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A Fast-Time Study of Aircraft Reordering in Arrival Sequencing and Scheduling

In order to ensure that the safe capacity of the terminal area is not exceeded, Air Traffic Management ATM often places restrictions on arriving flights transitioning from en route airspace to terminal airspace. This restriction of arrival traffic is commonly referred to as arrival flow management, and includes techniques such as metering, vectoring, fix-load balancing, and the imposition of miles-in-trail separations. These restrictions are enacted without regard for the relative priority which airlines may be placing on individual flights based on factors such as crew criticality, passenger connectivity, critical turn times, gate availability, on-time performance, fuel status, or runway preference. The development of new arrival flow management techniques which take into consideration priorities expressed by air carriers will likely reduce the economic impact of ATM restrictions on the airlines and lead to increased airline economic efficiency by allowing airlines to have greater control over their individual arrival banks of aircraft. NASA and the Federal Aviation Administration (FAA) have designed and developed a suite of software decision support tools (DSTs) collectively known as the Center TRACON Automation System (CTAS). One of these tools, the Traffic Management Advisor (TMA) is currently being used at the Fort Worth Air Route Traffic Control Center to perform arrival flow management of traffic into the Dallas/Fort Worth airport (DFW). The TMA is a time-based strategic planning tool that assists Traffic Management Coordinators (TMCs) and En Route Air Traffic Controllers in efficiently balancing arrival demand with airport capacity. The primary algorithm in the TMA is a real-time scheduler which generates efficient landing sequences and landing times for arrivals within about 200 no a. from touchdown. This scheduler will sequence aircraft so that they arrive in a first- come - first-served (FCFS) order. While FCFS sequencing establishes a fair order based on estimated times of arrival, it does not take into account individual airline priorities among incoming flights. NASA is exploring the possibility of allowing airlines to express relative arrival priorities to air traffic management through the development of new CTAS scheduling algorithms which take into consideration airline arrival preferences. The accommodation of airline priorities in arrival sequencing and scheduling would under most circumstances result in a deviation from a "natural" or FCFS arrival order. As a First step toward developing airline influenced sequencing algorithms, an investigation was conducted to determine the feasibility of reordering arrival traffic from a strict FCFS sequence. A fast-time simulation has been developed which allows statistical evaluation of sequencing and scheduling algorithms for arrival traffic at the Dallas/Fort Worth Airport. In contrast to real-time simulation or field tests, which would require on the order of ninety minutes to examine a single traffic rush period, the fast-time simulation allows examination of multiple rush periods in a matter of seconds.

Carr, Greg↗

Inaugural Technologist in Communities Scanning Tour: Automated and Electrified On-Demand Mobility (Follow-On Summary Report: April 24-25, 2023) [Slides]

In 2023, the Technologist in Communities (TIC) program hosted its inaugural scanning tour across the American Southwest, with a goal of investigating the region's leading public mobility systems and their integration with on-demand public mobility services. The scanning tour concept was inspired by and named after a U.S. Department of Transportation Federal Highway Administration practice of hosting "scanning tours," both domestically and abroad, to explore innovative transportation practices throughout the 1990s and early 2000s. Guided by the idea that "seeing is believing," scanning tours created opportunities for government and industry representatives to collectively experience new technologies and best practices firsthand. In 2023, the National Renewable Energy Laboratory (NREL) followed suit by leading the inaugural TIC scanning tour. TIC, part of the Technology Integration program within the U.S. Department of Energy's (DOE's) Vehicle Technologies Office, supports positive energy and mobility outcomes in communities across rural to urban contexts. TIC enables technical experts to work directly with leaders and stakeholders in communities and assist them in implementing promising new technologies. This first TIC scanning tour invited NREL, DOE, and industry experts to survey innovative public mobility practices and their integration into public transit systems across the Southwest. The tour's goals included examining the state of innovation in public mobility in cities, communities, and airports; facilitating collaboration between entities; and sparking potential new partnerships. The following report summarizes key findings from the scanning tour.

