June 2015 Welcome to your Digital Edition of Aerospace & Defense Technology Maximizing Thermal Cooling Efficiencies in High-Performance Processors Stand-Off Scanning and Pointing with Risley Prisms Getting It Right with Composites June 2015 Solutions for RF Power Amplifier Test com ensetech. .aerodef www Supplement to NASA Tech Briefs

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Free Info at http://info.hotims.com/55590-873 ➮ Intro Cov ToC + – A ➭ Aerospace & Defense Technology Contents FEATURES ______DEPARTMENTS ______6 Rugged Computing 35 Technology Update 6 Maximizing Thermal Cooling Efficiencies 43 Application Briefs in High Performance Processors 46 New Products 12 Lasers & Optics 49 Advertisers Index 12 Stand-Off Scanning and Pointing with Risley Prisms 50 What’s Online 18 Simulation/Manufacturing ______18 Getting It Right with Composites ON THE COVER 24 Aircraft In an attempt to reduce the noise footprint of aircraft during landing, NASA has expand- 24 Regional and Bizjets Refined and Redefined ed its use of Exa Corp’s PowerFLOW soft- 28 RF & Microwave Technology ware. This image shows the radiated sound field from a business jet with flaps and main 28 Solutions for RF Power Amplifier Test landing gear deployed. To learn more, check 34 Air-Ground Communications System Aims out the What’s Online section on page 50. to Make Flying Safer (Photo courtesy of Exa Corp) 37 Tech Briefs 37 Fabricating Transparent and Stretchable Supercapacitors Based on Wrinkled Graphene Electrodes 38 Modular Exhaust Design and Manufacturing Techniques for Build-to-Order Muffler Systems 40 Silicon Microsphere Fabrication 41 Designing and Fabricating a Multiple-Decade Battery

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espite the continuous devel- opment of new, higher per- forming processors, the thirst Dfor increased embedded com- puting capability remains unquenched. In fact, it seems like Moore’s Law may have slowed when it comes to fre- quency but increased in terms of driv- ing processor core and field program- mable gate array (FPGA) LUTS counts. The previous need for fewer frequency increases has become a need for in- creased core counts, faster front side bus speeds, and greater support chip inte- gration, all of which drive continually rising power requirements. Meeting these ever increasing "compute density escalations" while simultaneously maxi- mizing thermal cooling efficiencies re- quires innovative packaging solutions. The need to increase core counts in Figure 1. Intel®Microprocessor Pin Count Over Time (Credit: Lee Pavelich, Progression of CPU Pin Counts, processor chips and LUTs growth in Scrub Physics blog, September 19, 2011) FPGAs continues to grow at an un- precedented pace. Processor manufac- turers like Intel and AMD continue to integrate functionality and processor core count to achieve greater processor volumetric efficiency. FPGA suppliers like Xilinx and Altera that dominate 90% of the FPGA market are offering larger LUTs-size FPGAs that appeal to embedded computing engineers, but come at a higher thermal management cost. This thermal management chal- lenge is usually left to the end of the design process when engineers start to ask, “How will we cool these new chip densities?”

Size Matters Silicon chips continue to evolve. Fig- Figure 2 (left to right). Intel "Arrandale" mobile-class processor, Intel "Haswell" server-class processor with ure 1 articulates how the ball grid array integrated heat sink. (Images courtesy of Intel Corporation)

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Figure 3 (left to right). Thermal scans of mobile-class, server-class and FPGA chips.

