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The Kansas Aviation Research & Technology Growth Initiative uses funds provided by the Department of Commerce and the Kansas Legislature with the goal of strengthening a variety of aircraft industry technologies and marketing them to other areas outside the State of Kansas and the United States. This funding used in this program supports the retention and growth of over 30,400 direct aerospace jobs and 118,894 indirect jobs as a result of the aerospace industry with an average wage of $67,440, a total direct payroll of $2.3 billion and an indirect payroll of $5.2 billion. The Kansas Aviation Research & Technology Growth Initiative will help retain and grow the aviation cluster in Kansas and help Kansas aviation companies remain competitive throughout the 21st century. FY16 Program Year-End Report FY16 work has been completed and funds are 100% expended; the June 30, 2016 financial information is included on page 6 of this report. Several projects will continue into FY17 with State funds awarded into the WSU budget. Repair of Composite Structures (including sandwich) This was a continuation of two existing projects and included the following tasks:

• Surface Modification Methods for Bonded repairs of Composite Structures

• 2-D Repair Element Static and Residual Strength Substantiation (Environmental Effects, Effects of Defects, Impact Damage Resistance (service damage))

• Analytical Model of Scarf Repair of Composite Structures

• Residual Stress Characterization of Scarfed Substrates

• Spirit Aerosystems specific: OOA Laminate Factory Repair Evaluation using IM7/5320-1 (Baseline and damage tolerance properties) Repair Adhesive Fracture Toughness Characterization Chemical characterization of repair epoxy systems

• Textron Aviation specific: Wet Lay-Up Repair Material Allowables using EA9396 and 7781 Glass Fabric Wet Lay-Up Repair Material Equivalency using EA9396 and T650PW (Lamina and Laminate Equivalency) Wet Lay-Up Repair Material Equivalency using EA9396 and AS4PW (Lamina and Laminate Equivalency

with AS4 fiber) Bonded Composite Repair Operator Equivalency

• Bombardier: Composite Repair and Rework evaluation on monolithic and sandwich substrates Screening of adhesive systems for repair using a room temperature OOA storage prepreg

This project was continued into the FY17 program. Electromagnetic Characterization of Composite Fuselages This project continued to develop and validate analytical tools to predict the indirect effects of lightning. This tool can now be used to design and optimize structure and installations. Work now is progressing into developing better tests and approaches for certification. This work although developed for composite structures is directly applicable to metallic structures as well. As the project continues a change in the name is suggested. “Computational Analysis of Indirect Lightning Effects and HIRF” In prior years, we have successfully established methodology that provides a simple but accurate means for determining IEL and have published design handbooks with the information. These have been applied to the analysis and testing of small laboratory test articles and small-business jet fuselage shells. Modeling took on the extreme complexity of modeling actual aircraft installations and is looking to validate simplifications where the same degree of accuracy can be attained with considerably less effort. The continuation effort needs to expand the methodology to full aircraft testing where tools and a data base can be established. This effort needs to continue to full complexity flight-ready aircraft, and medium/large business jet aircraft. The importance of

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this will be strongly evident this coming year as NIAR assists in the actual testing/certification of Indirect Effects and HIRF on an aircraft that is currently in the development/certification stage. It is the goal of this project to greatly simplify the certification process and provide better predictability (less program risk) of IEL/HIRF protection and certification schemes. This project was not continued into FY17. Effects of Manufacturing Defects on Composites Materials (NDI Development)

• Continue CT comparison of porosity levels relative to acid digestion and photomicrocraphs

• Evaluate fastener head pull-thru with 2 – 3 levels of porosity and voids, thin and thick laminates, 2 fastener diameters, RTD and ETW, Hexcel 8552 material

• Cyclic evaluation of fastener head pull-thru, Hexcel 8552 material

• Static and cyclic tests, TAI and CAI with voids, Hexcel 8552 material This project was continued into FY17. Development of Fuel Tank Lightning Protection Design Handbook

– Construction of a full-scale wing model structure and test site – Procurement of specialized characterization equipment for capturing the current, voltage, and

thermal effects – Procurement of software

• 1. Completion of Phase 1: – Construction/calibration of scaled-down lightning generator: June 2015 – Fastener testing for the Industry Database: September 2015 – Publishing of "Metal Fuel Tank Sparking Threshold Database of Nominal and Fault Fastener

