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An overview of the FAA's icing program is presented. The program involves certification of various types of aircraft for flight in known icing conditions, the study of icing conditions, and the preparation of certification standards. Test and technology transfer programs are also included.
A growing requirement over the past decade for a new assessment of aircraft icing conditions in wintertime clouds at altitudes up to about 10,000 feet is discussed. The requirement was documented in past workshops and comes primarily from the helicopter community which wants ice-protected rotorcraft to meet increasing demands for all-weather operations. Currently, only a few of the larger helicopters are equipped with certification of ice-protection devices. This is because the current FAA criteria for design and certification of ice-protection equipment results in power and payload penalties that smaller rotorcraft cannot tolerate. The FAA criteria were actually designed for large, transport-category aircraft capable of flying to 20,000 feet or more. For this reason, there have been concerns that the current criteria may be too severe for low-performance aircraft, such as helicopters, which generally operate at altitudes below 10,000 feet.
The results of a Space Shuttle Orbiter nose cap entry aeroheating assessment, thermal analysis, and correlation of flight data using multidimensional thermal math models (TMM's) and a chemically reacting boundary-layer program are described in this paper. The object of this study was to verify and revise, if required, the nose cap design heating methods and the TMM's used for flight certification. Flight temperature measurements from two Orbiter vehicles, Columbia and Challenger, have been used in this analysis and provide the basis for verification and correlation of the aerothermodynamic environment. Nose cap thermal response predictions, using TMM's verified from certification tests, show that the aerothermodynamic environment can be satisfactorily predicted using accepted analytical methods.
The Space Shuttle Main Engine (SSME) represents the beginning of reusable rocket engine operations in the space transportation system (STS). Steps taken to reduce the overall cost of flight operations of the SSME by improving turnaround operations, extending the life of the engine, and improving the cost effectiveness of overhaul operations at the Canoga Park home plant are described. Ground certification testing to ensure safe launch operations is described, as well as certification extension testing that leads to a service life equivalent to 40 flights. The proven flight record of the SSME, which has demonstrated the utility of the SSME as a key component of America's space transportation system, is discussed.
This paper reports on the design and thermal vacuum certification testing of the Space Station Heat Pipe Advanced Radiator Element (SHARE) Shuttle flight experiment, with primary emphasis on the heat pipe radiator system. The main objective of the SHARE experiment is to demonstrate suitable 0 g heat transfer performance of a 50 ft-long high-capacity monogroove heat pipe radiator element being developed for possible Space Station application. All of the flight certification tests were achieved, including a maximum heat rejection of 2 kW and thawing of a frozen heat pipe; and uninterrupted operation under cycling environmental and evaporator heat loads.
Activities that will be conducted in support of the development and verification of the Block 2 Solid Rocket Motor (SRM) are described. Development includes design, fabrication, processing, and testing activities in which the results are fed back into the project. Verification includes analytical and test activities which demonstrate SRM component/subassembly/assembly capability to perform its intended function. The management organization responsible for formulating and implementing the verification program is introduced. It also identifies the controls which will monitor and track the verification program. Integral with the design and certification of the SRM are other pieces of equipment used in transportation, handling, and testing which influence the reliability and maintainability of the SRM configuration. The certification of this equipment is also discussed.
The assembly test article (ATA) consisted of two live loaded redesigned solid rocket motor (RSRM) segments which were assembled and disassembled to simulate the actual flight segment stacking process. The test assembly joint was flight RSRM design, which included the J-joint insulation design and metal capture feature. The ATA test was performed mid-November through 24 December 1987, at Kennedy Space Center (KSC), Florida. The purpose of the test was: certification that vertical RSRM segment mating and separation could be accomplished without any damage; verification and modification of the procedures in the segment stacking/destacking documents; and certification of various GSE to be used for flight assembly and inspection. The RSRM vertical segment assembly/disassembly is possible without any damage to the insulation, metal parts, or seals. The insulation J-joint contact area was very close to the predicted values. Numerous deviations and changes to the planning documents were made to ensure the flight segments are effectively and correctly stacked. Various GSE were also certified for use on flight segments, and are discussed in detail.
