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Fabrication and assembly of the majority of control surfaces for Boeing’s 777X airplane is completed at the Boeing Defense, Space and Security (BDS) site in St. Louis, Missouri. The former 777 airplane has been revamped to compete with affordability goals and contentious markets requiring cost-effective production technologies with high maturity and reliability. With tens of thousands of fasteners per shipset, the tasks of drilling, countersinking, hole inspection, and temporary fastener installation are automated. Additionally and wherever possible, blueprint fasteners are automatically installed. Initial production is supported by four (4) Electroimpact robotic systems embedded into a pulse-line production system requiring strategic processing and safeguarding solutions to manage several key layout, build and product flow constraints.

Both humans and onboard radiosensitive systems (electronics, materials, payloads and experiments) are exposed to the deleterious effects of the harsh space radiations found in the space environment. The purpose of this paper is to present the space radiation environment extended to deep space based on environment models for the moon, Mars, Jupiter, and Saturn and compare these radiation environments with the earth's radiation environment, which is used as a comparative baseline. The space radiation environment consists of high-energy protons and electrons that are magnetically “trapped” in planetary bodies that have an intrinsic magnetic field; this is the case for earth, Jupiter, and Saturn (the moon and Mars do not have a magnetic field). For the earth this region is called the “Van Allen belts,” and models of both the trapped protons (AP-8 model) and electrons (AE-8 model) have been developed.

A discussion is given of the ongoing research related to laminar flow airfoils, nacelles, and wings where the laminar flow is maintained by a favorable pressure gradient, surface suction or a combination of the two. Design methologies for natural laminar flow airfoil sections and wings for both low and high speed applications are outlined. Tests of a 7-foot chord, 23° sweep laminar-flow-control-airfoil at high subsonic Mach numbers are described along with the associated stability theory used to design the suction system. The state-of-the-art of stability theory is simply stated and a typical calculation illustrated. In addition recent computer simulations of transition using the time dependent Navier-Stokes (N-S) equations are briefly described. Advances in wind tunnel capabilities and instrumentation will be reviewed followed by the presentation of a few results from both wind tunnels and flight. Finally, some suggestions for future work will complete the paper.

Solar proton events (SPEs) represent the single-most significant source of acute radiation exposure during space missions. Historically, an exponential in rigidity (particle momentum) fit has been used to express the SPE energy spectrum using GOES data up to 100 MeV. More recently, researchers have found that a Weibull fit better represents the energy spectrum up to 1000 MeV (1 GeV). In addition, the availability of SPE data extending up to several GeV has been incorporated in analyses to obtain a more complete and accurate energy spectrum representation. In this paper we discuss the major SPEs that have occurred over the past five solar cycles (~50+ years) in detail - in particular, Aug 1972 and Sept & Oct 1989 SPEs. Using a high-energy particle transport/dose code, radiation exposure estimates are presented for various thicknesses of aluminum. The effects on humans and spacecraft systems are also discussed in detail.

An automated system drills the outer moldline holes on a military aircraft wing. Currently, the operator manually checks countersink diameter every ten holes as a process quality check. The manual method of countersink inspection (using a countersink gauge with a dial readout) is prone to errors both in measurement and transcription, and is time consuming since the operator must stop the automated equipment before measuring the hole. Machine vision provides a fast, non-contact method for measuring countersink diameter, however, data from machine vision systems is frequently corrupted by non-gaussian noise which causes traditional model fitting methods, such as least squares, to fail miserably. We present a solution for circle measurement using a statistically robust fitting technique that does an exceptional job of identifying the countersink even in the presence of large amounts of structured and non-structured noise such as tear-out, scratches, surface defects, salt-and-pepper, etc.

A study was conducted to investigate the impacts of obstacles on pilot performance, workload, and perceptions of safety in a visual flight rule (VFR) obstacle-rich environment (ORE). The study was conducted using a piloted simulation of a single-rotor, multi-engine helicopter operating in a highly detailed urban visual scene database. The database contained multiple obstacle types, with variable obstacle heights and densities. Nine pilots completed the approaches and departures into and out of a heliport located in the center of the generic urban environment. Two flight routes offered unique presentations of terrain and obstacle types. Obstacle height/density and time of day/lighting parameters were systematically manipulated. A multi-dimensional data collection methodology employing the simultaneous collection of direct aircraft state, pilot performance data, pilot physiological data and pilot subjective responses was employed.

