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Dedicated technology has been developed to support long-term biological experiments on-board spacecraft. These developments include a microgravity compatible tubular photo bioreactor for the cultivation of micro algae at very high biomass concentrations and with very high gas exchange rates, a microgravity compatible gas / liquid phase separator which also works as a pneumatic low shear-stress pump, a microgravity compatible dehumidifier, and a maltose separating reverse osmosis unit. Integration of these technologies into a partially closed artificial ecosystem form the foundation of the SYMBIOSE concept (System for Microgravity Bioregenerative Support of Experiments).

The requirement for crew resource management (CRM), or aircrew coordination training (ACT) in military parlance, has been well documented and attested to. In addition, aircraft systems training has become more intense and more in-depth in the new aircraft designs, especially in multi-crew and complex aircraft such as the MV-22 Osprey Tiltrotor. (see Figure 1) Former training systems detailed training procedures that called for classroom training and simulation/simulator training followed by flight training. Improvements in aircraft flight skills training provide increased flying training capability coupled with reduced training time by integrating a mixed simulation/flight training syllabus, e.g. two to three simulation periods followed by one or two flight training periods covering the same material/skills. In addition, the simulation training will introduce new skills; the following flight periods will further refine/hone those skills.

THE performance characteristics of various devices applicable for jet directional control, lift augmentation, and VTOL-STOL studied at the NACA Lewis Laboratory are discussed, including jet deflection devices applicable to the conventonal round nozzle and novel nozzle configurations. The results indicate that many of the deflection devices applicable to conventional nozzles can readily be used for directional control or lift augmentation. Other deflection devices, such as movable plug, internal flap, cylindrical thrust reverser, swiveled primary with fixed shroud, and 90 deg side-bleed nozzle, are limited in application to jet directional control or aircraft trim because the loss in axial thrust for a given deflection force is prohibitive or the maximum deflected force obtainable is limited.

In a 2-year program sponsored by SJAC, an aqueous electroplating process using alkaline Zn-Ni with trivalent chromium post treatment is under evaluation for high strength steel for aircraft application as an alternative to cadmium. Commercial Zn-15%Ni rack/barrel plating solutions are basis for plating aircraft parts or fasteners. Brightener was reduced from the original formula to form porous plating that enables bake-out of hydrogen to avoid hydrogen embrittlement condition. Properties of the deposit, such as appearance, adhesion, un-scribed corrosion resistance, and galvanic corrosion resistance in contact with Al alloy, were evaluated. Coefficient of friction was compared with Cd plating by torque-tension measurements. Evaluation of the plating for scribed corrosion resistance, primer adhesion, etc. will continue in FY2007.

In spite of environmental issues related to cadmium and its electroplating process, electroplated cadmium is still extensively used in the aerospace and defense sectors. This trend is likely to continue especially for high strength steels because cadmium provides the best known corrosion and embrittlement protection for this application. Consequently, the environmental concerns related to the cadmium electroplating have been addressed using an alternative Zero-waste Physical Vapor Deposition (Z-PVD). This method does not use liquids, it recycles cadmium in situ, and is free of hydrogen embrittlement. The Z-PVD process is now in commercial production for the aerospace fasteners. The quality of the coatings has been at least equal to that of the electroplated cadmium.

This paper presents a trade-off study to select a water separator system for a 3-man, 140-day, zero-g mission. Included is a summary of feasible concepts, a compilation of data on existing hardware, and a comparison of the performance characteristics of each with respect to the overall system. Six approaches to zero-g water separation were considered and are discussed: hydrophobic/hydrophilic screens; integrated condenser-water separators; centrifugal separators; cellular sponges; vortex separators; and elbow separators. Some of these techniques have high-performance characteristics with regard to water removal efficiency. However, when reduced to hardware, these same techniques may not integrate well with the overall system. The system selected was the integrated condenser-water-separator. This system requires no power, has no moving parts, and has a very small envelope.

