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Advanced Technology Composite Fuselage - Materials and Processes

The goal of Boeing's Advanced Technology Composite Aircraft Structures (ATCAS) program was to develop the technology required for cost and weight efficient use of composite materials in transport fuselage structure. This contractor report describes results of material and process selection, development, and characterization activities. Carbon fiber reinforced epoxy was chosen for fuselage skins and stiffening elements and for passenger and cargo floor structures. The automated fiber placement (AFP) process was selected for fabrication of monolithic and sandwich skin panels. Circumferential frames and window frames were braided and resin transfer molded (RTM'd). Pultrusion was selected for fabrication of floor beams and constant section stiffening elements. Drape forming was chosen for stringers and other stiffening elements. Significant development efforts were expended on the AFP, braiding, and RTM processes. Sandwich core materials and core edge close-out design concepts were evaluated. Autoclave cure processes were developed for stiffened skin and sandwich structures. The stiffness, strength, notch sensitivity, and bearing/bypass properties of fiber-placed skin materials and braided/RTM'd circumferential frame materials were characterized. The strength and durability of cocured and cobonded joints were evaluated. Impact damage resistance of stiffened skin and sandwich structures typical of fuselage panels was investigated. Fluid penetration and migration mechanisms for sandwich panels were studied.

Scholz, D. B.↗

Midtail plasma flows and the relationship to near-Earth substorm activity: A case study

Recent simulations of magnetotail reconnection have pointed to a link between plasma flows, dipolarization, and the substorm current wedge. In particular, Hesse and Birn (1991) have proposed that earthward jetting of plasma from the reconnection region transports flux into the near-Earth region. At the inner edge of the plasma sheet this flux piles up, producing a dipolarization of the magnetic field. The vorticity produced by the east-west deflection of the flow at the inner edge of the plasma sheet gives rise to field-aligned currents that have region 1 polarity. Thus in this scenario the earthward flow from the reconnection region produces the dipolarization ad the current wedge in a self-consistent fashion. In this study we examine observations made on April 8, 1985 by the Active Magnetospheric Particle Tracer Explorers (AMPTE)/Ion Release Module (IRM), the geosynchronous satellites 1979-053, 1983-019, and 1984-037, and Syowa station, as well as AE. This event is unique because IRM was located near the neutral sheet in the midnight sector for am extended period of time. Ground data show that there was ongoing activity in the IRM local time sector for several hours, beginning at 1800 UT and reaching a crescendo at 2300 UT. This activity was also accompanied by energetic particle variations, including injections, at geosynchronous orbit in the nighttime sector. Significantly, there were no fast flows at the neutral sheet until the great intensification of activity at 2300 UT. At that time, IRM recorded fast eartheard flow simultaneous with a dipolatization of the magetic field. We conclude that while the aforementioned scenario for the creation of the current wedge encounters serious problems explaining the earlier activity, the observations at 2300 UT are consistent with the scenario of Hesse and Birn (1191). On that basis it is argued that the physics of substorms is not exclusively rooted in the development of a global tearing mode. Processes at the inner edge of the cross-tail current that cause a disruption of the current and a consequent dipolarization and current wedge may be unrelated to the formation of a macroscale reconnection region. Thus the global evolution of a substorm is probably a complicated superposition of such processes operating on a very localized scale and a global macroscale process that allows for such things as releasing te energy stored in lobe flux and creation of plasmoids.

Lopez, R. E.↗

Microactuator production via high aspect ratio, high edge acuity metal fabrication technology

LIGA is a procession sequence which uses x-ray lithography on photoresist layers of several hundred micrometers to produce very high edge acuity photopolymer molds. These plastic molds can be converted to metal molds via electroplating of many different metals and alloys. The end results are high edge acuity metal parts with large structural heights. The LIGA process as originally described by W. Ehrfeld can be extended by adding a surface micromachining phase to produce precision metal parts which can be assembled to form three-dimensional micromechanisms. This process, SLIGA, has been used to fabricate a dynamometer on a chip. The instrument has been fully implemented and will be applied to tribology issues, speed-torque characterization of planar magnetic micromotors and a new family of sensors.