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Report of the Interagency Optical Network Testbeds Workshop 2, NASA Ames Research Center, September 12-14, 2005

The Optical Network Testbeds Workshop 2 (ONT2), held on September 12-14, 2005, was cosponsored by the Department of Energy Office of Science (DOE/SC) and the National Aeronautics and Space Administration (NASA), in cooperation with the Joint Engineering Team (JET) of the Federal Networking and Information Technology Research and Development (NITRD) Program's Large Scale Networking (LSN) Coordinating Group. The ONT2 workshop was a follow-on to an August 2004 Workshop on Optical Network Testbeds (ONT1). ONT1 recommended actions by the Federal agencies to assure timely development and implementation of optical networking technologies and infrastructure. Hosted by the NASA Ames Research Center in Mountain View, California, the ONT2 workshop brought together representatives of the U.S. advanced research and education (R&E) networks, regional optical networks (RONs), service providers, international networking organizations, and senior engineering and R&D managers from Federal agencies and national research laboratories. Its purpose was to develop a common vision of the optical network technologies, services, infrastructure, and organizations needed to enable widespread use of optical networks; recommend activities for transitioning the optical networking research community and its current infrastructure to leading-edge optical networks over the next three to five years; and present information enabling commercial network infrastructure providers to plan for and use leading-edge optical network services in that time frame.

OEP(Open Exchange Points)↗

2004-2006 Puget Sound Traffic Choices Study

The 2004-2006 Puget Sound Traffic Choices Study tested the hypothesis that time-of-day variable road tolling in Seattle, Washington, could reduce traffic congestion and generate revenue. In 2002, the Puget Sound Regional Council received a grant from the Federal Highway Administration for a pilot project on congestion-based tolling. To test the hypothesis, the study placed global positioning system data loggers into the vehicles of about 275 households in the Seattle metropolitan area. The project recorded roughly 18 months of trip data (from November 2004 to April 2006) and included more than 400 vehicles. For most vehicles, the tolling influence experiment phase of the study began in July 2005 and lasted for 32 weeks. The three months immediately preceding the experiment period for each vehicle served as the control period.

1Hz data↗

Preparing For Advanced Air Mobility: A System-Level Framework For Infrastructure, Investment, and Deployment

Advanced air mobility (AAM) is moving from demonstration toward early deployment, supported by a growing national strategy that outlines how these systems may evolve across airspace, infrastructure, and operations. As this transition takes shape, a more practical question comes into focus: what does it mean to be ready? This paper introduces a Capability Maturity Model (CMM) as a structured way to think about that challenge. Rather than treating readiness as a fixed condition, it frames it as a progression - one that develops across multiple, interdependent domains over time.

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USACE FUSRAP Records Management Challenges in the Digital Age - 20242

In late 2016, the U.S. Army Corps of Engineers (USACE) implemented a Headquarters-supported nationwide records management initiative managed by the USACE-New England District to address the digitization and organization of Formerly Utilized Sites Remedial Action Program (FUSRAP) project files. This initiative will prepare USACE FUSRAP for moving toward a fully electronic system of records management. Additionally, the records management initiative streamlines the process and prepares the Administrative Record (AR) and Permanent Record (PR) file for transfer from USACE to the U.S. Department of Energy (DOE)-Office of Legacy Management (LM) following project closeout. Over the past couple of years, USACE and DOE-LM have been working to finalize a joint guidance document to assist in the FUSRAP records transition process. However, there remain key records management topics that require further discussion and development. Specifically, these topics include the implementation, process, and procedure for the capture of social media records and compliance with Section 508 of the Rehabilitation Act of 1973 (29 USC 794d), as amended. Due to advances in technology and the ease of communication it provides, USACE is using social media more often to interface with the public than 5, 10 or 15 years ago. The identification and capture of these records are challenging because it requires each USACE district or producer of a record to track what has been released through social media so that it can be captured as part of the AR or PR. USACE is currently evaluating processes and procedures for social media records capture. This paper explores how social media is being used by USACE across FUSRAP projects and best practices for the capture of social media records. Public accessibility to the project AR is required under the Comprehensive Environmental Response, Compensation, and Liability Act, which USACE FUSRAP must follow. As USACE FUSRAP ARs are converted to a digital format, greater accessibility to the files can be provided through web sites or other electronic media. However, Section 508 of the Rehabilitation Act must be considered when releasing electronic files to the public. Under Section 508, government agencies must ensure that information is made available to the public in a format that provides equal access to persons with disabilities. This paper discusses the electronic records requirements under Section 508 and addresses broad implementation of compliance across large digital records sets. Records management challenges are presented in the context of the FUSRAP records management program; however, these records management considerations and best practices are applicable across all Federal agency records management programs. Examples presented will further aid in understanding electronic records requirements that may be included on new USACE FUSRAP contracts as well as upcoming National Archives Records Administration requirements that will move us toward an electronic government. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