(BGA) ball quantities of server and mo- bile-class chips have continued to grow in package size as functionality is inte- grated into the processor or scaled into the FPGAs. The portable device market requires a smaller volumetric approach and a cooling demand driven by size, weight and power (SWaP). Handheld devices, tablets, and laptops require maximum cooling in a very small environment. Server-class chips, however, use a differ- ent approach. Figure 2 shows a mobile- class processor and a server-class processor that offers a built-in heat spreader to aid in the mass transfer of thermal energy. Each of these chips requires a differ- ent approach to dealing with this chal- lenge. The smaller device demands an approach that controls the distribution of energy in a manner that does not add weight. The server-class chips are driv- ing larger BGA ball counts and control- ling the thermal heat spread of the chip with copper surfaces and volume to mass transfer energy to server-designed Figure 4. Mercury's 6U OpenVPX payload cards may be packaged in a variety of standards-compatible heat sinks. The size and weight is signif- cooling options without modification. icantly different. increase in size and carry a non-linear square inch is no longer a sensible Thermal Densities — The Hidden thermal distribution in thermal energy measure for linearly analyzing these Variables heat flux. challenges. When sophisticated compu- When looking at these very different Figure 3 shows some of the enormous tational fluid dynamic (CFD) software technologies in silicon-based chips and challenges present in all three silicon tools like Flotherm, Ice Pack, or others their ever-shrinking lithography imple- technologies. The FLIR camera analysis are utilized, linear energy distribution is mentations, one attribute is extremely shows that there are significant differ- not observed. Thermal energy density consistent. As functionality and capa- ences in the thermal heat generation in and the ability to mass transfer the con- bilities are scaled into the chips, they the silicon. This means that watts per centrated heat is becoming a thermal

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Figure 5. Thermal Resistance Comparison, Air Flow-By™ (AFB) vs. Conduction Cooled (CC). analyst’s "Disneyland", where copper or ground radar, a mobile vehicle, a f) VITA 48.6 is an open standard for liq- diamonds are preferred due to their manned aircraft, or an unmanned aerial uid cooling. conductivity. The weight or costs of vehicle (UAV) need significantly differ- g) VITA 48.7 supports Air Flow-By™ these technology implementations are ent cooling solutions. An agnostic ap- cooling. outside the scope of this article. So, the proach allows affordable rugged VPX h) VITA 48.8 …What will it be? images shown in Figure 3 illustrate how cooling solutions to be used in each of As a final example, Figure 5 shows the some of these chips require a new ap- these very different environments, effective mathematical solution be- proach to cooling to help absorb these while also saving precious design, devel- tween Mercury's VITA 48.7 Air Flow- highly concentrated energy loads. opment and deployment time. By™ cooling and VITA 48.2 conduction cooling technologies. Agnostic Cooling Open Standards, VITA and Each of these cooling technologies One example of solving this outstand- Standardized Module Cooling has a direct impact on reliability ing thermal energy non-linear challenge It’s here where the VMEbus Industry through temperature impact and its as- was developed by engineers at Mercury Trade Association (VITA) has really em- sociated direct variable of Coefficient Systems. As shown in Figure 4, Mercury braced cooling agnostics. VITA contin- of Thermal Expansion (CTE) impacts. developed a 6U OpenVPX design ap- ues to drive standardized cooling As the power levels, thermal densities, proach, utilizing a standardized and technologies into VPX computational and concentrated heat fluxes drive em- scalable approach to VPX open standard cooling to support these requirements. bedded systems forward, companies cooling, and a common printed circuit Below are some examples: like Mercury Systems are driving math- board assembly across each different a) VITA 48.1 supports air cooling. ematical high reliability cooling solu- type of cooling technology. b) VITA 48.2 supports conduction tions to meet these ever increasing de- This approach affords engineers the cooling. mands. ability to solve these complex thermal c) VITA 48.3 is an open unfinished stan- This article was written by Darryl density challenges in various environ- dard for liquid cooling. McKenney, Vice President, Engineering ments, with the same computational ar- d) VITA 48.4 is a developing standard Services Mercury Systems, Inc. (Chelms- chitecture. A VPX solution in a lab envi- for liquid cooling. ford, MA). For more information, visit ronment needs a certain cooling e) VITA 48.5 supports air flow through http://info.hotims.com/55590-500. solution, while a VPX solution in cooling.

