Many studies have been performed looking at methods for reduced drag, improved separation and even reduced impact on aircraft signature for external store carriage. In the early 1970s, conformal carriage studies were conducted for the F-4 Phantom to reduce drag. Additional studies have addressed conformal carriage, semisubmerged carriage, and light weight structures (shrouds, etc.) mounted to the external store for improved carriage performance.
External carriage and radar cross section seem to be at odds; however, innovative methods for shape modification, appropriately designed external pods, and specialized materials need to be explored to improve weapons load out while maintaining acceptable signature levels.
One of the largest volume stores carried on most aircraft is the external fuel tank. These all have a similar look to maximize the volume of fuel that can be carried. Conformal fuel tanks and collapsible concepts have been put forth as reduced drag alternatives with varying degrees of acceptance. One recent study has shown that aerodynamic shaping can be used to reduce drag and improve store separation characteristics near these large external stores (see reference 5). This area has a large potential for improved range/energy efficiency.
With this background, the Air Force is interested in technologies that can improve delivery of weapons to the target. The scale of the platform to be considered is representative of the F-35 both in size and flight regime of interest. The goal is to have multiple innovative external carriage concepts produced with computational, as well as experimental, evidence that the concepts will perform with better characteristics than traditional external carriage. Considerations of impact on aircraft range, weapons separation, performance and handling, as well as survivability, should be considered.
PHASE I: Multiple unique external carriage concepts will be developed. An engineering/preliminary design review (form, fit, function, weights and balances) will be conducted to evaluate the potential of candidate concepts to yield achievable performance gains. Limited computational/experimental data will be required to evaluate concepts. Plan testing and refinement of the most successful concepts in Phase II.
PHASE II: During this phase, evaluation and refinement of concepts will be achieved. Both computational and experimental testing and validation of concepts will be accomplished. The analysis should include computational and/or experimental assessment of drag, separation, and signature. Possible preparation for flight test may be required depending on the concepts explored and funding level.
PHASE III DUAL USE APPLICATIONS: Weapons carriage technologies developed could be applied to legacy military aircraft for improved performance, increased weapons load out, etc. Commercially, extended range fuel tanks and drag reduction technologies may be applied.
REFERENCES:
1. Burns, B.R.A., "Fundamentals of Design-IV: Weapon Carriage and Delivery," Air International, October 1979, pp.176-179.
2. NATO Research and Technology Organization, "RTO Meeting Proceedings 16, Aircraft Weapon System Compatibility and Integration," Chester, United Kingdom, 28-30 September, 1998, RTO-MP-16, DTIC Accession Number ADA363078, pp. 24-1 to 24-12, K2-1 to K2-3, 14-1 to 14-12.
3. Wilcox, F., "Tangential, Semi-submerged, and Internal Store Carriage and Separation at Supersonic Speeds," AIAA 91-0198, 29th Aerospace Sciences Meeting, January 7-10, 1991, Reno, Nevada.
4. Knott, E.F., Shaeffer, J.F., and Tuley, M.T., "Radar Cross Section: Its Prediction, Measurement and Reduction," Norwood, Massachusetts Artech House, 1985.
5. Charlton, E.F., and Davis, M.B., "Computational Optimization of the F-35 External Fuel Tank for Store Separation," AIAA 2008-376, 46th AIAA Aerospace Sciences Meeting and Exhibit, 7-10 January 2008, Reno, Nevada.
KEYWORDS: internal carriage, external carriage, store carriage, conformal carriage, semisubmerged carriage, tandem carriage, radar cross section, store separation
AF141-080 TITLE: Air Cycle Toolsets for Aircraft Thermal Management System (TMS) Optimization
KEY TECHNOLOGY AREA(S): Air Platforms
The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 5.4.c.(8) of the solicitation and within the AF Component-specific instructions. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. Please direct questions to the AF SBIR/STTR Contracting Officer, Ms. Kristina Croake, kristina.croake@us.af.mil.
