ohio aerospace institute - background and capabilities · aerospace research (aerospace think tank)...
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Ohio Aerospace Institute -
Background and Capabilities
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Andrew GyekenyesiAssociate Chief Scientist/OAI
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Aerospace Sector
■ Domestic aerospace manufacturing is most successful sector of US economy
500k workers in scientific and technical fields plus 700k additional jobs in related fields
$226B aerospace production value
$147B in export sales with a positive $91B trade surplus
65% of aerospace production is exported
Much of the aerospace work retained within US
• High wage positions, e.g., machinist, engineers, etc.
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Aerospace Sector
■ Fasteners and aerospace
Of Boeing 747’s 6M parts, half are fasteners (about 3-5% of total cost)
Aerospace bolts/fasteners are rigorously tested, manufactured, and studied
2016 global aerospace fastener market was $5.5B and projected to grow to $7.7B by 2021 (7% annual growth)
Demand for precision made, technologically sound, lightweight, and high-performance fasteners (resistant to corrosion and ET)
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OAI Mission
Enhancing our partners’ aerospace competitiveness
through research and technology development,
workforce preparedness, and engagement with global
networks for innovation and advocacy
Research & Technology
Development
Education &
Training
Collaboration +
Innovative Solutions
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History & Background
■ Private, not-for-profit 501 (c) (3) founded in 1989
■ First NASA-associated collaborative Institute chartered to foster relationships between universities, aerospace industries, and government organizations
■ Strong support from:
NASA Glenn Research Center
Wright Patterson Air Force Base - Air Force Research Laboratory
Ohio research universities
State of Ohio
Aerospace industry
■ More than 325 federal awards ($270M)
■ 60 employees in two locations
Cleveland HQ (Adjacent to NASA Glenn)
Dayton – adjacent to Wright-Patterson AFB
Cleveland
Dayton
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OAI Core Capabilities
■ Aerospace research (aerospace think tank)
■ Building and managing collaborations, consortia and public-private
partnerships
Neutral, unbiased management
■ Workforce development: Internships, scholarships, visiting faculty,
short courses, educational outreach, student and faculty
engagement with industry, federal labs
■ Technology development, transfer, commercialization
■ IP management
■ Small business assistance
■ International services
■ Leverage aerospace network: government labs, industry,
academia
Making connections
■ Hosting events for the benefit of members (connect, share,
succeed)
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Specialized Research Teams
■ Computational Modeling
■ Materials
■ Structures
■ Vehicle Health Monitoring and Safety
■ Space Science and Exploration Technologies
OAI Researchers
■ Areas of expertise include
Aerospace engineering, materials science, chemistry,
mathematics, physics, and electrical, mechanical and chemical
engineering, and other disciplines
80% Advanced Degrees (72% Ph.D)
Provide core competencies in many technology areas at both
NASA GRC and AFRL
5 “R&D100” Awards, 32 U.S. and 5 foreign patents; 18
licenses; 3 copyrights; 2 trademarks; leadership roles in
societies and standards organizations; editors of many journals
and proceedings
OAI Researchers
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Aerospace Systems Sensing, Characterization & Safety
NDE and Health Monitoring■ Utilize health monitoring data from
smart sensors distributed throughout
structure
■ Specimen scale, sub-component
level, and full scale damage
characterization tests of advanced
materials
High Temp. Electronics■ SiC based sensors for 500 oC
aerospace and harsh environment
applications
■ Conventional materials fail beyond
225 oC
■ Expertise in packaging
technologies
Laser Diagnostics for
Combustion Research■ Measure flame temperatures, gas
composition, and chemical species
using Raman Spectroscopy
■ Optimize fuel/air mix
■ Subsonic/supersonic and pressure
controlled cruise conditions
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Aerospace Systems Sensing, Characterization & Safety
Computational tools
■ Develop validated tools for predicting ice
growth, ice protection system behavior, and the
effects of ice contamination for design,
analysis, and certification
Expertise in thermo-mechanical
characterization and modeling of basic ice
behavior
■ Improve current ice accretion and ice protection
system prediction methods to allow use of
codes for design and certification over a broad
range of icing conditions, aircraft geometries,
and flow conditions. This approach also
ensures that codes are accurate, robust, fast,
and easy to uses
Ice Adhesion Behavior
■ Characterize impact ice properties and
adhesion strength
Develop new test techniques and employ
various in-situ monitoring tools
Fabricate statistically significant amount of
specimens under various icing conditions
Aircraft Icing Research
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Advanced Aerospace Materials
Light-weight, High-performance Polymers and Structures
■ Develop molecularly engineered advanced polymeric materials and
composites from design to end-use applications—including synthesis,
characterization, process optimization, component design and prototyping,
and manufacturing optimization
■ Research performance - durability evaluation and prediction for various
applications; aeronautics, space, marine, auto, medical, durable goods.
■ Current activities: High voltage insulations for hybrid electric aircraft, high
temperature organics for Stirling convertors, Curved PMCs for automotive,
nanocomposites, high temperature polymer aerogels for aerospace
applications.