Reynolds number effects noted from selected test programs conducted in the Langiey 0.3-Meter Transonic Cryogenic Tunnel (0.3-m TCT) are discussed. The tests, which cover a unit Reynolds number range from about 2.0 to 80.0 million per foot, summarize effects of Reynolds number on: 1) aerodynamic data from a supercritical airfoil, 2) results from several wall interference correction techniques, and 3) results obtained from advanced, cryogenic test techniques. The test techniques include 1) use of a cryogenic sidewall boundary layer removal system, 2) detailed pressure and hot wire measurements to determine test section flow quality, and 3) use of a new hot film system suitable for transition detection in a cryogenic wind tunnel. The results indicate that Reynolds number effects appear most significant when boundary layer transition effects are present and at high lift conditions when boundary layer separation exists on both the model and the tunnel sidewall.

The direct first order effect of Reynolds number on the determination of drag-divergence conditions is summarized for six airfoils which were tested in the Langley 0.3-Meter Transonic Cryogenic Tunnel. A second order effect, derived through the effect of Reynolds number on the sidewall boundary layer, is included. In addition, a comparison of how the drag-divergence condition is affected on going from one class of airfoil to another is presented. The drag-divergence condition is affected first order by Reynolds number for each of the six airfoils and of course all data are affected second order, since the presence of the boundary layer necessitates a sidewall correction.

This paper discusses a project for adapting advanced technology, much of it borrowed from the jet transport, to general aviation design practice. The NASA funded portion of the work began in 1969 at the University of Kansas and resulted in a smaller, experimental wing with spoilers and powerful flap systems for a Cessna Cardinal airplane. The objective was to obtain increased cruise performance and improved ride quality while maintaining the take-off and landing speeds of the unmodified airplane. Some flight data and research pilot comments are presented. The project was expanded in 1972 to include a light twin-engine airplane. For the twin there was the added incentive of a potential increase in single-engine climb performance. The expanded project is a joint effort involving the University of Kansas, Piper Aircraft Company, Robertson Aircraft Company, and Wichita State University. The use of a new high-lift Whitcomb airfoil is planned for both the wing and the propellers.

The characteristics of the friction materials used in aircraft brakes are extremely important to the performance and safe operation of transport airplanes. These characteristics can change during exposure to environmental effects in the duty cycle, which can lead to problems, such as abnormally low friction, or brake induced vibration. Water vapor in the atmosphere produces a direct lubricant effect on carbon. Observed transition temperatures within the range of 140°C to 200°C, associated with increases in friction and wear of carbon brake materials, are attributed to water vapor desorption. Friction and wear transitions in the range of 500°C to 900°C may be associated with oxygen desorption.

An advanced analytical methodology has been developed for predicting the residual strength of stiffened thin-sheet riveted shell structures such as those used for the fuselage of a commercial transport aircraft. The crack-tip opening angle elastic-plastic fracture criterion has been coupled to a geometric and material nonlinear finite element shell code for analyzing complex structural behavior. An automated adaptive mesh refinement capability together with global-local analysis methods have been developed to predict the behavior of fuselage structure with long cracks. This methodology is currently being experimentally verified. Advanced nondestructive inspection technology has been developed that will provide airline operators with the capability to conduct reliable and economical broad-area inspections of aircraft structures.

Metal cutting is a substantial constituent of airframe manufacturing. During the past several decades, it has evolved significantly. However, most of the changes and improvement were initiated by the machine tool industry and cutting tool industry, thus these new technologies is generally applicable to all industries. Among them, few are developed especially for the airframe manufacture. Therefore, the potential of high efficiency could not be fully explored. In order to deal with severe competition, the aerospace industry needs improvement with a focus on achieving low cost through high efficiency. The direction of research and development in parts machining must comply with lean manufacturing principles and must enhance competitiveness. This article is being forwarded to discuss the trend of new developments in the metal cutting of airframe parts. Primary driving forces of this movement, such as managers, scientists, and engineers, have provided significant influence to this trend.

Design data are presented for a class of high-performance single-engine business airplanes. The design objectives include a cruise speed of 300 knots, a cruise altitude of 10,700 m (35,000 ft), a cruise payload of six passengers (including crew and baggage), and a no-reserves cruise range of 1300 n.mi. Two unconventional aerodynamic technologies were evaluated: the individual and combined effects of cruise-matched wing loading and of a natural laminar flow airfoil were analyzed. The tradeoff data presented illustrate the ranges of wing geometries, propulsion requirements, airplane weights, and aerodynamic characteristics which are necessary to meet the design objectives. very large design and performance improvements resulted from use of the aerodynamic technologies evaluated. Is is shown that the potential exists for achieving more than 200-percent greater fuel efficiency than is achieved by current airplanes capable of similar cruise speeds, payloads, and ranges.

