S PENN TATE 1 8 5 5 Contact: Prof. Ed Smith 814-863-0966 [email protected] April 6-8, 2010 Penn State Vertical Lift Research Center of Excellence Army/Navy/NASA 2009 Annual Program Review http://www.engr.psu.edu/rcoe/
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SPENN TATE1 8 5 5
Contact: Prof. Ed Smith814-863-0966 [email protected]
April 6-8, 2010
Penn State Vertical Lift Research Center of Excellence
Army/Navy/NASA 2009 Annual Program Review
http://www.engr.psu.edu/rcoe/
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VLRCOE Annual Review
Management Review
• Center’s program as a whole- technical merits- relevance- technology transfer- leveraging resources- educational quality- cooperation inside and outside
• Contribution to the Vertical Lift Community- technology- quality students- help industry’s competitiveness
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VLRCOE Annual Review
Technical Review
For Each Task :- Technical Merits- Relevance- Technology Transfer / Technical Approaches
Emphasis on- basic research in nature, but relevant- unique technical contribution- creativity, innovation
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Guidelines for Presentations :
• 20-25 min (max) for presentation• 5-10 min for discussion
• Explain in terms of physics, physical phenomena- technical barriers / challenges- unique contribution- innovation, new concepts, new understanding
• Don’t spend time on equation derivations, test setup,or code/grid developments
(use as backup material, if wanted)
• Last year accomplishments
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Review Members
• Help presenters to keep their assigned presentation time
• Need good technical discussion after presentation
- basic research- relevance
• No Funding issues
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AGENDA – PSU VLRCOE Review 2010 Tuesday, April 6
8:00 – 8:15 Opening Remarks (Rutkowski/Milgram/Gorton)8:15 – 9:05 Penn State VLRCOE Program Overview (Smith)
Aeroacoustics and CFD9:05 – 9:35 Army Task 9 Nonlinear Propagation of Helicopter High-Speed Impulsive Noise (Brentner,
Morris)9:35 – 10:05 BREAK
10:05 – 10:30 Army Task 2 Overset Grid/Gridless Methods for Fuselage and Rotor Wakes (Duque)10:30 – 11:00 NASA NRA 2 Ice Accretion (Noack, Morris)11:00 – 11:30 NASA NRA 1 Unstructured Overset for Rotorcraft (Noack)11:30 – 12:50 LUNCH
Structures and Materials12:50 – 1:40 Army Task 4 Rotor Blade Structures (Bakis, Smith, Koudela)
Drive Systems Technologies1:40 – 2:05 NASA NRA 6 High Fidelity CFD Analysis & Validation of Rotorcraft Gear Box
Aerodynamics Under Operational & Oil-Out Conditions (Kunz)2:05 – 2:35 Army Task 10 Planetary Gear Dynamics (Parker)2:35 – 3:05 NASA NRA 5 Vibration Propagation of Gear Dynamics in a Gear-Bearing
Housing System using Mathematical Modeling and Finite Element Analysis (Parker)
3:05 – 3:35 BREAK3:35 – 4:00 NASA NRA 4 Rotorcraft Transmission Noise Path Model, Including Distributed Fluid
Film Bearing Impedance Modeling (Hambric, Bill, Smith)4:00 – 4:45 Day 1 Review Team Caucus4:45 – 5:15 Day 1 Debriefing
Location: Atherton Hotel
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Applied and Computational Aerodynamics /Dynamics8:00 – 8:05 Welcome/Admin8:05 – 8:55 Army Task 8 Mini trailing Edge Effectors (Gandhi, Maughmer)8:55 – 9:20 Navy Task 091 Actuator Development and Wind Tunnel Test of Dynamic Roughness
(Palacios)9:20 – 9:45 Navy Task 072 Active Rotor Loads Control (Smith, Wang, Rahn)9:45 – 10:10 Army Task 12 Unsteady Aerodynamics (Maughmer)
10:10 – 12:00 LAB TOUR 12:00 – 1:15 LUNCH
Structures and Materials1:15 – 1:40 Army Task 13 Experimental Measurement of Ice Accretion on Rotating and
Simultaneously Oscillating Airfoils (Palacios)1:40 – 2:05 Army Task 6a Rotor Blade Anti-Icing (Smith, Rose)2:05 – 2:30 BREAK 2:30 – 2:55 Army Task 5 Nanotube Composites (Koratkar)2:55 – 3:05 Navy Task 071 Crashworthy Structures via Cellular SMA Honeycomb (Gandhi)3:05 – 3:30 Navy Task 092 Composite Materials for Crashworthy Mount Systems (Bakis, Smith)3:30 – 4:15 Day 2 Review Team Caucus 4:15 – 4:45 Day 2 Debriefing
Location: Atherton Hotel
AGENDA – PSU VLRCOE Review 2010Wednesday, April 7
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Variable Speed Rotors: Aeromechanics and Drive Systems8:00 – 8:05 Welcome/Admin8:05 – 8:30 Navy Task 073 Perf, Vibration, & Noise of Variable RPM Rotorcraft (Gandhi)8:30 – 8:55 Army Task 7 Variable RPM Rotor Flight Control (Horn)8:55 – 9:20 NASA NRA 1 Comprehensive Modeling & Analysis of Rotorcraft Variable Speed
Propulsion System with Coupled Engine/Transmission/Rotor Dynamics (Wang, DeSmidt, Smith, Bill)
9:20 – 9:50 BREAK
Ducted Fan Aeromechanics9:50 – 10:15 Navy Task 074 Wind Tunnel Testing and CFD for FANCRAFT (McLaughlin)
10:15 – 10:40 Army Task 3 Ducted Rotor Tip Casing (Camci)10:40 – 11:05 Navy Task 075 Dynamics of Ducted Rotors (Smith/Zhang)
11:05 – 11:30 Navy Task 076 Aeroacoustics of Advanced Ducted Fan Vehicles (Brentner)
Aeroacoustics and CFD11:30 – 12:20 Army Task 1 Interactional Aerodynamics & Acoustics (Brentner, Rajagopalan)
12:20 – 1:20 LUNCH
1:20 – 2:05 Day 3 Review Team Caucus2:05 – 2:35 Day 3 Debriefing
Location: ?
