Browse Topic: Supply chain management
Traditional safe-life methodologies for rotorcraft structural components rely on deterministic safety factors to account for uncertainty in loads, material properties, and operational usage. While effective for ensuring safety, these approaches lead to early retirement lives and reduced aircraft availability. This paper presents an updated digital twin-based probabilistic framework for rotorcraft component fatigue life assessment that integrates a probabilistic stress–life (S-N) material model, machine learning-based load estimation from flight data, and Monte Carlo uncertainty propagation. The approach is demonstrated for a critical location on the CH-146 Griffon main rotor yoke. Compared with earlier work, the present study advances the framework through independent validation of the load-estimation model and application to available in-service flight data from multiple mission categories. A probabilistic sensitivity analysis is used to examine the separate and combined effects of material variability and load-estimation uncertainty on fatigue life, cumulative probability of failure, and hazard rate. For the CH-146 demonstration case, the results indicate that the material fatigue strength uncertainty has a major impact on the lower tail of the life distribution and the corresponding reliability-based life, whereas load-estimation accuracy uncertainty has a secondary influence on risk metrics. The application of the digital twin framework to operational, search and rescue, and training mission data further shows that mission-specific usage variability plays an important role in the evolution of fatigue damage accumulation and structural risk. Overall, the proposed framework provides a more informative basis for risk-based rotorcraft life assessment by explicitly quantifying uncertainty and incorporating aircraft-specific operational data. The study is intended as a step toward validation of the framework rather than a completed operational deployment.
This specification establishes the requirements for brush plating of cadmium by electrodeposition.
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Stretch broken carbon fiber (SBCF) offers enhanced formability as compared to continuous carbon fiber (CCF). However, robust, quantitative evaluation of forming defects remains a challenge. This study introduces a unified formability index (UFI) that integrates multiple defect types, including texture anomalies, bridging, wrinkling, thickness variation, spring-back, and resin distribution variation (RDV), into a single weighted score. Each defect is ranked on a scale of 0-5 using normalized metrics with a tunable parameter, α, allowing users to balance defect magnitude and frequency as desired. The full scoring pipeline is demonstrated for texture defects using measured data, while normalized legacy scores from previous work are used for non-texture defects to enable complete formability index computation. Case studies on three laminates illustrate how variations in α affect both texture scoring and the overall formability index and demonstrate the geometry-agnostic nature of the updated ranking and UFI systems. This framework maintains compatibility with existing evaluations while offering improved resolution, consistency, and scalability for assessing laminate quality across complex geometries.
The paper presents a general framework for building an aeromechanic model in FLIGHTLAB, suitable for high fidelity, pilot-in-the-loop simulator. The focus is on aerodynamic modeling of AW609 tiltrotor in Airplane Mode flight regime. The framework can be extended to helicopter and conversion modes with additional considerations for rotors-airframe aerodynamic interference. It can also be adapted to different tiltrotor geometries, with some adjustments depending on their peculiarities. The model uses Blade Element Theory loads evaluation of lifting surfaces, corrected with tabulated distributed loads to tune FLIGHTLAB predictions against high-fidelity aerodynamic references. Bluff bodies are modeled using force and moment tabulated data. Verification was conducted against reference data in wind tunnel mode and against flight data in trim analysis. The proposed method allowed to match lift distribution on slender bodies, as well as lift and drag integral loads, with aerodynamic references. Trim analysis has shown satisfying accordance with experimental data for all the comparison parameters. However, rotor aerodynamic modeling is still being investigated to improve correlations in torque prediction. Additionally, installation effects, such as those related to the interaction between the wing and fuselage with the rotors, are under examination to address biases in flap motion evaluation.
This paper demonstrates extraction of linear models from a state-space free wake model by applying analytical linearization, extending the research presented in (Ref. 1). Two distinct Linear Time Invariant (LTI) models are developed: the first is a high-order LTI model derived from the direct conversion of the analytical Linear Time Periodic (LTP) model, and the second is a reduced-order LTI model generated by first applying the Proper Orthogonal Decomposition (POD) model order reduction technique to the LTP model, followed by conversion. In both cases, the LTP-to-LTI conversion is achieved using harmonic decomposition. A substantial reduction in the number of wake states, from 15552 to 4050, is accomplished while maintaining a similar degree of accuracy. The time domain responses of step and doublet inputs for rotor collective and cyclic pitch are analyzed by comparing the GENHEL rotor model coupled with the LTI wake against the non-linear free wake model. Good agreement is observed in the rotor forces and hub moments. The paper investigates the feasibility of converting the linearized wake model into a linear parameter-varying inflow model with radial and azimuthal basis functions representative of a Peters-He inflow model. A least squares mapping technique is used to derive equivalent Peters-He inflow coefficients which are shown to accurately model the inflow distribution over the rotor disk and the time variation in induced velocities when compared to the non-linear free wake model.
