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Dimensional Management (DM) is a methodology to predict and control the impact of variation on assembly from, fit, and function. Application of Dimensional Management tools and other modeling and simulation techniques are combined in a process called 3D Re-Engineering for application to existing production designs. Analytical techniques for predicting the impact of variation on assembly fit, and corresponding methods for controlling variation are presented, as used in a production environment for root cause corrective action on existing assembly fit problems. Assembly variation analysis is typically performed early in the product development phases, by coordinating datums, assembly sequences, assembly methods, and detail part tolerances across the product development team.

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.

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.

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.

Titanium’s high strength-to-weight ratio and corrosion resistance makes it ideal for many aerospace applications, especially in heat critical zones. Superplastic Forming (SPF) can be used to form titanium into near-net, complex shapes without springback. The process uses a machined die where inert gas is applied uniformly to the metal sheet, forming the part into the die cavity. Standard titanium alpha-beta alloys, such as 6Al-4V, form at temperatures between 900 and 925°C (1650-1700°F). Recent efforts have demonstrated alloys that form at lower temperatures ranging between 760 and 790°C (1400-1450°F). Lowering the forming temperature reduces the amount of alpha case that forms on the part, which must be removed. This provides an opportunity of starting with a lower gauge material. Lower forming temperatures also limit the amount of oxidation and wear on the tool and increase the life of certain press components, such as heaters and platens.

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.

A summary of information on airplane aerodynamics, ground effects, propulsion system aerodynamics, stability and control, and flying qualities of jet V/STOL airplanes - both direct jet lift and lift fan configurations is presented. The information is applicable to high-speed fighter-type airplanes. Research work in the following areas is reviewed: 1. Wind tunnel and other experimental research on jet-induced effects (including ground effects) on the aerodynamics and stability and control in the VTOL, STOL, hovering, and transition ranges of flight. 2. Experimental research on propulsion aerodynamics in the hovering and very low speed ranges of flight. 3. Flight-test experience on the flying qualities of several jet V/STOL airplanes.

An experimental investigation of the flow over the rear end of a 0.16 scale notchback automobile configuration has been conducted in the NASA Langley Basic Aerodynamics Research Tunnel (BART). The objective of this work was to investigate the flow separation that occurs behind the backlight and obtain experimental data that can be used to understand the physics and time-averaged structure of the flow field. A three-component laser velocimeter was used to make non-intrusive, velocity measurements in the center plane and in a single cross-flow plane over the decklid. In addition to off-body measurements, flow conditions on the car surface were documented via surface flow visualization, boundary layer measurements, and surface pressures.

A research program is in progress to study the effects of the propeller slipstream on natural laminar flow. Flight and wind tunnel measurements of the wing boundary layer have been made using hot-film velocity sensor probes. The results show the boundary layer, at any given point, to alternate between laminar and turbulent states. This cyclic behavior is due to periodic external flow turbulence originating from the viscous wake of the propeller blades. Analytic studies show the cyclic laminar/turbulent boundary layer layer to result in a significantly lower wing section drag than a fully turbulent boundary layer. The application of natural laminar flow design philosophy yields drag reduction benefits in the slipstream affected regions of the airframe, as well as the unaffected regions.

Currently scheduled to be delivered to the International Space Station (ISS) in 2009, Crew Quarters (CQs) will be installed in the Node 2 Module. The CQs provide crewmembers with private space, a place to sleep, and minimal storage. Analysis is to be performed to determine if the United States Operational Segment (USOS) Node 2 can maintain temperature between 47°C and 62°C (65°F and 80°F) [units are CCGS with U.S unit in parenthesis] within the CQ. The analysis will concentrate on the nominal hot environmental case. Environmental heat is due to solar heating of the external shell of the ISS. Configurations including both three and four CQs are examined, as well as multiple configurations of the Low Temperature Loop (LTL) that flows through the Node 2 Common Cabin Air Assembly (CCAA). This paper describes the analysis performed to determine if Node 2 will be able to maintain cabin temperature between 47°C and 62°C (65°F and 85°F).

Recently, the concept of the application of hybrid laminar flow to modern commercial transport aircraft was successfully flight tested on a Boeing 757 aircraft. In this limited demonstration, in which only part of the upper surface of the swept wing was designed for the attainment of laminar flow, significant local drag reduction was measured. This paper addresses the potential application of this technology to laminarize the external surface of large, modern turbofan engine nacelles which may comprise as much as 5-10 percent of the total wetted area of future commercial transports. A hybrid-laminar-fiow-control (HLFC) pressure distribution is specified and the corresponding nacelle geometry is computed utilizing a predictor/corrector design method. Linear stability calculations are conducted to provide predictions of the extent of the laminar boundary layer. Performance studies are presented to determine potential benefits in terms of reduced fuel consumption.

For new aircraft production, initial production typically reveals difficulty in achieving some assembly level tolerances which in turn lead to non-conformances at integration. With initial design, tooling, build plans, automation, and contracts with suppliers and partners being complete, the need arises to resolve these integration issues quickly and with minimum impact to production and cost targets. While root cause corrective action (RCCA) is a very well know process, this paper will examine some of the unique requirements and innovative solutions when addressing variation on large assemblies manufactured at various suppliers. Specifically, this paper will first review a completed airplane project (Project A) to improve fuselage circumferential and seat track joins and continue to the discussion on another application (Project B) on another aircraft type but having similar challenges.

Currently, the Aviation industry uses traditional methods of communication, coordination, & human interaction to give disposition to resolve any kind of nonconformance occurrences which occur during manufacturing or operation of commercial or defense products. This involves increased in-person interaction and additional travel, especially to address the nonconformance issues arising at supplier plants or airports around the globe. During Covid and post-Covid environments, human interactions for the transfer of detailed information at different & distant manufacturing plant locations has been difficult, since support engineering teams (Example: Liaison, Product Review, Quality, Supplier Quality, and Manufacturing Engineering, and/or Service Engineering) have been working remotely.

Temperature Sensitive Paint (TSP) technology coupled with the Reynolds number capability of modern wind tunnel test facilities produces data required for continuing development of turbulence models, stability codes, and high performance aerodynamic design. Data in this report include: the variation in transition location with Reynolds number in the boundary layer of a two-dimensional high speed natural laminar flow airfoil (HSNLF) model; additional bypass mechanisms present, such as surface roughness elements; and, shock-boundary layer interaction. Because of the early onset of turbulent flow due to surface roughness elements present in testing, it was found that elements from all these data were necessary for a complete analysis of the boundary layer for the HSNLF model.

In order to conserve mass and volume, it was proposed that the International Space Station (ISS) control the level of carbon dioxide (CO2) in the Space Shuttle Orbiter while the Orbiter is docked to the ISS. If successful, this would greatly reduce the number of lithium hydroxide (LiOH) canisters required for each ISS-related Orbiter mission. Because of the impact on the Orbiter Environmental Control and Life Support Subsystem (ECLSS), as well as on the Orbiter flight manifest, a Space Shuttle Program (SSP) analysis was necessary. STS-108 (ISS UF1) pre-flight analysis using the Personal Computer Thermal Analyzer Program (PCTAP) predicted that the ISS would be able to control the level of CO2 in the Orbiter (and throughout the stack) under nominal conditions with no supplemental LiOH required. This analysis assumed that the Carbon Dioxide Removal Assembly (CDRA) located in the U.S.