An experimental research effort was begun to develop a database of airplane aerodynamic characteristics with simulated ice accretion over a large range of incidence and sideslip angles. Wind-tunnel testing was performed at the NASA Langley 12-ft Low-Speed Wind Tunnel using a 3.5% scale model of the NASA Langley Generic Transport Model. Aerodynamic data were acquired from a six-component force and moment balance in static-model sweeps from α = -5 to 85 deg. and β = -45 to 45 deg. at a Reynolds number of 0.24x10⁶ and Mach number of 0.06. The 3.5% scale GTM was tested in both the clean configuration and with full-span artificial ice shapes attached to the leading edges of the wing, horizontal and vertical tail. Aerodynamic results for the clean airplane configuration compared favorably with similar experiments carried out on a 5.5% scale GTM.

This paper describes recent research in integrated aerodynamic-performance design optimization applied to a supersonic transport wing. The subsonic and supersonic aerodynamics are modeled with linear theory and the aircraft performance is evaluated by using a complete mission analysis. The goal of the optimization problem is to either maximize the aircraft range or minimize the take-off gross weight while constraining the total fuel load and approach speed. A major difficulty encountered during this study was the inability to obtain accurate derivatives of the aerodynamic models with respect to the planform shape. This work addresses this problem and provides one solution for the derivative difficulties. Additional optimization studies reveal the impact of camber design on the global optimization problem. In these studies, the plan-form optimization is first conducted on a flat plate wing and camber optimization is performed on the resulting planform.

An air quality simulation and assessment (AQSA) model was developed to simulate/evaluate the integrated system performance and obtain air quality characteristics and air contaminants inside the habitable compartments. This model applies both fixed control volume and quasi-steady-state approach for a multi-volume system to assess system performance, operating constraints, and capabilities. The model also integrates a state-of-the-art probabilistic analysis tool, UNIPASS, to compute failure probability due to the uncertainties of variables. In addition, this integrated model also predicts the most likely outcomes for analyzing risks and uncertainties as well as for quantitative toxicological evaluation. This model has been successfully and independently corrected/verified by NASA/JSC to be a very effective, reliable, and accurate tool, while providing savings in both the cost and time of the analysis.

A program is described in which statistical flight loads and operating practice data for airline transports in current operations are obtained from existing onboard digital flight data recorders. These data, primarily intended for use by manufacturers in updating design criteria, were obtained from narrow-body and wide-body jets. Unique procedures developed for editing and processing the data are discussed and differences from previous NACA/NASA VGH analog data are noted. The program is being expanded to include control surface and ground-operational parameters. Efforts to develop an onboard data processing system to derive direct statistical aircraft operating parameters are reviewed.

This paper presents the status of the airbreathing hypersonic airplane and space-access vision-operational-vehicle design matrix, with emphasis on horizontal takeoff and landing systems being studied at Langley; it reflects the synergies and issues, and indicates the thrust of the effort to resolve the design matrix including Mach 5 to 10 airplanes with global-reach potential, pop-up and dual-role transatmospheric vehicles and airbreathing launch systems. The convergence of several critical systems/technologies across the vehicle matrix is indicated. This is particularly true for the low speed propulsion system for large unassisted horizontal takeoff vehicles which favor turbines and/or perhaps pulse detonation engines that do not require LOX which imposes loading concerns and mission flexibility restraints.

The Aircraft Landing Dynamics Facility (ALDF), formerly called the Landing Loads Track, is described. The paper gives a historical overview of the original NASA Langley Research Center Landing Loads Track and discusses the unique features of this national test facility. Comparisions are made between the original track characteristics and the new capabilities of the Aircraft Landing Dynamics Facility following the recently completed facility update. Details of the new propulsion and arresting gear systems are presented along with the novel features of the new high-speed carriage. The data acquisition system is described and the paper concludes with a review of future test programs.

Fuel costs comprise a major portion of air transport operating costs. Thus, energy efficiency is an essential design goal for future transport aircraft. Advanced composite structures, advanced wing geometries, and active control systems all promise substantial benefits in fuel efficiency and direct operating cost for derivative and new aircraft introduced by 1985. Technology for maintenance of a laminar boundary layer in cruise offers great benefits in fuel efficiency and direct operating cost and may be ready for application to transports introduced in the 1990's. NASA and the air transport industry are cooperating in a comprehensive Aircraft Energy Efficiency Program to expedite the introduction of these advanced technologies into production aircraft.