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Technical Paper
John F. Lewis, John Granahan, Matt Russell, John Lumpkin
Abstract: One of the most critical functions of ECLSS is to maintain the atmospheric oxygen concentration within habitable limits. On the ISS, this function is provided by the Major Constituent Analyzer (MCA). During ISS (International Space Station) crew increments 7 thru 9, the MCA was at risk of imminent failure as evident by sustained high ion-pump current levels. In the absence of continuous constituent measurement by the MCA, manual methods of estimating partial pressure of oxygen (ppO2) and concentration levels need to be developed and validated to: (1) ensure environmental control and life support, (2) prohibit ISS system and hardware damage, and (3) enable planned ISS activities that effect constituent balance.
Technical Paper
Alan Drysdale
ALS metrics are required to meet congressional requirements, but if they are well thought out will help focus technical efforts in appropriate and productive directions. This paper addresses the benefits and limitations of using equivalent system mass as an ALS metric.
Technical Paper
Tim Brown, John Hartmann, Peter Zieve, Mark Woods
The Boeing 787 Dreamliner will be the most fuel-efficient airliner in the world when it enters service in 2008. To help achieve this, Boeing will utilize state-of-the-art carbon fiber for primary structures. Advanced manufacturing techniques and processes will be used in the assembly of large composite structures. Electroimpact has proposed a system utilizing the low recoil Low Voltage Electromagnetic Riveter (LVER) to drill and install bolts. A test program was initiated between Boeing Materials Process and Engineering (MP&E) and Electroimpact to validate the LVER process for swaging titanium collars on titanium pins in composite material. This paper details the results of these tests.
Technical Paper
Matthew J. Pohlman, Jerry Varsik, John W. Steele, Johnny L. Golden, William E. Boyce, Michael D. Pedley
Increased nickel concentrations in the IATCS coolant prompted a study of the corrosion rates of nickel-brazed heat exchangers in the system. The testing has shown that corrosion is occurring in a silicon-rich intermetallic phase in the braze filler of coldplates and heat exchangers as the result of a decrease in the coolant pH brought about by cabin carbon dioxide permeation through polymeric flexhoses. Similar corrosion is occurring in the EMU de-ionized water loop. Certain heat exchangers and coldplates have more silicon-rich phase because of their manufacturing method, and those units produce more nickel corrosion product. Silver biocide additions did not induce pitting corrosion at silver precipitate sites.
Journal Article
Pinar Acar, Avinkrishnan A. Vijayachandran, Veera Sundararaghavan, Anthony Waas, Mostafa Rassaian
Abstract Minimizing the stress concentrations around cutouts in a plate is often a design problem, especially in the Aerospace industry. A problem of optimizing spatially varying fiber paths in a symmetric, linear orthotropic composite laminate with a cutout, so as to achieve minimum stress concentration under remote unidirectional tensile loading is of interest in this study. A finite element (FE) model is developed to this extent, which constraints the fiber angles while optimizing the fiber paths, proving essential in manufacturing processes. The idea to be presented could be used to derive fiber paths that would drastically reduce the Stress Concentration Factor (SCF) in a symmetric laminate by using spatially varying fibers in place of unidirectional fibers. The model is proposed for a four layer symmetric laminate, and can be easily reproduced for any number of layers.
Technical Paper
Paul E. Jennerjohn
Abstract The use of paint automation in commercial aircraft production is being studied to reduce process cycle times, provide a higher quality paint finish, lower emissions, and increase process consistency. The cost of new aircraft paint hangars and increasing production rates is driving a need for increased capacity in existing facilities by using new coatings and technology. Testing of robotic painting at Boeing has uncovered unique differences between aerospace and automotive applications. Paint cure times, number of paint colors, environment control, and part size considerations are some of the issues that make aerospace application of coatings more difficult than automotive applications. Understanding the unique factors involved in the robotic application of commercial aerospace coatings is important for future advancements in application technology, gains in aircraft paint hangar capacity, delivering quality coating finishes, and lowering environmental footprint.
Technical Paper
Scott Tomchick, Joshua Elrod, Dave Eckstein, James Sample, Dan Sherick
Abstract A new automated production system for installation of Lightweight Groove Proportioned (LGP) and Hi-Lock bolts in wing panels has been implemented in the Boeing 737 wing manufacturing facility in Renton, Washington. The system inserts LGP and Hi-Lok bolts into interference holes using a ball screw mechanical squeeze process supported by a back side rod-locked pneumatic clamp cylinder. Collars are fed and loaded onto a swage die retaining pin, and swaging is performed through ball screw mechanical squeeze. Offset and straight collar tools allow the machine to access 99.9% of fasteners in 3/16″, ¼″ and 5/16″ diameters. Collar stripping forces are resolved using a dynamic ram inertial technique that reduces the pull on the work piece. Titanium TN nuts are fed and loaded into a socket with a retaining spring, and installed on Hi-Loks Hi-Lok with a Bosch right angle nut runner.
Technical Paper
Sami Movsesian
In the wake of the 9/11/2001 hijacking events, the Federal Aviation Administration (FAA) has emphasized the need for enhanced flight deck doors on commercial airplanes. The paper describes enhanced flight deck door, which meets the new FAA requirements for intrusion resistance and ballistic protection. In addition, the new door meets the existing requirements for rapid decompression, flight crew security and rescue.