This paper investigates the use of several zero-ozone depleting potential (zero-ODP) HFC refrigerants, including HFC-134a, HFC-227ca, HFC-227ea, HFC-236ea, HFC-236cb, HFC-236fa, HFC-245cb, and HFC-254cb, for centrifugal chiller applications. We took into account the thermodynamic properties of the refrigerant and aerodynamic characteristics of the impeller compression process in this evaluation.. For a given operating temperature lift, there are significant differences in the pressure ratio required by each refrigerant and this variation in pressure ratio directly affects compressor size, efficiency, and performance. A comparison of the HFC refrigerant candidates with CFC-114 shows that HFC-236ea, HFC-227ca and HFC-227ea are viable alternatives for centrifugal water chillers. HFC-236ea has properties closest to CFC-114, and will result in comparible performance, but will require a slightly larger impeller and a purge system.

The X-38 vehicle will be used to demonstrate the future technology on durable TPS for the CRV. Astrium has produced two large CMC Nose Skirt side panels for the current X-38 configuration. The design of the 3 dimensional curved and large side panels comprises a light-weight, stringer stiffened concept which compensates the thermal expansion by a system of flexible metallic stand-offs. An optimum in flexibility and stiffness to fulfil all requirements had to be found: strong and stiff enough to carry the thermo-mechanical loads, but flexible enough to realise a fastening concept which does not fail due to thermal expansion. The fastening concept has been tested on development test level. Some thermal and mechanical tests on sub-structure level confirmed the design and analysis work of the complete TPS concept.

It was anticipated that during X-29 extended duration, high angle-of-attack flight (40 to 70 deg), aircraft ECS performance would significantly degrade. Computer modelling of the system indicated that the performance of the ECS decreased as the angle of attack increased. Modifications to improve system performance were analyzed and, as a result of this analysis, ECS hardware modifications have been incorporated on the aircraft. The High-Alpha Flight Test Program has proven the validity of these modifications. To date, the ECS on Ship No. 2 has performed well within its nominal operating parameters in the high-alpha regime.

Performance of Avionics systems is dictated by the timely availability and usage of critical health parameters. Various sensors are extensively used to acquire and communicate the desired parameters. In today's scenario, sensors are hardwired. The number of sensors is growing due to automation which increases the accuracy of intended Aircraft functions. Sensors are distributed all over the Aircraft and they are connected through wired network for signal processing and communication. LRUs (Line Replaceable Unit) which are integrating various sensors also use a wired approach for communication. The use of a wired network approach poses challenges in terms of cable routing, stray capacitances, noise, mechanical structure and added weight to the structure. The weight of cables contributes significantly to the overall weight of the aircraft. As the weight of Aircraft increases, the required fuel quantity also increases. The Key driver for Airline operational cost is fuel.

TAKING as basic requirements such fundamental characteristics as can be largely separated from the problem of wing design or assumed as attributes of the complete airplane, the author discusses the independent variables consisting mainly of the geometrical characteristics that can be varied to obtain maximum performance without changing the basic requirements. He develops a weight and a drag equation, each founded on the chosen basic requirements and including in the simplest possible form the combined effect of the independent variables. The terms in these equations are defined and the equations are applied to a low-wing monoplane in power and gliding fight and to a rectangular-wing biplane in gliding flight. The results are tabulated in some instances but are principally shown on charts. The accuracy of the results obtained is stated to depend largely upon the proper choice of approximations with an appreciation of their limitations.

On the whole, strategic sourcing and supplier rationalization have been successful Original Equipment Manufacturer (OEM) strategies. Often ignored however, are some of the longer-term ramifications of strategic sourcing and supplier rationalization that are less favorable, particularly if, in the process of embarking upon these strategies, an OEM looses visibility into and/or relinquishes control over, the finished part bill of material (BOM). Finished part BOM is defined as all of the material “inputs” that go into a manufactured part materials such as bar, sheet, tube, wire, fasteners, etc. This negative consequence of outsourcing, the loss of BOM visibility and control, can dilute and even undermine the very strategy that spawned it.

Resistance spot welding, projection welding, and drawn arc stud welding, are discussed as processes for the attachment of welded fasteners. Recent development work in the drawn arc stud welding process is emphasized. The drawn arc stud welding process offers the greatest flexibility of fastener design with minimal heat affected zone problems.