2009 National Household Travel Survey - California Add-On

The California add-on survey supplements the 2009 National Household Travel Survey (NHTS) with additional household samples and detailed travel behavior for an assigned travel day. The NHTS was conducted by the Federal Highway Administration, which collected data on the demographic and socioeconomic composition of households, as well as detailed information on travel behavior nationwide. State transportation departments and metropolitan planning agencies had the opportunity to purchase extra household samples as part of the NHTS add-on program. These additional samples, along with national samples collected in the add-on areas, are compiled for use in transportation planning, forecasting, and research. The California Department of Transportation participated in the NHTS add-on program and received a total of 21,225 household samples in California, from March 2008 through May 2009.

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2017 National Household Travel Survey - California Add-On

The California add-on survey supplements the 2017 National Household Travel Survey (NHTS) with additional household samples and detailed travel behavior for an assigned travel day. The NHTS was conducted by the Federal Highway Administration, which collected data on the demographic and socioeconomic composition of households, as well as detailed information on travel behavior nationwide. State transportation departments and metropolitan planning agencies had the opportunity to purchase extra household samples as part of the NHTS add-on program. These additional samples, along with national samples collected in the add-on areas, are compiled for use in transportation planning, forecasting, and research. The California Department of Transportation participated in the NHTS add-on program and received a total of 26,095 household samples in California, from April 2016 through April 2017.

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2009 National Household Travel Survey - Wisconsin Add-On

The Wisconsin add-on survey supplements the 2009 National Household Travel Survey (NHTS) with additional household samples and detailed travel behavior for an assigned travel day. The Federal Highway Administration and Wisconsin Department of Transportation conducted the survey from March 2008 through May 2009. It collected detailed information on travel behavior nationwide, as well as data on the demographic and socioeconomic composition of households. State transportation departments and metropolitan planning agencies had the opportunity to purchase extra household samples as part of the NHTS add-on program. These additional samples, along with national samples collected in the add-on areas, are compiled for use in transportation planning, forecasting, and research. The Wisconsin Department of Transportation participated in the NHTS add-on program and received a total of 1,707 household samples in Wisconsin. (The total number of household samples nationwide is 26,000.)

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Modeling and Evaluating Pilot Performance in NextGen: Review of and Recommendations Regarding Pilot Modeling Efforts, Architectures, and Validation Studies

NextGen operations are associated with a variety of changes to the national airspace system (NAS) including changes to the allocation of roles and responsibilities among operators and automation, the use of new technologies and automation, additional information presented on the flight deck, and the entire concept of operations (ConOps). In the transition to NextGen airspace, aviation and air operations designers need to consider the implications of design or system changes on human performance and the potential for error. To ensure continued safety of the NAS, it will be necessary for researchers to evaluate design concepts and potential NextGen scenarios well before implementation. One approach for such evaluations is through human performance modeling. Human performance models (HPMs) provide effective tools for predicting and evaluating operator performance in systems. HPMs offer significant advantages over empirical, human-in-the-loop testing in that (1) they allow detailed analyses of systems that have not yet been built, (2) they offer great flexibility for extensive data collection, (3) they do not require experimental participants, and thus can offer cost and time savings. HPMs differ in their ability to predict performance and safety with NextGen procedures, equipment and ConOps. Models also vary in terms of how they approach human performance (e.g., some focus on cognitive processing, others focus on discrete tasks performed by a human, while others consider perceptual processes), and in terms of their associated validation efforts. The objectives of this research effort were to support the Federal Aviation Administration (FAA) in identifying HPMs that are appropriate for predicting pilot performance in NextGen operations, to provide guidance on how to evaluate the quality of different models, and to identify gaps in pilot performance modeling research, that could guide future research opportunities. This research effort is intended to help the FAA evaluate pilot modeling efforts and select the appropriate tools for future modeling efforts to predict pilot performance in NextGen operations.

pilot human performance models↗

2017 National Household Travel Survey - Wisconsin Add-On

The Wisconsin add-on survey supplements the 2017 National Household Travel Survey (NHTS) with additional household samples and detailed travel behavior for an assigned travel day. The Federal Highway Administration and Wisconsin Department of Transportation conducted the survey. The NHTS ran from April 19, 2016, through April 25, 2017. It collected detailed information on travel behavior nationwide, as well as data on the demographic and socioeconomic composition of households. State transportation departments and metropolitan planning agencies had the opportunity to purchase extra household samples as part of the NHTS add-on program. These additional samples, along with national samples collected in the add-on areas, are compiled for use in transportation planning, forecasting, and research. The Wisconsin Department of Transportation participated in the NHTS add-on program and received a total of 11,675 household samples in Wisconsin. (The total number of household samples nationwide is 129,112.)

