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Increased emphasis on standardizing processes and controlling variability in production operations includes validating perishable tools used in daily operations. Even though dealing with reputable manufacturers, many factors including communication, custom specifications and personnel turnover can lead to the perpetuation of mistakes if errors are not discovered and corrective action implemented. However, inspection is costly and inspection costs far outweigh many item costs unless considering product defects. A beneficial balance may be obtained by employing statistical sampling techniques similar to ISO 2859 [1] to verify the quality of incoming tools.

Schedule/Cost Risk, politics, competition for capital dollars are all factors affecting our project decisions and choices. Not understanding the key elements of a project that will contribute to schedule and cost risk will invariably result in overruns that can quickly absorb the returns expected from the investment. This paper attempts to provide the project team with a model that considers some risk factor elements to assist with the selection of project alternatives and more intelligent schedule/cost estimating.

The development of new commercial airliners is a very risky proposition. To get it right, airframe manufacturers must balance new technologies and manufacturing methods with global participation and business considerations. The 787 is Boeing's popular new wide body aircraft incorporating state of the art composites design and manufacturing methods. But new technology alone is not enough. A new logistics system was needed to integrate global partners in order to fully benefit from new technologies. The Boeing 747-400 Dreamlifter is a special purpose 747-400 modified to transport Boeing 787 airplane components through various stages of manufacturing.

A review is made of previously reported status of the augmentor wing concept, including test work of de Havilland Aircraft of Canada and the NASA Ames Research Center. More recent NASA data which formed the basis for proceeding with a flight research vehicle program on the Buffalo CV-7A are discussed. This background is used to show potential application to a turbofan-powered production airplane concept whose highly integrated propulsion and aerodynamics show promise for a very quiet STOL. Proposed future augmentor wing development programs are also briefly discussed.

Solid Waste Management (SWM) requirements need to be defined prior to determining what technologies should be developed by the Advanced Life Support (ALS) Project. Since future waste streams will be highly mission-dependent, missions need to be defined prior to developing SWM requirements. The SWM Working Group has used the mission architectures outlined in the System Integration, Modeling and Analysis (SIMA) Element Reference Missions Document (RMD) as a starting point in the requirement development process. The missions examined include the International Space Station (ISS), a Mars Dual Lander mission, and a Mars Base. The SWM Element has also identified common SWM functionalities needed for future missions. These functionalities include: acceptance, transport, processing, storage, monitoring and control, and disposal. Requirements in each of these six areas are currently being developed for the selected missions.

As part of NASA’s Aviation Safety and Security Program, a simulation study of a twin-jet transport aircraft crew training simulation was conducted to address fidelity for upset or loss-of-control flight conditions. Piloted simulation studies were conducted to compare the baseline crew training simulation model with an enhanced aerodynamic model that was developed for high-angle-of-attack conditions. These studies were conducted in a flaps-up configuration and covered the approach-to-stall, stall and post-stall flight regimes. Qualitative pilot comments and preliminary comparison with flight test data indicate that the enhanced model is a significant improvement over the baseline. Some of the significant unrepresentative characteristics that are predicted by the baseline crew training simulation for flight in the post-stall regime have been identified.

The Boeing Company is developing and implementing the tools for the 21st Century for product development with their Design Manufacturing and Producibility Simulation (DMAPS) program. DMAPS combines the best of people, hardware and software tools commercially available to develop product and process simulation applications. The DMAPS toolset enhances the process of preparing concept layouts, assembly layouts and build-to-packages. Comprised of an Integrated Product and Process Team (IPPT), DMAPS produces products faster and with higher quality. The result is a process that eliminates costly changes and rework, and provides all IPPT's the tools and training necessary to perform their tasks right the first time. Boeing applies DMAPS tools to a variety of existing and new programs to build more affordable products. Savings goals set forth by the program are shown in Figure 1.

