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Increasing the Efficiency of High-Pressure Systems in Aerospace Through 3D Metal Printing

2020-11-02
Heat exchangers are a prolific application found in all things that concern fluid and power; they are mission-critical applications that affect overall performance in aircraft of all sizes. Yet, for years, heat exchangers have been constrained, by traditional manufacturing, in terms of limited geometric freedom and lengthy lead times. Consider the following � Heat exchangers are commonly fabricated with stainless steel and then gold brazed, which can be extremely costly � Each weld joint costs $100; in traditionally manufactured fuel and high-pressure systems, there could be hundreds of welds � There can be a lack of integration with other systems like electrical motors or conformal cooling with batteries. Assembly integration, testing, and validation are lengthy and difficult. Additive manufacturing (aka 3D printing) has opened new possibilities for thermal conductivity and heat-exchanger design that enable end users to push the limits of what is possible.
Video

Visionary's Take: An Engineering Journey into the Marketplace (Part 3 of 3)

2017-10-12
Can you become a visionary or are you born one? How does a visionary capture an opportunity and makes it a successful business? Are engineers more qualified to solve technical problems or run companies? SAE's "The Visionary's Take" addresses these and many other questions, by talking directly with those who have dared to tackle difficult engineering problems, and create real-life products out of their experience. In these short episodes, Sanjiv Singh and Lyle Chamberlain, respectively CEO and Chief Engineer from Near Earth Autonomy, talk about their experience in creating a brand-new company in the UAV world. Founded in 2011, Near Earth Autonomy brought together a group of engineers and roboticists, looking for unconventional solutions to very hard logistics problems, presenting danger to human life. The answers were developed by pushing technology to a higher level, testing quickly and often, and keeping an open mind to alternative ways of framing engineering challenges.
Video

Visionary's Take: An Engineering Journey into the Marketplace (Part 1 of 3)

2017-10-12
Can you become a visionary or are you born one? How does a visionary capture an opportunity and makes it a successful business? Are engineers more qualified to solve technical problems or run companies? SAE's "The Visionary's Take" addresses these and many other questions, by talking directly with those who have dared to tackle difficult engineering problems, and create real-life products out of their experience. In these short episodes, Sanjiv Singh and Lyle Chamberlain, respectively CEO and Chief Engineer from Near Earth Autonomy, talk about their experience in creating a brand-new company in the UAV world. Founded in 2011, Near Earth Autonomy brought together a group of engineers and roboticists, looking for unconventional solutions to very hard logistics problems, presenting danger to human life. The answers were developed by pushing technology to a higher level, testing quickly and often, and keeping an open mind to alternative ways of framing engineering challenges.
Video

Sensor Video Integration and Processing in the Modular Avionics Architecture

2012-03-19
Use of airborne high resolution digital sensor imagery is ever increasing. Color HDTV, infrared cameras and radar are examples of such sensors. And they are becoming increasingly used for mission purposes by the military, police, customs and coast guard onboard helicopters and fixed wing aircraft. These users have requirements for onboard presentation, analysis and storage. Use of weather radars and other similar types of sensors are flight oriented applications in major types of aircraft. Another application is the integration of cockpit and cabin surveillance systems onboard commercial airlines. Cabin surveillance systems, growing from cockpit door cameras to complete cabin surveillance, will use several cameras. The purpose is to acquire and store imagery from un-normal events including unruly passengers and eventual terrorists. The primary intentions are security awareness in the cockpit as well as collecting evidence for a potential prosecution.
Video

Fiber Optic Strain Sensor Standardization - International and European Activities

2012-03-16
There are worldwide activities in developing guidelines and standards for fiber optic sensors. Fiber optic sensors (FOS) are increasingly demanded for structural health monitoring purposes and for measurement of physical and chemical quantities because of their specific features. However, they are not yet widely established for practical use due to a lack of guidelines and confirmed standards. Therefore, there are few groups worldwide which are very active in developing standards for use of FOS in different fields, particularly driven from aircraft industry, oil industry or the necessity to provide sensor systems for health monitoring of structures with a certain level of risk. The benefits of guidelines and/or standards on the way to well-validated and well-specified sensor systems will be presented by means of related examples. The presentation will also give an overview on the state-of-the-art and most relevant activities. Results achieved are discussed.
Video

A Quantitative Risk Analysis for AeroMACS Network Security in SESAR

2012-03-16
The growing need for an efficient worldwide airspace system management, generated by an increasing traffic load, requires new capabilities for air-ground data communication technologies. In order to cope with these requirements, the Federal Aviation Administration (FAA), EUROCONTROL, and the International Civil Aviation Organization (ICAO) have jointly made specific recommendations for candidate technologies for the airport surface communication network. In the SESAR project, the Aeronautical Mobile Airport Communication System (AeroMACS) technology is being developed in such a way to provide next generation broadband and wireless data communications for airport surface applications (i.e. Air Traffic Control ? ATC, Airline Operational Communications ? AOC, and surface vehicles services).
Video