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2001 National Household Travel Survey - Wisconsin Add-On

The Wisconsin add-on survey supplements the 2001 National Household Travel Survey (NHTS) with additional household samples and detailed travel behavior for an assigned travel day. The Federal Highway Administration and Wisconsin Department of Transportation conducted the survey. The NHTS ran from March 2001 through May 2002, with data collection for the Wisconsin add-on occurring May 1, 2001, to May 6, 2002. The NHTS collected detailed information on travel behavior nationwide, as well as data on the demographic and socioeconomic composition of households. State transportation departments and metropolitan planning agencies had the opportunity to purchase extra household samples as part of the NHTS add-on program. These additional samples, along with national samples collected in the add-on areas, are compiled for use in transportation planning, forecasting, and research. The Wisconsin Department of Transportation participated in the NHTS add-on program and received a total of 17,610 household samples in Wisconsin. (The total number of household samples nationwide is 26,038.)

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Operational Integration Assessment (OIA) of Midterm UAM Operations: Class C Airspace Tabletop Exercise and Integration Checkpoint

The National Aeronautics and Space Administration (NASA), in collaboration with the Federal Aviation Administration (FAA), is conducting research into evolving today’s air traffic management system towards a more automated and operationally flexible airspace to accommodate Urban Air Mobility (UAM) operations at scale. UAM operations, enabled by electric Vertical Takeoff and Landing (eVTOL) aircraft, may change the role of aviation in the movement of people and goods and provide practical, cost-effective air transport in metropolitan areas. FAA UAM Concept of Operations v2.0 describes three evolutionary stages of UAM operations: Initial, Midterm, and Mature State operations. Midterm operations are comprised of many complex changes to the national airspace system (NAS). The Operational Integration Assessment (OIA) was created as a capability to address the need to study the progression and identify interdependencies of those changes that may occur during the midterm UAM operations timeframe. The OIA includes a series of tabletop exercises and integration checkpoints planned to explore various use cases from end-to-end, evaluated by NASA’s Air Traffic Management eXploration (ATM-X) project in partnership with the FAA’s William J. Hughes Technical Center (WJHTC) and industry partners. The use cases were exercised in an immersive, integrated live-virtual-constructive (LVC) airspace simulation environment, called the NASA/FAA Laboratory Integrated Test Environment (NFLITE), as part of an effort to learn how UAM operations can scale beyond the as-is NAS and through the transition to higher-tempo and highly automated operations of the future. This document describes the events of the tabletop exercise held from January 24-26, 2023, at the National Airspace Research & Technology Park (NARTP) in Egg Harbor Township, New Jersey, adjacent to the WJHTC and the subsequent integration checkpoint performed on March 28, 2023,at NASA Langley Research Center (LaRC) in Hampton, Virginia.

UAM↗

An Interoperability Concept for Detect and Avoid and Collision Avoidance Systems: Results from a Human-In-The-Loop Simulation