AGENDA – PSU VLRCOE Review 2010Thursday, April 8
Location: Atherton Hotel
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Research Thrusts Educational ActivitiesTechnology Transfer & LeveragingStatistics and Metrics Strategic Plans
2009 VLRCOE Management Overview
Navy 6.1 (via ONR)
Army VLRCOE (via AATD)
NASA NRA(via GRC, LaRC, ARC)
SPENN TATE1 8 5 5Vertical Lift Research Center Goals
Long Range Goals:
1) Focus research personnel and facilities on timely solution of 21st century technicalbarrier problems
2) Provide an exciting and effective educationalenvironment to train the next generationof rotorcraft engineers
SPENN TATE1 8 5 5VLRCOE Goals and Technical Approach
1) Engage industry & governmentto identify capability gaps
2) Develop new design tools, materials, devices, and processes to impact performance and cost
3) Analytical and computational methods that allow prediction of complex behavior andenhance physical understanding
4) Experiments to guide and validate design analyses
5) Educational initiatives: Train Best and brightest
Focus on cutting edge of emerging technology
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6.1 Basic Research (University Base and Labs) 1-3 YRs 6.2 Applied Research (above w/industry, & SBIR) 2-4 YRs 6.3 Full-Scale Prototypes (Industry-led) 2-YRs6.4 Flight Test (get ready for insertion) 2-YRs
Science and Technology Base
Navy (ONR, NAVAIR, NACRA)
Army(AATD, AFDD, ARO, ARL)
NASA Fundamental Aeronautics
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Vertical Lift Center Tech Base
31Faculty
60 +GraduateStudents
100 Undergraduate
Students(Freshman Sem, AHS Chapter,Senior Class, Design projects)
40 ContinuingEducationStudents
(Short course)
5Res Assoc
Penn State ARLNRTC CRI
SBIR Programs
apply & transition
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VLRCOE TEAM
2008 AHS Forum, Montreal
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Vertical Lift Center Faculty @ PSU
Ed Smith dynamics, aeromechanics
Ken Brentner aeroacoustics, VLRCOE AdminFarhan Gandhi dynamics and smart structures, VLRCOE EducationJoe Horn flight mechanics and control
Barnes McCormick aerodynamics, stability & controlPhil Morris aeroacousticsMark Maughmer airfoil design, aerodynamicsCengiz Camci experimental fluid mechanics and heat transferLyle Long aeroacoustics, CFD, high perf computingRob Kunz (ARL) CFD, multi-phase flow, propulsion and gearsRalph Noack (ARL) CFD, Overset grids, multiphase flowsDennis McLaughlin experimental aerodynamics and aeroacoustics
Director
Affiliated Faculty - Aerodynamics, Aeroacoustics, and Flight Controls
Deputy Directors
Administrative AidesDebbie Mottin (VLRCOE), Rhonda Beard
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VLRCOE Center Faculty @ PSU
George Lesieutre Structural dynamics, materialsChuck Bakis (ESM) Composite structuresBill Mark (ARL) Gear optimization and noiseMary Frecker (ME) Compliant mechanisms, optimizationTom Donnellan (ARL) Manufacturing, Advanced CompositesJoe Rose (ESM) Ultrasound, NDE, guided waves, icingKevin Koudela (ARL) Composite structures, nanomaterials, FEMBob Bill (AERSP) Propulsion and powertrainsEric Mockensturm (ME) Smart structuresMike Yukish (ARL) Crashworthiness, optimal designSuren Rao (IE, ARL) Drivetrain technologies, manufacturingChris Rahn (ME) Controls and structural dynamics
Affiliated Faculty - Structures and Dynamics
Stephen Conlon (ARL) SHM, HUMS, sensors, structural acousticsKarl Reichard (ARL) HUMS, signal, processingJeff Banks (ARL) HUMS System integration
Affiliated Faculty and Research Scientists - Condition Based Maintenance
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Dr. Jack Langalaan, Assistant Professor of Aerospace Engineering
Guidance and ControlSafety of FlightEnabling tech for new UAVs
New Faculty of the VLRCOE Team
http://www2.aero.psu.edu/jack/
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Off-campusVLRCOE Faculty Partners
Koratkar (RPI) Parker (OSU)
CFD
Nanomaterials Gear & drive systemdynamics
Dr. Earl Duque(Intelligent Light)Rotorcraft CFD
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New VLRCOE Faculty & Staff Contributors/Collaborators
Here at Penn State:Steve Hambric (ARL) Structural acousticsQiming Zhang (EE) Smart materials and sensors
“We are committed to seeking collaborations with the “best and brightest talent”
Kon-Well Wang (ME) smart structures, structural control
Hans DeSmidt (U Tenn) Active control, driveline dynamics, HUMS
Wade Huebsch (WVU) CFD, Ice Accretion, flow control
And beyond….