OBJECTIVE: Development of complementary hardware and software toolsets which allow assessment and characterization of different military aircraft air cycle or hybrid-cycle thermal management system architectures.
DESCRIPTION: Current tactical aircraft face enormous challenges associated with increasing operational envelope while reducing fuel burn. To that aim, there is a growing desire within the power and thermal systems community to explore the hybridization of complementary thermal cycles as a means for improving tactical aircraft thermal management system (TMS) energy efficiency and dynamic responsiveness. To accomplish this, a flexible set of air cycle hardware components coupled with validated computational models are required for hardware-in-the-loop system development and performance assessment activities. It is envisioned that these toolsets could be used to explore impacts of different potential air cycle system (ACS) configurations on overall vehicle TMS performance in both steady state and dynamic operation. The data obtained from these studies could then be used for assessment and optimization of vehicle TMS against developer-defined mission parameters including vehicle speed, altitude, and accessory power and thermal needs.
To realize this vision, several significant technical challenges must be addressed. Specifically, co-development of rugged ACS wheel sets (compressors and turbines) which incorporate interchangeable, reusable, and reliable pneumatic and rotational interconnects with complementary computational models which facilitate selection of appropriate wheel-pairs is necessary. It is anticipated that this activity will result in the demonstration of a series of radial or axial air cycle compressors and turbine wheels that can be mounted (onto a drive stand or high-speed rotational drive) into three or more different configurations in order to explore potential tactical aircraft mission scenarios. Further, these components would permit operation in conjunction with other TMS subsystems (cooled air to vapor compression systems) to explore promising vehicle-level TMS architectures. A set of complementary computational models is also required to analytically predict thermodynamic performance, aerodynamic performance, and consider mechanical safety of the high speed rotational machinery tools.
For the purposes of this tool demonstration, all componentry should be designed to be operated onto a typical high speed (60 krpm, 10 to 100 kWth, 300 kWrot) drive stand (dynamometer) or similar high-speed motor with minimal rebalancing of each of the ACS wheels between tests. Further, the offeror must demonstrate that an appropriate number of wheel pairs could be independently configured such that the final toolset is flexible and not an ACS point design. Phase II deliverables should include two to three compressor wheel sets, one to two turbine wheel sets, reconfigurable ducting for pneumatic connectivity, and complementary Matlab (or similar environment) open-source codes.
A particular design point of interest includes delivery of 1 pps (lb/s) of air at 40 to 70°F at a delivery pressure of no less than 100 psi from ambient air (~90°F, 14.7 psi). A secondary design point would include delivery of 1 pps of air at 40°F from precompressed 300 psi, 100°F supply air. Power generation is of secondary importance.
PHASE I: In context of modern high performance aircraft TMS specifications, demonstrate feasibility of developing a set of ACS hardware toolsets which meet the topic objectives. Develop and demonstrate a set of computational toolsets to facilitate appropriate and safe pairing of compressor and turbine wheel sets.
PHASE II: Develop and demonstrate a prototype version of the ACS wheel sets designed under the Phase I activity. Demonstrate that these tools can be used to simulate two or more vehicle ACS configurations in terms of power, pressure ratio, or discharge temperatures based upon the notional vehicle’s performance desirements developed during the Phase I. Identify necessary facility or testing requirements necessary to operate the tools over USAF relevant operational tactical fighter mission scenarios.
PHASE III DUAL USE APPLICATIONS: Commercial applications include development of air cycle units for commercial aircraft APUs, ground carts, and pressurization units.
REFERENCES:
1. T.R. Ensign and J.W. Gallman, "Energy Optimized Equipment System for General Aviation Jets," Proceedings of the 44th AIAA Aerospace Sciences Meeting and Exhibit, January, 2006 (228).