Guckel, H.↗

Burst Testing of Triaxial Braided Composite Tubes

Applications using triaxial braided composites are limited by the materials transverse strength which is determined by the delamination capacity of unconstrained, free-edge tows. However, structural applications such as cylindrical tubes can be designed to minimize free edge effects and thus the strength with and without edge stresses is relevant to the design process. The transverse strength of triaxial braided composites without edge effects was determined by internally pressurizing tubes. In the absence of edge effects, the axial and transverse strength were comparable. In addition, notched specimens, which minimize the effect of unconstrained tow ends, were tested in a variety of geometries. Although the commonly tested notch geometries exhibited similar axial and transverse net section failure strength, significant dependence on notch configuration was observed. In the absence of unconstrained tows, failure ensues as a result of bias tow rotation, splitting, and fracture at cross-over regions.

Triaxial Braided Composites↗

Wire Detection Algorithms for Navigation

In this research we addressed the problem of obstacle detection for low altitude rotorcraft flight. In particular, the problem of detecting thin wires in the presence of image clutter and noise was studied. Wires present a serious hazard to rotorcrafts. Since they are very thin, their detection early enough so that the pilot has enough time to take evasive action is difficult, as their images can be less than one or two pixels wide. Two approaches were explored for this purpose. The first approach involved a technique for sub-pixel edge detection and subsequent post processing, in order to reduce the false alarms. After reviewing the line detection literature, an algorithm for sub-pixel edge detection proposed by Steger was identified as having good potential to solve the considered task. The algorithm was tested using a set of images synthetically generated by combining real outdoor images with computer generated wire images. The performance of the algorithm was evaluated both, at the pixel and the wire levels. It was observed that the algorithm performs well, provided that the wires are not too thin (or distant) and that some post processing is performed to remove false alarms due to clutter. The second approach involved the use of an example-based learning scheme namely, Support Vector Machines. The purpose of this approach was to explore the feasibility of an example-based learning based approach for the task of detecting wires from their images. Support Vector Machines (SVMs) have emerged as a promising pattern classification tool and have been used in various applications. It was found that this approach is not suitable for very thin wires and of course, not suitable at all for sub-pixel thick wires. High dimensionality of the data as such does not present a major problem for SVMs. However it is desirable to have a large number of training examples especially for high dimensional data. The main difficulty in using SVMs (or any other example-based learning method) is the need for a very good set of positive and negative examples since the performance depends on the quality of the training set.

Kasturi, Rangachar↗

On sound radiation from the trailing edge of an isolated airfoil in a uniform flow

An experimental investigation has been conducted to determine the physical process of the noise production from the trailing edge of an isolated two-dimensional airfoil embedded in a low turbulence uniform mean flow. The Reynolds number of the airfoil based on chord was greater than 1,000,000 and that the boundary layer was fully turbulent at the trailing edge. Smoke injection technique and spark shadowgraphy were used to study the structural features of the boundary layer. Two point joint statistical analyses were made on the surface pressure, the radiated sound and the relationship between the two quantities. Operating conditions included two free stream velocities and two angles of attack for both a naturally developed and an artificially tripped boundary layer. Flow visualizations revealed the existence of large scale coherent motions in the outer region of the boundary layer. The observed coherent motions had scales of the order of boundary layer thickness and a convection velocity near the free stream velocity. The production process of the airfoil trailing edge noise was determined to be the convection of the large scale coherent eddies over the trailing edge of the airfoil. The noise field so generated was found to be rather coherent and dipole-like.

Yu, J. C.↗

Quantification of geologic lineaments by manual and machine processing techniques

A study was conducted to investigate the effect of operator variability and subjectivity in lineament mapping and to examine methods to minimize or eliminate these problems by use of several machine preprocessing methods. LANDSAT scenes from the Anadarko Basin of Oklahoma and the Colorado Plateau were analyzed as test cases. Four geologists mapped lineaments on an Anadarko Basin scene, using transparencies of MSS bands 4-7, and their results are compared statistically. The total number of fractures mapped by the operators and their average lengths varied considerably, although comparison of lineament directions revealed some consensus. A summary map (785 linears) produced by overlaying the maps generated by the four operators showed that only 0.4% were recognized by all four operators, 4.7% by three, 17.8% by two and 77% by one operator. Two methods of machine aided mapping were tested, both simulating directional filters. One consists of computer (digital) processing of CCTs using edge enhancement algorithms, the other employs a television (analog) scanning of an image transparency which superimposes the original image and one offset in the direction of the scan line.