Installations”: December 2015 • 2. Beginning Phase 2:

– Development of computational design tool for mapping of coupled transients: July 2015 – Full-scale wing structure lightning testing: March 2016

This project was continued into FY17. Damage Growth of Fluid ingression in Sandwich Panels Develop finite element analysis (FEA) techniques to investigate fatigue disbond initiation and growth of fluid-ingressed sandwich structures subjected to ground-air-ground (GAG) and in-plane loading; use of single-cantilever beam (SCB) test data and mesh-independent (xFEM) modeling techniques for structural modeling. 1. Develop a standardized test methodology to characterize fatigue disbond initiation and growth of internally

pressurized (simulating pressure differential at high altitudes) sandwich structures with large (facesheet-

to-core) disbonds; validate FEA for combined GAG and in-plane load scenarios.

2. Improve the current (pressure and load cycling) test setup to include freeze-thaw cycling.

The project was continued into FY17.

Aerodynamics and CFD Complete Computation Fluid Dynamic (CFD) analysis of the Walter H. Beech Wind Tunnel test section area and expand into SC(2)0414 airfoil analysis with flap and angle of attack settings.

• Gather additional wind tunnel flow survey data to support CFD needs as arise and complete empty test

section flow survey to support CFD and experimental analyses.

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• Procure new pressure scanning equipment to replace existing aged system to ensure current and future

pressure measurement needs for the KART community.

• Design and fabricate new robotic two-dimensional probe traverse system for the test section of the Beech Wind Tunnel to support flow survey needs and accurate off-surface measurements for the KART community.

This project was not continued into FY17. Utilization of Aramis for 3D Strain Mapping This project investigated and reviewed the capabilities of Photogrammetry techniques for potential use for NDI and strain mappings of large scale aircraft structures with the goals of developing a robust setup and software parameters and creating a standard procedure for digital image correlation measurements and analysis. This project was not continued into FY17. EU Material Targets – REACH Compliance

• Continue testing/monitoring/evaluating FY15 materials in test � Corrosion, Weathering, Electrochemical Impedance, Etc.

• Continue industry review of new technologies for chrome replacement

• Test new technologies for chrome replacement � UV Cure pretreatment and paint systems � Pretreatment/Primer technologies

• Inhibispheres

• WSU(NIAR) innovative technologies (sol gel with inhibitors) � E-Coat primer REACH compliance research

This project was continued into FY17. Evaluation of Prepregs and Sensors for Repair Applications

(1) “ Evaluation of a Room Temperature storage OOA prepreg for Repair Application”. This would be a continuation of the discrete sensor program.

The following tasks were addressed: 1. 3 batch qualification of the Henkel Benzoxizine prepreg material 2. Limited aging studies using Rhealogy, DSC, DMA, Tg, SBS, OHC at 2 month intervals 3. Compatibility studies with popular epoxy systems ( 5320-1EO)

This project was not continued into FY17. Foundations for Composite Fuselage Repair Methods 1. Complete fatigue testing of bolted repairs to evaluate the damage containment and validate the finite

element analysis predictions of strain energy release rate and onset of damage propagation.

2. Develop a thermoelastic stress analysis technique with microbolometer to detect hotspots near

bonded/bolted repairs, notches, fastener holes, etc., during fatigue cycling of elements to full-scale

structures; investigate the potential for automation using robotics and 3D image reconstruction for refined

fatigue analysis.

3. Develop in-situ process monitoring and structural health monitoring techniques for composite repairs

using embedded optical fiber sensors.

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This project was continued into FY17. Simulate and Predict Failure Strengths and Allowables Development Process of Composites 1. Develop a procedure (software package) to calibrate constituent properties for predicting strength

predictions for new materials and to generate material allowables by automating simulations.

(incorporating variability of fiber/matrix properties, process- and production-induced variability).

2. Develop a user-defined material subroutine (UMAT in ABAQUS) for progressive damage modeling (PDM)

by incorporating constituent based failure criteria.

3. Evaluate the predictive capabilities for woven fabric lamina/laminate strength based on representative

volume element (RVE) and constituent properties for PDM and generating allowables through automated

simulations.

