Aerospace Division Overview Dr Richard Chester Acting Chief - - PowerPoint PPT Presentation

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Aerospace Division Overview Dr Richard Chester Acting Chief - - PowerPoint PPT Presentation

Oct 12, 2022 128 likes •643 views

UNCLASSIFIED Approved for public release Aerospace Division Overview Dr Richard Chester Acting Chief Aerospace Division DSTO Partnerships week 1 UNCLASSIFIED Approved for public release DSTO Roles in the Aerospace Domain Defence

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Aerospace Division

Overview

Dr Richard Chester

Acting Chief Aerospace Division DSTO Partnerships week

UNCLASSIFIED – Approved for public release

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Defence Operations Acquisition Projects Sustainment Strategic Research

DSTO Roles in the Aerospace Domain

UNCLASSIFIED – Approved for public release

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Changing Australian Air Domain platforms

KC30B Multi-Role Tanker Transport F/A-18G Growler C-17 Globemaster Joint Strike Fighter F-35 Lightning II Wedgetail AEW&C MRH-90 ARH Tiger C-27J P- 8

UNCLASSIFIED – Approved for public release

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DSTO Aerospace Division

Purpose:

To provide advice on the exploitation of aerospace science and technology in support

  • f Australian Defence Force (ADF), operations,

the acquisition of ADF aircraft, the cost- effective sustainment of ADF aircraft and to conduct strategic research in selected areas.

6 Branches:

  • Aircraft Structures
  • Airframe Technologies & Safety
  • Applied Hypersonics
  • Aerospace Systems Effectiveness
  • Aircraft Performance & Survivability
  • Aircraft Health & Sustainment
  • 300 staff and contractors

UNCLASSIFIED – Approved for public release

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Aerospace Division Major Recent Projects

  • HIFiRE Hypersonics program 2006->, wins ICAS Von Karman award 2012
  • Helicopter gearbox fault diagnosis by application of time frequency analysis
  • Live Virtual Constructive Simulation Exercises, - Black Skies, Coalition Virtual Flag
  • Development of Joint Air Warfare Battle Lab, JAWBL at RAAF Williamtown
  • C-130 J - Full Scale Fatigue test, Main wing
  • JDAM-ER gliding weapon, extended range
  • F/A-18 - Centre Barrel fatigue life extension
  • Hawk Mk127 - Full Scale Fatigue Test

HIFiRE

UNCLASSIFIED – Approved for public release

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Aerospace Domain

Aerospace Systems Effectiveness Aircraft Performance & Survivability Aircraft Health & Sustainment Airframe Technology & Safety Aircraft Structures Applied Hypersonics

Aircraft Structural Sciences Aircraft Performance and Health Aerospace Systems and Mission Effectiveness Strategic Research Program

= Strong synergies

Aerospace Capability Analysis

Aerospace Operations

JOAD Joint & Operations Analysis Division AD Aerospace Division UNCLASSIFIED – Approved for public release

MD Maritime Division LD Land Division WCSD Weapons & Combat Systems Division CEWD Cyber & Electronic Warfare Division NSID National Security & Intelligence, Surveillance & Reconnaissance Division

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  • Synthetic Collective Training
  • Live Virtual Constructive Simulation
  • Team training in realistic multi-aircraft

& multi-national mission scenarios

Interaction of humans & systems for optimal performance

  • Helicopter Systems Effectiveness
  • Flight models, ship wakes, slung loads,

degraded visual environment

  • Human Factors, Vision, Perception,

Autonomy, Training, Cognitive Modelling

Aerospace Systems Effectiveness

UNCLASSIFIED – Approved for public release

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  • Aircraft IR Signature Modelling ,

Measurement and Control

  • Aero-Thermodynamic Test Facilities,

Combustion Test Facility

  • Trusted Autonomy
  • Novel UAV Technologies: Alternative

Navigation, Power & Energy

Aerodynamics, Aerothermodynamics, Aeroelasticity, Aerial Autonomy

  • Aerodynamic Test Facilities,

Transonic and Low Speed (Subsonic) Wind Tunnels

  • Advanced Computational Fluid

Dynamics, including Fluid-Structure Interaction

Aircraft Performance & Survivability

UNCLASSIFIED – Approved for public release

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  • Vibration based condition monitoring
  • Acoustic signature measurement & modelling
  • Wear debris analysis and HUMS
  • Systems acquisition and sustainment analysis

Asset management strategies & health management technologies

  • Fuel technology
  • Advanced Experimental Stress Techniques (TSA)
  • Diagnostic Systems for Airframe Structural Management
  • Aero-engine life prediction, risk and durability analyses