NASA has long recognized the advantages of providing improved information interfaces to EVA astronauts and has pursued this goal through a number of development programs over the past decade. None of these activities or parallel efforts in industry and academia has so far resulted in the development of an operational system to replace or augment the current extravehicular mobility unit (EMU) Display and Controls Module (DCM) display and cuff checklist. Recent advances in display, communications, and information processing technologies offer exciting new opportunities for EVA information interfaces that can better serve the needs of a variety of NASA missions. Hamilton Sundstrand Space Systems International (HSSSI) has been collaborating with Simon Fraser University and others on the NASA Haughton Mars Project and with researchers at the Massachusetts Institute of Technology (MIT), Boeing, and Symbol Technologies in investigating these possibilities.

Power quality has become a subject of increased attention for electrical power systems on both commercial and military aircraft. Several power quality guidelines and specification documents exist that govern today's power system operation and the contributing characteristics of electrical load equipment. This paper presents power quality requirements for future Boeing commercial airplanes, driven by advances in aerospace applications of power electronic equipment, increased load demand and complexity, as well as new power system architectures. The influence of new equipment types on electrical system power quality is described including the effects of motor controllers, AC power converters, and large dynamic loads. The impact of power type classifications such as variable frequency AC power and multiple DC voltage levels is also discussed. Simulation results are presented to develop and validate these power quality requirements.

Trace chemical contaminants produced by equipment offgassing and human metabolic processes are removed from the atmosphere of the International Space Station's U.S. Segment by a trace contaminant control subassembly (TCCS). The TCCS employs a combination of physical adsorption, thermal catalytic oxidation, and chemical adsorption processes to accomplish its task. A large bed of granular activated charcoal is a primary component of the TCCS. The charcoal contained in this bed, known as the charcoal bed assembly (CBA), is expendable and must be replaced periodically. Pre-flight engineering analyses based upon TCCS performance testing results established a service life estimate of 1 year. After nearly 1 year of cumulative in-flight operations, the first CBA was returned for refurbishment. Charcoal samples were collected and analyzed for loading to determine the best estimate for the CBA's service life.

This paper is an explanation of some of the Flight Test Safety (FTS) methods used to reduce the risk associated with military rotorcraft development. Two flight test programs are addressed, the V-22 Osprey tiltrotor and the RAH-66 Comanche helicopter. A short history of the development of each program is provided as background information. Some of the challenges and strengths of joint ventures are also identified and discussed. Four critical elements of an FTS program are identified: 1) Organizational Risk Management (ORM), 2) issue/anomaly resolution, 3) incident recording and corrective action documentation and 4) interface between FTS and other organizations. Methods used in the two programs to address these elements are reviewed and can be applied to other flight test programs.

Security is a serious concern for all Internet users, and all the more so if the implications of security failure can potentially affect safety of flight or the public's perception of air travel. However, when designing networked aircraft and onboard systems, technical security features are only one aspect of the implementation that must be addressed. Given the unique operational, support, and regulatory environment of commercial air transports, careful consideration must also be given to both design and operational requirements in order to develop an aircraft that can be safely operated and maintained within the constraints of the existing infrastructure and personnel available. This paper addresses the unique Operational Considerations for Securing Airborne Networks in commercial air transport aircraft.

The International Space Station (ISS) supplies and recycles water. Until the water system loop is closed with 100 percent recycling, monitoring water usage on-orbit is critical. The water supply on-orbit is monitored to stay above the skip cycle. If the rate is higher than predicted, then the water supply may become too low to support the crew. Both U.S. and Russian water experts use the water usage rate to determine the quantity of water to be re-supplied on each vehicle. The paper provides an overview of the ISS water system. It discusses the newly revised water balance. The paper describes the methodology used to calculate water usage rates. The analysis provides the water usage rates for each Expedition crew. The analysis compares these results to the consumable reports and the Russian water expert reports. The paper provides a discussion of the results of the various usage rates. It provides the most accurate methods for assessing water usage.