This project was not continued into FY17. Infrastructure Three areas were identified to receive funds designated to enhance the NIAR infrastructure: Composites and Advanced Materials, Virtual Reality, and Environmental Test. The Composites and Advanced Materials Laboratory procured equipment and software to enhance lab capabilities. Major purchases included a 40-controller system and additional equipment from MTS for material testing; a TecScan NDT Ultrasonic Gantry System for nondestructive quality testing and raster scanning of large structures and parts; and a Plasmatreat Openair Plasma System for high efficiency plasma cleaning, activation and nano-coating of surfaces. The lab also purchased ASI Datamyte quality management software to improve the institute’s quality control processes. In the Virtual Reality Lab, funds were allocated to custom design, build and install the largest reconfigurable Flex immersive visualization system ever deployed by Mechdyne. The system, called the “CAVE,” is part of the 3DExperience Center, a joint initiative with Dassault Systèmes. The Environmental Test laboratory (ETL) used KART fund relocation services and equipment needed to combine all environmental and electromagnetic test labs in one space, creating a full-service DO-160 test site at Air Capital Flight Line, adjacent to Spirit AeroSystems. Additional expenses included lease negotiation and payment, building modifications and CAM, taxes and insurance, equipment leases, service agreements and repair, a reverse osmosis system and office furniture.

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This project was continued into FY17. Process Certification for Seat and Surrounding Structure Using computer modeling in a building block approach comprised of: software verification, v-ATD calibration, material characterization, subsystem tests, seat system validation and sensitivity analysis. Use of computer simulation will reduce the number of physical tests required by using rational analysis (computer modeling) when possible and physical tests only when necessary. This project was not continued into FY17. Corrosion Detection with Smart Coatings Field reports of corrosion are increasing on aircraft across the industry. Operators tend to feel that the aircraft shouldn’t corrode in the first place - an unrealistic expectation, especially in highly corrosive environments and operational conditions. For the operator generally inclined to only perform the minimum maintenance necessary to care for their aircraft there needs to be a positive means of alerting the operator that immediate action needs to be taken. Smart Coatings provide a means of early detection of potential corrosion by changing colors when exposed. (Smart Coatings have not been developed into a commercial application as of yet. Only scientific research has been conducted.) This project was continued into FY17. Development of Load Enhancement Factors for Composite Structures Lower level Laminate test data is needed to provide an accurate scatter analysis and to assess the ability of a

structure to sustain the required mechanical loads without failure and is required to establish the design

allowables in addition to the load enhancement and life enhancement factors essential to structural

qualification. Laminate tests are necessary to verify the models and criteria that use lamina stiffness and

strength inputs laminate test data is needed to develop empirical trends. Recommended laminate tests will

cover generic laminate layups that represent the M530 design space. The material forms that will be tested for

these generic laminates include plain weave and unidirectional tape. In addition, sandwich specimens will be

tested to provide honeycomb properties to be used in the design and to verify failure criteria for sandwich

failure modes.

This project was continued into FY17. Non-Destructive Joint Strength for Bonded Structures The aerospace industry desires to have fully bonded structure with minimum or no fasteners. Currently the

state of the art of Non-destructive Inspection (NDI) is not able to discern the strength of the bondline. NDI can

find a bad bond but cannot prove that a bond is good. Regulatory rules require the assumption that bonded

structure must be shown adequate for limit loads assuming that any individual bonded connection has been

separated. If a reliable means of inspecting the bond line to evaluate the joint strength and confirm that there

is no “kissing bond” can be developed it would enable the certification of fully bonded structure without having

to use fasteners as disbond arrestment features.

This project was continued into FY17.

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Static, Fatigue and Damage Tolerance Qualifications of Additive Manufactured Specimens Manufacture a number of representative metallic specimens by both Power-bed and Wirefeed ALM processes varying the associated manufacturing parameters. Assess the damage tolerance and fatigue characteristics of the resulting samples to understand how they vary as a function of the ALM process parameters. This project was not continued into FY17. Deferred Severity Spectrum Validation Supplement Dr. Seneviratne’s on-going KART work with FAA research. Further funding to investigate failure modes and crack growth (micro-CT and analysis). Feasibility study of Uniform load vs. Deferred severity spectrum for Hybrid make ups (Metallic and Composite). This project was not continued into FY17. Material Characteristics of 3D Non-Metallic Reinforced Materials Current non-metallic materials used in 3D printing don’t meet mechanical properties or performance requirements for many aerospace structural applications. To evaluate the potential for reinforced 3D printed non-metallic materials, preliminary mechanical property data is needed. Data for comparison of properties to existing qualified materials such as reinforced nylons, Nomex or fiberglass is of primary interest. This project was not continued into FY17.

