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Aircraft fire safety research

During the past 15 years, very significant progress has been made toward enhancing aircraft fire safety in both normal and hostile (combat) operational environments. Most of the major aspects of the aircraft fire safety problem are touched upon here. The technology of aircraft fire protection, although not directly applicable in all cases to spacecraft fire scenarios, nevertheless does provide a solid foundation to build upon. This is particularly true of the extensive research and testing pertaining to aircraft interior fire safety and to onboard inert gas generation systems, both of which are still active areas of investigation.

Botteri, Benito P.↗

The practical application of mishap data in Army aircraft system safety programs

The means are discussed by which the the United States Army Board for Aviation Accident Research (USABAAR) now utilizes the vast store of historical accident data in the application of the system safety concept for developmental aircraft. USABAAR serves as the central agency for the Army Accident Prevention Program which includes the receipt, processing, and analysis of all data and information related to Army aircraft accident experience. It is pointed out that methods which served the cause of accident prevention so well in the past are no longer adequate and that traditional parameters used to measure mishap experience have become obsolete. USABAAR has developed, and recently put into use, completely revised accident reporting forms which greatly expand the scope and detail of information provided as a result of investigation. This and other factors which have resulted in an improved data system are discussed in detail.

James T. Darrah, Jr↗

The Ultimate Factor of Safety for Aircraft and Spacecraft Its History, Applications and Misconceptions

The ultimate factor of safety (FOSULT) concept used in aircraft and spacecraft has evolved over many decades. Currently an FOSULT 1.5 is the FAR‐mandated value for aircraft while an FOSULT of 1.4 has been used in various spacecraft. This paper was motivated by the desire to concisely explain the origins, proper interpretation and application of the ultimate factor of safety concept, since the authors have seen throughout their careers many misconceptions and incorrect applications of this concept. The history of the ultimate factor of safety concept is briefly summarized, the proper application of the factor of safety in aircraft design, structural analysis and operations is covered in detail, examples of limit load exceedance in aircraft and spacecraft are discussed, the evolution of the 1.4 FOSULT for spacecraft is described and some misconceptions regarding the ultimate factor of safety concept are addressed. It is hoped that this paper can be a summary resource for engineers to understand the origin, purpose and proper application of the ultimate factor of safety.

Zipay, John J.↗

Verification and Validation of Safety-Critical Aircraft Systems Operating under Off-Nominal, Contingency, and Emergency Conditions

Verification and validation (V&V) of safety-critical technologies developed for loss of control (LOC) prevention and recovery and other aviation safety concerns pose significant challenges. Aircraft LOC can result from a wide spectrum of hazards, often occurring in combination, which cannot be fully replicated during evaluation. Technologies developed for LOC prevention and recovery must therefore be effective under a wide variety of hazardous and uncertain conditions, and the verification and validation of these technologies must provide some measure of assurance that the new vehicle safety technologies do no harm (i.e., that they themselves do not introduce new safety risks). V&V technologies must also enable the identification of system limitations and constraints, as well as enable the identification of safe and unsafe operating conditions (and their boundaries). Additionally, the V&V of complex, increasingly autonomous systems is a fundamental concern. Scalable, reproducible and cost-effective techniques for the assurance of safety critical systems during their design and operation is a key barrier to fielding new systems or updating current systems. Moreover, these techniques need to provide artifacts that enable a comprehensive evidence-based approach to certification. This briefing summarizes research performed under NASA’s Aviation Safety Program and follow-on research for the V&V of safety-critical aircraft system technologies developed for LOC prevention and recovery and increasingly autonomous systems, and for a broad assurance capability in both current and emerging aviation applications. Note that, in this briefing, the term “validation” refers to a confirmation that the system implementation (e.g., algorithms etc.) is performing the intended function(s), as well as an affirmation of effectiveness in these functions. “Verification” refers to a confirmation that the system implementation in the software and hardware meets its (hopefully validated) specifications (e.g., correctly executes algorithms as designed).