Aircraft Health & Sustainment

UNCLASSIFIED – Approved for public release

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  • Aircraft Forensic Engineering & Accident

Investigation

  • Additive metallic repair and

manufacturing technologies

Structural & Damage Mechanics, Composites, Metallics , Forensics

  • Crack growth modelling
  • Structural mechanics
  • Advanced composite systems
  • Composite sustainment support
  • Corrosion structural life modelling

Airframe Technology and Safety

UNCLASSIFIED – Approved for public release

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  • Fatigue Crack Analysis
  • Advanced Investigative Techniques

Aircraft Structural Integrity

  • Full Scale Fatigue Test Capability
  • Structural Life prediction capability
  • Airframe Life extension expertise

Aircraft Structures

UNCLASSIFIED – Approved for public release

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  • Research, Design, Build, Fly, Analyse
  • An aero-thermodynamic problem

Hypersonic Flight Research & Flight Test Trials

  • Hypersonic air-breathing combustion

for sustained controlled flight

  • Integration of complex systems
  • perating in extreme environments

Applied Hypersonics

UNCLASSIFIED – Approved for public release

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  • An Opportunity to Revolutionise Airframe Testing

Dr Albert Wong

  • DSTO Rework Shape Optimisation Technology

Dr Stephen Galea

  • Trusted Autonomous Systems

Dr Michael Skinner

  • Ultra High Temperature Materials

Dr Ross Antoniou UNCLASSIFIED – Approved for public release

Presentations to follow

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An Opportunity to Revolutionise Airframe Testing

Dr Albert K. Wong

Research Leader – Aircraft Structures

UNCLASSIFIED – Approved for public release

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Full Scale Fatigue Tests (FSFTs)

form the cornerstone of the certification process for any new aircraft type

Comet FSFT, Farnborough UK, 1954 Airbus A380 FSFT, Dresden, 2005-2009 F-35 FSFT, Ft Worth & Brough, 2010 - …

…at tremendous costs! Some major F-35 STOVL FSFT failures: 2010: bulkhead cracking @ ~1500 hrs (cf 16,000 hrs scheduled testing) 2011: wing root cracking @ ~2100 hrs 2013: bulkhead cracking @ ~9100 hrs UNCLASSIFIED – Approved for public release

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A Unique DSTO Technology…

that can change how FSFTs are conducted in the future viz., Thermoelastic Stress Analysis (TSA) using microbolometers

FLIR Lepton Size: 9mm x9mm x 6mm FPA: 80x60

Free trial microbolometer TSA (MiTE) software: http://www.dsto.defence.gov.au/mite/ Reference: http://onlinelibrary.wiley.com/doi/10.1111/str.12116/epdf POC: nik.rajic@dsto.defence.gov.au

UNCLASSIFIED – Approved for public release

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William Thomson Lord Kelvin (1824-1907)

s K T T    

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  • 30
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10 20 30 40 1 2 3 4 5 time (sec) Stress (MPa)

  • 0.24
  • 0.18
  • 0.12
  • 0.06

0.06 0.12 0.18 0.24

Temp (C)

  • 40
  • 30
  • 20
  • 10

10 20 30 40 1 2 3 4 5 time (sec) Stress (MPa)

  • 0.24
  • 0.18
  • 0.12
  • 0.06

0.06 0.12 0.18 0.24

Temp (C)

The Thermoelastic Effect

UNCLASSIFIED – Approved for public release

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The Thermoelastic Effect

UNCLASSIFIED – Approved for public release

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The Thermoelastic Effect

UNCLASSIFIED – Approved for public release

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TSA used to validate stressing model

F/A-18 CB fatigue test region of interest computed stresses TSA scan close-up TSA scan

Applications to F/A-18 Centre Barrel Fatigue Test

UNCLASSIFIED – Approved for public release

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TSA Robot (TSAR) Demonstrator

Hardware:

  • 6DOF Robotic Arm
  • A35 IR microbolometer
  • digital camera for 3-D

reconstruction TSAR Mk I

  • Perform pervasive & persistent

surveillance of a large section of F/A-18 bulkhead FSFT UNCLASSIFIED – Approved for public release

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TSAR Preliminary Results

UNCLASSIFIED – Approved for public release

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23 FSFT Analyst inspects test via virtual environment TSARs provide pervasive & persistent surveillance of FSFT Virtual wireframe in Cloud rendered with TSA data

