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Presentation for Aging Aircraft conference covering chafing fault diagnostics using Time Domain Reflectometry. Laboratory setup and experimental methods are presented, along with initial results that summarize fault modeling and detection capabilities.
Age-related concerns associated with operating the 50-year-old NASA Airborne Science Program DC-8 Flying Laboratory aircraft are raising concerns about the prospects of someday retiring the NASA DC-8. Given that eventuality, this study examines how current and anticipated science requirements can be incorporated with aeronautical performance and cost metrics for assessing, comparing, and down-selecting candidate replacement aircraft. A literature review of NASA DC-8 missions and interviews with current DC-8 science users provides context for the initial phase of this study and offers a pathway for collecting aircraft specifications. Performance models are developed and calibrated against published range-payload data for various mission fuel and payload weight combinations. The models are extended to three airborne science missions, with payload weights ranging from 30,000-52,000 lb and mission ranges up to 5,050 nmi. Results point towards the 767-200ER aircraft as a top contender offering a bit more experimenter floor-space, payload capacity, and range than the NASA DC-8, and to the U.S. Navy P-8 aircraft as a viable option offering perhaps not too much less of those items, with the relative benefit of using less fuel per mission.
There are currently more than 1,000 Boeing airplanes around the world over 20 years old. That number is expected to double by the year 1995. With these statistics comes the reality that structural airworthiness will be in the forefront of aviation issues well into the next century. The results of previous and recent test programs Boeing has implemented to study the structural performance of older airplanes relative to pressurized fuselage sections are described. Included in testing were flat panels with multiple site damage (MSD), a full-scale 737 and 2 747s as well as panels representing a 737 and 777, and a generic aircraft in large pressure-test fixtures. Because damage is a normal part of aging, focus is on the degree to which structural integrity is maintained after failure or partial failure of any structural element, including multiple site damage (MSD), and multiple element damage (MED).
The damage tolerance experience in the United States Air Force with military aircraft and in the commercial world with large transport category aircraft indicates that a similar success could be achieved in commuter aircraft. The damage tolerance process is described for the purpose of defining the approach that could be used for these aircraft to ensure structural integrity. Results of some of the damage tolerance assessments for this class of aircraft are examined to illustrate the benefits derived from this approach. Recommendations are given for future damage tolerance assessment of existing commuter aircraft and on the incorporation of damage tolerance capability in new designs.
This report summarizes the participation of the University of Denver in an airborne measurement program, SULFUR 6, which was undertaken in late September and early October of 1998 by the Deutsches Zentrum fur Luft und Raumfahrt (DLR). Scientific findings from two papers that have been published or accepted and from one manuscript that is in preparation are presented. The SULFUR 6 experiment was designed to investigate the emissions from subsonic aircraft to constrain calculations of possible atmospheric chemical and climatic effects. The University of Denver effort contributed toward the following SULFUR 6 goals: (1) To investigate the relationship between fuel sulfur content (FSC--mass of sulfur per mass of fuel) and particle number and mass emission index (El--quantity emitted per kg of fuel burned); (2) To provide upper and lower limits for the mass conversion efficiency (nu) of fuel sulfur to gaseous and particulate sulfuric acid; (3) To constrain models of volatile particle nucleation and growth by measuring the particle size distribution between 3 and 100 nm at aircraft plume ages ranging from 10(exp -1) to 10(exp 3) s; (4) To determine microphysical and optical properties and bulk chemical composition of soot particles in aircraft exhaust; and (5) To investigate the differences in particle properties between aircraft plumes in contrail and non-contrail situations. The experiment focused on emissions from the ATTAS research aircraft (a well characterized, but older technology turbojet) and from an in-service Boeing 737-300 aircraft provided by Lufthansa, with modem, high-bypass turbofan engines. Measurements were made from the DLR Dassault Falcon 900 aircraft, a modified business jet. The Atmospheric Effects of Aviation Program (AEAP) provided funding to operate an instrument, the nucleation-mode aerosol size spectrometer (N-MASS), during the SULFUR 6 campaign and to analyze the data. The N-MASS was developed at the University of Denver with the support of NOAA's Office of Global Programs and NASA's AEAP and measures particle size distributions in the 4-100 nm range.
People from the airlines, the FAA, and the manufacturers have worked together in an effort to improve the Service Difficulty Reporting system. Their work to date is summarized as follows. - Goals were generalized into three broad work statements; (a) design a worldwide reporting system to provide safety alerts to aircraft operators, manufacturers, repair facilities, and regulatory authorities. (b) design a companion system to provide worldwide reliability experience. (c) overhaul regulatory requirements to be consistent with (a) and (b) to provide information necessary and useful for public consumption.
This paper presents ideas for consideration by those concerned with commercial aircraft nondestructive inspection (NDI). The perspective is that of an individual with a background in military aircraft NDI, and important differences are indicated between the commercial NDI and military NDI activities. In particular, it is significantly more expensive to implement some new NDI technology, and therefore, in-depth cost-benifit studies for commercial users are recommended.
Human factors research and development investigates the capabilities and limitations of the human within a system. Of the many variables affecting human performance in the aviation maintenance system, training is among the most important. The advent of advanced technology hardware and software has created intelligent training simulations. This paper describes one advanced technology training system under development for the Federal Aviation Administration.