The work done in developing stretch broken carbon fiber technology is described. The objectives of the program include the scale up of the process to demonstrate production feasibility, as well as reducing the maximum filament stretch break length to ~50mm/2” or below, less than half of what was achieved on previous programs. The shorter break length is considered to be critical in order to achieve formability into complex geometries. The new stretch break line at Montana State University, BC3, has been commissioned to achieve the required material characteristics and throughput. To date, 6 tows have been successfully stretch broken simultaneously, representing a significant improvement compared with what was achieved on previous programs. Possible geometries and forming evaluation methods are described. Mechanical testing is to be conducted, including both equivalency testing of continuous vs stretch broken carbon fiber and a later minimal level allowables program. It is expected that there will be no strength reduction when using SBCF in a cured laminate as was the case on the prior programs; this will be verified under the current program with material from the new BC3 stretch break line. Single tow SBCF spools will shortly be available for evaluation by potential prepreg manufacturers and other end users.
Acoustic flight testing of rotorcraft often involves generating noise source hemispheres to gain an understanding about the aircraft's acoustic emissions. However, aerodynamically complex Urban Air Mobility and Future Vertical Lift vehicles may not maintain a steady aerodynamic state during flight, making source hemispheres measured using traditional linear arrays unreliable or difficult to interpret. To address this challenge, all emission angles need to be measured simultaneously. This has lead to the concept of the two dimensional 'snapshot' array layout. A mathematically defined microphone distribution was utilized to achieve uniform coverage on the source hemisphere. Within the chosen distribution, two lower microphone count distributions are embedded, allowing for a comparison of the effects of number of microphones. The array was deployed as part of a joint Army/NASA acoustic research flight test in July of 2024. Data were collected using an MD530F helicopter as the test vehicle, executing both steady and unsteady flight. Analysis of the array resolution is used to determine adequate channel count and spatially varying sensitivity to array density.
This study investigates Reynolds number effects on rotor wake vortex development using a hyperbaric rotor facility capable of pressurizing air up to 100 bar. Background-oriented schlieren (BOS) and hot-wire anemometry (HWA) were applied to characterize vortex trajectories, core growth, and circumferential velocity distribution. BOS measurements revealed consistent blade-to-blade trajectory deviations and vortex pairing across all operating conditions, despite that the investigated three-bladed rotor was milled from a single piece of aluminum, ensuring precise manufacturing and a highly symmetric geometry. A statistical scheme was developed to analyze the radial structure of fluctuating tip vortices, which traverse the pointwise fiber-film sensor in a fixed position. With increasing vortex Reynolds number, the tip vortices are more compact with a reduction in core growth. The circulation in the vortices grows with the vortex radial coordinate, and converges at a radial position basically independent of the vortex core size. Observed asymmetries in young vortices at low Reynolds numbers indicate enhanced roll-up dynamics. The results demonstrate the facility’s ability to isolate Reynolds number effects in rotor wake dynamics.
Execution of a Modular Open Systems Approach (MOSA) on government procurement programs is enacted into United States law (Ref. 1-2) and, if implemented properly, can enable more efficient accomplishment of business and technical objectives for an organization (Ref. 3-8). Open Systems are well defined (Ref. 9) and mature. Successful implementations of open standards have governance and conformance processes associated with them (Ref. 10-12). By using open system standards for integration of complex cyber-physical systems, like Future Airborne Capability Environment (FACETM) (Ref. 13) and Open Mission System (OMS) (Ref. 14), it is a straightforward exercise to determine if open system requirements of a MOSA are adequately addressed. However, adherence to these standards alone is insufficient to fully realize MOSA’s benefits (Ref. 10). This paper focuses solely on how to develop enterprise modularity as one part contributing to a comprehensive enterprise MOSA strategy.
Rotor performance in a Martian environment was analyzed with an objective of increasing thrust with minimal impact on efficiency. The Sample Recovery Helicopter (SRH) and Rotorcraft Optimization for the Advancement of Mars Exploration (ROAMX) rotors were studied by varying solidity, blade count, and chord distribution to determine which configuration delivered the most desirable performance. For all configurations, the ROAMX rotor displayed better performance than the SRH rotor. It was observed that increasing solidity reduced the blade loading required to achieve the peak figure of merit, and beyond a solidity ratio of 0.3 the figure of merit was negatively impacted. For both rotors a 6-bladed configuration with a solidity ratio of 0.3 delivered the optimal figure of merit.