TSARs to Rule over Future FSFTs

UNCLASSIFIED – Approved for public release

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PARTNERS IN CRIME TO: 1. CO-DEVELOP Tsar Marcus 1st 2. Co-develop tsarS of the future

Reward

To effect transformational impact on future airframe certification tests

UNCLASSIFIED – Approved for public release

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UNCLASSIFIED – Approved for public release

Dr Stephen Galea

Acting Research Leader Airframe Technology and Safety Branch

Contact POC Manfred Heller, manfred.heller@dsto.defence.gov.au

Rework Shape Optimisation for Structural Life Extension

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Structural optimisation background

  • A design process to best distribute material

in a loaded structure

  • DSTO focus is on repair & life extension of

fatigue critical airframe components by stress minimisation

  • Aim is to improve aircraft availability and

reduce sustainment costs

  • Small shape changes can lead to significant

improvements in fatigue life

Critical regions High initial stresses

UNCLASSIFIED – Approved for public release

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Concept of optimised shape reworking

Improved rework shapes remove the damaged material and minimise stresses

Initial shape Traditional rework DSTO Improved rework

(limited benefit) (lower stress) (lowest stress)

Crack

UNCLASSIFIED – Approved for public release

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Features of the DSTO approach

Modelling

  • Aim is constant local stress via material

removal

  • In house software & commercial Finite

Element Analysis codes

  • Iterative method based on biological

growth

  • Can handle manufacturing constraints and

load orientation variability Manufacturing

  • Accurate in-situ methods developed – 2.5D

UNCLASSIFIED – Approved for public release

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Optimised holes

  • Aim was to achieve Planned

Withdrawal Date & extend inspection intervals

  • 25 - 50% stress reduction
  • Implemented on 6 aircraft
  • 16 locations per aircraft

Example: F-111 wing pivot fitting application

Optimised stiffener run-out

UNCLASSIFIED – Approved for public release

Stiffener run-outs and fuel flow vent holes

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Example: F/A-18 A/B

  • Cracking at housing guide rails
  • 33 % stress reduction
  • Portable rework jig developed
  • Successful flight trials completed
  • Fleet wide implementation pending

Fwd Outboard

Forward hanger

ASRAAM Cracking

Guide rail

FWD hanger

LAU-7

Nominal Reworked

UNCLASSIFIED – Approved for public release

LAU-7 missile launcher optimal rework

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Example: F/A-18 A/B

  • Cracking at grounding holes
  • Family of enlarged rework shapes
  • 18% stress reduction
  • Portable rework jig developed
  • Fleet wide implementation expected

After reworking Before rework

UNCLASSIFIED – Approved for public release

Front spar grounding hole rework optimisation

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  • Potential to transition technology more

widely

– Airframes – Other vehicles

  • Potential collaboration to further develop the

current capabilities to full 3D

– Modelling – Machining via compact robotics

Partnering opportunities

UNCLASSIFIED – Approved for public release

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Trusted Autonomous Systems

Dr Michael Skinner

Autonomy Team Leader Aerospace Systems Effectiveness Human Machine Teaming

UNCLASSIFIED – Approved for public release

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  • Automation versus Autonomy
  • What will Trusted Autonomous Systems Deliver?

Intelligent machines seamlessly integrated with humans – Maximising mission performance in complex and contested environments (AFRL Autonomy S&T Strategy)

What are Trusted Autonomous Systems?

Human Machine Teaming

UNCLASSIFIED – Approved for public release

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Philosophical and mathematical basis; Significantly reduce exposure to harmful consequences; Guaranteed to not exceed boundary conditions; new means to certify for ADF use. Exploit existing and develop new: sensors, platforms, materials & propulsion; Sound validation and test with increasing accuracy of uncertainty (simulation to field); Innovations with high technical risk, but low strategic program risk. Fast reactive and simultaneous slow logical “thinking”; Machine high-level fusion, planning and intent subject to uncertainty; Large scale control of machines; Machine-machine interaction and tasking.

Foundations of Autonomy

Interacting hybrid teams more effective than human-only teams; Understand organisation changes required to acquire and operate; Trust of machines; Mission Command of machines.