Podwysocki, M. H.↗

Logarithmic spiral grids for image processing

A picture digitization grid based on logarithmic spirals rather than Cartesian coordinates is presented. Expressing this curvilinear grid as a conformal exponential mapping reveals useful image processing properties. The mapping induces a computational simplification that suggests parallel architectures in which most geometric transformations are effected by data shifting in memory rather than arithmetic on coordinates. These include fast, parallel noise-free rotation, scaling, and some projective transformations of pixel defined images. Conformality of the mapping preserves local picture-processing operations such as edge detection.

Weiman, C. F. R.↗

An optimized cubic interpolator for image resampling

It is noted that the cubic resampling function is only one member of a family of functions, defined by the single parameter of the slope of the cubic function at its first zero crossing, whose other members are in some cases superior to the standard cubic. This superiority is especially noteworthy with respect to the extent of gray level overshoot induced by the resampling process at high contrast edges. It is shown that there is an optimum member of this 'parametric cubic convolution' family which minimizes the mean-squared radiometric error arising from interpolation. This interpolator requires no additional computation time over the conventional cubic one. These conclusions are supported and illustrated by resampling simulations with both a high resolution digitized aerial image and a Landsat Multispectral Scanner image.

Schowengerdt, R. A.↗

Silicon sheet surface studies

Results of the program are presented on developing an understanding of the basic mechanisms of abrasion and wear of silicon and on the nondestructive measurement of residual stresses in sheet silicon. Experiments were conducted at various temperatures and in the presence of various fluids. In abrasive wear, it was shown that dislocations, microtwins, and cracks are generated beneath the contact surface. Residual stresses in ribbon by the edge defined film growth process were measured by use of a shadow moire interferometry technique.

Danyluk, S.↗

A new method for recognizing quadric surfaces from range data and its application to telerobotics and automation

Pose and orientation of an object is one of the central issues in 3-D recognition problems. Most of today's available techniques require considerable pre-processing such as detecting edges or joints, fitting curves or surfaces to segment images, and trying to extract higher order features from the input images. We present a method based on analytical geometry, whereby all the rotation parameters of any quadric surface are determined and subsequently eliminated. This procedure is iterative in nature and was found to converge to the desired results in as few as three iterations. The approach enables us to position the quadric surface in a desired coordinate system, and then to utilize the presented shape information to explicitly represent and recognize the 3-D surface. Experiments were conducted with simulated data for objects such as hyperboloid of one and two sheets, elliptic and hyperbolic paraboloid, elliptic and hyperbolic cylinders, ellipsoids, and quadric cones. Real data of quadric cones and cylinders were also utilized. Both of these sets yielded excellent results.

Alvertos, Nicolas↗

Spectral evidence for stirring scales and two-dimensional turbulence in the auroral ionosphere

Electric field power spectra from two auroral sounding rocket flights show evidence of a distinct scale size regime for injection of energy into the auroral oval. The signature of this process is a broad plateau in the spectrum, with power law dependences at both shorter and longer scale sizes. We argue that the spectral properties at high k are dominated by processes occurring near the edges of inverted-V electron precipitation regions (auroral arcs). We see no compelling reason to conclude that a linear local plasma instability is occurring but rather, that nonlinear mixing and forward cascade yield the observed velocity field. The spectra of simultaneously observed density irregularities are quite different from those of the electric field, implying that the plasma density does not behave as a passive scalar in the auroral zone during active conditions. At low-k values we show that the rocket spectra are consistent with the power spectra of magnetospheric electric fields measured by the DE, AE-C, and Hilat stallites.

Earle, G. D.↗

A robust line extraction and matching algorithm

This paper presents an algorithm for extracting straight lines from intensity mages and describes a line matching algorithm for solving the line correspondence problem. The line extraction process begins by detecting edges in the intensity image. Next, line support regions are formed where image points (pixels) have similar gradient orientation. A line fitting algorithm is then used to fit a line to the points in the line support region based on a least means square fitting algorithm. Finally, line segments are linked together to form the final lines by using an adaptive line linking method; this results in much stronger lines and a smaller set of lines to be considered. Once the lines are detected in a sequence of images, a line matching algorithm is used to match lines in one image to the lines in the other image. The images are either from a motion or stereo sequence. The matched lines may then be used with the sensor position and orientation data to estimate range to objects corresponding to the lines. We present results based on applying the line extraction and line matching algorithms to a synthetic image and an outdoor scene captured by a camera on a helicopter.