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National Transportation Safety Board Aircraft Accident Investigation Supported

The main purpose of this investigation was for NASA to help the National Transportation Safety Board (NTSB) gain better understanding of the events that led to the loss of Comair Flight 3272 over Monroe, Michigan, on January 9, 1997. In-flight icing was suspected as being the primary cause of this accident. Of particular interest to the Safety Board was what NASA could learn about the potential performance degradation of the wing of the Embraer EMB-120 twin-turboprop commuter aircraft with various levels of ice contamination. NASA agreed to undertake (1) ice-accretion prediction computations with NASA s LEWICE program to bound the kind of contaminations that the vehicle may have developed, (2) testing in the NASA Lewis Research Center's Icing Research Tunnel to verify and refine the ice shapes developed by LEWICE, (3) a two-dimensional Navier- Stokes analysis to determine the performance degradation that those ice shapes could have caused, and (4) an examination using three-dimensional Navier-Stokes codes to study the three-dimensional effects of ice contamination.

Reehorst, Andrew L.↗

NASA technical advances in aircraft occupant safety

NASA's aviation safety technology program examines specific safety problems associated with atmospheric hazards, crash-fire survival, control of aircraft on runways, human factors, terminal area operations hazards, and accident factors simulation. While aircraft occupants are ultimately affected by any of these hazards, their well-being is immediately impacted by three specific events: unexpected turbulence encounters, fire and its effects, and crash impact. NASA research in the application of laser technology to the problem of clear air turbulence detection, the development of fire resistant materials for aircraft construction, and to the improvement of seats and restraint systems to reduce crash injuries are reviewed.

Enders, J. H.↗

Materials research for aircraft fire safety

The thermochemical and flammability characteristics of two polymeric composites currently in use and seven others being considered for use as aircraft interior panels are described. The properties studied included: (1) limiting oxygen index of the composite constituents; (2) fire containment capability of the composite; (3) smoke evolution from the composite; (4) thermogravimetric analysis; (5) composition of the volatile products of thermal degradation; and (6) relative toxicity of the volatile products of pyrolysis. The performance of high-temperature laminating resins such as bismaleimides is compared with the performance of phenolics and epoxies. The relationship of increased fire safety with the use of polymers with high anaerobic char yield is shown. Processing parameters of the state-of-the-art and the advanced bismaleimide composites are detailed.

Kourtides, D. A.↗

NASA Research Being Shared Through Live, Interactive Video Tours

On June 2, 2000, the NASA Glenn Research Center Learning Technologies Project (LTP) coordinated the first live remote videoconferencing broadcast from a Glenn facility. The historic event from Glenn's Icing Research Tunnel featured wind tunnel technicians and researchers performing an icing experiment, obtaining results, and discussing the relevance to everyday flight operations and safety. After a brief overview of its history, students were able to "walk through" the tunnel, stand in the control room, and observe a live icing experiment that demonstrated how ice would grow on an airplane wing in flight through an icing cloud. The tour was interactive, with a spirited exchange of questions and explanations between the students and presenters. The virtual tour of the oldest and largest refrigerated icing research tunnel in the world was the second of a series of videoconferencing connections with the AP Physics students at Bay Village High School, Bay Village, Ohio. The first connection, called Aircraft Safety and Icing Research, introduced the Tailplane Icing Program. In an effort to improve aircraft safety by reducing the number of in-flight icing events, Glenn's Icing Branch uses its icing research aircraft to conduct flight tests. The presenter engaged the students in discussions of basic aircraft flight mechanics and the function of the horizontal tailplane, as well as the effect of ice on airfoil (wing or tail) surfaces. A brief video of actual flight footage provided a view of the pilot's actions and reactions and of the horizon during tailplane icing conditions.

Petersen, Ruth A.↗

Polymer materials research at NASA Ames Research Center

Polymers that provide significant improvements in both efficiency and safety for civilian transport aircraft and military combat aircraft were developed. High strength to weight structures such as carbon fiber composites with long term durability are requirements common to both classes of aircraft. Aircraft safety improvements in fire resistance and crashworthiness of primary and secondary structures are long term objectives for transport aircraft. Void filler ballistic foams, intumescent coatings, and radiation-resistant transparent plastics contribute to vulnerability reduction in combat military aircraft. Low and high velocity impact tolerance, fire resistance, thermal stability, and long term durability of polymers and components are emphasized.