It is shown that the single-TDRS S-band tracking configuration satisfies the navigation certification requirements for operational orbit determination support for the Landsat-5, SMM, SME, and Earth Radiation Budget Satellite (ERBS) spacecraft. It is also shown that a pair of 3-min bilateration ranging transponder system (BRTS) tracking passes every 4 hrs, one each from two different BRTS locations, is sufficient to maintain user orbit accuracy to the navigation certification requirements. The BRTS tracking requirements for the single-TDRS configuration will also apply to each TDRS in a multiple-TDRS configuration.
NASA's Kennedy Space Center employs a Training and Certification Record System (TCRS) which tracks and maintains records for each of its employees, encompassing all aspects of training history: training courses, physical examinations, proficiency tests, on-the-job training, standboards, and certifications with completions and expiration dates. TCRS, which is fully automated, includes an expiration-alert notification capability to project recurring expirations, thereby functioning as a forecasting tool for training budgets.
Major considerations in structural design of a transatmospheric aerospacecraft are discussed. The general direction of progress in structures and materials technology is indicated, and technical areas in structures and materials where further research and development is necessary are indicated. Various structural concepts under study and materials which appear to be most applicable are discussed. Structural design criteria are discussed with particular attention to the factor-of-safety approach and the probabilistic approach. Structural certification requirements for the aerospacecraft are discussed. The kinds of analyses and tests which would be required to certify the structural integrity, safety, and durability of the aerospacecraft are discussed, and the type of test facility needed to perform structural certification tests is identified.
The Analysis Criteria Evaluation System (ACES) is a knowledge based expert system that automates the final certification of the Space Shuttle onboard flight software. Guidance, navigation and control of the Space Shuttle through all its flight phases are accomplished by a complex onboard flight software system. This software is reconfigured for each flight to allow thousands of mission-specific parameters to be introduced and must therefore be thoroughly certified prior to each flight. This certification is performed in ground simulations by executing the software in the flight computers. Flight trajectories from liftoff to landing, including abort scenarios, are simulated and the results are stored for analysis. The current methodology of performing this analysis is repetitive and requires many man-hours. The ultimate goals of ACES are to capture the knowledge of the current experts and improve the quality and reduce the manpower required to certify the Space Shuttle onboard flight software.
Issues of flight deck automation are multi-faceted and complex. The rapid introduction of advanced computer based technology on to the flight deck of transport category aircraft has had considerable impact on both aircraft operations and the flight crew. As part of NASA's responsibility to facilitate an active exchange of ideas and information between members of the aviation community, an Industry/NASA/FAA workshop was conducted in August 1988. One of the most important conclusions to emerge from the workshop was that the introduction of automation has clearly benefited aviation and has substantially improved the operational safety and efficiency of our air transport system. For example, one carrier stated that they have been flying the Boeing 767 (one of the first aircraft to employ substantial automation) since 1982, and they have never had an accident or incident resulting in damage to the aircraft. Notwithstanding its benefits, many issues associated with the design, certification, and operation of automated aircraft were identified. For example two key conceptual issues were the need for the crew to have a thorough understanding of the system and the importance of defining the pilot's role. With respect to certification, a fundamental issue is the lack of comprehensive human factors requirements in the current regulations. Operational considerations, which have been a factor in incidents involving automation, were also cited. Viewgraphs used in the presentation are given.
Development of probabilistic structural analysis methods for hot structures is a major activity at Lewis Research Center. It consists of five program elements: (1) probabilistic loads; (2) probabilistic finite element analysis; (3) probabilistic material behavior; (4) assessment of reliability and risk; and (5) probabilistic structural performance evaluation. Recent progress includes: (1) quantification of the effects of uncertainties for several variables on high pressure fuel turbopump (HPFT) blade temperature, pressure, and torque of the Space Shuttle Main Engine (SSME); (2) the evaluation of the cumulative distribution function for various structural response variables based on assumed uncertainties in primitive structural variables; (3) evaluation of the failure probability; (4) reliability and risk-cost assessment, and (5) an outline of an emerging approach for eventual hot structures certification. Collectively, the results demonstrate that the structural durability/reliability of hot structural components can be effectively evaluated in a formal probabilistic framework. In addition, the approach can be readily extended to computationally simulate certification of hot structures for aerospace environments.
