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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.

Pressure Sensitive Paint (PSP) has been used for several years by the aircraft industry in transonic wind tunnel testing where the oxygen concentrations are low and the luminescence of the paint is easily recorded. Extending PSP to slower speeds where the oxygen concentrations are closer to atmospheric conditions is much more challenging. For the past few years, work has been underway at both Wright Patterson Air Force Base and Ford Motor Company to advance PSP techniques for testing at slower speeds. The CRADA (Cooperative Research and Development Agreement) provided a way for comparisons to be made of the different PSP systems that were being investigated. This paper will report on PSP tests conducted as part of the CRADA.

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.

A scramjet exhaust simulation technique for hypersonic wind tunnel testing has been developed. Mixtures of Argon and Freon correctly match the inviscid simulation parameters of Mach number, static-pressure ratio, and the ratio of specific heats at the combustor exit location; this simulation is accomplished at significantly reduced temperatures and without combustion. An investigation of nozzle parametrics in a Mach 6 freestream showed that the external nozzle ramp angle, the cowl trailing-edge angle, an external nozzle flow fence and the nozzle static-pressure ratio significantly affected the external nozzle thrust and pitching moment as measured by the integration of surface-pressure data. A comparison of Argon-Freon and air exhaust simulation showed that the external nozzle thrust and pitching moment were in error by roughly a factor of 2 using air due to the incorrect match of the ratio of specific heats.

This paper identifies an approach to the definition of a National Airspace System (NAS) architecture which will support the future development of the U.S. air transportation system, consistent with long-range needs of the various users of the NAS. The approach outlined identifies the development of an FAA preliminary design methodology, with supporting tools and processes to provide the basis for NAS modernization. This approach begins with the quantification of the primary long-range objectives of the NAS, which the system architecture must support over its design life. These objectives are the basis of the mission analysis and requirements development, which, in turn, are used for technology tradeoff studies and the baselining of an architecture for evaluation.

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.

This paper presents a simplified orbit analysis program developed to calculate orbital parameters for the thermal analysis of spacecraft and space-flight instruments. The program calculates orbit data for inclined and sunsynchronous earth orbits. Traditional orbit analyses require extensive knowledge of orbital mechanics to produce a simplified set of data for thermal engineers. This program was created to perform orbital analyses with minimal input and provides the necessary output for thermal analysis codes. Engineers will find the program to be a valuable analysis tool for fast and simple orbit calculations. A description of the program inputs and outputs is included. An overview of orbital mechanics for inclined and Sun-synchronous orbits is also presented. Finally, several sample cases are presented to illustrate the thermal analysis applications of the program.

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.

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.

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 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.

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.

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.