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NASA NTRS2009

Proceedings of the Third International Workshop on Proof-Carrying Code and Software Certification

This NASA conference publication contains the proceedings of the Third International Workshop on Proof-Carrying Code and Software Certification, held as part of LICS in Los Angeles, CA, USA, on August 15, 2009. Software certification demonstrates the reliability, safety, or security of software systems in such a way that it can be checked by an independent authority with minimal trust in the techniques and tools used in the certification process itself. It can build on existing validation and verification (V&V) techniques but introduces the notion of explicit software certificates, Vvilich contain all the information necessary for an independent assessment of the demonstrated properties. One such example is proof-carrying code (PCC) which is an important and distinctive approach to enhancing trust in programs. It provides a practical framework for independent assurance of program behavior; especially where source code is not available, or the code author and user are unknown to each other. The workshop wiII address theoretical foundations of logic-based software certification as well as practical examples and work on alternative application domains. Here "certificate" is construed broadly, to include not just mathematical derivations and proofs but also safety and assurance cases, or any fonnal evidence that supports the semantic analysis of programs: that is, evidence about an intrinsic property of code and its behaviour that can be independently checked by any user, intermediary, or third party. These guarantees mean that software certificates raise trust in the code itself, distinct from and complementary to any existing trust in the creator of the code, the process used to produce it, or its distributor. In addition to the contributed talks, the workshop featured two invited talks, by Kelly Hayhurst and Andrew Appel. The PCC 2009 website can be found at http://ti.arc.nasa.gov /event/pcc 091.

Ewen, Denney, W.↗

NASA NTRSDate not supplied

Pathways to International Coordination in Space Weather

The United Nations Committee for the Peaceful Uses of Outer Space(UN-COPUOS) in its 2022 Space Weather Expert Group report, called upon the World Meteorological Organization (WMO), the InternationalSpace Environment Service (ISES) and the Committee on Space Research (COSPAR) to take a leadership role in improving the global coordination of space weather activities in consultation and collaboration with other relevant actors and international organizations. The three organizations have established a framework for trusting partnership while minimizing duplication of efforts and have agreed on three distinct domains in which the particular expertise and strengths of each of the three were identified: Research and Development (COSPAR), Facilitating Integration (WMO), andServices (ISES). The next stage in building a pathway to improved coordination is to lay the same foundation with other relevant organizations and actors engaged in space weather. We will present outcomes of the first International Space Weather Coordination Forum intending to shape the future of international collaboration on space weather with the ultimate aim of increasing the community’s ability to mitigate space environment threats. We will discuss approaches to alignments of bottom-up initiatives and community-driven roadmaps with national/regional strategic planning activities and funding programs. We will also review opportunities for taking advantage ofInternational Space Weather Action Teams (ISWAT) for planning pilot projects to demonstrate the value of collaboration and coordination.

Maria M Kuznetsova↗

NASA NTRS2004

Multisensor Arrays for Greater Reliability and Accuracy

Arrays of multiple, nominally identical sensors with sensor-output-processing electronic hardware and software are being developed in order to obtain accuracy, reliability, and lifetime greater than those of single sensors. The conceptual basis of this development lies in the statistical behavior of multiple sensors and a multisensor-array (MSA) algorithm that exploits that behavior. In addition, advances in microelectromechanical systems (MEMS) and integrated circuits are exploited. A typical sensor unit according to this concept includes multiple MEMS sensors and sensor-readout circuitry fabricated together on a single chip and packaged compactly with a microprocessor that performs several functions, including execution of the MSA algorithm. In the MSA algorithm, the readings from all the sensors in an array at a given instant of time are compared and the reliability of each sensor is quantified. This comparison of readings and quantification of reliabilities involves the calculation of the ratio between every sensor reading and every other sensor reading, plus calculation of the sum of all such ratios. Then one output reading for the given instant of time is computed as a weighted average of the readings of all the sensors. In this computation, the weight for each sensor is the aforementioned value used to quantify its reliability. In an optional variant of the MSA algorithm that can be implemented easily, a running sum of the reliability value for each sensor at previous time steps as well as at the present time step is used as the weight of the sensor in calculating the weighted average at the present time step. In this variant, the weight of a sensor that continually fails gradually decreases, so that eventually, its influence over the output reading becomes minimal: In effect, the sensor system "learns" which sensors to trust and which not to trust. The MSA algorithm incorporates a criterion for deciding whether there remain enough sensor readings that approximate each other sufficiently closely to constitute a majority for the purpose of quantifying reliability. This criterion is, simply, that if there do not exist at least three sensors having weights greater than a prescribed minimum acceptable value, then the array as a whole is deemed to have failed.