The following subject areas are covered: hierarchy of civil space technology program; evolution of technology development; technology validation process; potential impacts; impacts of technology infusion into flight certifications; potential solutions; examples of current technology infusion into flight certification; OAET-CSTI health monitoring and controls; and challenges for future space vehicle propulsion systems.
Development of probabilistic structural analysis methods for hot structures is a major activity at NASA-Lewis, and consists of five program elements: (1) probabilistic loads, (2) probabilistic finite element analysis, (3) probabilistic material behavior, (4) assessment of reliability and risk, and (5) probabilistic structural performance evaluation. Attention is given to quantification of the effects of uncertainties for several variables on High Pressure Fuel Turbopump blade temperature, pressure, and torque of the Space Shuttle Main Engine; the evaluation of the cumulative distribution function for various structural response variables based on assumed uncertainties in primitive structural variables; evaluation of the failure probability; reliability and risk-cost assessment; and an outline of an emerging approach for eventual hot structures certification. Collectively, the results demonstrate that the structural durability/reliability of hot structural components can be effectively evaluated in a formal probabilistic framework. In addition, the approach can be readily extended to computationally simulate certification of hot structures for aerospace environments.
The risks associated with old aeroplanes arise in the main from the difficulty of obtaining support from the manufacturer and other skilled people, and from a general loss of reliability caused by wear and other deterioration. The loss of reliability is caused by two broad classes of problem. There are those problems which are self evident, and hazardous rather than catastrophic. These are the problem areas where characteristically there have been multiple overhauls, repairs, and replacements, and where aging really means the results of repair ineffectiveness that accumulates. The other class of problem is the insidious and potentially catastrophic class. It includes the progressive deterioration of items which are not maintained, and often cannot be maintained because the deterioration cannot be seen. It includes loss of physical properties in adhesives and other organic compounds, corrosion, and the response to repeated loads. This paper deals with a currently unnecessarily troublesome aspect of that response. The present working definition of "commuter aeroplanes" encompasses a wide range of aging types, from the Fairchild F27, through deHavilland Canada Twin Otters to the smaller twin engined Piper and Cessna models. It includes such types as the Lockheed 10, the Beech 18, and the Grumman Mallard. Although we must remain concerned about those types which have been certificated under a design standard or operational rule which embodies the elementary fail-safe concept and which have not been subjected to a subsequent structural audit, this paper is directed, in the first instance, towards types for which fatigue and damage tolerance evaluation was not required as a condition of certification. It will be seen, however, that the principles are robust enough for more general application.
The thermal characteristics of microbursts are utilized by the AWAS IR and OAT features to provide predictive warning of hazardous microbursts ahead of the aircraft during landing or take off. The AWAS was evaluated satisfactorily in 1990 on a Cessna Citation that was intentionally flown into a number of wind shear events. The events were detected, and both the IR and OAT thermal features were shown to be effective. In 1991, AWAS units were flown on three American Airline MD-80's and three Northwest Airlines DC-9's to study and to decrease the nuisance alert response of the system. The AWAS was also flown on the NASA B737 during the summer of 1991. The results of these flights were inconclusive and disappointing. The results were not as promising as before because NASA conducted research flights which were outside of the normal operating envelope for which the AWAS is designed to operate. In an attempt to compensate for these differences in airspeed and mounting location, the automatic features of the system were sometimes overridden by NASA personnel during the flight. Each of these critical factors is discussed in detail. The effect of rain on the OAT signals is presented as a function of the air speed. Use of a 4 pole 1/20 Hertz filter is demonstrated by both the IR and thermal data. Participation in the NASA 1992 program was discussed. FAA direction in the continuing Certification program requires the addition of a reactive feature to the AWAS predictive system. This combined system will not require flight guidance on newer aircraft. The features of AWAS-IV, with the NASA algorithm included, were presented. Expected completion of the FAA Certification plan was also described.
This guide is intended to provide methodology and describe the intent of the Pressure Vessel and System (PV/S) Certification program. It is not meant to be a mandated document, but is intended to transmit a basic understanding of the PV/S program, and include examples. After the reader has familiarized himself with this publication, he should have a basic understanding of how to go about developing a PV/S certification program.