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Technical Paper

A Study on the Strength of Catalytic Converter Ultra Thin Wall Substrates

2003-03-03
2003-01-0662
Application of Ultra Thin Wall (UTW) ceramic substrates in the catalytic converter system requires the canner and component manufacturers to better understand the root cause and physics behind substrate breakage during the canning process. For this purpose, a ceramic substrate strength study for shoebox design has been conducted within Visteon Corporation. Computer Numerical Control (CNC) machined top and bottom fixtures, with identical inner surfaces as shoebox converter upper and lower shells, were used to crush mat wrapped substrates. Thin film pressure sensor technology enables the recording of substrate surface pressure during the compression process. Shell rib, washcoat, canning speed and cell density effects on substrate failure have been experimentally investigated. The development of a mathematical model helps to identify a better indicator to evaluate the substrate strength in the canning process and establish the strength for uncoated & coated substrates.
Technical Paper

Development of the Internal Thermal Control System (ITCS) for International Space Station (ISS)

2001-07-09
2001-01-2332
The International Space Station (ISS) internal thermal control system (ITCS) has been developed jointly by the Boeing Corporation, Huntsville, Alabama, and Honeywell Engines & Systems, Torrance, California, to meet ISS internal thermal control needs. The ITCS provides heat removal for the critical life support systems and thermal conditioning for numerous experiment racks. The ITCS will be fitted on a number of modules on the ISS. The first module, the US Laboratory Module, was launched in February 2001 and is now operational on the ISS. The dual loop system is comprised of a low-temperature loop (LTL) and a moderate-temperature loop (MTL). Each loop has a pump package assembly (PPA), a system flow control assembly (SFCA), a three-way mixing valve (TWMV), several rack flow control assemblies (RFCA), cold plates, pressure sensors, temperature sensors, a pump bypass assembly (PBA), and a heat exchanger.
Technical Paper

Correlation Study of Exhaust Manifold - Lab Test Results vs Customer Fleet Results

2002-03-04
2002-01-1317
The purpose of this study is to develop specifically a correlation between Exhaust Manifold Cracking Laboratory Test results and 150,000 mile customer fleet usage test results. The study shows that the exhaust manifold design meets the reliability requirements of 10 years or 150,000 miles, given 90th percentile customer usage without an evidence of cracking or audible leaks. This correlation between the Lab Test and the customer Fleet results has been expressed as an acceleration factor. An acceleration factor is the ratio of how much quicker the engine dynamometer test ( i.e. Lab Test ) can accumulate the effect of customer usage over time versus the customers themselves. The acceleration factor is provided for useful life time period of 10 years or 150,000 miles. The recommended acceleration factor, determined in this study, is 38 to 1, comparing the engine dynamometer test ( i.e. Lab Test ) results to 150,000 mile modular truck customer fleet field results.
Technical Paper

Fully Recyclable Olefinic Instrument Panels

2002-03-04
2002-01-0310
Recycled resins can meet performance requirements on products which were initially designed for virgin materials. Olefinic instrument panel (I/P) scrap is being recycled from the Mazda Tribute and the Ford Escape into glove box bins. As a result, a quality part is being supplied to the customer and Visteon's Saline Plant has realized both increased plant operating efficiencies and landfill cost avoidance. The development process is described including: plant regrind sources, part molding and testing.
Technical Paper

Electronics Environmental Testing in Perspective - A Fresh Approach

2003-03-03
2003-01-1360
A major part of product development is to validate robustness to the environment (e.g. temperature, vibration, EMC). Although much time and expense is spent doing so, using traditional approaches often leads to “feel good” results since the product “passes”. Such a false sense of security is misleading since such validation methods can have serious deficiencies. Presented is a Design Assurance process (Accelerated Stress Assurance Plan - ASAP) to validate modules that addresses these deficiencies. It places major emphasis on the analysis and development stages. It does not require large sample sizes, and overall test time and facilities is reduced (30-50% possible).. Just as for electronic modules, new and major changes to IC's need a shorter validation process. As an example, a relatively fast procedure for the production and application release of improved molding compounds for IC's is presented.
Technical Paper