Immer, Christopher↗

NASA NTRS2024

Development of a Data Fusion Methodology for Lineload Aerodynamic Databases for a Launch Vehicle during Liftoff and Transition

The need for databases for the distributed loading on launch vehicles during the early portion of flight necessitates the use of expensive computational flows in regimes where wake effects dominate. While also being expensive, this is a regime that computational tools tend to historically have problems simulating accurately. To help tackle this problem, a method of data fusion to combine computational results to wind tunnel derived force and moment data is developed. Using this method, significant reduction in computational costs and increases in confidence of the final product is possible and has been used to generate several databases for the Space Launch System (SLS) at NASA. While the full details of database generation are not part of this work, the crucial method at its core is developed here. Two SLS geometries are used throughout the work to demonstrate the techniques. These are two of the larger geometries and represent both planned crewed missions to the Moon as well as potential cargo missions to deep space. The method uses principal component analysis (PCA) to generate a reduced ordered model (ROM) to help fill in the full parameter space. Other similar techniques are explored, but were not found to have a significant result on the predictions of the ROM. Because the full number of components are kept to generate the model, this lack of difference is expected. This method is then extended to ensure that predicted surfaces match trusted force and moment data derived from wind tunnel testing. This extension is done by setting up a constrained optimization problem in order to minimize the deviation from the surface resolved computational data while still integrating to the desired values. When generating the constrained optimization problem, a weighting factor to balance these competing needs is introduced. The work compares previously introduced weighting terms from similar work to the proposed terms and shows that the previously used terms do not have as desirable behavior in this flow regime. This method is then expanded by developing a technique to incorporate uncertainty quantification into the developed data fusion methodology. This expansion takes a two pronged approach. One examines transferring the uncertainties in the force and moment database and characterizes how those adjustments change the predicted lineloads. The second looks at model form error and looks how rebuilding the model using slightly different data changes the predictions. These two terms are then combined in order to create an uncertainty model that takes both effects into account. The limitations of the proposed methods is then discussed as well as possible techniques to address these shortcomings.

Launch Vehicles↗

NASA NTRS2018

Addressing Human Error in International Space Station Flight Control Teams: Advances in Ground Training for Science Operators

In flight control, as with any human in the loop system, operator error is an inevitable reality. On the International Space Station (ISS) where crew time and physical resources are precious and often irreplaceable, operator errors can result in significant, irreversible consequences. Flight controllers at the Payload Operations Integration Center (POIC) located at NASA’s Marshall Space Flight Center (MSFC) in Huntsville, Alabama know this reality well. At the POIC, operator errors can be caused by a variety of factors, from poor hardware or software design to environmental factors such as time pressure or fatigue. The most difficult errors to address, however, are those which result from ineffective teamwork.Academic research in teamwork has resulted in the identification of many factors which make cross-functional teaming difficult, including leadership, trust building, and communication challenges. These factors, especially when combined with the challenging environmental factors flight control teams must contend with daily, make the goal of minimizing operator errors in payload operations challenging to achieve. To address such teamwork errors, trainers at the POIC have drawn best practices from high reliability industries such as commercial aviation, healthcare, and nuclear power plants, as well as from our sister ISS control center in Houston, Texas, to develop and institute a new training program focused specifically on teamwork skills.This training program, called the Team Skills Curriculum, is based on the concept of Crew Resource Management (CRM) which was developed by NASA in the 1970s for the commercial aviation industry in response to a series of aviation disasters resulting from ineffective teamwork. CRM was later tailored by the Johnson Space Center (JSC) for use in astronaut and flight control training. The result, called Space Flight Resource Management (SFRM) was formally introduced into manned spaceflight training in the late 90s. SFRM has evolved over the years, but the focus has remained on helping operators develop the skills needed to work as part of an effective team. Using these concepts as well as the latest research in cross-functional teaming and data on specific errors occurring at the POIC, trainers in the integrated flight control training branch created a custom training program for both new and certified payload operations specialists.