2. R. Slingerland and S. Zandstra, "Bleed Air Versus Electric Power Off-takes from a Turbofan Gas Turbine over the Flight Cycle," Proceedings of the 7th AIAA Aviation Technology, Integration and Operations Conference, September 2007 (7848).
3. E.A. Walters and S. Iden, "Invent Modeling, Simulation, Analysis and Optimization," Proceedings of the 48th AIAA Aerospaces Sciences Meeting, January 2010 (287).
KEYWORDS: aircraft thermal management, air cycle systems, air cycle systems, ACS, environmental control systems, ECS, aircraft power and thermal subsystems
AF141-081 TITLE: Launch Vehicle Systems Intended to Execute Suppressed Trajectories for Hypersonic
Testing
KEY TECHNOLOGY AREA(S): Air Platforms
The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 5.4.c.(8) of the solicitation and within the AF Component-specific instructions. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. Please direct questions to the AF SBIR/STTR Contracting Officer, Ms. Kristina Croake, kristina.croake@us.af.mil.
OBJECTIVE: Develop an innovative approach(es) for new and/or existing launch systems to execute suppressed trajectories for hypersonic flight testing. Perform analysis and testing to mature technology, validate models, reduce risk, and demonstrate capability.
DESCRIPTION: The Air Force is working on next-generation hypersonic systems for various missions, including high-speed strike, space access, and penetrating intelligence, surveillance, and reconnaissance (IS&R). Conducting affordable flight testing is necessary to understanding physical phenomena, validating models, and building stakeholder support. In hypersonic testing, getting the test article into the necessary test window with the required flight environment can be challenging, given existing booster systems. Getting into relevant test windows for extended test times usually requires challenging suppressed trajectories that state-of-the-art booster systems have difficulty achieving. A trajectory can be considered suppressed if it does not utilize exoatmospheric flight prior to entering hypersonic flight environments.
As an example, the HIFiRE-2 Program required a suppressed trajectory for propulsion testing. The flight vehicle used three solid boosters, coasting gravity turns, and risky timing techniques to ignite upper stages. This suppressed trajectory included multiple unpowered passes through transonic flight, creating high uncertainty.
Capabilities of systems to be developed under this effort include one or more of the following: reduction of software verification and validation, simplification in meeting test range safety requirements, simplification in test range integration, reduction of uncertain flight environments (e.g., transonic), reduction in stages, reduction in additional hardware, reduction of undesirable loads on the payload (e.g., acoustic, vibration, heating), maximization of test time, reduction of ground infrastructure and personnel, reduction in aerodynamic loads, and allowing for a more vertical launch direction from the ground (not applicable to air-launched systems). For the purposes of this SBIR solicitation, these desired capabilities are considered of roughly equal importance.
The approaches developed under this effort will need to be demonstrated as enabling at least one government-supplied test window. It is anticipated that test windows defined by parameters such as dynamic pressure, Mach number, angle of attack, and flight path angle will be provided. A sample test window includes Mach 4 to 8 and dynamic pressures from 1,000 psf to 3,000 psf. The offeror’s proposed approach should maximize coverage of the government-supplied test windows. These test windows are subject to modifications during Phase I.
Candidate technology approaches could include new booster systems, fin set upgrades for existing systems, new control algorithms and effectors, trajectory shaping, and/or rocket motor throttling/gimbaling. A proposed solution could include a single or combination of methods.
Both Phase I and Phase II will consist of an appropriate level of design and systems engineering efforts to understand what it will take to make the proposed solution(s) operational. These efforts should address all lifecycle issues but focus in on the demonstrations that will be conducted in Phase II.
For the purpose of Phase I proposals, the payload can be assumed to have the following characteristics: 300-lbm gross weight, 2-ft length, 6-inch diameter, 30-percent front is a blunted ogive with the rest being a cylinder, and 20-percent increase in drag on the stage attached to the payload (to account for inlets, exhaust ports, and/or surface irregularities). It is desirable for technology approach(es) to be scalable to systems supporting larger payloads and/or more energetic trajectories.
