quadrelli, Marco B.↗

Neural network based decomposition in optimal structural synthesis

The present paper describes potential applications of neural networks in the multilevel decomposition based optimal design of structural systems. The generic structural optimization problem of interest, if handled as a single problem, results in a large dimensionality problem. Decomposition strategies allow for this problem to be represented by a set of smaller, decoupled problems, for which solutions may either be obtained with greater ease or may be obtained in parallel. Neural network models derived through supervised training, are used in two distinct modes in this work. The first uses neural networks to make available efficient analysis models for use in repetitive function evaluations as required by the optimization algorithm. In the second mode, neural networks are used to represent the coupling that exists between the decomposed subproblems. The approach is illustrated by application to the multilevel decomposition-based synthesis of representative truss and frame structures.

Hajela, P.↗

Active Flow Control: Instrumentation Automation and Experimental Technique

In investigating the potential of a new actuator for use in an active flow control system, several objectives had to be accomplished, the largest of which was the experimental setup. The work was conducted at the NASA Langley 20x28 Shear Flow Control Tunnel. The actuator named Thunder, is a high deflection piezo device recently developed at Langley Research Center. This research involved setting up the instrumentation, the lighting, the smoke, and the recording devices. The instrumentation was automated by means of a Power Macintosh running LabVIEW, a graphical instrumentation package developed by National Instruments. Routines were written to allow the tunnel conditions to be determined at a given instant at the push of a button. This included determination of tunnel pressures, speed, density, temperature, and viscosity. Other aspects of the experimental equipment included the set up of a CCD video camera with a video frame grabber, monitor, and VCR to capture the motion. A strobe light was used to highlight the smoke that was used to visualize the flow. Additional effort was put into creating a scale drawing of another tunnel on site and a limited literature search in the area of active flow control.

Gimbert, N. Wes↗

Economic impact of fuel properties on turbine powered business aircraft

The principal objective was to estimate the economic impact on the turbine-powered business aviation fleet of potential changes in the composition and properties of aviation fuel. Secondary objectives include estimation of the sensitivity of costs to specific fuel properties, and an assessment of the directions in which further research should be directed. The study was based on the published characteristics of typical and specific modern aircraft in three classes; heavy jet, light jet, and turboprop. Missions of these aircraft were simulated by computer methods for each aircraft for several range and payload combinations, and assumed atmospheric temperatures ranging from nominal to extremely cold. Five fuels were selected for comparison with the reference fuel, nominal Jet A. An overview of the data, the mathematic models, the data reduction and analysis procedure, and the results of the study are given. The direct operating costs of the study fuels are compared with that of the reference fuel in the 1990 time-frame, and the anticipated fleet costs and fuel break-even costs are estimated.

Powell, F. D.↗

A typical pointed observation in IRAS designed to fit into a 15 minute window

A typical pointed observation in the Infrared Astronomical Satellite (IRAS) was designed to fit into a 15 minute window. Observing constraints, however, did not always permit targets from the scientific program to be observed on exactly 15 minute centers and a few months into the mission it was realized that the automatic scheduling program left times when no observations were being made. In order to use this potentially wasted observing time, a mode of pointed observations, the 'filler' mode, with shorter observation duration was initiated. Locations were picked on an arbitrary grid, spaced relatively uniformly in ecliptic coordinates, and the telescope was pointed to one of these sites whenever a gap potentially occurred. One of us (GXN) was the coordinator of this effort (the FL sub-group). There are a total of 22 FL fields, 13 of which have more than 50 component observations. These 13 fields cover about 30 square degrees. It was proposed to concentrate on one filler field, FL29, a field with 53 coverages which thus had among the deepest coverage of those observed in this mode. This field was also observed extensively at various non-infrared wavelengths by a variety of techniques. Because the IRAS observations of FL29 were made at the limits of the survey sensitivity and at different twist angles it was necessary to make significant technical advances in the methods used in the processing and analyzing the data. In particular, if normal IRAS coaddition procedures were used, the noise resulting from coaddition of the multiple frames did not decrease in the manner expected once significantly different twist angles were included in the coaddition. The technical effort needed to reduce the observations of FL29 was completed and now the noise behavior is understood and well behaved. The reduction of the field FL29 observations is done.