Platforms, Sensors & Effectors Trustworthy Partners Cognitive Machines

TAS Strategic Research Initiative: Research Themes

UNCLASSIFIED – Approved for public release

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Alternative Navigation for UAS

Uninhabited Aerial Systems

Bio-inspired micro-UAS Hybrid Propulsion and Power Management Autonomous UAS Platform Management

Key enabling challenges for trusted autonomy in aerial systems

UNCLASSIFIED – Approved for public release

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Tactical Urban Operations for Micro-UAS

  • Challenges of the urban environment
  • Current system limitations

Uninhabited Aerial Systems

http://www.darpa.mil/uploadedImages/Content/NewsEvents/Releases/2014/FLAMissionGraphicMedium.jpg http://en.wikipedia.org/wiki/List_of_slums#mediaviewer/File:Petare_Slums_in_Caracas.jpg

UNCLASSIFIED – Approved for public release

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  • Research themes

– Integration of Human and autonomous systems – Advanced interfaces for Adaptive Supervisory Control – Artificial Intelligence approaches to optimised human-machine teaming

Human Machine Teaming

UNCLASSIFIED – Approved for public release

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Partnering Opportunities

  • Uninhabited Aerial Systems
  • Human Machine Teaming
  • Trusted Autonomous Systems

Strategic Research Initiative

UNCLASSIFIED – Approved for public release

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POC Chris A. Wood

Ultra-High Temperature Ceramic (UHTC) Materials Development Program for Hypersonic Applications

Dr Ross A. Antoniou

Acting Research Leader-Aircraft Health and Sustainment UNCLASSIFIED – Approved for public release

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Motivation

  • The next step beyond ‘heat-sink’ experimental vehicles
  • Develop materials suitable for leading edges of experimental hypersonic air vehicles
  • Geometric stability essential over flight duration
  • Explore use of these materials in other applications

Sustained Hypersonic Flight

Velocities >Mach 6+ Heat flux at leading edges >4 MW/m2 Thermal equilibrium! UNCLASSIFIED – Approved for public release

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The Development Program (1)

  • Research candidate materials;

– Refractory metals, carbon composites, UHTCs considered – UHTCs identified as the most viable way ahead

– High temperature properties – Ability to fabricate – Cost

  • Develop UHTC compositions and fabricate test specimens

– Focus on carbide and boride-based compositions – HfB2, ZrB2, HfC, etc. – Hot-pressing and spark plasma sintering (SPS) processing routes UNCLASSIFIED – Approved for public release

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The Development Program (2)

  • Microstructural characterisation of densified UHTC specimens

– Assessment of microstructure, phases, porosity

  • Thermal testing of UHTC specimens

– High-temperature exposure of leading edge geometries

  • Microstructural characterisation of heat-exposed UHTC test

specimens

– Material changes – Oxide layers – Oxide adherence UNCLASSIFIED – Approved for public release

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Development of UHTCs

60.0 70.0 80.0 90.0 100.0 110.0 Density (%)

Densification of test specimens

  • Hot pressing
  • 1900oC, 25 MPa

UNCLASSIFIED – Approved for public release

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Development of UHTCs

Microstructures

  • Single and multi-phase microstructures
  • Carbides, Diborides, Oxides, Nitrides, Silicides
  • 1900oC, 25 MPa

50 mm 10 mm 100 mm 10 mm

HfC-based material HfB2-based material

UNCLASSIFIED – Approved for public release

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Introducing HoMER - High-temperature Materials Evaluation Rig

  • Oxygen-acetylene flame; Flame temp >3300oC; Heat flux >8 MWm-2
  • Programmable X-Y stage; H.T. pyrometer; video acquisition

Test specimen

Thermal test specimen geometry – 20 degree wedge

UNCLASSIFIED – Approved for public release

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Post-Test Results (1)

  • Good performance, above.

Sharp leading edge geometry maintained after 3 minutes.

  • Poor performance, right.

Low melting point phase causes rapid LE recession.

UNCLASSIFIED – Approved for public release

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Post-Test Results (2)

Cross-sections show leading edge geometry, oxidation products and material changes after high-temperature exposure.

Specimen 4 Specimen 30

Oxide Heat-Affected Material Original Material Original Material Oxide Heat-Affected Material Heat-Affected Material Original Material Oxide Heat-Affected Material Original Material Oxide

1 minute 3 minutes

UNCLASSIFIED – Approved for public release

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Where to next…

  • Benchmark tests against refractory metals
  • Explore different processing routes

– Pressure vs. Pressureless processing – Contrast dry vs. Colloidal processing

  • Composition refinement of best performing materials
  • Fabrication of full-scale leading edge geometries

– Traditional and EDM Machining (potential for collaboration) – Near Net Shape Formation

  • Thermal Testing of full-scale leading edge geometries

– HoMER – Arc-jet

UNCLASSIFIED – Approved for public release

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Aerospace Division

UNCLASSIFIED – Approved for public release