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VLRCOE Research Associates
Penn State:Dr. Jinhua Zhang rotor design, composites, rotor dynamics
Dr. Robert Bill propulsion and drive systems
Dr. Jose Palacios icing, flow control, smart structures
Dr. Han Dong rotor dynamics
COL (Ret.) Sam Evans logistics, condition based maintenance
Dr. Fabio Semperlotti Structural Health Monitoring
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Background / UARC RelationshipBackground / UARC Relationship
Established in 1945 by the Navy Largest Interdisciplinary Research Unit at Penn State – 1,200+
faculty/engineers, staff, students and 350,000 sq.ft. Classified facilities and programs to SCI Research expenditures FY 2009: $165M Designated a University Affiliated Research Center by DoD in
1996
GARFIELD THOMAS WATER TUNNEL
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PSU ARL as a Technology Asset
In the past 3 years….PSU ARL has become integratedinto 95% of VLRCOE Portfolios(up from 20% from 1996-2005)
> Manufacturing and Materials
> Computational Mechanics and CFD
> Drivetrain and Propulsion Systems
> Structural Health Monitoring, Maintenance & Sustainment
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VLRCOE Executive Advisory Board(2nd Annual Meeting: Nov 19-20 2009)
DOD
DOD Industry
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VLRCOE Executive Advisory Board(2nd Annual Meeting: Nov 19-20 2009)
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Small Business PartnersState College, PA Based:INVERCON (Dr. Joe Szefi) structural dynamics, actuators, controlsFBS Worldwide (Roger Royer) ultrasonics (ice protection, SHM)KCF (Dr. Jeremy Frank) Noise control, energy harvestingAirfoils Inc (Dan Sommer) airfoil design and applied aerodynamics
Around the US:Barron and Associates flight controlsContinuum Dynamics CFD and aeromechanicsART flight simulationIntelligent Light CFDPiasecki Aircraft VTOL Aircraft
We are presently engaged in several Phase I and Phase II SBIR projects with the above partners.
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VLRCOE Research Portfolio: 2010
1. ROTOR AEROMECHANICS & DYNAMICS
2. AIRFOIL DESIGN and TESTING
3. COMPUTATIONAL FLUID DYNAMICS
4. ACOUSTICS
9. FLIGHT CONTROLS and SIMULATION
8. PROPULSION and DRIVE SYSTEMS
5. STRUCTURES, MATERIALS, and MANUFACTURING
7. ICE PROTECTION
6. CONDITION-BASED MAINTENANCE
10. DUCTED FAN AIR VEHICLES
11. VARIABLE SPEED (RPM) & COMPOUND ROTORCRAFT
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NASA NRA Programs
• 4 selected proposals from NASA Glenn Research Center• Integrated Propulsion System Modeling
– (Wang, Smith, Bill, DeSmidt @ Univ of Tennessee)• Gearbox Windage Loss CFD
– (Kunz, Morris, Long)• Ice Accretion CFD
– (Kunz, Morris, Noack)• Bearing Noise
– (Hambric, Bill, Smith)• 1 selected proposals from NASA Langley Research Center
• Innovative Overset Grid Connectivity Software for Unstructured Rotorcraft Simulations (Noack)
1 NASA GSRP Fellow(Jason Slaby)
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Other DoD Programs
• Army Research Office• Structural Damping and Health Monitoring Enhancement via
Multifunctional Carbon Nanotube Based Composites Tailoring (Bakis, Wang)
• Army Ames• Airfoil Testing and Design Support (Maughmer, Airfoils Inc. with Somers)• Airframe Vibration Control (Smith, Rahn , INVERCON. with Szefi)
• Army AATD• Structural Health Monitoring (Conlon, Smith)
• DARPA• Gear Health Monitoring (Mark, with Northrup/Grumman)• Nastic Structures (Bakis,Wang, Rahn, et al)
• Army AED • HUMS Data Analysis Support (Evans, Smith)• Icing Test Facility Development (Palacios, Smith)
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Other DoD Programs
New VLRCOE (2009)• Experimental Measurements of Ice Accretion on Oscillating Rotor
Sections (Palacios, Smith)
• Rotor Airfoil Design using Unsteady Aerodynamics (Maughmer)
New ONR (2009)• Crashworthy Payload Restraint Systems (Bakis, Smith)
• Active Flow Control via Dynamic Roughness (Palacios, Smith)
AFDDActive Rotors for Gust Response and HQ (Horn, Rahn, Smith) –FUNDING CUT SHORT in 2010
DoD Fellowships• William Kong (Crashworthiness)• Mihir Mistry (Rotor Dynamics)• Gabe Murray (Moroping structures)
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CRI and Industry Programs(new in Blue)