Harris, Samantha S.↗

NASA NTRSDate not supplied

A Distributed Simulation-to-Flight Framework to Support Investigating Trust/Trustworthiness in Multi-Agent Systems

As autonomous systems continue to grow both in use and complexity, the necessity for robust and extensible simulation-to-flight methods is paramount for establishing an effective architecture for autonomous systems. A fundamental objective of the ATTRACTOR (Autonomy Teaming and TRAjectories for Complex Trusted Operational Reliability) project was to design and develop a distributed mixed-reality simulation environment to begin establishing a basis for certification of autonomous systems via research into trust and trustworthiness. In this paper, we present an autonomous systems architecture and development framework paired with a persistent distributed modeling and simulation environment for test and evaluation of autonomous systems. The Autonomous Entity Operations Network (AEON) framework enables autonomous system development with an easily extensible collection of libraries and plug-n-play nodes facilitated by the Data Distribution Service (DDS) communication protocol standard. The Baseline Environment for Autonomous Modeling (BEAM) simulation environment is a distributed mixed-reality Unity™-based environment built around the same DDS communication paradigm allowing for easy integration with AEON-based autonomous applications. They were designed under ATTRACTOR in order to measure and establish trustworthiness and trust in single- and multi-agent human-machine systems whether these machines are fixed-wing general aviation, rotary-wing Unmanned Aerial Vehicles (UAVs), ground rovers, or even spacecraft. Together AEON and BEAM enable sim-to-flight with minimal configuration changes. By using AEON and BEAM, source code that runs in simulation ports directly to hardware and has successfully flown in the lab and in the National Airspace System (NAS) at NASA LaRC many times over the lifetime of ATTRACTOR.

Benjamin N Kelley↗

NASA NTRSDate not supplied

A Distributed Simulation-to-Flight Framework to Support Investigating Trust/Trustworthiness in Multi-Agent Systems

Benjamin N Kelley↗

NASA NTRSDate not supplied

Zero-Trust Architecture for Autonomous Edge Computing

We are at the apex of an aviation revolution where autonomy will play a central role in enabling complex, multi-agent systems to communicate, interact, and collaborate on a myriad of applications spanning autonomous swarms to wild-fire management. Autonomy is not an absolute but rather a spectrum ranging from a system requiring significant human intervention to one requiring little to none [1]. For example, the extreme, in the case of an autonomous aircraft, is one that operates independently in the airspace interacting with all other elements (air traffic controllers, other pilots) as if it were a human pilot. Critical to this vision is an architecture that enables autonomous agents to interact with minimal latency. Edge computing is an emerging architecture where compute and storage is pushed to the ‘edge’ of the network in order to minimize the round-trip time from agent to resource thereby mitigating the latency associated with cloud-only based approaches. Additionally, services can generate massive amounts of data (e.g., video feeds), which may require analysis in near real-time. Moving this data to the cloud for further processing may not be feasible due to latency, bandwidth, and cost. Privacy, security, and reliability can also be improved by edge computing architectures. However, this geo-distributed and dynamic* architecture complicates the establishment of unambiguous network security boundaries and can lead to vulnerabilities including man in the middle attacks, replay attacks, physical security breaches of edge nodes, signal interception, etc. This motivates the need for zero-trust architectures [2–4] which de-emphasize the notion of static network perimeters and, as the name implies, do not instill any innate trust in any particular agent. It is required that all agents must be authorized and approved in every transaction. In this paper, we present a zero-trust architecture suitable for edge-computing applications that demand significant low-latency, security, privacy, and reliability.

