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The paper summarizes the experience gained with the ISS water management system during the missions ISS-1 through ISS-17 (since November 2, 2000, through October 23, 2008). The water supply sources and structure, consumption and supply balance and balance specifics at various phases of space station operation are reviewed. The performance data of the system for water recovery from humidity condensate SRV-K and urine feed and pretreatment system SPK-U in the Russian orbital segment are presented. The key role of water recovery on board the ISS and the need to supplement the station's water supply hardware with a system for water reclamation from urine SRV-U is emphasized. The prospects of regenerative water supply system development are considered.

Titanium is a difficult material to fabricate into complex configurations. There is several elevated temperature forming processes available to produce titanium components for aerospace applications. The processes to be discussed are Superplastic Forming (SPF), hot forming and creep forming. SPF uses a tool that contains the required configuration and seals around the periphery so inert gas pressure can be used to form the material. Of the processes to be discussed, this is the one that can produce the most complex shapes containing the tightest radii. A variation of the process combines an SPF operation with diffusion bonding (SPF/DB) of two or more pieces of titanium together to produce integrally stiffened structure containing very few fasteners. Another process for shaping titanium is hot forming. In this process, matched metal tools, offset by the thickness of the starting material, are used to form the part contour at elevated temperature.

We live in an era of increasing twin-engine commercial airplane operations, with large and very quiet high bypass ratio engines. At the same time, due to several decades of increased attention to the environment, we have large and increasing hazardous species bird populations. These trends, when combined, are not a prescription for continued assurance of a remarkable and enviable safety record for commercial aviation. Therefore, greater diligence must be placed on the evaluation of the current and future aviation wildlife hazard. We have some new weapons in this fight for greater capability to live with this situation. The basic problem is that different databases are populated independently from one another and often contain conflicting, contradictory, and erroneous data. Databases that were used individually, but not necessarily combined, are being utilized in a conjoined methodology to give us a better picture of the actual risk involved.

Current methods of life cycle assessment (LCA) include input-output (IO) models and process-based LCA. These methods either require excessive effort and time to reach a conclusion (process LCA) or do not adequately model how a change in a product's design will affect the environmental footprint (IO LCA). A variation of process-based LCA developed specifically for aircraft is presented in this study. A tool implementing this LCA, “qUWick,” is rapid and easily applicable to multi-disciplinary design optimization of aircraft. Models developed for the material production, manufacturing, usage, and end-of-life of an aircraft are examined. Outputs of qUWick are discussed for future air vehicles. When compared to process LCAs with similar boundaries, qUWick gives similar results, however qUWick models several stages of an aircraft's life cycle more accurately than other aircraft process-based LCAs.

The Boeing Company is striving to improve quality and reduce defects and injuries through the implementation of lightweight “Right Sized” automated drill and fasten equipment. This has lead to the factory adopting Boeing developed and supplier built flex track drill and countersink machines for drilling fuselage circumferential joins, wing panel to spar and wing splice stringers. The natural evolution of this technology is the addition of fastener installation to enable One Up Assembly. The critical component of One Up Assembly is keeping the joint squeezed tightly together to prevent burrs and debris at the interface. Traditionally this is done by two-sided machines providing concentric clamp up around the hole while it is being drilled. It was proposed that for stiff structure, the joint could be held together by beginning adjacent to a tack fastener, and assemble the joint sequentially using the adjacent hole clamp up from the previous hole to keep the joint clamped up.

The use of portable automated equipment has increased in recent years with the introduction of flex track, crawling robots, and other innovative machine configurations. Portable automation technologies such as these lower infrastructure costs by minimizing factory floor space requirements and foundation expenses. Portable automation permits a higher density of automated equipment to be used adjacent to aircraft during assembly. This equipment also allows concurrent work in close proximity to automated processes, promotes flexibility for changes in rate, build plan, and floor space requirements throughout the life of an airplane program. This flexibility presents challenges that were not encountered with traditional fixed machine drilling centers. The work zone surrounding portable machines is relatively small, requiring additional setup time to relocate and position machines near the airframe.