Advancing Aircraft Cyber Security - Potential New Architectures and Technologies

2012-03-16
Cyber security in the aviation industry, especially in relation to onboard aircraft systems, presents unique challenges in its implementation and management. The cyber threat model is constantly evolving and will continually present new and different challenges to the aircraft operator in responding to new cyber threats without either invoking a lengthy software update and re-certification process or limiting aircraft-to-ground communications to the threatened system or systems. This presentation discusses a number of system architectural options and developing technologies that could be considered to enhance the aircraft cyber protection and defensive capabilities of onboard systems as well as to minimize the effort associated with certification/re-certification. Some of these limit the aircraft?s vulnerabilities or in cyber terms, its ?threat surface?.
Video

Study of Materials and Coatings Used for Drilling Carbon Fiber Re-inforced Plastics

2012-03-14
With the increased usage of Carbon Fiber Reinforced Plastics (CFRP) in the aircraft industry, there has been increased pressure to improve cutting tool life. Tungsten carbide tools were the first to be applied to CFRP materials. Poly Crystalline Diamond (PCD) tools also became an acceptable material to be used as a cutting tool material. In recent years, Chemical Vapor Deposition (CVD) diamond tools have become more popular as a cutting tool material for CFRP. This study compares these possible cutting tool materials in the drilling of CFRP. Wear is measured as well as hole quality. Life is determined by common industry standards with regard to fiber break out in a common CFRP material. An economic analysis is conducted in order to determine cost per hole. Presenter Christophe Petit
Video

Vertical Picture-Frame Wing Jig Structure Design with an Eye to Foundation Loading

2012-03-14
The foundation of many production aircraft assembly facilities is a more dynamic and unpredictable quantity than we would sometimes care to admit. Any tooling structures constructed on these floors, no matter how thoroughly analyzed or well understood, are at the mercy of settling and shifting concrete, which can cause very lengthy and costly periodic re-certification and adjustment procedures. It is with this in mind, then, that we explore the design possibilities for one such structure to be built in Belfast, North Ireland for the assembly of the Shorts C-Series aircraft wings. We evaluate the peak floor pressure, weight, gravity deflection, drilling deflection, and thermal deflection of four promising structures and discover that carefully designed pivot points and tension members can offer significant benefits in some areas.
Video

Validating Time Triggered Ethernet on a Space Vehicle

2012-03-14
This presentation provides a overview of validating Time Triggered Ethernet (TTE) for use as the network to interconnect the avionics for manned Space Vehicle. The next manned Space Vehicle will use Time Triggered-Gigabit Ethernet (TT-GbE) leveraged from commercial development of TTE critical Intellectual Property. There are several validation considerations of either separating TTE segments or adding new TTE segments onto the network caused by the different phases of a manned space vehicle from pre-launch to re-entry. Considerable amount of validation testing has been successfully performed on TT-GbE/TTE. Presenter Victor Revelle, Honeywell International Inc.
Video

Ice Phobic Coatings for Control and Covered Surfaces

2012-03-14
Silicones have been utilized in multiple industries in the last 50 years and their applications are still expanding as technology grows. Ice phobic coatings, as an example, have been utilized on lock walls, navigation channels, wind turbines, hydropower intakes, and aircraft. Without protection these applications have a high risk of failure in the functions they perform. For example, ice build up on an aircraft?s aerodynamic surfaces increases drag which reduces lift during flight operations. Utilizing a silicone ice phobic coating significantly reduces the adhesion of ice to aerodynamic surfaces. Compared to other polymeric materials, silicones are known for their broad operating temperature range and lend themselves to excellent performance in a variety of harsh environments. Especially in low temperatures where ice adhesion is a concern, silicones retain their elastomeric physical properties and low modulus.
Video

Safety and Operational Improvements Using Head-Up Displays in Small Aircraft and Helicopters

2012-03-12
Small aircraft and helicopters have an increasing need for heads out presentations, which means a projected presentation of symbols and images, primarily infrared, on an optical combiner in the pilots field of view. The information presented will appear at an infinite distance i.e. the focal point is far away enabling the pilot to see the symbology superimposed on and correlated to the outside world. The driving factors for a heads out presentations are increased safety through improved situation awareness in almost all weather conditions as well as operational improvements due to reduced landing minimal prerequisites in adverse weather conditions. Also safety during taxiing and landing are improved through early detection of eventual other aircraft and objects. The landing aid is important for small aircraft like business jets that often fly into unequipped airfields. The overall benefits are reduction in number of incidents/accidents, cost savings and reduced number of diversions.
Video

Practical Process for Determining Explainable, Rational Distortion Levels Providing Adequate IPP

2011-12-05
Translating service information into multiple human natural languages is a major expense for multinational corporations. Indeed corporations spend significant amounts to reduce their translation expense by managing the reuse text and its translation. The new frontier in reducing translation expense is translation avoidance, eliminating text through using illustrations and animations to communicate. Presenter Arnold Taube
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