zero trust↗

NASA NTRS1993

An explicit solution to the optimal LQG problem for flexible structures with collocated rate sensors

We present a class of compensators in explicit form (not requiring numerical computer calculations) for stabilizing flexible structures with collocated rate sensors. They are based on the explicit solution, valid for both Continuum and FEM Models, of the LQG problem for minimizing mean square rate. They are robust with respect to system stability (will not destabilize modes even with mismatch of parameters), can be instrumented in state space form suitable for digital controllers, and can be specified directly from the structure modes and mode 'signature' (displacement vectors at sensor locations). Some simulation results are presented for the NASA LaRC Phase-Zero Evolutionary Model - a modal Trust model with 86 modes - showing damping ratios attainable as a function of compensator design parameters and complexity.

Balakrishnan, A. V.↗

NASA NTRS2018

Runtime Assurance Protection for Advanced Turbofan Engine Control

This paper describes technical progress made in the application of run time assurance (RTA) methods to turbofan engines with advanced propulsion control algorithms that are employed to improve engine performance. It is assumed that the advanced algorithms cannot be fully certified using current verification and validation approaches and therefore need to be continually monitored by an RTA system that ensures safe operation. However, current turbofan engine control systems utilize engine protection logic for safe combustion dynamics and stable airflow through the engine. It was determined that the engine protection logic should continue to be used to provide system safety and should be considered as a part of the overall RTA system. The additional function that an RTA system provides is to perform diagnostics on anomalous conditions to determine if these conditions are being caused by errors in the advanced controller. If this is the case, the RTA system switches operation to a trusted reversionary controller. Initial studies were performed to demonstrate this benefit. The other focus was to improve the performance of the engine protection logic, which was deemed too conservative and reduced engine performance during transient operations. It was determined that the conservative response was due to poor tuning of one of the controller channels within the protection logic. An automatic tuning algorithm was implemented to optimize the protection logic control gains based on minimizing tracking error. Improved tracking responses were observed with no change to the existing protection logic control architecture.

runtime monitoring↗

NASA NTRS2006

Verification of Autonomous Systems for Space Applications

Autonomous software, especially if it is based on model, can play an important role in future space applications. For example, it can help streamline ground operations, or, assist in autonomous rendezvous and docking operations, or even, help recover from problems (e.g., planners can be used to explore the space of recovery actions for a power subsystem and implement a solution without (or with minimal) human intervention). In general, the exploration capabilities of model-based systems give them great flexibility. Unfortunately, it also makes them unpredictable to our human eyes, both in terms of their execution and their verification. The traditional verification techniques are inadequate for these systems since they are mostly based on testing, which implies a very limited exploration of their behavioral space. In our work, we explore how advanced V&V techniques, such as static analysis, model checking, and compositional verification, can be used to gain trust in model-based systems. We also describe how synthesis can be used in the context of system reconfiguration and in the context of verification.

Brat, G.↗

NASA NTRS1975

ATS-6 - Television Relay Using Small Terminals Experiment

The Television Relay Using Small Terminals (TRUST) Experiment was designed to advance and promote the technology of broadcasting satellites. A constant envelope television FM signal was transmitted at C band to the ATS-6 earth coverage horn and retransmitted at 860 MHz through the 9-m antenna to a low-cost direct-readout ground station. The experiment demonstrated that high-quality television and audio can be received by low-cost direct-receive ground stations. Predetection bandwidths significantly less than predicted by Carson's rule can be utilized with minimal degradation of either monochrome or color pictures. Two separate techniques of dual audio channel transmission have been demonstrated to be suitable for low-cost applications.