• Damper Modeling and Design (LORD Corp)• Advanved Drive Systems (Timken- PURDY Div)• Rotor Blade Anti-Icing (FBS Inc. AATD Phase II SBIR, Boeing via AATD)• Flexible Composite Driveshafts I (Bell, Boeing, Goodrich , Kaman, CRI)• Shipboard Flight Simulation and Controls (Sikorsky, CRI)• Tiltrotor Stability Augmentation (Bell, CRI)• Airframe Structural Health Monitoring (AATD 6.2 Program)
2009 CRI TAJI starts• Rotor System Damage Detection (Boeing, Goodrich, CRI)• Flexible Composite Driveshafts II (Bell, Boeing, Sikorsky, CRI)• Active Rotors for Gust Response and HQ (Boeing, Sikorsky, CRI)• Crashworthy payload Restraint Systems (Bell, CRI)
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CRI and Industry Programs(new in Blue)
• Gearbox Windage CFD (Bell, CRI)• Pericyclic Transmission Design (Bell, CRI)• Swashplateless Rotor Analysis (Boeing, CRI)• Rotor Hub Loads Monitoring (KCF, via NAVAIR Phase I, II SBIRs)• Active Rotor Systems (LORD Corp)• Nano-Reinforced Resin Systems (Boeing via AATD)• Dynamic Roughness for Leading Edge Stall Control (PSI, via USAF SBIR)• Battery Diagnostics and Health Management (Bell, via AATD)• Compound Helicopter Simulation (Piasecki)• Flight Controls for Shipboard DI (Barron, via NAVAIR)
NEW starts scheduled for Summer 2010• Autoflare Assist Controller (CRI)• MiTE testing and Centrifugally Pumped Actuation (CRI)• Ultrasonic Icing Actuation (CRI)• Hub Drag and Separation CFD (CRI)
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Industry Programs
• Active Rotors for HQ and Gust Response• Advanced Drive Systems• Flight Controls for Shipboard Operations• Erosion• SHM
• Drive Systems • Rotor Lag Dampers• Tiltrotor Stability Augmentation• Crashworthy Payload Mounts• Rotor Damage Detection• Elec Sys Diagnostics
• Active Rotors• Advanced Drive Systems• Swashplateless rotors• Rotor System Damage Detection• Rotor Icing and Durability
• Dampers• Mounts• Bearings • Active Rotor Tech
• CBM• Icing• Driveshafts
• Drive Components
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Overall VLRCOE Program $4M in 2007 to $6.5M in 2009
Major growth in “6.2” Applied and transitional programs
Now approx 1/3 of our $6M+/year program
Major growth in CRI Projects with industry
Partnerships as team in AATD, NASA, DARPA, etc
Direct industry investment in fellowships, hardware, etc
Sustaining strong performance in competitive 6.1 Programs
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Educational Activities• 1st Year: Hand’s on Helicopters 101 (Smith/Bill)
• Rotorcraft Aerodynamics • Rotorcraft Dynamics • Rotorcraft Stability and Control • Rotorcraft Propulsion • Rotorcraft Lab and Design• VSTOL Aerodynamics
• Aeroacoustics • CFD and Parallel Computing • Structural Dynamics • Smart Structures • Summer Short Courses • AHS Design Competition• Educational programs for pre K-12 kids
• STEM Initiatives (with SCASD Navy, NASA, Heli Museum)
SPENN TATE1 8 5 5Student Population
T = mv
• Graduate students at PSU53 total Full-time Graduate Students15 on VLRCOE8 + 1.5 postdoc on ONR
• Graduate students at Partner Universities
- OSU (3), RPI (2), ISU (1)
• Undergraduate students
- 6-10 in AHS Student Design Team- 25 in Undergrad Senior Elective- Helicopter Aero I- 15 in Industry-sponsored Design-Build-test- 40 in First Year Seminar (Hands-On Helicopters)
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1) Vibration Simulation Seat, Active Rotors (SIKORSKY)
2) Museum Exhibit Design and RC Heli Projects(BOEING)
3) Clutch-engaged tail rotor drive (BELL)
Recent Industry Sponsored Senior Design Projects
2010
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Student Recognition
• Bell Helicopter Graduate Fellow: Stan Sollenberger
• Lord Corp Graduate Fellows: Conor Marr (Fluidlastic Dampers),Jonas Corl (Active Rotors), Lloyd Scarborough (Balancing Systems)
• Agusta Westland Graduate Fellow: Maryam Khoshlahjeh
• NASA Graduate Student Research Fellow: Jason Slaby
• 3 DoD Fellowship Winners: Gabe Murray, William Kong, Mihir Mistry
• 2 DoD SMART Fellowship Winners: Eric Hayden (w/NAVAIR),Leighton Myers (w/NAVAIR)
• 1st Place in Undergraduate AHS Design Competition, 2006-2008 (3 years in a row)
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Student Recognition
