Technology Update
Osprey makes its return to flight
 An improved MV-22 Osprey makes its return to flight testing after being grounded nearly 17 months ago. |
The MV-22 Osprey returned to flight testing in late May since being grounded over 17 months ago. The first MV-22 test aircraft to resume flying features improvements in its hydraulic and flight control software systems to improve safety. According to Col. Dan Schultz, V-22 Program Manager, the flight plan for the test flight called for the aircraft to take off, hover, and land. After successfully completing several vertical takeoffs, landings, and hovering maneuvers over the runway, pilots conducted rearward and sideward flights to check the aircraft's maneuverability in helicopter mode. The pilots gradually built up maneuver speeds up and down the runway, went into landing pattern circuits, and began conversion work. Later in the testing, the Osprey performed a full conversion to airplane mode at level flight speeds of 250 kts. The Osprey logged nearly 2.5 h of flight time during its first day of testing.
Tom MacDonald and Bill Leonard, senior Bell Boeing V-22 Integrated Test Team pilots, who have a combined total of 13,000 flight hours in both fixed- and rotary-wing aircraft and over 500 hours each in the MV-22, took the aircraft through a series of maneuvers to evaluate its handling and performance. Part of this series included converting out from helicopter to airplane mode to take standard vibration measurements to check out the tracking and balance of the individual blades of the two proprotors.
In preparation for its return to flight, several days of aircraft ground runs and a systems checkout were conducted so both pilots would have further opportunity to reacquaint themselves with the aircraft's cockpit prior to the actual flight. As part of their training for this flight, Macdonald and Leonard had a dress rehearsal simulation at the Manned Flight Simulator, which allowed them to practice the first flight following the development of the actual test cards and procedures, with the telemetry room engineering team directing the flight and monitoring the progress and instrumentation in the control room.
The Osprey's return to flight marks the beginning of an 18-month developmental flight test plan that will validate the engineering and design changes made to the aircraft and continue with developmental testing that will further test such areas as vortex-ring state boundaries, dynamic shipboard compatibility, formation flying, and low-speed hovering and landing conditions. Other areas to be tested include the aircraft's icing, cargo handling, and radar warning systems. A total of 1800 flight test hours are scheduled over this period of time using seven MV-22 aircraft.
- Frank Bokulich
Howmet offers F-22 casting alternatives
 Howmet will provide cast parts for a variety of components on the F-22, including the arresting gear. |
Howmet Castings, a business of Alcoa, has been awarded $8 million in new contracts for large titanium castings for the F-22. The contracts, issued by the Boeing Co., cover LOT 2 procurement of existing side-of-body and aileron castings. The order also includes a new component, the F-22 arresting gear. Delivery of the first unit is scheduled for October 2002.
According to William Lahavich, Howmet's Director of Airframe Sales and Marketing, a growing number of airframe components are being converted to castings because they save time and money. "Howmet supplies an increasing number of components for airframe applications," he said. "We find that, generally, airframers will not proceed with a conversion unless cost savings of 30% or more are realized. It is also typical to realize cycle-time advantages of 50%."
However, factors beyond cost savings and production speed are accelerating the conversion to castings, claims the company. These factors include advances in casting process control, inspection techniques, and end-product predictability, all of which enhance product quality. "We are making inroads with customers on 'design allowables,' which permit the use of castings in fracture-critical applications," said Lahavich. "These shifts, coupled with Howmet's ability to offer design services and finished-to-print capabilities, extend to the customer a complete supply-chain solution."
Howmet's Prime Operation unit will manage post-cast manufacturing processes and deliver ready-to-install components for the F-22. Lahavich says that continuing advances in the casting process and the in-use performance achievements of cast components are likely to open the door to wider application of these part types in future platforms.
- Frank Bokulich
Boeing develops innovative cabin soundproofing method
Engineers at Boeing are working on a technology that could actively suppress unwanted sound inside airplanes and even make life more comfortable for astronauts in space. The technology, called "fluidic wallpaper," has many potential applications for protection, privacy and stealth, and is being developed by Boeing Phantom Works.
Anders Andersson, a Phantom Works Technical Fellow in Seattle, said the system promises to be "a breakthrough in acoustics technology."
The wallpaper is an active-control system using "smart" materials and will be about 0.25-in. thick. It will employ compressed air to counterbalance oscillating pressures that make up low-frequency noise emitted by systems such as propellers and jet engines.
Reducing sound has traditionally commanded heavyweight solutions, such as layers of sound-suppression materials that give vehicles added weight and cost. Fluidic wallpaper would weigh much less than traditional materials, take up less space, and be produced inexpensively. The compressed air used within the wallpaper could be generated by aircraft engines or air-conditioning systems and would not require electrical power.
Unwanted sound currently is controlled by various methods. The first strategy Boeing uses is to design systems that are quiet in the first place. When necessary, however, noise treatment measures must be developed. Current treatments include: acoustic panels in the engine enclosure; insulation and vibration-damping materials in the fuselage walls; vibration isolation mounts for mechanical equipment; and mufflers in the air-conditioning and auxiliary power unit systems.
Andersson foresees plenty of applications for fluidic wallpaper. Some of these include: wall trim in commercial airplanes and in executive and military aircraft to satisfy command-post communication and stealth requirements; noise treatment for armored vehicles; and rocket fairing liners for protecting sensitive satellite payloads from noise generated at launch.
Information was provided by William Cole, the Boeing Co.
Engine troubleshooting via the Web
 Honeywell has added an engine troubleshooting service called Spotlight to its e-Engine Website. |
Honeywell has added a new TFE731 engine troubleshooting service called "Spotlight" to its e-Engine Website. Working with Casebank Technologies, the company's Spotlight software system uses field service reports, maintenance manuals, and troubleshooting experience to lead technicians to the most relevant solutions based on a maintenance problem type. Spotlight will also assist pilots and mechanics by identifying previously experienced maintenance issues and how those problems were solved.
"Honeywell Field Service Engineers have been using the program for more than a year and have been able to significantly reduce their troubleshooting times," said Rob Richardson, Manager, e-Engine, Honeywell Engines Systems & Services. Spotlight is now available to all Honeywell authorized service centers, and was to be released to all MSP operators in June 2002. Additional troubleshooting tools for APUs, CFE738, and AS907 are currently in development and will be available between July and early next year.
Honeywell's e-Engine is capable of integrating information from several aircraft data systems and will provide operators with:
- Engine Condition Trend Monitoring (ECTM) and Jet-Care Analysis
- Technical Publications and Engine/GSE Software Downloads
- Electronic logbook compatible with Aircraft Technical Publishers (ATP) maintenance director software
- Communications tools for operators and service centers.
Since the launch of e-Engine at www.e-engine.Honeywell.com nearly 20 months ago, more than 2000 users representing 880 owner/operators of business and regional aircraft and 173 service providers have used the service for aircraft and engine maintenance operation and support activities. Use of the e-Engine website has nearly doubled to more than 40,000 logons since September of 2001.
- Frank Bokulich