J. A. Parker↗

On-Board Battery Monitoring and Prognostics for Electric-Propulsion Aircraft

The reliability of the propulsion system of an aircraft is paramount for the aircraft safety and hence the aircraft health must be monitored continuously. In contrast to fuel- operated aircraft, electric battery-operated propulsion system poses specific problems, such as, the remaining battery power does not linearly decrease and cannot be measured directly. In this paper, we describe a combined monitoring and prognostics architecture that can continuously monitor all components of the electric propulsion system with respect to safety and performance properties as well as state of charge and rest of useful life for the battery. Our system combines a detailed electrochemical battery model for Li-ion batteries with a powerful prognostics engine based upon an Unscented Kalman Filter with the R2U2 monitoring device, which provides efficient observers for metric temporal logic and Bayesian reasoning. R2U2 is a real-time, realizable, responsive, unobtrusive unit, which continuously monitors sensor readings, outputs of the prognostics engine, as well as the ight software status for safety, performance, and security properties. We illustrate our architecture with two case studies, one reporting actual ight tests with an X8+ octocopter and the other a software-in-the-loop simulation with an unmanned Edge 540 electric aircraft model.

Kulkarni, Chetan↗

Modeling Programs Increase Aircraft Design Safety

Flutter may sound like a benign word when associated with a flag in a breeze, a butterfly, or seaweed in an ocean current. When used in the context of aerodynamics, however, it describes a highly dangerous, potentially deadly condition. Consider the case of the Lockheed L-188 Electra Turboprop, an airliner that first took to the skies in 1957. Two years later, an Electra plummeted to the ground en route from Houston to Dallas. Within another year, a second Electra crashed. In both cases, all crew and passengers died. Lockheed engineers were at a loss as to why the planes wings were tearing off in midair. For an answer, the company turned to NASA s Transonic Dynamics Tunnel (TDT) at Langley Research Center. At the time, the newly renovated wind tunnel offered engineers the capability of testing aeroelastic qualities in aircraft flying at transonic speeds near or just below the speed of sound. (Aeroelasticity is the interaction between aerodynamic forces and the structural dynamics of an aircraft or other structure.) Through round-the-clock testing in the TDT, NASA and industry researchers discovered the cause: flutter. Flutter occurs when aerodynamic forces acting on a wing cause it to vibrate. As the aircraft moves faster, certain conditions can cause that vibration to multiply and feed off itself, building to greater amplitudes until the flutter causes severe damage or even the destruction of the aircraft. Flutter can impact other structures as well. Famous film footage of the Tacoma Narrows Bridge in Washington in 1940 shows the main span of the bridge collapsing after strong winds generated powerful flutter forces. In the Electra s case, faulty engine mounts allowed a type of flutter known as whirl flutter, generated by the spinning propellers, to transfer to the wings, causing them to vibrate violently enough to tear off. Thanks to the NASA testing, Lockheed was able to correct the Electra s design flaws that led to the flutter conditions and return the aircraft to safe flight. Today, all aircraft must have a flutter boundary 15 percent beyond the aircraft s expected maximum speed to ensure that flutter conditions are not encountered in flight. NASA continues to support research in new aircraft designs to improve knowledge of aeroelasticity and flutter. Through platforms such as Dryden Flight Research Center s Active Aeroelastic Wing (AAW) research aircraft, the Agency researches methods for in-flight validation of predictions and for controlling and taking advantage of aeroelastic conditions to enhance aircraft performance.

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Light aircraft crash safety program

NASA is embarked upon research and development tasks aimed at providing the general aviation industry with a reliable crashworthy airframe design technology. The goals of the NASA program are: reliable analytical techniques for predicting the nonlinear behavior of structures; significant design improvements of airframes; and simulated full-scale crash test data. The analytical tools will include both simplified procedures for estimating energy absorption characteristics and more complex computer programs for analysis of general airframe structures under crash loading conditions. The analytical techniques being developed both in-house and under contract are described, and a comparison of some analytical predictions with experimental results is shown.