Neugebauer, G.↗

The Use of Field Programmable Gate Arrays (FPGA) in Small Satellite Communication Systems

This paper will describe the use of digital Field Programmable Gate Arrays (FPGA) to contribute to advancing the state-of-the-art in software defined radio (SDR) transponder design for the emerging SmallSat and CubeSat industry and to provide advances for NASA as described in the TAO5 Communication and Navigation Roadmap (Ref 4). The use of software defined radios (SDR) has been around for a long time. A typical implementation of the SDR is to use a processor and write software to implement all the functions of filtering, carrier recovery, error correction, framing etc. Even with modern high speed and low power digital signal processors, high speed memories, and efficient coding, the compute intensive nature of digital filters, error correcting and other algorithms is too much for modern processors to get efficient use of the available bandwidth to the ground. By using FPGAs, these compute intensive tasks can be done in parallel, pipelined fashion and more efficiently use every clock cycle to significantly increase throughput while maintaining low power. These methods will implement digital radios with significant data rates in the X and Ka bands. Using these state-of-the-art technologies, unprecedented uplink and downlink capabilities can be achieved in a 1/2 U sized telemetry system. Additionally, modern FPGAs have embedded processing systems, such as ARM cores, integrated inside the FPGA allowing mundane tasks such as parameter commanding to occur easily and flexibly. Potential partners include other NASA centers, industry and the DOD. These assets are associated with small satellite demonstration flights, LEO and deep space applications. MSFC currently has an SDR transponder test-bed using Hardware-in-the-Loop techniques to evaluate and improve SDR technologies.

Varnavas, Kosta↗

Demonstration of How Manufacturing Innovations Challenge Conventional Structural Design

For almost 100 years, commercial aircraft have been fabricated using riveted aluminum alloy structures. Aside from refining aircraft designs for better aerodynamic efficiency, improving alloy compositions, and automating assembly steps, fuselage construction remains largely unchanged today. The intent of the lightweight metallic fuselage prototype undertaken in NASA’s Advanced Air Transport Technology project was to demonstrate innovative forming and joining processes that advance the design paradigm, i.e. achieve high-rate manufacturing and reduce assembly time/costs. Over the past decade, researchers at NASA Langley Research Center have evaluated the potential to modify the flow forming process to produce near-net shaped cylinders, integrally stiffened along the cylinder axis, for space launch vehicles. The production of integral stiffeners in a formed aluminum cylinder, the size of the Space Shuttle external tank, replaced machined thick plate and welding steps to eliminate > 500,000 pounds of machining chips and ~ 0.5 miles of welds. The flow forming method, called the Integrally Stiffened Cylinder (ISC) process, was successfully demonstrated up to the 10-foot diameter scale, which laid the groundwork for the current investigation of metallic fuselage structures. Using the ISC process as the basis for the re-design of a metallic fuselage eliminates hundreds of thousands of holes and rivets, while significantly reducing assembly time and crack initiation sites in the integral structure. However, the ISC process is not currently configured to fabricate circumferential ring frames for carrying fuselage internal pressure loads. Consequently, a trade study was performed to assess existing and advanced manufacturing processes, including additive manufacturing, forming, and welding. The approach with the lowest barriers to success, while simultaneously improving manufacturing time and cost, was to use formed ring frame segments attached to the ISC via Refill Friction Stir Spot Welding (RFSSW). The RFSSW process is five times faster than drilling, reaming, and riveting and provides similar mechanical performance. Finishing the fuselage structure with conventional windows, floor beams, and floor panels can then be accomplished using incumbent assembly methods, thereby maximizing reuse of existing infrastructure for aircraft construction. Structural analyses were performed to assess and optimize the geometric variables of integrated skin and stiffener configurations. A cost benefit and manufacturing rate analysis was also performed to compare against the current state-of-the-art for single aisle transport class aircraft. The resulting structure offers a weight reduction that rivals current graphite-epoxy composite fuselage structures. The projected manufacturing rate is close to double current metallic fuselages and six times faster than current composite manufacturing practices. The damage tolerance properties of a monocoque fuselage structure have yet to be assessed, but past integral airframe structural work has exploited geometric features to blunt or turn cracks. This concept offers promise that integrated structures can meet stringent aircraft durability specifications. An important benefit is that such aluminum fuselage structures may be inspected and repaired using established practices and existing expertise. Finally, pursuit of advanced manufacturing processes for future aluminum fuselages minimizes waste and the structure is 100% recyclable at the end-of-life for maximum sustainability.

aluminum↗