Computational resources from the DoD Supercomputing Resource Center (DSRC) will be provided at no additional cost for use on this effort to appropriately cleared contractor personnel.
PHASE I: Investigate innovative approaches to achieve the test windows. Define the system requirements for the solution(s). Define trajectories for the test windows. Early verification and validation by analysis of the solution(s) to achieve reference trajectories, meet requirements and meet testing needs. Develop integration, verification and validation plans for the entire system and tests for Phase II.
PHASE II: Further refine and develop a detailed-level design of proposed solution(s). Update as needed the integration, verification, and validation plans focusing on the Phase II efforts. Fabricate, assemble, and integrate the items for testing. Conduct testing to mature the technology solutions. Tests will provide insight into how the solution(s) support suppressed trajectories. At the end of Phase II, viability is shown with testing, design analysis, and future development planning.
PHASE III DUAL USE APPLICATIONS: Potential commercial applications include providing launch services and/or launch hardware to support development of hypersonic technology and systems such as a hypersonic IS&R aircraft, an upper stage for a space-access vehicle, or a tactical hypersonic missile.
REFERENCES:
1. Kimmel, R., and Adamczak, D., "HIFiRE-1 Background and Lessons Learned," 50th AIAA Aerospace Sciences Meeting including the New Horizons Forum and Aerospace Exposition, AIAA-2012-1088, Nashville, TN, January 9-12, 2010.
2. Jackson, K., Gruber, M., and Bucceellato, S., "HIFiRE Flight 2 Project Overview and Status Update 2011," 17th AIAA International Space Planes and Hypersonic Systems and Technologies Conference, AIAA-2011-2202, San Francisco, CA, April 11-14, 2011.
3. Bolender, M., Dolvin, D., and Staines, J., "HIFiRE 6: An Adaptive Flight Control Experiment," 50th AIAA Aerospace Sciences Meeting including the New Horizons Forum and Aerospace Exposition, AIAA-2012-0252, Nashville, TN, January 9-12, 2012.
4. Walker, S., et al., "The DARPA/AF Falcon Program: The Hypersonic Technology Vehicle #2 (HTV-2) Flight Demonstration Phase," 15th AIAA International Space Planes and Hypersonic Systems and Technologies Conference, AIAA-2008-2539, Dayton, OH, April 28 - May 1, 2008.
5. Hellman, B., et al., "Critical Flight Conditions of Operation Rocketback Trajectories," AIAA Space 2012 Conference & Exposition, AIAA-2012-5208, Pasadena, CA, September 11-13, 2012.
6. Hellman, B.M., "Hypersonic Flight Test Windows for Technology Development Testing." AFRL-RQ-WP-TM-2013-0260, November 2013, 16 pages, uploaded in SITIS 12/17/13.
7. EXCEL file containing the graphs contained in AFRL-RQ-WP-TM-2013-0260 (see Ref. 6), uploaded in SITIS 12/17/13.
KEYWORDS: hypersonic, trajectory, suppressed trajectory, flight testing, launch vehicle, booster, rocket, high speed
AF141-082 TITLE: Development of Approaches to Minimize Icing in Aircraft Heat Exchanger/Condenser
Applications
KEY TECHNOLOGY AREA(S): Air Platforms
The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 5.4.c.(8) of the solicitation and within the AF Component-specific instructions. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. Please direct questions to the AF SBIR/STTR Contracting Officer, Ms. Kristina Croake, kristina.croake@us.af.mil.
OBJECTIVE: Develop and evaluate innovative concepts to minimize icing in heat exchanger/condenser applications associated with an air cycle machine for aircraft cooling requirements.