Structural testing of full-scale blade geometries with flap-bending/twist composite coupling was performed to evaluate the impact of coupling. Full-scale spar geometries were first fabricated with three different coupling distributions, including two with a uniform positive flap-bending/twist coupling, in which a flap up deformation induces a nose down elastic twist. The third spar geometry incorporated a mixed coupling, with a uniform positive coupling at the inboard end and a uniform negative coupling at the outboard end, where the negative flap-bending twist coupling produces a nose up elastic twist when experiencing flap up deformation. A full-scale blade was then fabricated with a positive flap-bending/twist coupling. Measurements of the structural twist distribution of the cured spars were taken to ensure the coupling did not result in any hygrothermal instabilities. Tip twist and strains were then measured under various combinations of flatwise bending and torsional bending loads and correlated with Rotorcraft Comprehensive Analysis System (RCAS) and Variational Asymptotic Beam Sectional Analysis (VABS) predictions for both the spars and blade. Using the strain measurements, stiffness properties of the test articles were also calculated to confirm the predicted coupling levels. Generally good agreement was observed between the measurements and analytical predictions for both the full-scale spars and the full-scale blade.
A velocity potential-based finite state model (VPBFSM) has been developed to analyze an isolated rotor in ground effect. The model uses mass source distributions to represent the ground and enforces the non-penetration of flow boundary condition. In previous VPBFSM approaches to impose this boundary condition, the r = j terms were excluded to avoid singularities. This exclusion required adjustments to the source strengths and ground rotor size in order to impose the boundary condition properly, which reduced the model’s robustness. In the present study, the r = j terms are incorporated using a solution for the gradient of the velocity potential from the literature, which avoids singularities. This inclusion allows for effectively enforcing the boundary condition without requiring adjustments. The model is applied to an isolated rotor in full, inclined, and partial ground effect cases, including analysis of the R−50 rotor using geometric and aerodynamic data from the literature. Results for full ground effect show excellent correlation with the Hayden model. The normalized induced torque also exhibits good agreement with experimental data for full, inclined, and partial ground effect cases.
Dynamic rollovers represent a major hazard for helicopters during near-ground operations, often resulting in significant aircraft damage and passenger injuries. To improve safety in operations, recent studies have focused on developing a Helicopter Flight Data Monitoring framework to provide data-driven insights on operational safety. This work contributes to that effort by proposing an approach to identify precursors to dynamic rollovers. According to NTSB reports, approximately 60% of such incidents occur during in-flight phases like hover, hover-taxi, or landing. To capture the complex non-linear dynamics of helicopters, physics-based simulations were conducted to estimate a first hitting time metric, defined as the time until blade-ground contact, across a wide range of initial conditions for an inflight initial state of the helicopter. Eight parameters were identified as driving the first hitting time, and a probabilistic model was created to predict the distribution of that metric for different values of those parameters. Based on the predicted distributions, a risk-based metric was derived to robustly assess the risk of dynamic rollover and identify safer operational boundaries.
Traditional safe-life methodologies for rotorcraft structural components often result in overly conservative life estimates, increasing maintenance costs and reducing aircraft availability. This study explores the integration of digital twin concepts with probabilistic modeling and machine learning to enhance structural life assessment, demonstrated through a practical case involving the Royal Canadian Air Force CH-146 Griffon helicopter. A probabilistic fatigue model determines a fatigue life distribution by incorporating material variability and uncertain operational loads inferred directly from flight data. Unlike conventional approaches, this method dynamically estimates load spectra, including uncertainty instead of relying on conservative assumptions. Monte Carlo simulations are used to quantify structural risk and assess the impact of load and material uncertainties. Sensitivity analyses highlight these uncertainties’ contributions to failure probability. The proposed approach provides probabilistic life predictions, supporting risk-based maintenance strategies to potentially optimize operational efficiency. The long-term goal is to develop an adaptive digital twin model that continuously updates with new operational flight data, enhancing predictive accuracy for helicopter fleet management.
The Shake-The-Box technique was applied to experimentally quantify the time-resolved volumetric flow field around a free-flying quadcopter UAV with an overall span of about 0.5 m. State-of-the-art LED illumination and high-speed camera equipment was combined with modern Lagrangian tracer particle tracking and data assimilation techniques, facilitating a measurement volume larger than 1.5m3. The setup allowed for both hover and limited maneuvering of the quadcopter, while resolving even small details of the complex interactional aerodynamics. In hover out of ground effect, the four individual rotor wakes merged into a single jet within a few rotor radii below the rotor planes. Evaluating the mass and momentum fluxes over suitable control volumes yields accurate estimates for the quadcopter's total thrust, the asymmetric thrust distribution between front and back rotors, and the entrainment of external flow through turbulent mixing. Hover in ground effect decreases the power requirement and induces recirculating flow in the center of the four rotors. The outwash pattern is non-uniform with jets developing between the rotors and pointing in radially outward directions. Forward flight cases result in a skewed, rapidly merging wake flanked by the roll-up of two "super-vortices" similar to the wingtip vortices of fixed-wing vehicles.