• 5 Vertical Flight Foundation Fellows in 2009(Chandrashekar Tiwari, William Kong, Stan Sollenberger, Mihir Mistry, Seongkyu Lee)
• NASA AHS Robert L. Lichten Internship Winners2008: Conor Marr (Fluidlastic damper modeling)
2009: Sollenberger (Composite driveshafts)2010: Ed Brouwers (Ice accretion, ice shedding)
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Faculty Recognition
• 2010 AIAA Aeroacoustics Award: Dennis McLaughlin
• 2010 PSU Outstanding Research Award: Ken Brentner
• 2010 PSU Outstanding Research Award: Chuck Bakis
• 2010 PSU Outstanding Teaching Award: Jack Langalaan
• 2010 PSU Premier Research Award: Chris Rahn
• 2010
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VLRCOE Highlights
Progress on Major New Facilities (AERTS, Crash Rig, Filament Winder, Ducted Fans)
2 Major Phase II SBIRs (AATD and NAVAIR) Numerous Transition Programs (CRI, AATD, NAVAIR) Expanded Icing Program Executive Advisory Board #2
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VLRCOE Highlights
AATD SHM 6.2 Program completion Smart ROD Ends with KCF Pericycler and DARPA Drives Proposals First Dynamics MiTE testing (and DARPA MAR) Double Duct
SPENN TATE1 8 5 5Year 3 Summary
Accomplishment:
- Invented a new idea termed as Tailored Waveguide (TWG)- Parametric studies on TWG structure
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New Facilities
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New FacilitiesDucted Fan Testbeds
5” Dia Ducted Fan
10” Dia Ducted FansTandem and single
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Experimental FacilitiesDucted Fan Testbed
22” DIAMETER DUCTED FAN
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New Facilities _ Wind Tunnel Instruments
6-axis Dynamic Load cell
Airfoils with Dynamic Roughness
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New Facilities
INSPIRE our
YOUTH
SOLVEour 21st
CenturyProbs
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Filament winder
Allows precise automated fab of composite tubes, blades,Etc (complex layups)
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Design Specifications:• Linear Bearings Support a Rail Cart that
Traverses the Rail– Rail Cart is tethered to one end of the test specimen
while the other end is held fast– Rail Cart is the means of imparting the Crash
Dynamics Energy onto the test specimen.
• Impact Velocities up to 42 ft/sec [13 m/sec]– Controlled via a Pneumatic-Powered Cylinder– Velocity is Measured via a Photo-Eye Sensor
– Load Cell Capability of 2000 lbf [9000 N]
Dynamic Crash Sled
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INSPIRE our YOUTH
SPENN TATE1 8 5 5Penn State ARL Rotorcraft Research
Manufacturing and Materials
Automated Rotor Blade Stripping System with SAC and NAVAIR
Erosion Resistant coatings for Compressor blades with NAVAIR and Praxair, etc
Blade repair with FRC East Cherry Point. (Ted Reutzel)
Gear box Corrosion resistant coatings (Tim Eden) –
With ONR, Army Research Lab, NAVAIR, Sikorsky, JSF)
SPENN TATE1 8 5 5Penn State ARL Rotorcraft Research
CFDCFD Simulations of Gearbox Windage Losses, NASA (Kunz et al)
CFD Grid Methods for Rotorcraft Flowfields, NASA (Noack et al)
CFD for Ice Accretion, NASA (Noack, Morris, Kunz)
AcousticsNoise Analysis for Wave Bearing Test Facility, NASA (Hambric, Bill, Smith)
Health and Usage Monitoring and CBM
Gear Health Monitoring - DARPA via Northrup Grumman (Mark)
Structural Intensity for Structural Health Monitoring - US Army AATD (Conlon)
Battery and Electrical System Diagnostics, Bell via AATD (Banks)
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Multilayer erosion resistant coating system for protection against hard particle (sand) erosion
Project Number: A2087 Title: Erosion Resistant Coatings for Stage I
Compressor BlisksPerforming Activity: iMAST/ARL Penn StateObjective: Develop manufacturing/process for
applying erosion-resistant duplex or multilayer coating system against wide range of hard particles (e.g., sand) impingement angles (20-90o)
Start / End Dates: FY05 – FY07 Project Cost: $2,166K
ManTech Investment: $1,496KCost Share: >$670K (GE)
Weapon System: H-60 (SH-60, UH-60) helicopter fleet (T700 engine)
Performing Activities:• iMAST/ARL - Project leader• NAVAIR - Stakeholder/Program manager• Univ. of Cincinnati – Erosion testing• Praxair Surface Technologies - Implementation• MetCut Inc - Fatigue testing• MDS-PRAD - Implementation