Miller, J. E.↗

NASA NTRS2011

The Analysis of Rush Orders Risk in Supply Chain: A Simulation Approach

Satisfying customers by delivering demands at agreed time, with competitive prices, and in satisfactory quality level are crucial requirements for supply chain survival. Incidence of risks in supply chain often causes sudden disruptions in the processes and consequently leads to customers losing their trust in a company's competence. Rush orders are considered to be one of the main types of supply chain risks due to their negative impact on the overall performance, Using integrated definition modeling approaches (i.e. IDEF0 & IDEF3) and simulation modeling technique, a comprehensive integrated model has been developed to assess rush order risks and examine two risk mitigation strategies. Detailed functions sequence and objects flow were conceptually modeled to reflect on macro and micro levels of the studied supply chain. Discrete event simulation models were then developed to assess and investigate the mitigation strategies of rush order risks, the objective of this is to minimize order cycle time and cost.

Mahfouz, Amr↗

NASA NTRSDate not supplied

A Distributed Simulation-to-Flight Framework to Support Investigating Trust/Trustworthiness in Multi-Agent Systems

As autonomous systems continue to grow both in use and complexity, the necessity for robust and extensible simulation-to-flight frameworks is paramount for establishing an effective architecture for autonomous systems. Hardware test flights are time-consuming and cost prohibitive during early system design and development. Simulation environments can be useful tools to accelerate algorithm development and testing. However, transitions from simulation to flight (sim-to-flight) can be challenging, unless systems are designed with this transition in mind and with the necessary capabilities built into the architecture and framework. One of the objectives of Autonomy Teaming and TRAjectories for Complex Trusted Operational Reliability (ATTRACTOR) was to design and develop a distributed mixed-reality simulation environment to begin establishing a basis for certification of autonomous systems via research into trust and trustworthiness. ATTRACTOR’s objective was to construct computational concepts of trustworthiness and justifiable trust in multi-agent autonomous teams, to inform future certification of safety-critical and time-critical autonomous systems in aviation. In this paper, we present an autonomous systems architecture and development framework paired with a persistent distributed modeling and simulation (ModSim) environment for test and evaluation of autonomous systems. They were designed under ATTRACTOR in order to measure and establish trustworthiness and trust in single-and multi-agent human-machine systems whether these machines are fixed-wing general aviation, rotary-wing Unmanned Aerial Vehicles (UAVs), ground rovers, or even spacecraft. The Autonomous Entity Operational Network (AEON) framework enables autonomous system development with an easily extensible collection of libraries and plug-n-play nodes facilitated by the Data Distribution Service (DDS) communication protocol standard. The Baseline Environment for Autonomous Modeling (BEAM) simulation environment is a distributed mixed-reality Unity™-based environment built around the same DDS communication paradigm allowing for easy integration with AEON-based autonomous applications, enabling sim-to-flight with minimal configuration changes. Using AEON and BEAM, source code that runs in simulation ports directly to hardware and has successfully flown in the National Airspace System (NAS) at NASA LaRC many times over the lifetime of ATTRACTOR.

