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This paper presents, chemistry, test data and processing procedures on a non toxic and environmentally friendly chrome-free conversion coating alternative with the same level of adhesion and secondary corrosion resistance as that found in chrome containing conversion coating systems. Test data from military and independent sources will be presented on secondary coating adhesion, electrical conductivity, filiform and neutral salt-spray corrosion resistance as compared to chromate based systems .on magnesium, aluminum and zinc and their respective alloys. The European “RoSH” initiative will not allow for the presence of any hexavalent chromium on imported electrical components as of July first of 2006. Trivalent chromium based systems generate hexavalent chromium due to the oxidation of the trivalent chromium and as such will not be allowed.

In recent years there has been increasing interest in quantifying the emissions from aircraft in order to generate inventories of emissions for climate models, technology and scenario studies, and inventories of emissions for airline fleets typically presented in environmental reports. The preferred method for calculating aircraft engine emissions of NOx, HC, and CO is the proprietary “P3T3” method. This method relies on proprietary airplane and engine performance models along with proprietary engine emissions characterizations. In response and in order to provide a transparent method for calculating aircraft engine emissions non proprietary fuel flow based methods 1,2,3 have been developed. This paper presents derivation, updates, and clarifications of the fuel flow method methodology known as “Fuel Flow Method 2”.

A wide body aircraft carries almost a half–ton of water and ice between the cabin and skin of the aircraft. The water can get on wires and connectors, which can cause electrical problems, cause corrosion and rust, and, eventually, “rain in the plane”. The speaker is the CEO of CTT Systems that has developed a system that solves the condensation by using dry air. The speaker will discuss how condensation can be prevented and how airlines can also save maintenance costs in the process. This topic is relevant for the attendees at the Aerospace Expo, as they are decision makers who need to be aware of this issue. It is also important for the MRO shows as the attendees are on the front lines of dealing with this problem.

The airline industry seems to be providing more leisure features on planes like inflight entertainment, Internet access and Digital TV, but it seems the airline industry has ignored the issue of excess condensation on aircraft, which had plagued carriers since the birth of the airline industry. How safe are passengers when a wide body aircraft carries in excess almost a half ton of water and ice between the cabin and skin of the aircraft? Besides the added weight straining the aircraft, excess condensation soaks wires and connectors which can cause electrical shorts. There have been instances of emergency doors frozen shut, locked by ice stemming from excess water dripping inside the plane. Extra water also causes “rain-in-the-plane”, an issue that has gained national attention and causes passenger discomfort. It's time for the industry to address what has become a serious issue.

STRUCTURAL MATERIALS for Mach 3 jet transports pose difficult problems for the design engineer. Reasons for this problem are the incomplete information available on the many possible metals and the diversity of critical properties that are added by supersonic requirements. The material properties discussed in this paper include tensile strength, resistance to crack propagation, ease of fabrication, weldability, and thermal expansion. Cost factors are also considered. The structural configuration of the wing and fuselage is an example of the complexity of the material selection problem. The wing may be rigidity-critical, and the fuselage strength-critical; each requires diferent material properties to solve the problem.*

NEW WELDING processes are dropping costs while providing improvements in weld quality. This paper describes some of the more promising new developments in pressure and fusion welding and brazing. Included in the discussion are ultrasonic, high frequency resistance, foil seam, magnetic force, percussion, friction, and thermopressure welding and diffusion bonding. The description of adhesive bonding includes the development of glass or ceramic materials as structural adhesives.*

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.

The X-29A aircraft is a fascinating combination of integrated technologies incorporated into a unique research aircraft. The X-29A program is a multiple-agency program with management and other responsibilities divided among the National Aeronautics and Space Administration (NASA), the Defense Advanced Research Projects Agency (DARPA), the U.S. Air Force, and the Grumman Corporation. This paper presents an overview of the recently completed X-29A flight research program, the objectives achieved to date, and a discussion of the future of the flight research program. Also discussed are the flight test approach expanding the envelope, typical flight maneuvers performed, X-29A program accomplishments, lessons learned for the Number One aircraft, and future plans with the Number Two aircraft. A schedule for both the Number One and Number Two aircraft is presented.

The X-29 Fuel/Auxiliary Oil Thermal Management System provides total aircraft accessory oil cooling, including both flight and combined hydraulics, Integrated Drive Generator oil, and Accessory Drive Gearbox oil, with onboard fuel. Fuel cooling rates that are independent of engine demand are achieved through the use of a recirculation loop. Recirculation is minimized by maintaining the engine fuel inlet temperature at the maximum allowable. Fuel cooling results in lower, more uniform subsystem oil temperatures, less ram drag, and smaller, lighter-weight heat exchangers. Initial design studies and laboratory development testing will be discussed, along with comparisons of analytical predictions with flight test results.

The AS6224 specification covers environment resistant, permanent insulation repair sleeves for repairing different types of insulation damages of wire or cable jackets in installed applications. The repair sleeve is intended to repair damaged primary wire or cable jacket covers where the shielding and wire conductors are not damaged.

Paralleling synchronous generators requires a priori voltage matching and frequency synchronization. Exceeding normal limits can lead to severe electrical transients. The classical three-phase short circuit analysis is extended to include the case of two initially unloaded synchronous generators. An analytical solution is developed neglecting winding resistances and saturation. Of particular interest is the tendency to induce negative field currents that cause inverse voltages across the rotating rectifier in a brushless design. Typical aircraft generator parameters are used to predict the paralleling transient vs. initial rotor electrical angle mismatch. Results are compared to simulation and limited test results.

Selection of working fluid is one of the main criterions for designing of heat pipes thermal control systems (TCS) for space application. In this paper we will describe how we solved the task of development of the TCS with working fluid of high thermal physical properties. In 2004-2006 we developed the Engineering model of Deployable Radiator based on Loop Heat Pipe by CAST purchase order. It was developed for qualification tests. Ammonia application as LHP working fluid is stipulated by its high thermal physical properties. However Ammonia freezing temperature is of minus 77ºC. Such fact impedes Ammonia application when operation temperatures of LHP Radiator are lower than this value, for example, It takes several tens of hours to orbit a spacecraft and prepare it for work (at that moment the spacecraft is out of power supply) and the working fluid can be frozen in a condenser-radiator when the spacecraft being in the shadow over a long period of time.

Currently, many factors influence the NASA Kennedy Space Center (KSC) workforce. These factors include the drive for return to flight, a Shuttle Program end date of 2010, and the Vision for Space Exploration which calls for the development of a new launch vehicle. Additionally, external factors exist as well, such as the area's cost of living, the availability of skilled resources, and the unemployment rate affect the overall workforce climate. To manage the human capital in a manner consistent with safety and mission success, and to strategically position NASA KSC to execute its future mission, it is necessary to understand how all of these different influencing factors work together to produce an overall workforce climate. We have been using System Dynamics models in order to capture some of these factors. These system dynamics models are also the starting point of agent-based models.

AS23190 is a procurement specification that covers a series of plastic and metal components and devices used for the tying, positioning, and supporting cable, cable assemblies, wire, and wire bundles in electrical, electronic and communication equipment, and in interconnection systems.

AS23190 is a procurement specification that covers a series of plastic and metal components and devices used for the tying, positioning, and supporting cable, cable assemblies, wire, and wire bundles in electrical, electronic and communication equipment, and in interconnection systems.