Modern aircraft have an established need for a high-performance, open standards solution to interconnect increasing number of digital components including sensors, actuators, controllers, processors, displays and data concentrators. The aircraft can be envisioned as a distributed system requiring highly available, reliable, and deterministic communication network - often termed as digital backbone - for safe operation. This paper introduces a new zonal architecture for aerospace onboard networks using Time-Sensitive Networking (TSN). TSN is an open standard based deterministic Ethernet solution for mission and safety critical networks in aerospace industry that truly meets the Modular Open Standards Approach (MOSA) requirements. This paper also presents a reference implementation of the proposed digital backbone architecture using commercial-off-the-shelf hardware from multiple vendors. Experimental data from laboratory evaluation shows stability, performance, and reliability that meets or exceeds the needs of aerospace use cases. The proposed next generation digital backbone provides significant size, weight, and power savings as well as enables hardware and software modularity using open standards. A specific use case of such a digital backbone is the US Army's Future Vertical Lift (FVL) program, but the proposed architecture is generally applicable to all aircraft networks.
The engineering model determining the onset of Vortex Ring State (VRS) was applied to eVTOL aircraft, and the effect of different landing trajectories and aircraft drag was investigated. Next, the new model to compare the VRS susceptibility according to the different blade geometries and trajectories is proposed by extending Ahlin & Brown's model to incorporate the two-dimensional thrust and inflow distribution on the rotor disc. For validation, two different trajectories crossing the boundary of the onset of the VRS were simulated, and the results were compared with the Vorticity Transport Method (VTM). Furthermore, the disturbance distribution of moderately and highly twisted blades are compared. The extended model can capture the physical phenomena by the distribution of the disturbances and reflect the effect of blade geometries and trajectories. It is essential to investigate the model further through a correlation analysis using experiments or numerical analysis.
Deos includes an industry standard lightweight TCP/IP stack (LwIP) with a DAL-A sockets library so it can provide data transport during in flight or on ground as part of its standard package. While it may have high data integrity (e.g., through CRC or other such mechanisms), TCP/IP over Ethernet is a non-deterministic protocol. As such, it is not suitable for avionics applications that require determinism or high robustness. In contrast, there are several are several redundant and deterministic data network technologies such as ARINC-664/AFDX, time triggered ethernet (TTE), and time sensitive networking (TSN). These interfaces are based on switched Ethernet technologies and can include system redundancy such that they are applicable for aircraft data network applications. Their feature set enables them to be used as a digital backbone for aircraft control and other applications where both integrity and availability are essential. Each of these solutions generally requires specific end point hardware to implement the protocols in firmware in order to meet the required communication timing and throughput. The implementation of the software device drivers for these technologies on Deos can leverage Deos' I/O Infrastructure (IOI) data distribution service for data decoupling. IOI is a DO-178 DAL-A module that can distribute data based on XML configuration files that specify the data paths, access control and optionally data formatting. It implements an inter-partition communications data interface between avionics applications including ARINC-653 partitions using the ARINC-653 APEX API sampling/queueing ports. Together, these features allow developers to readily adapt to changes in communication structures all through XML configuration files, versus recompiling which would impact the verification evidence of the module. This paper will talk about the different networking standards and how the use of Deos' IOI provides a way for the system to easily adapt to different network configurations without causing the driver library or end application(s) to be modified and thereby minimize change impact for reuse/reverification.
In over actuated aircrafts a simple relationship between control inputs and forces/moments generated does not exist, however they have become very attractive for their wide range of applications. Control allocation aims at finding a unique surface control distribution as function of flight condition to perform the desired maneuver. The goal of this paper is to present a control allocation methodology applied on a generic over actuated aircraft aimed to determine the surface gearing matrix weights in different operative conditions to minimize the total power consumption. First, the non-linear model of the control forces and moments is derived for an over actuated aircraft. Then, two different optimization problems are introduced: the first to compute the trim equilibrium for any flight condition to minimize power consumption by the aircraft; the second to minimize the surface deflections required to produce desired control forces/moments starting from the trim point previously found. Finally, the optimized solution is subjected to engineering judgement to neglect the ineffective surfaces that do not provide a significant contribution to the required maneuver.
This paper presents an original method that takes advantage of existing large in-service flight data, damper load Machine Learning models as well as the inventory of degraded dampers (elastomeric part), to link the estimated loads and operational conditions to damper degradation cases. The Machine Learning models are trained on flight test campaigns data, and then applied on in-service helicopter data to estimate damper loads as a function of flight parameters. The estimated load history is then used as an input to generate engineering load indicators. These latter, jointly with operational and usage data, are correlated with the reported dampers' degradation observations. Finally, an explainability mechanism is investigated to better understand the Machine Learning models inferences, opening perspectives towards precise damper degradation root causes identification. The obtained results are promising, showing that the occurrence of damper degradation correlates with load history and helicopter operations.
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