Technical Goals: • Identify leading edge curl mechanism on T700 engine
components• Identify duplex/multi erosion-corrosion resistant coating
system for T700 engine components• Determine processing/manufacturing feasibility of high-
angle erosion resistant coatings
Implementation:System: H-60 helicopter fleetSite: Praxair Surface Technologies
Indianapolis, IndianaSchedule: Implementation targeted for Apr 2008Status: 3 month behind schedule
Payoff:• Increased engine life to 2500-5000 hours in erosive
environments.• Improve corrosion resistance• Reduce repair costs by 25%• Increase engine performance by 20-30%• Reduce fuel consumption by 8%• Increase mean time between overhaul (MTBO) by 100%
Erosion Resistant Coatings
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Performing Activities:iMAST ARL Penn State – Project LeadESTCP Team (ONR, Army Research Lab, NAVAIR, Sikorsky, JSF) – Co-Funding SponsorSikorsky Aircraft – Project Technical AssistantNADEP Cherry Point – Project Customer and Implementation SiteNAVAIR SH-60 Program – Project Stakeholder
Technical Achievements:Complete initial evaluation of aluminum coatings Established baseline for coating density, bond strength and hardnessDesigned and ordered new nozzles to improve deposition efficiencyMet with ESTPC Team Supersonic Particle Deposition Technology for Repair of Magnesium Aircraft Components) to start developing joint test protocol
Project Number: A2138Title: Corrosion Resistant Coatings for
Magnesium Transmission Gearboxes for SH60
Performing Activity: iMAST / ARL Penn State Objective: Develop process to apply corrosion
resistant coatings that will meet refurbishment/repair requirementsQualify coating process and materials for use on SH-60 Helicopters
Start/End Dates: FY06 – FY08Project Costs: $550k
MANTECH Investment: $50k thru FY06Cost Share: $1,087k ESTCP
$760k JSF, $400k ArmyWeapon System: SH-60 Seahawk and H-60 Helicopters
Implementation: System: SH-60 and H-60 Helicopters, other rotor wing aircraftSite Naval Aviation Depot Cherry Point, NCSchedule: FY07/08 Status: Initial coating trials have been conducted
ESTCP team meeting planned for Aug 2006 to establish JTP for technology implementation
Payoff:Benefits Analysis/ROI: 2.7:1Double the life of the transmission housingsReduce the number of transmission housings that have to be removed from service Reclaim 60% of the hardware that has been removed from serviceReduce risks to worker health and safetyReduce environmental impact
SH-Magnesium Transmission Gearbox Housing
Corrosion Resistant Coatings
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.
Implementation: System: CH-53E Super Stallion Helicopter, other rotor wing aircraftSite Naval Aviation Depot Cherry Point, NCSchedule: FY07/08 CPP PurchaseStatus: NCMS/CTMA Phase II Initiated, Kick-Off in May 2006
Payoff:• Benefits Analysis/ROI: 2.2:1• Reduce rotor blade stripping cost by 50% or more.• Technology will benefit refurbishment of more than 900 blades
each year at NADEP Cherry Point• Potential implementation at Sikorsky Reduce rotor blade stripping
time by 66% or more.• Reduced process emissions compared to conventional manual
hand sanding• Reduced risks to worker health and safety• Reduced environmental impact
Performing Activities:REPTECH ARL Penn State – Project LeadNational Center for Manufacturing Sciences – Co-Funding SponsorSikorsky Aircraft – Project Technical Assistant and SponsorGeneral Lasertronics – Project Technical Assistant and SponsorNADEP Cherry Point – Project CustomerNAVAIRSYSCOM 4.0, 6.0 – Project StakeholderNUWCDIVKEYPORT – Project Customer & Participant
Technical Achievements:• Evaluation and Downselect of Alternative Depainting Technologies• OEM Approved Process Qualification Test Plan• Final Process Qualification Test Report• System Specification Complete for Automated Rotor Blade Stripping
System (ARBSS)• Detailed Cost Justification Updated• NCMS/CTMA Phase II Initiated to Implement at NADEP CP• Repeat Tensile Test Completed – Results Successful for Laser Strip
Project Number: A1014Title: Automated Rotorblade Paint StrippingPerforming Activity: iMAST(REPTECH) / ARL Penn State
NCMS/CTMA TeamObjective: Develop, qualify, and build an
Automated Rotor Blade Paint Stripping System for CH-53E rotor blades.