Hussien, B.↗

Laser Heated Oxide Fiber Growth Using Melt Modulation Technique

As a reinforcement for structural composites, single crystal alumina fibers offer low density, high modulus, and high creep resistance. In this study, the laser heated float zone approach was employed to grow c-axis Al2O3 continuous fibers of high purity and high strength. A new melt modulation technique, laser scanning, avoids the formation of surface induced ripples and allows the growth of 50 micro-m diameter sapphire fibers with strengths (approx. 7 GPa) significantly greater than either commercially available fibers grown by the edge-defined film growth process (approx. 2-3 GPa) or laboratory fibers grown by stationary laser heating (approx. 5 GPa). The present work suggests that surface striations are the predominant defects controlling the tensile strength of laser-scanned fibers at room temperature. Several possible mechanisms for inducing surface striations are systematically discussed for several oxide fiber compositions.

Sayir, Ali↗

Improved Discrete Approximation of Laplacian of Gaussian

An improved method of computing a discrete approximation of the Laplacian of a Gaussian convolution of an image has been devised. The primary advantage of the method is that without substantially degrading the accuracy of the end result, it reduces the amount of information that must be processed and thus reduces the amount of circuitry needed to perform the Laplacian-of- Gaussian (LOG) operation. Some background information is necessary to place the method in context. The method is intended for application to the LOG part of a process of real-time digital filtering of digitized video data that represent brightnesses in pixels in a square array. The particular filtering process of interest is one that converts pixel brightnesses to binary form, thereby reducing the amount of information that must be performed in subsequent correlation processing (e.g., correlations between images in a stereoscopic pair for determining distances or correlations between successive frames of the same image for detecting motions). The Laplacian is often included in the filtering process because it emphasizes edges and textures, while the Gaussian is often included because it smooths out noise that might not be consistent between left and right images or between successive frames of the same image.

Shuler, Robert L., Jr.↗

Automated Solvent Seaming of Large Polyimide Membranes

A solvent-based welding process enables the joining of precise, cast polyimide membranes at their edges to form larger precise membranes. The process creates a homogeneous, optical-quality seam between abutting membranes, with no overlap and with only a very localized area of figure disturbance. The seam retains 90 percent of the strength of the parent material. The process was developed for original use in the fabrication of wide-aperture membrane optics, with areal densities of less than 1 kg/m2, for lightweight telescopes, solar concentrators, antennas, and the like to be deployed in outer space. The process is just as well applicable to the fabrication of large precise polyimide membranes for flat or inflatable solar concentrators and antenna reflectors for terrestrial applications. The process is applicable to cast membranes made of CP1 (or equivalent) polyimide. The process begins with the precise fitting together and fixturing of two membrane segments. The seam is formed by applying a metered amount of a doped solution of the same polyimide along the abutting edges of the membrane segments. After the solution has been applied, the fixtured films are allowed to dry and are then cured by convective heating. The weld material is the same as the parent material, so that what is formed is a homogeneous, strong joint that is almost indistinguishable from the parent material. The success of the process is highly dependent on formulation of the seaming solution from the correct proportion of the polyimide in a suitable solvent. In addition, the formation of reliable seams depends on the deposition of a precise amount of the seaming solution along the seam line. To ensure the required precision, deposition is performed by use of an automated apparatus comprising a modified commercially available, large-format, ink-jet print head on an automated positioning table. The printing head jets the seaming solution into the seam area at a rate controlled in coordination with the movement of the positioning table.

Rood, Robert↗

Improved Edge Performance in MRF

The fabrication of large segmented optics requires a polishing process that can correct the figure of a surface to within a short distance from its edges-typically, a few millimeters. The work here is to develop QED's Magnetorheological Finishing (MRF) precision polishing process to minimize residual edge effects.

Shorey, Aric↗

Sliding mean edge estimation

A method for determining the locations of the major edges of objects in digital images is presented. The method is based on an algorithm utilizing maximum likelihood concepts. An image line-scan interval is processed to determine if an edge exists within the interval and its location. The proposed algorithm has demonstrated good results even in noisy images.

Ford, G. E.↗