Thomson, R. G.↗

NASA aeronautics

Aeronautical research programs are discussed in relation to research methods and the status of the programs. The energy efficient aircraft, STOL aircraft and general aviation aircraft are considered. Aerodynamic concepts, rotary wing aircraft, aircraft safety, noise reduction, and aircraft configurations are among the topics included.

Anderton, D. A.↗

Radiation safety in aircraft operations

Data from a 7-yr flight experiment program to measure the significant biological components (tissue ionization rates, neutron flux, and nuclear reaction star rates) as a function of solar cycle, altitude, latitude and longitude from which biological risk from radiation is estimated are used to evaluate radiation dose and dose equivalents along specific flight trajectories. The data base used and the corresponding time-dependent global model are described. Ionization rates in air measured by argon filled chambers at solar minimum and maximum, and radiation measurements of the Brookhaven National Laboratory instrument compared to the present model are illustrated in tabular form. The global pressure distribution for solstice conditions at 14 km is shown.

Wilson, J. W.↗

Ultrasonics Equipped Crimp Tool: A New Technology for Aircraft Wiring Safety

We report on the development of a new measurement technique to quantitatively assess the condition of wire crimp connections. This ultrasonic (UT) method transmits high frequency sound waves through the joint under inspection. The wire-crimp region filters and scatters the ultrasonic energy as it passes through the crimp and wire. The resulting output (both time and frequency domains) provides a quantitative measure of the joint quality that is independent and unaffected by current. Crimps of poor mechanical and electrical quality will result in low temporal output and will distort the spectrum into unique and predictable patterns, depending on crimp "quality". This inexpensive, real-time measurement system can provide certification of crimps as they are made and recertification of existing wire crimps currently in service. The measurements for re-certification do not require that the wire be disconnected from its circuit. No other technology exists to measure in-situ the condition of wire joints (no electrical currents through the crimp are used in this analytical technique). We discuss the signals obtained from this instrument, and correlate these signals with destructive wire pull tests.

Yost, William T.↗

Detectors Ensure Function, Safety of Aircraft Wiring

Pedro Medelius waited patiently in his lab at Kennedy Space Center. He had just received word that a colleague was bringing over a cable from a Space Shuttle solid rocket booster to test Medelius new invention. Medelius was calm until his colleague arrived, with about 30 other people. "Talk about testing under pressure," says Medelius. "There were people there from the Navy, the Air Force, and the Federal Aviation Administration." After the group s arrival, Medelius took a deep breath and connected his Standing Wave Reflectometer (SWR) to the cable. He wiggled the cable around, and the display showed a fault (a short or open circuit in wire) about an inch and a half inside the connector on the cable. His colleague questioned the results, because he had already checked that area on the cable. Medelius used the SWR to check again but got the same result. "That is when we took the cable apart and looked inside," Medelius says. "Lo and behold, that was exactly where the fault was." The impetus for Medelius new wire inspection technology came about in 1999 when one of the space shuttles lost power due to a fault somewhere in its more than 200 miles of electrical wiring. "The backup circuit was activated and prevented a major dysfunction, but nevertheless, there was a problem with the wiring," Medelius describes. Even though technicians used a device called a multimeter to measure the electrical current to find which wire had a fault, it could not pinpoint exactly where on the wire the fault was located. For that, technicians had to visually inspect the wire. "Sometimes they would have to remove the whole wire assembly and visually inspect every single wire. It was a very tedious operation because the wires are behind cabinets. They go all over the place in the shuttle," says Medelius. "NASA needed an instrument capable of telling them exactly where the faults were occurring." To meet NASA s needs for a highly precise device to inspect electrical power bundles, wires, and connectors, Medelius devised the SWR. "It came down to what was affected when a wire is short circuited or opened," he says. "We worked out a few equations based on physical principles." The SWR proved very sensitive, and the technology was patented.

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