At the initial phase of the construction of the international space station (ISS) water supply will be provided by the systems located in the Russian segment. The paper reviews the systems for water recovery from humidity condensate and urine to be incorporated in the Russian segment of the ISS. The similar systems have been successfully operated on the Mir space station. The updates aim at enhancing system cost-effectiveness and reliability. The system for water recovery from humidity condensate (WRS-C) features an added assembly for the removal of organic contaminants to be catalytically oxidized in an air/liquid flow at ambient temperature and pressure. The system for water reclamation from urine (WRS-U) incorporates a new distillation subsystem based on vacuum distillation with a multistage rotary distiller and a vapor compression or thermoelectric heat pump. The updating of the WRS-C system will enable an increase in the multifiltration bed's life at least two fold.

In traditional manufacturing when a product (such as a wing panel or wing spar) was designed the manufacturing process to build the product was of little consideration. The design of the product was manually created on a 2 dimensional drawing without investigation of what data could be included to achieve a more productive automated assembly (fastening) system. Even less development was expended on integration of part design and manufacturing to improve downstream processes and product quality. Today, every avenue of optimization and continuous quality improvement must be explored to create a lean manufacturing environment that produces low costs with high productivity at all levels. This paper will describe design and manufacturing engineering processes used to streamline creation of machine control data for automated fastening systems. Applying design for manufacturing concepts and automation of upstream processes to provide significant benefits in the production environment.

The paper summarizes the six years' experience gained with the ISS water management system during the missions ISS-1 through ISS-14 (since November 2, 2000 through October 31, 2006). The water supply sources, consumption structure and supply balance and balance specifics at various phases of space station operation are reviewed. The performance data of the system for water recovery from humidity condensate SRV-K and urine feed and pretreatment system SPK-U in the Russian orbital segment are presented. The key role of water recovery during space missions and the prospects of regenerative water supply of an interplanetary space station are discussed. The aim of this paper is to summarize the water supply experience and to provide recommendations for a perspective water supply integrated system based on water recovery.

The paper presents the results of ground and flight (on OSS Mir) tests of an updated purification assembly of the WRS-C system outfitted with a filter-reactor. The tests have proved that the filter-reactor oxidizes effectively basic organic contaminants in humidity condensate including ethyleneglycol to ones that easily undergo sorption, enables the operation of the recovery system in the event of an off-design increase in organic contaminants in condensate and significantly improves the lifetime of the purification assembly. The data obtained confirm a wise selection of the purification assembly hardware for the system for water recovery from humidity condensate WRS-CM for the ISS service module.

Based on experience obtained in operation of the water and oxygen recovery systems installed onboard the Russian space stations Salut, Mir and the International Space Station ISS, data on the water and oxygen balance for a space station are presented as well as operational parameters and performance data of the systems. Using the data obtained design analysis of an integrated life support system for water and oxygen recovery based on physical/chemical means to be installed on a promising space station is carried out. Mandatory verification tests of new process (technologies) and recovery systems are to be conducted on ISS.

The paper summarizes the experience gained on the ISS water management system during the missions of ISS-1 through ISS-16 (since November 2 2000, through December 31, 2007). The water supply sources and structure, consumption and supply balance at various phases of space station operation are reviewed. The performance data of the system for water recovery from humidity condensate SRV-K and urine feed and pretreatment system SPK-U in the Russian orbital segment are presented. The key role of water recovery on a board the ISS and the need to supplement the station's water supply hardware with a system for water reclamation from urine, water from a carbon dioxide reduction system and hygiene water is shown.

Boeing has relied upon the 767 ASAT (ASAT1) since 1983 to fasten the chords, stiffeners and rib posts to the web of the four 767 wing spars. The machine was originally commissioned with a Terra five axis CNC control. The Terra company went out of business and the controls were replaced with a custom DOS application in 1990. These are now hard to support so Boeing solicited proposals. Electroimpact proposed to retrofit with a Fanuc 31I CNC, and in addition, to replace all associated sensors, cables and feedback systems. This work is now complete on two of the four machines. Both left front and right front are in production with the new CNC control.