The integration of Unmanned Aircraft Systems (UAS) into the National Airspace System (NAS) poses a variety of technical challenges to UAS developers and aviation regulators. In response to growing demand for access to civil airspace in the United States, the Federal Aviation Administration (FAA) has produced a roadmap identifying key areas requiring further research and development. One such technical challenge is the development of a "detect and avoid" system (DAA) capable of providing a means of compliance with the "see and avoid" requirement in manned aviation. The purpose of the DAA system is to support the pilot, situated at a ground control station (GCS), in maintaining "DAA well clear" of nearby aircraft through the use of GCS displays and alerts. In addition to its primary function of aiding the pilot in maintaining DAA well clear, the DAA system must also safely interoperate with existing NAS systems and operations, such as the airspace management procedures of air traffic controllers (ATC) and Collision Avoidance (CA) systems currently in use by manned aircraft, namely the Traffic Alert and Collision Avoidance System (TCAS II). It is anticipated that many UAS architectures will integrate both a DAA system and a TCAS II. It is therefore necessary to explicitly study the integration of DAA and TCAS II alerting structures and maneuver guidance formats to ensure that pilots understand the appropriate type and urgency of their response to the various alerts. This paper presents a concept of interoperability for the two systems. The concept was developed with the goal of avoiding any negative impact on the performance level of TCAS II while retaining a DAA system that still effectively enables pilots to maintain DAA well clear. The interoperability concept described in the paper focuses primarily on facilitating the transition from a late-stage DAA encounter (where a loss of DAA well clear is imminent) to a TCAS II Corrective Resolution Advisory (RA), which requires pilot compliance within five seconds of its issuance. The interoperability concept was presented to 10 participants (6 active UAS pilots and 4 active commercial pilots) in a medium-fidelity, human-in-the-loop simulation designed to stress different aspects of the DAA and TCAS II systems. Pilots' ability to maintain separation, their rate of compliance and response times using the interoperability concept are reported. Results indicated that pilots exhibited comprehension of, and appropriate prioritization within, the DAA-TCAS II combined alert structure. Pilots demonstrated a high rate of compliance with TCAS II RAs and were also seen to respond to corrective RAs within the five second requirement established for manned aircraft. The DAA system presented under test was also shown to be effective in supporting pilots' ability to maintain DAA well clear in the overwhelming majority of cases in which pilots had sufficient time to respond.

Rorie, R. Conrad↗

Space Environments and Spacecraft Effects Organization Concept

The National Aeronautics and Space Administration (NASA) is embarking on a course to expand human presence beyond Low Earth Orbit (LEO) while also expanding its mission to explore the solar system. Destinations such as Near Earth Asteroids (NEA), Mars and its moons, and the outer planets are but a few of the mission targets. Each new destination presents an opportunity to increase our knowledge of the solar system and the unique environments for each mission target. NASA has multiple technical and science discipline areas specializing in specific space environments disciplines that will help serve to enable these missions. To complement these existing discipline areas, a concept is presented focusing on the development of a space environments and spacecraft effects (SENSE) organization. This SENSE organization includes disciplines such as space climate, space weather, natural and induced space environments, effects on spacecraft materials and systems and the transition of research information into application. This space environment and spacecraft effects organization will be composed of Technical Working Groups (TWG). These technical working groups will survey customers and users, generate products, and provide knowledge supporting four functional areas: design environments, engineering effects, operational support, and programmatic support. The four functional areas align with phases in the program mission lifecycle and are briefly described below. Design environments are used primarily in the mission concept and design phases of a program. Engineering effects focuses on the material, component, sub-system and system-level selection and the testing to verify design and operational performance. Operational support provides products based on real time or near real time space weather to mission operators to aid in real time and near-term decision-making. The programmatic support function maintains an interface with the numerous programs within NASA, other federal government agencies, and the commercial sector to ensure that communications are well established and the needs of the programs are being met. The programmatic support function also includes working in coordination with the program in anomaly resolution and generation of lessons learned documentation. The goal of this space environment and spacecraft effects organization is to develop decision-making tools and engineering products to support all mission phases from mission concept through operations by focusing on transitioning research to application. Products generated by this space environments and effects application are suitable for use in anomaly investigations. This paper will describe the scope of the TWGs and their relationship to the functional areas, and discuss an organizational structure for this space environments and spacecraft effects organization.

Edwards, David L.↗

An Overview of the Space Environments and Spacecraft Effects Organization Concept

