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Electroimpact and Kawasaki Heavy Industries (KHI) have produced a new riveting process for the forming of Briles type rivets in Boeing 777 and 777X fuselage assemblies. The Briles rivet is typically used for fuselage assembly and is unique in that it has a self-sealing head. Unlike conventional headed rivets such as the NAS1079, this fastener does not require aircraft sealant under the head to be fluid tight. This unique fastener makes for a difficult fastening process due to the fact that interference must be maintained between the hole and fastener shank, as well as along the sides of the fastener head. Common issues with the formed fasteners include gapping under the fastener head and along the shank of the fastener. Electroimpact has employed a host of different technologies to combat these issues with Briles fastening. First, Electroimpact’s patented “Air Gap” system allows the machine to confirm that the head of the rivet is fully seated in the countersink prior to forming.

In the modern aircraft manufacturing, the cost reduction, the manufacturing time reduction, and the weight saving of aircraft are strongly demanded. The Refill Friction Spot Joining [1,2](FSJ, in other words FSSW, Friction Stir Spot Welding), which is one of innovative solid-state joining methodologies based on the Friction Stir Welding[3], is a promising technology that can replace rivets and fasteners. This technology is expected to offer cost reduction and weight saving for the aircraft manufacturing. In this study, to make stronger and reliable joints, the shoulder-plunging process of Refill FSJ was employed. The weldability of the Alodine or Chromic Acid Anodize coated materials along with a faying-surface sealant was investigated. The joint properties, such as tensile shear strengths and corrosion resistance, were evaluated.

In the expansion of composite material application, it is one of the most important subjects in assembly of aircraft structure how drilling of composite/metal stack should be processed in an efficient way. This paper will show the result of development of a drill bit for CFRP/Aluminum-alloy stack by Kawasaki Heavy Industries (KHI) and Sumitomo Electric Hardmetal (SEH). In order to improve workability and economic performance, the drill bit which enables drilling CFRP/Al-alloy stack: at 1 shot; from both directions; without air blow and coolant (just usual vacuuming); was required. A best mix drill bit which has smooth multi angles edge and pointed finishing edge was produced as a result of some trials. Developed drill bit achieved required performance and contributed to large cost reduction, labor hour saving, production speed increase and work environment improvement.

A Temperature and Humidity Control (THC) assembly an essential system in order to provide comfortable environment for crew members in Japanese Experiment Module (JEM). Development of an engineering model (EM) and a proto model (PM) of JEM THC assembly started from March 1991 and completed on March 1995 successfully. In this development phase, it is called JEM EM phase, qualification test of THC was conducted to verify the THC design. This paper presents JEM THC design and an outline of the assembly model development.

In the closed environments, removal of trace contaminants generated from persons, animals, and plants is important function to keep the environment below the allowable level. We conducted the fundamental tests in order to confirm design of TCCA (Trace Contaminants Control Assembly) for Closed Ecology Experiment Facilities (CEEF), and obtained the following results; 1) The palladium-on-alumina catalyst is suitable for CO, CH4, C2H4 conversion at temperature lower than 400°C. 2) The alkali impregnated AC (activated charcoal) is effective for NO2, SO2 removal and prevents catalyst poisoning from SO2. 3) The active-desorbing conducted by hot air blow-throw an AC is effective for C2H5OH, CH2Cl2 desorbing. We discuss the fundamental test and design conditions for TCCA.

In the closed environments such as manned space station, it is necessary to remove contaminant gas to keep a suitable environment. Removal of gaseous contaminants generated from crew, animals, and plants is important function to keep the environment below the allowable level in the Closed Ecology Experiment Facilities (abbreviated as CEEF). CEEF consist of three modules for habitat, animal and plant, the supporting facilities for each module and a plant cultivation facility. CEEF are scheduled to be constructed from 1994 in Aomori Prefecture, northern part of Japan. For designing Trace Contaminant Control Assembly (TCCA) for CEEF, the following six (6) trace contaminants have been selected as major contaminant gas in CEEF; Ammonia (NH3) Methane (CH4) Ethylene (C2H4) Carbon Monoxide (CO) Nitrogen Dioxide (NO2) Sulfur Dioxide (SO2) Ethylene is well-known as an aggressive contaminant to plant growth and maturity.