Benjamin N Kelley↗

NASA NTRSDate not supplied

NASA’s Strategic Analysis Cycle 2021 (SAC21) Human Mars Architecture

[Note: this is the presentation for a companion paper with the following abstract] The National Aeronautics and Space Administration’s (NASA) Mars Architecture Team (MAT) was challenged to develop a mission architecture capable of transporting humans to the surface of Mars and back as fast—and as soon—as practical. This challenge represented a significant departure from previous approaches that minimized Earth-launched mass and maximized in-space transportation efficiency, often resulting in roundtrip missions of three years or more in duration. In the interest of crew health, MAT’s cross-Agency team of subject matter experts was challenged to develop an architecture capable of shortening crew time away from Earth to about two years. MAT was given specific mission constraints, such as number of crew, as well as mandates to minimize surface infrastructure as much as possible and to incorporate nuclear transportation options. The resulting MAT-developed concept, referred to here as the Strategic Analysis Cycle 2021 (SAC21) architecture, leverages Artemis elements and emerging commercial capabilities for cargo and logistics launches, and features a hybrid Nuclear Electric Propulsion (NEP)/Chemical transportation system able to complete the 1.8 billion kilometer round-trip journey to Mars and back in 760 to 850 days transit time for the 2039 Earth departure opportunity. Three Mars Descent Systems (MDS), each capable of landing about 25 metric tons of useful cargo on the surface of Mars, would be pre-deployed in advance of crew departure from Earth; two of these MDS’s would deliver a partially fueled Mars Ascent Vehicle (MAV), a fission power system, surface mobility, and additional MAV propellant. To minimize surface infrastructure, only two of the four Mars crew would descend and live in an MDS-landed pressurized rover, exploring the martian surface for 30 martian days, or sols, before returning to Mars orbit aboard their MAV and rejoining the other two crew on the Deep Space Transport for the Earth return voyage. Specifics of many of these architecture elements are detailed in separate technical publications; this paper outlines the end-to-end integrated architecture performance and concept of operations, including synergies with Artemis lunar architecture elements. It is important to note that NASA does not have a formal human Mars program and no decisions have been made; the architecture described here is intended to fill in an often-overlooked corner of the trade space, helping to complete the menu of options available to decision-makers as they chart the course for humans to Mars. Note: Slide 9 contains a ~2 min video, best viewed when downloaded. Once downloaded to begin video you may be requested to hit options and Trust this document.

Long-duration spaceflight↗

NASA NTRS2014

Collaborative WorkBench for Researchers - Work Smarter, Not Harder

It is important to define some commonly used terminology related to collaboration to facilitate clarity in later discussions. We define provisioning as infrastructure capabilities such as computation, storage, data, and tools provided by some agency or similarly trusted institution. Sharing is defined as the process of exchanging data, programs, and knowledge among individuals (often strangers) and groups. Collaboration is a specialized case of sharing. In collaboration, sharing with others (usually known colleagues) is done in pursuit of a common scientific goal or objective. Collaboration entails more dynamic and frequent interactions and can occur at different speeds. Synchronous collaboration occurs in real time such as editing a shared document on the fly, chatting, video conference, etc., and typically requires a peer-to-peer connection. Asynchronous collaboration is episodic in nature based on a push-pull model. Examples of asynchronous collaboration include email exchanges, blogging, repositories, etc. The purpose of a workbench is to provide a customizable framework for different applications. Since the workbench will be common to all the customized tools, it promotes building modular functionality that can be used and reused by multiple tools. The objective of our Collaborative Workbench (CWB) is thus to create such an open and extensible framework for the Earth Science community via a set of plug-ins. Our CWB is based on the Eclipse [2] Integrated Development Environment (IDE), which is designed as a small kernel containing a plug-in loader for hundreds of plug-ins. The kernel itself is an implementation of a known specification to provide an environment for the plug-ins to execute. This design enables modularity, where discrete chunks of functionality can be reused to build new applications. The minimal set of plug-ins necessary to create a client application is called the Eclipse Rich Client Platform (RCP) [3]; The Eclipse RCP also supports thousands of community-contributed plug-ins, making it a popular development platform for many diverse applications including the Science Activity Planner developed at JPL for the Mars rovers [4] and the scientific experiment tool Gumtree [5]. By leveraging the Eclipse RCP to provide an open, extensible framework, a CWB supports customizations via plug-ins to build rich user applications specific for Earth Science. More importantly, CWB plug-ins can be used by existing science tools built off Eclipse such as IDL or PyDev to provide seamless collaboration functionalities.

Ramachandran, Rahul↗

NASA NTRS2020

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↗