The National Aeronautics and Space Administration (NASA) is embarking on a course to expand human presence beyond Low Earth Orbit (LEO) while also expanding its mission to explore our Earth, and the solar system. Destinations such as Near Earth Asteroids (NEA), Mars and its moons, and the outer planets are but a few of the mission targets. Each new destination presents an opportunity to increase our knowledge on the solar system and the unique environments for each mission target. NASA has multiple technical and science discipline areas specializing in specific space environments fields that will serve to enable these missions. To complement these existing discipline areas, a concept is presented focusing on the development of a space environment and spacecraft effects (SESE) organization. This SESE organization includes disciplines such as space climate, space weather, natural and induced space environments, effects on spacecraft materials and systems, and the transition of research information into application. This space environment and spacecraft effects organization will be composed of Technical Working Groups (TWG). These technical working groups will survey customers and users, generate products, and provide knowledge supporting four functional areas: design environments, engineering effects, operational support, and programmatic support. The four functional areas align with phases in the program mission lifecycle and are briefly described below. Design environments are used primarily in the mission concept and design phases of a program. Environment effects focuses on the material, component, sub-system, and system-level response to the space environment and include the selection and testing to verify design and operational performance. Operational support provides products based on real time or near real time space weather to mission operators to aid in real time and near-term decision-making. The programmatic support function maintains an interface with the numerous programs within NASA, other federal government agencies, and the commercial sector to ensure that communications are well established and the needs of the programs are being met. The programmatic support function also includes working in coordination with the program in anomaly resolution and generation of lessons learned documentation. The goal of this space environment and spacecraft effects organization is to develop decision-making tools and engineering products to support all mission phases from mission concept through operations by focusing on transitioning research to application. Products generated by this space environments and effects application are suitable for use in anomaly investigations. This paper will describe the scope and purpose of the space environments and spacecraft effects organization and describe the TWG's and their relationship to the functional areas.

Edwards, David L.↗

NASA's Ares I and Ares V Launch Vehicles -- Effective Space Operations Through Efficient Ground Operations

The United States (U.S.) plans to return to the Moon by 2020, with the development of a new human-rated space transportation system to replace the Space Shuttle, which is due for retirement in 2010 after it completes its missions of building the International Space Station and servicing the Hubble Space Telescope. Powering the future of space-based scientific exploration will be the Ares I Crew Launch Vehicle, which will transport the Orion Crew Exploration Vehicle to orbit where it will rendezvous with the Lunar Lander. which will be delivered by the Ares V Cargo Launch Vehicle. This new transportation infrastructure, developed by the National Aeronautics and Space Administration (NASA), will allow astronauts to leave low-Earth orbit for extended lunar exploration and preparation for the first footprint on Mars. All space-based operations begin and are controlled from Earth. NASA's philosophy is to deliver safe, reliable, and cost-effective solutions to sustain a multi-billion-dollar program across several decades. Leveraging 50 years of lessons learned, NASA is partnering with private industry, while building on proven hardware experience. This paper will discuss how the Engineering Directorate at NASA's Marshall Space Flight Center is working with the Ares Projects Office to streamline ground operations concepts and reduce costs. Currently, NASA's budget is around $17 billion, which is less than 1 percent of the U.S. Federal budget. Of this amount, NASA invests approximately $4.5 billion each year in Space Shuttle operations, regardless of whether the spacecraft is flying or not. The affordability requirement is for the Ares I to reduce this expense by 50 percent, in order to allow NASA to invest more in space-based scientific operations. Focusing on this metric, the Engineering Directorate provides several solutions-oriented approaches, including Lean/Six Sigma practices and streamlined hardware testing and integration, such as assembling major hardware elements before shipping to the Kennedy Space Center for launch operations. This paper provides top-level details for several cost saving initiatives, including both process and product improvements that will result in space transportation systems that are designed with operations efficiencies in mind. The Engineering Directorate provides both the intellectual capital embodied in an experienced workforce and unique facilities in which to validate the information technology tools that allow a nationwide team to collaboratively connect across miles that separate them and the engineering disciplines that integrate various piece parts into a whole system. As NASA transforms ground-based operations, it also is transitioning its workforce from an era of intense hands-on labor to a new one of mechanized conveniences and robust hardware with simpler interfaces. Ensuring that space exploration is on sound footing requires that operations efficiencies be designed into the transportation system and implemented in the development stage. Applying experience gained through decades of ground and space op'erations, while using value-added processes and modern business and engineering tools, is the philosophy upon which a new era of exploration will be built to solve some of the most pressing exploration challenges today -- namely, safety, reliability, and affordability.