Start/End Dates: FY04 – FY08Project Costs: $1.36M
MANTECH Investment: $617K thru FY05Cost Share: $742K in NCMS Phase I (thru Mar05 05
$2.7M in Phase II (estimated)Weapon System: CH-53E Super Stallion HelicopterAutomation of Rotorblade Paint Stripping Process
Automated Rotorblade Stripping System
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UH-60ATest Overview
• UH-60A Tail # 24468– Testing performed on 7 August 2008 at AATD
/ Fort Eustis Virginia• Transmission Frame
– Critical area of interest– Junction of FS 360 & BL 16.5
FS360
BL16.5
Fwd
ARLPenn State
UH-60ATest OverviewSHM for Airframe Cracks
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d)
c)
a & b)
Incr
easi
ng C
ompl
exity
• Plate & stiffened plate
• Transmission frame joint mock-up
• UH-60 upper cabin structure
Structural Complexity
Homogeneous plate
Plate + stiffener
I-beam frame structure
• Joint strap w/ fasteners
Real aircraft structure• Skin• Stiffeners / ribs• Riveted joints
ARLPenn State SHM Verification / Validation Test Beds
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CRI: Rotor System Damage Detection
Design a defect detection SHM system utilizing ultrasonic guided waves to evaluate the structural health of the CH-47 rotor root end. The system should meet the following requirements:
Automated Reliable and robust Sensitive to delaminations and fiber breakage Low false-positive rate
UMAT(steady state)
Guided Wave
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Rotor Loads Monitoring
Ruggedized loads sensing for CBM
Self powered, wireless
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2 “Smart” Rod End Sensor Concepts
M ax V elocity Experim ent vs P redicted
0
50
100
150
200
250
300
350
400
450
500
0 1 2 3 4 5 6
C yclic (deg)
Velocity (m
m/s
)
E xperim ent
P redicted
Inverted pendulum inertial “motion” harvestor (PSU)
Piezo-based “force” harvester and Terfenol force sensor (KCF)
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Load Cell Demonstrations@ Lord Corp in 2010
294.9 295 295.1 295.2 295.3 295.4 295.5
-3000
-2000
-1000
0
1000
2000
3000
Time (sec)
Forc
e (lb
.)
Sine Excitation
Basic sensor functionality, wireless transmission, and energy harvesting was demonstrated under simulated operating conditions
RF Antenna
Harvester
Load Sensor
Harvester Circuit, Microprocessor, and RF
Transmitter
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New Facility Needs
>> 2009 DURIP Proposals NOT FUNDED>> 2010 DURIP Proposals NOT FUNDED
Still many unfilled Instrumentation & Test Needs
• Rotor dynamics testing (damper testing, loads)• Icing testing (cooling system, particle sensor) • Flight Sim Facility (modernize electronics)• Active Flow Control Lab (actuators, sensors, etc)
SPENN TATE1 8 5 5
Professional DevelopmentShort Courses
1 week Rotary Wing Tech Short Course at PSU - August(McCormick et al)
42nd annual offering in August 2009> Great Army turnout> Weak industry and Navy turnout
#43 in August 2010
T = mv
http://app.outreach.psu.edu/RotaryWing/
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Vertical Lift
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VLRCOE MUSEUM: LIFTNASA Attempt #2 (Oct 2009) – NOT FUNDED
1) Modernize and expand the educational exhibits at the AHMEC
2) Develop new high quality exhibitsfor the LIFT museum
3) Enhance both AHMEC and LIFT educational experiences
(coordinated programs)
4) Stimulate interactions across generations (retired and practicing rotorcraft engineers working side-by-side with engineers-in-training K-12-grad school)
SPENN TATE1 8 5 5
Mastering the Air: A Dynamic Partnership to Bring Rotary Wing Aeronautics to the Public
$600K over 2 years
SPENN TATE1 8 5 5AHS Seminars
Tom Lawrence, SAC, X2Jeff Lowinger from Bell + and Bell BBQBrett Hoftstadt, BOEING, V-22 Operational StoryBill Geyer NAVAIR, V-22 Shipboard testingRob King, Opportunities at AED HuntsvillePilot Panel (Q&A for students and faculty)Rotorfest Groups (2009)Prof. Leishman Seminars (Fall 2009, Spring 2010)
SPENN TATE1 8 5 5
Trips and ServiceProf. Brentner on sabbatical at LaRC (2008-09)Prof. Gandhi on sabbatical at Bristol Univ (2009-10)Prof. Smith Co-Chaired Nanjing AHS Conf (Oct 2009)Prof. Smith/Sam Evans on American Helicopter Museum Board (2009)AHS Journal Editor in Chief (Brentner)AHS Forum Technical Chair (Gandhi)SAE Icing Committee (Palacios)AHS Test & Eval Comm (Palacios)
USMC Warrior Enterprise Panel (Oct 2008)Shipboard Dynamic Interface Workshop (Horn)AHS Structures and Survivability Workshop (Oct 2009)USN/USMC Ducted Fan and MULE Briefings (Oct 2009)
Boeing Research Workshop (June 2008)UT Group Strategic Visit (Oct 2009)Bell Group Strategic visits (June 09, Sep 09, April 10)
SPENN TATE1 8 5 5Statistics - 2006-1010 VLRCOE Program
Journal Conf. MS PhDPapers Papers degs degs
Year Prog.