As part of the Sustaining Engineering program for the International Space Station (ISS), a ground simulator of the Internal Thermal Control System (ITCS) in the Lab Module was designed and built at the Marshall Space Flight Center (MSFC). To predict ITCS performance and address flight issues, this facility is operationally and functionally similar to the flight system and flight-like components were used when available. Flight software algorithms, implemented using the LabVIEW® programming language, were used for monitoring performance and controlling operation. Validation testing of the low temperature loop was completed prior to activation of the Lab module in 2001. Assembly of the moderate temperature loop was completed in 2002 and it was validated in 2003. Even before complete validation the facility was used to address flight issues, successfully demonstrating the ability to add silver biocide and to adjust the pH of the coolant.

The International Space Station (ISS) Environmental Control and Life Support (ECLS) system includes regenerative and non-regenerative technologies that provide the basic life support functions to support the crew, while maintaining a safe and habitable shirtsleeve environment. This paper provides a summary of the U.S. ECLS system activities over the past year, covering the period of time between March 2004 and February 2005. The ISS continued permanent crew operations, with the start of Phase 3 of the ISS Assembly Sequence. Work continued on the Phase 3 pressurized elements and the continued manufacturing and testing of the regenerative ECLS equipment.

The International Space Station (ISS) Environmental Control and Life Support (ECLS) system includes regenerative and non-regenerative technologies that provide the basic life support functions to support the crew, while maintaining a safe and habitable shirtsleeve environment. This paper provides a summary of the U.S. ECLS system activities over the past year, covering the period of time between April 2003 and March 2004. The ISS continued permanent crew operations, with the start of Phase 3 of the ISS Assembly Sequence. Work continued on the Phase 3 pressurized elements and the continued manufacturing and testing of the regenerative ECLS equipment.

The International Space Station (ISS) Environmental Control and Life Support (ECLS) system includes regenerative and non-regenerative technologies that provide the basic life support functions to support the crew, while maintaining a safe and habitable shirtsleeve environment. This paper provides a summary of the U.S. ECLS system activities over the past year, covering the period of time between May 2001 and April 2002. The ISS continued permanent crew operations, with Phase 2 completion accomplished during this period. Work continued on the Phase 3 elements with Node 3 proceeding toward a final design review and the regenerative ECLS equipment proceeding into manufacturing.

Crewmember ingress of the International Space Station (ISS) before that time accorded by the original ISS assembly sequence, and thus before the ISS capability to adequately control the levels of temperature, humidity, and carbon dioxide, poses significant impacts to ISS Environmental Control and Life Support (ECLS). Among the most significant considerations necessitated by early ingress are those associated with the capability of the Shuttle Transportation System (STS) Orbiter to control the aforementioned levels, the capability of the ISS to deliver the conditioned air among the ISS elements, and the definition and distribution of crewmember metabolic heat, carbon dioxide, and water vapor. Even under the assumption that all Orbiter and ISS elements would be operating as designed, condensation control and crewmember comfort were paramount issues preceding each of the ISS Missions 2A and 2A.1.

The design challenges presented by the late evolving International Space Station (ISS) Launch to Activation (LTA) thermal concerns required concerted effort and tradeoffs to be made between affected subsystems. The resulting design and mission planning modifications were made with consideration of thermal, electrical power system and extravehicular activity impacts in mind. It was an excellent exercise in cooperative problem solving that allowed each subsystem visibility into potential impacts of their efforts on other related systems and therefore work towards balanced solutions. It was also an excellent exercise in preparing these subsystems for future quick response cooperative problem solving that will be required to support ISS during its lifetime.

The IATCS coolant has experienced a number of anomalies in the time since the US Lab was first activated on Flight 5A in February 2001. These have included: 1) a decrease in coolant pH, 2) increases in inorganic carbon, 3) a reduction in phosphate concentration, 4) an increase in dissolved nickel and precipitation of nickel salts, and 5) increases in microbial concentration. These anomalies represent some risk to the system, have been implicated in some hardware failures and are suspect in others. The ISS program has conducted extensive investigations of the causes and effects of these anomalies and has developed a comprehensive program to remediate the coolant chemistry of the on-orbit system as well as provide a robust and compatible coolant solution for the hardware yet to be delivered.