Premature wearout of augmentor hydraulic fuel pumps was being experienced in service on a fighter aircraft engine. The removal times ranged from 150 to 800 engine operating hours. Considerable effort had gone into the understanding of the physics of failure and overcoming this problem in a modified pump. However, there still remained the question of how best to proof test the new pump. The challenge was to demonstrate that the redesigned pump was significantly better than the old pump. The problems faced during design verification will be discussed in this case study. For example, does an accelerated test duplicate the service failure mode? When has an accelerated test run long enough to prove the redesign is in fact better than the old product? This paper illustrates the application of new technology to solve these research and development program problems through the use of Weibull and Weibayes Analysis.

Renewal theory concerns itself with the replacement of randomly failing parts. In the simplest case we have a one component system which is kept running continuously by replacing a failed component at the instant of failure with an identical “new” component. The random variable N(t) = the number of failures (or replacements) to time t is then of interest in many types of reliability analysis. In this paper the distribution of N(t) is considered when the underlying failure law is a Weibull distribution. Tables of the mean and standard deviation of N(t) for various values of the Weibull slope parameter are presented. Applications to warranty and spare parts analyses are also noted.

The technological advances made in the weaving of advanced materials show true promise for the automotive, aerospace and other industries. The capability to design and fabricate a fabric matching unique specifications exist today. Engineers have the liberty of specifying fiber placement and combinations unheard of before. The understanding of weaving can provide the Engineer with creative options during the design and fabrication of composite parts. Their work is made easier with a basic understanding. The ART of weaving has been with civilization since before the pharoahs of Egypt. The weaving of advanced composite materials represents only a second of time in comparison. That fact is made evident by the lack of written material delineating processes and methods by which advanced materials are woven into end products. I will attempt to introduce, explain and demonstrate the developing science and art of weaving with advanced composite materials.

The new DIF (Drill/Install Fastener) end effector machine series is being developed through implementing lean engineering. The end effectors will drill and install fasteners, eliminating many manufacturing process steps. Future enhancement capabilities are already designed in.

Water is of critical importance to space missions due to crew needs and the cost of supply. To control mission costs, it is essential to recycle water from all available wastes - both solids and liquids. Water recovery from liquid water wastes has already been accomplished on space missions. For instance, a Water Recycling System (WRS) is currently operational on the International Space Station (ISS). It recovers water from urine and humidity condensate and processes it to potable water specifications. However, there is more recoverable water in solid wastes such as uneaten food, wet trash, feces, paper and packaging material, and brine. Previous studies have established the feasibility of obtaining a considerable amount of water and oxygen from these wastes (Pisharody et al, 2002; Fisher et al, 2008; Wignarajah et al, 2008).

Spray drying is a continuous physical separation process where a solution is sprayed into a hot drying medium. The resulting products are dry solute particles and the drying medium bearing the solvent vapor. Using one of several methods the solvent is recovered from the drying medium. The exact nature of the dried solid and recovered solvent depends on the physical and chemical properties of the feed and the design and operation of the dryer. In this paper we discuss progress made on the development of a prototype for advanced life support applications, and provide data on its purification abilities. A system processing 1 kg hr−1 of aqueous brine solution consumes on the order of 1000 W, but this value was strongly tied to other processing parameters such as dryer inlet and exit temperatures and the heating mode. Analysis of recovered water having an initial concentration of 48000 ppm TDS had between 12 and 134 ppm TDS and strongly depended on the processing conditions.

An important milestone in the ongoing effort by NASA to develop and refine closed-loop water recycling systems for human space flight was reached during the summer of 1996 with the successful completion of Phase II of the Lunar Mars Life Support Testing Program at Johnson Space Center. Part of Phase II involved testing a water-recycling system in a closed test chamber continuously occupied by four human subjects for thirty days. The Phase II crew began the test with a supply of water that had been processed and certified for human use. As the test progressed, humidity condensate, urine, and wastewater from personal hygiene and housekeeping activities were reclaimed and reused several times. Samples were collected from various points in the reclamation process during the thirty day test. The data verified the water-processing hardware can reliably remove wastewater contaminants and produce reclaimed water that meets NASA standards for hygiene- and potable-quality water.