Acoustic Modeling and Radiated Noise Prediction for Plastic Air-Intake Manifolds

2003-05-05
2003-01-1448
Reliable prediction of the radiated noise due to the air pressure pulsation inside air-intake manifolds (AIM) is of significant interest in the automotive industry. A practical methodology to model plastic AIMs and a prediction process to compute the radiated noise are presented in this paper. The measured pressure at the engine inlet valve of an AIM is applied as excitation on an acoustic boundary element model of the AIM in order to perform a frequency response analysis. The measured air pressure pulsation is obtained in the crank-angle domain. This pressure is read into MATLAB and transformed into the frequency domain using the fast Fourier transform. The normal modes of the structure are computed in ABAQUS and a coupled analysis in SYSNOISE is launched to couple the boundary element model and the finite element model of the structure. The computed surface vibration constitutes the excitation for an acoustic uncoupled boundary element analysis.
Technical Paper

Photometric and Colorimetric Measurement Procedures for Airborne Electronic Flat Panel Displays — SAE ARP 4260

2009-11-10
2009-01-3143
SAE ARP 4260 Photometric and Colorimetric Measurement Procedures for Airborne Electronic Flat Panel Displays [1] has recently been revised. This new revision reaffirms that ARP 4260 is pertinent to the aviation industry, changes the content to keep up with the state of the art, and adds clarification where needed. ARP 4260 contains methods used to measure the optical performance of airborne electronic flat panel display systems and is referenced in SAE ARP 4256, Design Objectives for Liquid Crystal Displays for Part 25 (Transport) Aircraft [2] and in SAE AS 8034, Minimum Performance Standard for Airborne Multipurpose Electronic Displays [3].
Technical Paper

Power Steering Pump Sound Quality and Vibration - Test Stand Development

2003-05-05
2003-01-1662
The quietness of the interior of automobiles is perceived by consumers as a measure of quality and luxury. Great strides have been achieved in isolating interiors from noise sources. As noise is reduced, in particular wind and power train noise, other noise sources become evident. Noise reduction efforts are now focused on components like power steering pumps. To understand the contribution of power steering pumps a world-class noise and vibration test stand was developed. This paper describes the development of the test stand as well as it's objective to understand and improve the sound quality of power steering pumps.
Technical Paper

Improving Load Regeneration Capability of an Aircraft

2009-11-10
2009-01-3189
This paper presents new concepts for improving management of the electrical load power regeneration of an aircraft. A novel electrical system that allows for load regeneration back to the distribution bus is described. This approach offers the benefits of reduced weight, volume, and cost, as well as improved reliability. Also described is an electrical machine control mechanism that creates motor power to run the prime mover (i.e., the main engine to dissipate the regenerated power). Instead of main engine generation, this approach can be applied to an auxiliary power unit (APU) or power and thermal management system (PTMS). Background information regarding the regeneration concept is presented. The concept definition and the various modes of operation of the improved system are analyzed and described in detail. Results from the dynamic simulation of the system model are included.
Technical Paper

Statistical Modeling of Fatigue Crack Growth in Wing Skin Fastener Holes

2012-04-16
2012-01-0482
Estimation and prediction of residual life and reliability are serious concerns in life cycle management for aging structures. Laboratory testing replicating fatigue loading for a typical military aircraft wing skin was undertaken. Specimens were tested until their fatigue life expended reached 100% of the component fatigue life. Then, scanning electron microscopy was used to quantify the size and location of fatigue cracks within the high stress regions of simulated fastener holes. Distributions for crack size, nearest neighbor distances, and spatial location were characterized statistically in order to estimate residual life and to provide input for life cycle management. Insights into crack initiation and growth are also provided.
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