Ceramics and Metallics
■ Advance materials technology for aerospace as well as other applications
■ Integration technologies
Develop a wide range of approaches to join dissimilar materials for a wide range
of thermo-structural conditions
■ Shape memory alloys
Develop stable, high-work-output, shape memory alloys for a range of
application temperatures & stress levels for use in adaptive structures and
actuators through a fundamental understanding & control of material properties
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Mechanical Characterization
and Modelling
■ Develop testing methodologies for high temperature structural
materials, sub-elements, and components
■ Thermal, dynamic, and stress analyses of aerospace structural
elements (ex: sandwich structures and protective coatings on metallic
alloys and ceramic matrix composites) with finite element methods
■ Simulation of lightning strike effects on delamination of CFRP panels
with cohesive layers between plies to capture delaminations
■ Durability estimation of aerospace components with creep life models,
fatigue crack initiation models, and fracture mechanics
Life prediction of PM turbine disk
Crack propagation studies
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(a-c): Damage zones for varying fracture toughness
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Computational Modeling
Air-Augmented Pulse Detonation
Rocket Engine (AAPDRE)
Support technology development for air/space vehicle propulsion systems
■ Develop theoretical and computational models for system components
■ Advance knowledge and understanding
Reduce cost of access to space by improved performance and efficiency
Reduce environmental impact (noise and emissions)
Investigate new pulse detonation rocket-based combined-cycle (PDRBCC) engine concept
Develop models and prediction codes for propulsion system (jet) noise
Develop turbulence-chemistry interaction models for reacting multi-phase flow simulations
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Computational ModelingAFRL OAI on-site support:
• Efforts are broken down into two
major areas
– Basic Research
• Multi-disciplinary physics
• Uncertainty
Quantification/Sensitivity
Analysis
• High-speed flows
– Applications
• CFD support of
projects/experiments
• Software/Hardware
optimization for high
performance computing
•Non-equilibrium flow physics
•Shockwave-Boundary Layer
•Interaction
•High-speed flows
•UQ/SA
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Space Science and Exploration
Technology
Knowledge and technology to advance space
exploration
■ Develop space propulsion, power, and
communications technologies
■ Examine aspects of space science: environmental
interactions
Exploration technology
Advanced propulsion - high power Hall effect thrusters
Plasma propulsion - advanced concepts such as MPD,
plasma wave acceleration
NIAC advanced concepts
Advanced solar power - advanced cells, support to
DARPA FAST array testing
Advanced test sets for exploration communications
Solar and nuclear electric propulsion systems studies
Space sciences
Solar cell lifetime and arcing in space
Environmental monitoring instrumentation
Magnetoplasmadynamic
(MPD) thruster
Small inductive/wave
plasma source
HERMeS Hall
thruster
Solar array arc testing
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Additive Manufacturing of Ceramics
■ Laminated Object Manufacturing of ceramic matrix
composites
■ Binder jet printing technologies (with RP+M)
Study processing constituents (e.g., SiC powders, infiltrants,
fiber reinforcements)
Assess microstructure (optical and SEM) and properties
(densities and bend tests)
■ Develop and characterize feed materials for 3-D printing
of silicon carbide (SiC)-based ceramics
■ 3-D printing of multi-functional materials
Weight retention values are promising
for all samples secondary
infiltration steps may not be necessary
NASA Non-Metallic Turbine Engine
Project
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Thermal Management
■ Utilize new advanced materials, such as high conductivity porous graphite foams, for
solving thermal management challenges (e.g., aerospace, electronics, directed energy
weapons, energy production)
Low density, large surface area, and engineered, open pore structure
High ligament thermal conductivity (>1700 W/m•K) and bulk conductivity (up to 245 W/m•K)
Potential for high temperature and chemically aggressive environments
■ Use as a heat exchanger and replacement for metallic finned structures
■ Employ as conductivity enhancer for phase change materials within thermal energy
storage systems
■ OAI projects address large scale production, improved foam durability via coatings, joining
procedures, and basic design methodologies as well as test techniques for producing
thermal, flow, and mechanical characterization data
Graphite Foam Manufacturing Testing Modeling
Prototype Development
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STEM/Education ProgramsOhio Space Grant Consortium
■ 23 Ohio institutions of higher learning (Ohio STEM students)
■ More than $4.4M in scholarships and fellowships to date
■ 50 new undergraduate scholarships and 10 new graduate fellowships each year, plus renewals (over 500 undergrads and 150 graduate fellowships since inception)
Ohio Means Internship Program
■ OAI is teamed with LCCC, CSU, UC, UT, and Lourdes
■ Provide connections to industry using OAI’s membership network
NASA Glenn Summer Faculty Fellows/Glenn Academy
■ 10 week research experiences at NASA GRC
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STEM/Education Programs - cont.