Note: Total numbers higher for entire Penn State Vertical Lift Research Program activities(other funds from MURI, ARO, industry, etc.). These totals are available from Prof. Smith.
2007- Army: 7 33 4 32009 Navy: 3 17 5 1
NEED MOST CURRENT INFO HERE
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Recent VLRCOE GradsZihni Saribay, 2009 PhD ONR PSU PostdocJose Palacios , 2008 PhD, VLRCOE PSU PostdocFabio Semperlotti, 2009 PhD, AATD,CRI Michigan PostdocMike Jostes, 2009 BS NAVAIRAngela Santo 2009 BS Boeing PHLJoseph Wang, 2010 MS, ONR, LordWill Kong, 2010 MS, ONR, DoDEd Brouwers, 2010 MS Boeing PHLLloyd Scarborough, 2010 MS PSU PhD (LORD)Chandra Tiwari, 2009 MS, ONR PSU PhD , ONRPam Montanye, 2008 MS, ONR Boeing PHLKirsten Bossenbroek, 2008 MS, VLRCOE Boeing, SeattleWalter Schmidt, 2009 MS, AATD SikorskyJamie Bluman, 2008 MS West PointChris Duling, 2008 MS West PointJonas Corl, 2009 MS, ONR Optics CompanyDave Santarelli, 2010 MS, NAVAIROptics Company
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Recent VLRCOE GradsStan Sollenberger, 2010 MS, CRI,Bell US NavyMatt Hagon, 2008 MS, ONR GELance Antolick, 2009 MS, AED RMCI (Huntsville)Sade Sparbanie, 2008 MS ONR SikorskyBrian Geiger, 2008 PhD PiaseckiJustin Shirey, 2007 MS, VLRCOE Lockheed Martin
NEED MORE INFO HERE
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Total Rotorcraft Research Budget $6.1 M in total 2008 funding)
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123
45
678
910
111213
141516
1718
192021
22
VLRCOE(@PSU)
VLRCOE(subs)
ONR
Penn State(cost share)
NASA(NRA)
DoD (grad fellows)AFDD
Timken BellLORD
BoeingGoodrich
SikorskyDURIPS
CRI
AATD & NAVAIR SBIRs AED
AATD SHM
Total Rotorcraft Research Budget $6.5 M in total 2009 funding)
Include 6 ARL Paid students
65% Basic Research
ARO Core24 Funding Sources
PiaseckiAirfoils(AFDD)
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Rotorcraft Science and Technology Base Funding (University 6.1)
ArmyONR
NASA
$
1996 2000 2005 2009
?2M
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2009 Strategic Plans
1) Develop additional key VLRCOE facilities (A)*
2) Transition 6.1 tasks to CRI, SBIR, AATD, NAVAIR, DARPA, etc (A)
3) Pursue new MURI program with ONR (B-)
4) Expand relationship with USMC and USAF (A-)
5) Continue Penn State Vertical Lift Museum effort (B)
6) Continue to strengthen CFD and Flow Control Research (A-)
7) Explore opportunities to contribute to VTOL F-35 (C)
8) Expand International Outreach (B+)
9) Strengthen industry ties (A)
* However, unsuccessful in raising new equipment funds
SPENN TATE1 8 5 5
2010 Strategic Plans
1) Prepare for VLRCOE Renewal (2011-2016)
Identify and develop new project ideas NEW VLRCOE FACULTY at PSU New partners in industry/academia
2) Support Formation of VLC and expanded OSD programs
3) Develop additional key VLRCOE facilities (A)*
4) Transition 6.1 tasks to CRI, SBIR, AATD, NAVAIR, etc
5) Continue to strengthen CFD and Flow Control Research
6) Continue to strengthen NASA Collaborations
7) Continue Penn State Vertical Lift Museum effort
8) Conduct DoD/NASA Workshop on Variable Speed Rotorcraft in Sept
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Compound andVariable Speed Rotorcraft
Add wings and props
Vary RPM with speed, payload, altitude
> Aggressively develop enabling tech
Products are changing!Capabilities CAN change
SPENN TATE1 8 5 5Army-Navy-NASA-CRI Leveraging
• Variable Speed Rotorcraft
Army: Flight control lawsNavy: Mechanical Transmission SystemNavy: Active Loads and Vibration ControlNavy: Morphing Variable Speed RotorsNASA: Propulsion and Drive Elements
Bearings
Pericyclic Motion Converter (PMC)
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2010 Strategic Plans
9) as always, DON”T FORGET TO HAVE SOME FUN!
Enjoy the review!!!
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Graduate School Advice I
A. Your career will span 40+ years> ENJOY your WORK> THOROUGH training
B. Engineering is a Profession (similar to law, medicine, etc)
C. Today’s flying machines will not be competitive tomorrow
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Graduate School Advice II
INTEREST > MOTIVATION > HARD WORKHARD WORK + APTITUDE = Success & Happiness
KNOW your ADVISOR (meet, papers, students)KNOW the FACILITIES
EXPERIMENTAL vs COMPUTATIONAL balance?
Gain any research & project experience you can
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