Dumbacher, Daniel L.↗

AERoBOND Project Summary

Under NASA’s Convergent Aeronautics Solutions (CAS) project, the Adhesive-Free Bonding of Complex Composites (AERoBOND) project investigated off-stoichiometric epoxy polymers for fast, reliable assembly of epoxy matrix composite structures. The project goal was to demonstrate feasibility of the AERoBOND joining method by demonstrating mechanical properties greater than 80% of conventional co-cured materials while reducing structure weight by 1%. The project consisted of three convergent research areas: material and process development, systems analysis, and material and process modeling. Material and process development was the largest component of AERoBOND with approximately 6 FTE and 1WYE of support to formulate and characterize new resins, prepare carbon fiber prepregs, fabricate laminates, measure mechanical properties, analyze failure results, and select material and process improvements. The systems analysis activity estimated the potential reduction in part count and aircraft weight by comparing models of composite wing boxes with no fasteners (co-cured structure), fasteners in major joints (co-cured stringers), and fasteners in all joints. The materials and process modeling activity included a molecular model of the AERoBOND materials system to predict mechanical properties of resins with offset stoichiometry and a process model to predict the effect of resin formulation and processing conditions on the extent of mixing and degree of cure in a finished joint. As the number of airline passenger trips doubles in the next 20 years (IATA/Tourism Economics Air Passenger Forecasts, April 2019), the increased demand for new commercial aircraft is now the single greatest technical challenge to the airframe manufacturing industry. To meet efficiency requirements, new aircraft must be fabricated primarily from high performance structural composites, but manufacturing processes are inherently slow with the largest bottleneck attributed to assembly and installation of fasteners (NASA/TM–2019-220428). Manufactures of commercial transport aircraft are compelled to install more than 100,000 redundant fasteners into bonded joints to prevent failures due to unpredictable weak bonds. In structural adhesive bonds, the interface between adherend and adhesive is nearly two-dimensional making it susceptible to minute quantities of contamination, which can cause weak bonds. Currently, bond strength assessment is only possible through destructive testing (i.e., breaking the joint). For these reasons, regulatory organizations such as the Federal Aviation Administration (FAA) often require redundant load paths in secondary-bonded, primary-structures to alleviate concerns with bond performance. The AERoBOND process enables reflow of matrix resin during assembly to eliminate the material discontinuity at the interface, thereby eliminating the dependence of mechanical performance on interfacial adhesion. The AERoBOND joint is equivalent to the interlaminar region obtained during a co-cure process, so joint performance depends on the cohesive properties of the matrix resin. Conventional co-cured structures, although too costly and complex for large-scale manufacturing, are trusted by manufacturers and regulators, and are certified for flight with few or no redundant fasteners.Systems analysis performed on a composite wing model at the scale of a single-aisle commercial transport aircraft indicated that >20,000 redundant fasteners per wing could be eliminated by implementing the AERoBOND joining method. A total weight reduction of 15% was predicted in a wing box by eliminating fasteners and thinning components that must no longer support localized fastener loads and accommodate fastener dimensions. Interlaminar shear fracture toughness measured by the end-notched flexure test was greater than 1 kJ/m2 (nearly 140% of the co-cured benchmark property), which is greatly in excess of the project goals for mechanical properties. Testing was planned to measure interlaminar tensile fracture toughness as well as interlaminar tensile and shear strengths using the same AERoBOND configuration, but was delayed due to closure of LaRC facilities during the COVID-19 pandemic. The AERoBOND process model is partially validated and available for experimental use. It allows the user to input AERoBOND process parameters such as material composition, laminate configuration, and cure cycle to predict the final cure state of the AERoBOND joint. A preliminary, multi-scale material model was developed to predict AERoBOND joint mechanical properties (stiffness and strength) based on the cure state of the joint provided by the process model. The timing for transition of this technology within NASA is excellent as NASA initiates new enduring projects to address composites manufacturing rate challenges. AERoBOND technology is well suited to AAVP/AATT objectives for rapid manufacturing of a composite wing. A minimal effort (1 FTE/$15k procurement/0 WYE) is proposed in FY21 to continue a minor mechanical testing effort and maintain a SAA with ASX composites to develop commercial quality prepreg material. An RFI with the composites industry is suggested to quantify the technology gap between the current TRL and the TRL needed for transition to industry. A moderate effort [3-4 FTE/$150k/1 WYE (~$115k)] is proposed in FY22 for the “high rate composites manufacturing” project currently in planning. The partnership with ASX Composites will be expanded to produce material for sub-element/element-scale “panel-off” activities. Industry partnerships with airframe manufacturers is an expected component to explore damage tolerance and environmental stability. Further development of multi-scale modeling tools (process model, meso-scale model, and molecular model) is planned to enhance and deliver tools for rapid manufacturing infusion.

Frank Louis Palmieri↗