Alan Hiken, Dan Day, David M. Champa, George Nicholas Bullen, Carroll G. Grant
This essential information captures the state of the composites industry to assist engineering/technical professionals in charting a course for achieving economic success. The material characteristics of composites, their applications, and complex composites manufacturing processes depend on many factors. These are all fully considered and presented to meet the challenges that face this marketplace.
U.S. National Transportation Safety Board on April 23-24 will hold a hearing focusing on the design and certification of the 787's battery system.
Boeing entered into an agreement with India-based TAL Manufacturing Solutions, a wholly owned subsidiary of Tata Motors, for manufacturing structural components for the 787 Dreamliner program. Under the agreement, TAL will build floor beams for the 787 using new technology with advanced titanium and composite materials.
The Boeing Co. completed a detailed site survey of the Terma facility in Grenaa, Denmark, to assess its capabilities for possible commercial airplanes work. Boeing is moving forward with a plan to build long-term, sustainable partnerships with Danish industry as part of an industrial cooperation program for its F/A-18E/F Super Hornet bid in Denmark’s New Combat Aircraft competition.
Boeing on Oct. 21 celebrated the groundbreaking of its new 777X Composite Wing Center at the Everett, WA, campus. Permitting for the new 1 million-ft² facility was completed seven weeks earlier than anticipated, allowing for an accelerated start to construction.
Boeing and Mubadala Aerospace signed a 10-year direct contract for Strata Manufacturing, Mubadala Aerospace's advanced composite aerostructures facility in Al Ain, Abu Dhabi, to produce commercial composite aerostructures for the 777 and 787 Dreamliner.
Composite supplier Toray Industries signed an agreement to expand its current contract for the Boeing 787 Dreamliner to include the 777X wings. The addition of the 777X to the current 787 contract represents a significant increase in the material provided to Boeing by Toray.
SPF can be used to produce complex shapes containing tight radii, Boeing researcher finds.
A widely used material for lightning strike protection of CFRP structures within the aerospace industry is expanded metal foil (EMF). An issue with EMF is micro cracking of the paint, which can result in corrosion of the metal foil and subsequent loss of conductivity. Boeing researchers examined the issues of stress and displacement in the composite structure layup, which contribute to paint cracking caused by aircraft thermal cycling.
Polymer composites made with fibers covered in "forests" of carbon nanotubes are tougher than traditional unmodified fiber-reinforced polymer composites.
Boeing elected Aerojet to supply heavy alloy weights for Boeing's Composite Main Rotor Blade in support of the AH-64D Apache Block III (AB3) program. Aerojet will deliver completed rotor weights to support Boeing's production of the U.S.
The Boeing Co. and Canadian industry partners have launched a new research and development consortium aimed at strengthening Canada's position in the manufacturing of advanced composite materials for aerospace and other industries.
Boeing, Embraer, and the Sao Paulo State Research Foundation (FAPESP) announced plans to collaborate on long-term aviation biofuels-related research and development. Boeing, Embraer, and FAPESP are leading the development of a detailed report outlining the opportunities and challenges of creating a cost-effective, bio-derived, and sustainable jet-fuel production and distribution industry in Brazil.
Boeing awarded Magellan Aerospace Corp. a contract for the continuation of the production of complex, hard metal structural assemblies for the next-generation 737, 747-8, 767, 777, and the production of such assemblies for the new 787 Dreamliner airplanes.
Two heavyweights in the automotive and aerospace industries are joining minds on lighter materials. BMW and Boeing on Dec. 12 announced they would do joint research on carbon-fiber recycling and share knowledge about the material and its manufacture.
A family of water-based sol-gel coatings from Boeing were developed to replace conventional finishing materials and processes. One formulation, Boegel-EPII, is a nonhazardous coating that can be applied to a range of substrates (aluminum, titanium, nickel, steel) using a variety of methods (dip, immersion, spin, brushing, spraying). Applications beyond adhesion promoter include corrosion control and conductive coatings.
Combinations such as composites and titanium being used in future aircraft programs can be very challenging when drilling holes during manufacturing and assembly operations.
Engineers at NASA and Boeing are amongst the believers who foresee folding wings in-flight using advanced materials and technologies being a potential game-changer for future aircraft. The two organization have teamed to develop an actuation system that uses an SMA that will accomplish this goal using less complex, lighter, and more compact hardware than conventional systems.
The TenCate Advanced Composites Group in Morgan Hill, CA, reached a long-term supply agreement with The Boeing Co. This five-year contract extension culminates a multiyear initial design and build effort on compression-molded hydraulic and fuel line clamp assemblies for the Boeing 787 Dreamliner.
Boeing 787 Dreamliner will be first commercial airplane to fly with FAA-certified, additive-manufactured titanium structural components.
Usage of composite materials is increasing in the aerospace industry. However, the materials are difficult to machine. Specific problems are the excessive abrasive nature of the composite material and the poor thermal conductivity of titanium (about one-sixth that of steels).
Messier-Dowty completed on July 20 what it says is the first successful takeoff and landing of a commercial flight test aircraft equipped with composite braces on the main landing gear. The test flight is the culmination of major design and development efforts to introduce composite technologies on key structural landing gear components for the Boeing 787 program.
Viewing 1 to 30 of 35


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