Air Force Research Laboratory Capstone Program
■ University senior engineering students address AFRL-defined technical challenges
■ Program designed to identify candidates for hire, fresh technology ideas Outreach
FIRST Robotics Buckeye Regional
■ Treasurer and past Chair (10 years) managing fundraising for this annual event (over $150K raised per year)
■ Engage HS students in intensive 6-week robot build from standard kit, followed by regional/national competition
■ Community partnership activity for NASA GRC
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Networking and educational events■ Subject/product database for direct member-to-member connections
■ Workshops and conferences
■ Advocacy and awareness events
■ Supply chain events
■ Teaming opportunities
■ Access to international aerospace clusters
■ Distinguished lectures and development courses
Communication via news letters, emails and policy alerts
Connections■ Partnerships and collaborations
■ Introductions/key points of contact
■ On-site reps at NASA GRC and AFRL
■ Statewide aerospace industry network
Problem solving■ Small business growth services – reach new customers and markets
■ Strategy sessions
■ OAI’s Collaborative Federal Economic Development Program
■ Researchers/scientists
■ Commercialization services
OAI contracted services■ Technology commercialization, IP protection and licensing
■ Market studies and road mapping
■ Partner targeting
■ Subject matter experts and contracted use of OAI facilities
Industry and University MembershipConnect, Share, Succeed
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OAI Members
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Recent Business Assistance Projects
Small Business Assistance – Small Business Administration FAST Program
■ OAI awarded one of 20 grants nationwide (limited to one per state) to provide small
business assistance under the Small Business Administration Federal and State
Technology Partnership Program
■ Provide training, mentoring, proposal development and proposal writing assistance
focused on small women-, minority-, and veteran-owned businesses who have not
previously benefited from SBIR/STTR programs
■ Aerospace, aviation, related technology areas
Ohio Entrepreneurial Signature Program
■ Through Jumpstart, Inc. (Northeast Ohio entrepreneur support network) provide
proposal development and writing assistance to small businesses focused on
success in SBIR/STTR programs
■ Strengthen small business networks and capabilities through training
International Trade Shows
■ With JobsOhio (Ohio’s private business attraction/retention organization), led
delegation of Ohio companies to AirTec aerospace trade show in Munich
■ Coordinate Ohio presence/booth/participation
■ Provide financial assistance for companies to attend
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Aero Acoustics Research Consortium
■ Partners: Boeing, Honeywell, Pratt & Whitney, Rolls-Royce, NASA
■ Now in 17th successful year
■ Formed to promote world-class, pre-competitive research in engine noise source definition/prediction and mitigation
■ Established May, 2000 via cooperative agreement with NASA, separate industry teaming agreement
■ Partners form a peer review panel which evaluates and votes on proposals submitted by researchers through AARC website
■ 5:1 leverage for members’ individual funding
Propulsion Instrumentation Working Group■ Industry: GE Aviation/GE Energy, P&W, RR, Honeywell Aerospace,
Siemens, Williams International
■ Government: AFRL, Army Research Lab, NASA GRC, Arnold Engineering
and Development Complex, US Navy, DOE/Oak Ridge National Lab, DOE/
National Energy Technology Lab
■ Identifying common sensor and measurement needs and requirements
■ Create and implement a common R&D vision and strategy
■ Identifying and pursuing instrumentation development efforts
OAI Managed Partnerships/Consortia Private/Public Partnerships
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Distributed Engine Controls Working Group
■ Industry: GE Aviation, Honeywell, P&W, RR, BAE Systems, UTC Aerospace Systems, Boeing, LM, NG
■ Government: AFRL, NAVAIR, US Army, NASA
■ Consortium formed in October 2013. Working group since 2007
■ Provide a forum for the US government and aerospace industry to collaborate, in a pre-competitive environment, on the advancement of technologies required to implement distributed controls in aerospace propulsion systems
High temperature electronics for harsh engine thermal environment and flexible controls architecture for total system weight reduction
Halon Alternatives for Aircraft Propulsion Systems■ International need to find a replacement for halon
■ Aviation industry unsuccessful in working independently to find a solution
■ Airbus SAS, Boeing, Bombardier, Embraer S.A., and Textron, initiated
activity to leverage combined resources and knowledge
■ OAI selected in October 2014 to create and manage the HAAPS
consortium
■ Work to shorten time and expense required to find acceptable solutions for
engine and APU
OAI Managed Partnerships/Consortia – cont.
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Advanced Manufacturing Technology Consortium for
Aerospace■ Partners from aerospace value chain, Fed labs, academia and a
standards development organization
■ Identify technology gaps and required standards, procedures and
certification processes that will accelerate the implementation and flight
worthiness of AM aerospace parts/components Roadmap to identify technical and standards requirements as well as record
observations and make recommendations for the increased utilization of AM for
small and medium sized aerospace manufacturers
Roadmap will be used by Fed for defining future research topics (feedback from
all levels of value chain)
■ Establish sustainable, self funded research teams to enhance the
utilization of AM in aerospace
OAI Managed Partnerships/Consortia – cont.
Probabilistic Analysis Consortium for Engines■ Leverage resources and technical expertise of its members for the
accomplishment of selected research activities
■ GE Aviation, P&W, RR, Siemens and AFRL
■ Develop, apply and validate advanced probabilistic methods that
enable new engine analysis and design methods that quantify
uncertainty for achieving improvements in engine performance, cost
and reliability
■ Several challenges have been jointly identified by the industry and
government team – Five projects
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Thank You