DESCRIPTION: The demand for thermally unconstrained operations for aircraft has been driving the research of integrated thermal management designs for several years. Recent turbine engine efforts have focused on increasing the available air heat sink to help meet thermal requirements affected by the steady growth of avionics heat loads. Use of these cooler air heat sinks to dump aircraft heat loads can be improved through additional analysis/research of methods to reduce the impact of icing that may occur in heat exchanger/condenser components associated with aircraft thermal management. Approaches might include the development of ice resistant (ice phobic) coatings and/or the design of condenser equipment that partitions passageways or redirects available airflows to minimize icing conditions.
Condenser icing is a concern for aircraft air conditioning systems using a high-pressure water separator to remove moisture from cooling air supplied to equipment and the cockpit. A high-pressure water separator includes an air-to-air condenser heat exchanger. The condenser causes water droplets to form on the hot side fin surfaces by transferring heat from a cold side air stream. The condensed water droplets are then removed by a centrifugal device, and cool, relatively dry air is supplied to the equipment and the cockpit. In general, a cross-flow designed condenser may operate in a moist environment, with warm air entering at station 1 and exiting at station 3 after being cooled by cross-flow air generated by a cooling turbine at station 2. Both the hot and cold sides of the condenser contain moisture and have the potential to form ice. Table 1 provides typical operating conditions for this type design. Note that at station 3, the temperature is only 3°F above freezing. Current state-of-the-art condensers operate ~ 8 to 12°F above freezing to minimize ice build-up on the condenser heat transfer surfaces. A lower allowable temperature at station 3 would reduce the amount of air required to cool equipment and condition the cockpit. This lower air flow would reduce the amount of energy extracted from the propulsion system, resulting in lower fuel consumption for the same mission.
Table 1. Condenser Operating Conditions for Typical High Pressure Water Separator Configuration
Station Flow Pressure Temp Humidity
(ppm) (psia) (F) (grains/lbm dry air)
1 62.2 90.8 93 175
2 236.4 44.4 -16.4 14
3 62.2 87.3 35 175
A condenser heat exchanger designed to the performance requirements described in Table 1 is provided for reference. For the cross-flow design, the hot side inlet may have 90 to 95 percent as the main core with 5 to 10 percent reserved for anti-ice flow passages. The aluminum heat exchanger configuration would include a hot side flow length of 16.5 inches, a cold side flow length of 2.15 inches, and a no flow length of 6 inches. The selected fins have a height of 0.25 inch and the fin pitch is 15.6 fins per inch.
Collaboration and/or partnership with an Original Engine Manufacturer (OEM) and/or a Weapon Systems Company (WSC) to gain additional insight of operational requirements (such as heat transfer medium(s), flow rates, temperatures, pressures, heat transfer, life, reliability, structural requirements, etc.) and constraints (size, weight, potential installation locations, attachment methods, material compatibility, etc.) is highly encouraged for this effort. A final presentation at WPAFB will be conducted at the end of the Phase II effort.
PHASE I: Demonstrate the feasibility of proposed innovative concepts to minimize icing in heat exchanger/condenser components that are part of an aircraft turbine engine thermal management system. Identify the anticipated merits of the preferred solution related to thermal performance, manufacturing, installation, durability, and cost.
PHASE II: Fully develop and analyze the selected Phase I solution for a range of heat load/heat sink flow conditions. Develop subscale and/or full-scale hardware to demonstrate the selected approach and establish technology and manufacturing readiness level.
PHASE III DUAL USE APPLICATIONS: The improved heat exchanger concept will have primary applications in advanced military fighter aircraft and possibly future commercial applications.
REFERENCES:
1. Alizadeh et al., "Dynamics of Ice Nucleation on Water Repellent Surfaces," American Chemical Society, Langmuir 2012, Vol. 28, pp. 3180-3186.
2. Warner, John L., US Patent 5,086,622, "Environmental Control System Condensing Cycle," Feb 11, 1992.
KEYWORDS: thermal management, air cycle system, heat exchanger, condenser, ice phobic
AF141-083 TITLE: Smart Aircraft Conceptual Design in Multidisplinary Design Optimization
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