One of the most common damages occurred found on commercial airframes are dents and gouges. The usual repair for these damages includes installation of metallic doublers with rivets or with hi-loks. Sometimes these doublers are of complex design, because of multiple angles of the original damaged skin. Many times the damages are in hard to reach areas. In these cases the traditional metallic doubler repairs are not only time consuming and but also expensive. As the numerous holes are be drilled through the original structure, its fatigue life is adversely affected. For airline operators, time is valuable and they cannot afford to lose revenue by spending longer time for repairs. The use of bonded composite doublers offers the airframe manufacturers and aircraft repair facilities an alternative repair process that alleviates the abovementioned concerns.

The paper is dedicated to adequacy analysis of Simulation Model of Human Body Thermoregulation System (HTSSM), intended for design of air/space Autonomous Life Support System (ALSS) The formal description of the HTSSM consists 51 equations to describe different body compartments, which consider different properties and individualities of human body as well as complexity dynamic characteristics of the studied functional system, and also includes the equation, which describes heat exchange processes in the heart and lung area. Active heat exchange mechanisms of thermoregulation system are described on the basis of fuzzy set theory. This paper discusses the HTMSS and its applications for: The analysis of a human heat state under heat stress conditions for a helmet area ventilation system design. The analysis of the temperature/moisture fields in the extra-vehicular suit for design of thermal control system. The results of computed experiments obtained using the HTMSS are also reviewed.

The design of any complex system, especially eco-technical is very challenging due to the variety of processes, system composition, relation between different components and presence of the human. Process and technology selections affect the flow rate, composition, and phase of all resulting components. Therefore, evaluating alternative processes and/or technologies used often requires one to compare the relative environmental merits of distinctly different residual streams. Traditional thermodynamic analysis based on the first law of thermodynamics describes the conservation of energy. In this type of analysis all forms of energy are considered to be equivalent. The loss of quality of energy is not taken into account. It shows the energy flow to be continuous and energy balance is always closed. There can never be an energy loss, only energy transfer to the environment in which case it is useless.

The paper deals with the performance data of the service module Zvezda water supply and urine collection systems of the International Space Station (ISS) as of December 31, 2002. The water supply and demand balance are analyzed. The data of humidity condensate and recovered water compositions are reviewed. The effective cooperation of the international partners on part of life support is shown.

This paper reviews the preliminary definition of integrated life support system configurations based on a single criterion decision-making task (SCDMT). Comparative analysis results are shown for currently used effectiveness models based on SCDMT. Possible areas of application for those models are determined. It is also proven that well-known effectiveness model, which uses an equivalent mass approach to determine system expenditures, can be used only in cases where useful effect from system operation is the same. The article proposes the use of a global thermodynamic effectiveness criterion based on the exergy method to account for ECLSS functional expenditures, i.e. functional costs. Exergy is a concept that fuses energy and material quality information in a measure that is both descriptive and physically significant. This method accounts for nonequivalence of different forms of energy and allows measuring technological flows in the system using same measuring units.

The paper deals with the construction and performance data of the service module Zvezda water supply system of the International Space Station (ISS). The performance data at an initial phase of manned station functioning are provided. The data on humidity condensate and recovered water composition are reviewed. The water supply and demand balance are analyzed. The effective cooperation of international partners on part of water supply for the crew is shown.

The paper deals with the construction and performance data of the service module Zvezda water and oxygen supply systems of the International Space Station (ISS). The performance data at the first 14 months of manned station functioning are provided. The data of humidity condensate and recovered water compositions are reviewed. The water supply and demand balance are analyzed. The system of oxygen generation “Electron-VM” and its functioning results are reviewed. The effective cooperation of the international partners on part of life support is shown.