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