In the present paper we are as a manufacturer of airliners, certified according to the FAR 25 regulations, describing what considerations in terms of design, sizing, verification, maintenance, etc., that are essential to ensure long term structural integrity. In the first part we are describing the main features of the design concepts of Saab 340 and Saab 2000 aircraft with respect to structural integrity and high reliability. Secondly we are describing the approach we have adopted at Saab Aircraft to ensure structural integrity and high reliability of Saab Aircraft products. We are describing the concepts of global and local loads and sequences, the fatigue and damage tolerance sizing and its verification. We are also describing the quality assurance in production and the structural maintenance programme according to the MSG-3. Structural repair and feedback from operators are also covered.
Thermographic characterization of aircraft bonded lap joints offers a quick noncontacting technique to acquire information for structural integrity assessment. This paper discusses recent research to optimize the technique and determine the limits of its applicability. The temperature of the outer surface of the lap joint is increased by the application of heat flux from either flash or quartz lamp heaters. The time dependence of the surface temperature of the lap joint is imaged radiometrically. Measurements are presented for a range of specimens, ranging from samples fabricated with well characterized disbonds to actual aircraft. A technique for processing these images to enhance the contrast between bonded and disbonded regions of the lap joint is presented. Numerical models of the technique simulate the procedure. These simulations provide a cost efficient method for optimizing the technique by varying parameters such as the time for application of heat. These simulations facilitate the definition of parameters difficult to determine experimentally, such as the minimum air gap required for a disbond to be detected. Good agreement between measurements and these simulations is found.
The Center for Aviation Systems Reliability (FAA-CASR), a part of the Institute for Physical Research and Technology at Iowa State University, began operation in the Fall of 1990 with funding from the FAA. The mission of the FAA-CASR is to develop quantitative nondestructive evaluation (NDE) methods for aircraft structures and materials including prototype instrumentation, software, techniques, and procedures and to develop and maintain comprehensive education and training programs in aviation specific inspection procedures and practices. To accomplish this mission, FAA-CASR brings together resources from universities, government, and industry to develop a comprehensive approach to problems specific to the aviation industry. The problem areas are targeted by the FAA, aviation manufacturers, the airline industry and other members of the aviation business community. This consortium approach ensures that the focus of the efforts is on relevant problems and also facilitates effective transfer of the results to industry.
A multitude of design considerations is involved in ensuring the structural integrity of Boeing jet transports that have common design concepts validated by extensive analyses, tests, and three decades of service. As airplanes approach their design service objectives, the incidences of fatigue and corrosion may become widespread. Continuing airworthiness of the aging jet fleet requires diligent performance from the manufacturer, the airlines, and airworthiness authorities. Aging fleet support includes timely development of supplemental structural inspection documents applicable to selected older airplanes, teardown inspections of high-time airframes retired from service, fatigue testing of older airframes, and structural surveys of more than 130 airplanes operated throughout the world. Lessons learned from these activities are incorporated in service bulletin recommendations, production line modifications, and design manual updates. An overview of traditional Boeing fleet support activities and the anticipated benefits for future generations of commercial airplanes based on the continuous design improvement process are presented.
NASA is conducting the Airframe Structural Integrity Program in support of the aging commercial transport fleet. This interdisciplinary program is being worked in cooperation with the U.S. airframe manufacturers, airline operators, and the FAA. Advanced analysis methods are under development and an extensive testing program is underway to study fatigue crack growth and fracture in complex built-up shell structures. Innovative nondestructive examination technologies are also being developed to provide large area inspection capability to detect corrosion, disbonds, and cracks. This paper reviews recent fracture mechanics results applicable to predicting the growth of cracks under monotonic and cyclic loading at rivets in fuselage lap-splice joints.
Multiple site damage (MSD) is a type of cracking that may be found in aging airplanes and which may adversely affect their continuing airworthiness. The Volpe National Transportation Systems Center has supported the Federal Aviation Administration Technical Center on structural integrity research for the past two and half years. The work has focused on understanding the behavior of MSD, detection of MSD during airframe inspection, and the avoidance of MSD in future designs. These three elements of the MSD problem are addressed and a summary of the completed work, the current status, and requirements for future research.
The structural behavior of stiffened fuselage shells with local cracks is influenced by the local deformations and stress gradients near the cracks, and this behavior must be understood to predict fuselage structural integrity and residual strength. As a crack grows, the stiffness and internal load distributions in a stiffened shell change, affecting the local deformations and stress gradients near the crack. Transport fuselage shells are designed to support internal pressure and mechanical loads which cause a geometrically nonlinear response. Research is being conducted at NASA LaRC to develop and demonstrate a verified nonlinear stiffened shell analysis methodology for accurately predicting the global and local behavior of nonlinear stiffened fuselage shells with local cracks and with combined internal pressure and mechanical loads. The nonlinear structural analysis methodology being developed and planned at NASA LaRC for damaged stiffened fuselage shells and the experiments being planned to verify this analysis methodology are summarized in the present paper.
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.
This paper presents an overview of some of the recent (1984-1991) developments in computational/analytical methods in the mechanics of fracture: (i) analytical solutions for elliptical or circular cracks embedded in isotropic or transversely isotropic solids (the crack-plane being at an arbitrary angle to the axis of transverse isotropy), with crack-faces being subjected to arbitrary tractions; (ii) finite-element or boundary-element alternating methods for two- and three-dimensional crack problems; (iii) a "direct-stiffness" method for stiffened panels with flexible fasteners and with multiple cracks, using the alternating method; (iv) multiplesite-damage near a row of fastener holes; (v) analysis of cracks with bonded repair patches; (vi) methods for generation of weight-functions for 2- and 3-D crack problems, and (vii) domain-integral methods for elastic-plastic or inelastic crack mechanics.
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