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NIAR

KART Program

FY16 Cost Share

Capital Assets

Reporting Period: Qtr-3: 4/1/16 to 6/30/16

KART NIAR

FY16 Proposed Total Actual FY16 to

Cost Match Actual FY16 Proposed

NIAR Labs Budget Quarter-1 Quarter-2 Quarter-3 Quarter-4 Cost Match Cost Match

Environmental Test Lab 6,000.00$ 2,117.08$ 14,857.66$ 57,960.94$ 22,599.18$ 97,534.86$ 91,534.86$

Composites & Structures 200,000.00 71,020.08 30,350.15 42,429.86 31,685.96 175,486.05 (24,513.95)

CAD/CAM 10,500.00 5,350.00 124.00 632.00 2,262.00 8,368.00 (2,132.00)

Crash Dynamics Lab 1,000.00 75,269.06 13,974.20 4,028.41 3,905.04 97,176.71 96,176.71

Full Scale Structural Test Lab 200,000.00 3,356.04 1,403.40 16,892.31 2,293.50 23,945.25 (176,054.75)

Computational Mechanics 5,000.00 21,386.45 50.00 22,515.44 37,265.97 81,217.86 76,217.86

Wind Tunnel 10,000.00 0.00 1,107.64 0.00 6,569.50 7,677.14 (2,322.86)

Metrology Lab 7,500.00 10,325.18 0.00 0.00 0.00 10,325.18 2,825.18

Totals 440,000.00$ 188,823.89$ 61,867.05$ 144,458.96$ 106,581.15$ 501,731.05$ 61,731.05$

Percent of NIAR FY16 Actual Capital Expenses to FY16 KART Budget 42.9% 14.1% 32.8% 24.2% 114.0%

Actual NIAR FY16 Capital Expenses

For KART Cost Match

(See Note-1)

NIARKART ProgramFY16 Cost MatchIndustry Revenue ReceivedReporting Period: 07/01/15 to 06/30/16

KART NIARFY16 Proposed Total Actual FY16 to

KART NIAR Cost Match Actual FY16 Proposed

Matching Funding Category Laboratories Budgets Quarter-1 Quarter-2 Quarter-3 Quarter-4 Cost Match Cost Match

Composite Material Research Composites 850,000.00$ 1,478,951.92$ 775,976.00$ 2,429,286.75$ 1,227,704.00$ 5,911,918.67$ 5,061,918.67$ Advanced Material Characterization ASTEC 1,350,000.00 688,547.53 318,922.00 3,194,574.36 4,177,309.10 8,379,352.99 7,029,352.99 Aerodynamics Walter H. Beech Wind Tunnel 75,000.00 164,438.12 79,600.00 69,944.00 93,769.40 407,751.52 332,751.52 Modeling & Simulation CadCam, CompMech 25,000.00 794,869.21 672,692.49 810,182.59 762,434.87 3,040,179.16 3,015,179.16

Protection from Environmental Effects Environmental Test, Advanced Coating, Aging Aircraft Research, Metrology 450,000.00 651,940.44 1,025,642.24 795,746.87 569,694.00 3,043,023.55 2,593,023.55 Crashworthiness Crash Dynamics 250,000.00 248,150.00 76,850.00 193,587.51 295,326.63 813,914.14 563,914.14

Totals 3,000,000.00$ 4,026,897.22$ 2,949,682.73$ 7,493,322.08$ 7,126,238.00$ 21,596,140.03$ 18,596,140.03$

Percent of NIAR FY16 Actual Revenue to FY16 KART Budget 134.2% 98.3% 249.8% 237.5% 719.8%

Actual NIAR FY16 Industry Revenue Received

For KART Cost Match

WICHITA STATE UNIVERSITY1845 FAIRMOUNT STWICHITA, KS 67260www.wichita.edu