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ith the ever increasing their carried axis designs typically result apertures are required. Fast steering threat of improvised explo- in much larger, heavier designs requir- mirrors can provide the necessary re- sive devices, both in the mil- ing more power to drive. Non-carried sponse time and aperture but they are Witary arena and the civilian axis systems (such as galvanometer generally limited to small fields of view. realm, there is a growing demand for scanners) are challenged when large Oftentimes a better solution to these technologies with the ability to detect ex- plosives and their precursors from a safe stand-off. While a wide variety of tech- nologies have been investigated for this application, laser-based spectroscopic techniques designed to detect chemical traces on personnel, vehicles and other objects have garnered a lot of attention. These laser-based techniques include Raman spectroscopy, laser induced break- down spectroscopy (LIBS), diffuse re- flectance spectroscopy (DRS), and photo- thermal spectroscopy (PTS), among others. Laser-based approaches concen- trate a large amount of power on a single target location, which enables reasonable Figure 1. Risley Prism Beam Steering signal-to-noise ratio (SNR) to be obtained 1 despite the ⁄R2 drop-off in return signal strength (where R represents stand-off distance). Regardless of which laser-based spec- troscopic approach is used, explosive detection maps provide more useful in- formation than point sampling ap- proaches. Such a capability is achieved by coupling these laser based spectrom- eters with a scanner. In the interest of adapting these standoff explosive detection technolo- gies to the widest number of applica- tions and platforms, the ideal scanner would be compact, lightweight, low power and vibration insensitive. Fur- ther benefit is achieved with a scanner that can both continuously scan the field of regard to look for potential ex- plosives and then rapidly point to a sus- pected location and confirm the exis- tence of an explosive using high resolution spectroscopic information. Potential approaches include gimbal type mirrors, galvo scanners, fast steer- ing mirrors, and Risley Prism scanners. While gimbal scanners are used for a wide variety of scanning applications, Figure 2. Risley Prism Scanner Opto-Mechanical Arrangement

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scanner requirements is the Risley prism scanner, which can achieve all of the re- Spiral Rosette quirements in a smaller package requir- ing less operating power.

Standoff Trace Explosive Detection A potential real application involves the evaluation of vehicles entering a facil- ity. Trace explosive levels (10’s of μg/cm2) are typically found in fingerprint residues left on a car door handle. A number of requirements exist for an effective stand- off explosive detection system in this ap- plication, including the ability to main- tain a modest vehicle throughput rate (vehicles per hour) as well as the ability to operate both autonomously and with lit- tle cooperation from the entering vehi- cles. From a scanner perspective this re- Figure 3. Sample scan patterns that can be achieved by setting the prism rotation velocities to a constant quires a wide field of coverage; a typical value, resulting in power savings. car door handle is about 25 cm in length and has a separation between handles of Mechanical Arrangement zinc selenide, silicon, and germanium. approximately 1.25 m, which results in A Risley Prism scanner is realized in Additionally, the high refractive index an angular field of 120 degrees. It also re- practice with the optical-mechanical of these materials results in a small quires good spatial resolution – a typical arrangement shown in Figure 2. Hol- prism to achieve a large field of regard: fingerprint size of 5 cm2 at a 0.5 m stand- low core brushless motors are ideal for a 120 deg full angle field of regard can off results in an angular resolution of bet- providing high torque (acceleration), be achieved with a pair of 7.6 deg ter than 5 milliradians. Fast acceleration smooth scanning (electronically con- wedge angle germanium prisms. and scanning capability are also neces- trolled commutation), and low operat- Matching the prism pair angles to sary – at a maximum of 5 seconds to scan ing power since the shaft (i.e. prisms) is within an arc-minute is easily achiev- a vehicle (or 2.5 s per handle with one thin and close to the axis of rotation able with standard optical shop fabri- system for each side of the vehicle), a with a resulting low moment of inertia. cation methods and results in a so- scan velocity of 20 deg/sec results in a In practice, peak powers of 10’s of watts called Nadir error (region about the dwell time per fingerprint area on a han- can be obtained for 25mm and larger dle of 25 ms and is supported by an accel- clear aperture systems that have eration of 20,000 deg/sec2 (negligible full field response times on amount of time to point from handle to the order of 100 millisec- handle of less than 100 ms). Finally, ex- onds. Duplex bearings plosive materials exhibit unique spectral minimize axial play signatures – so-called spectral fingerprints and provide high – in the mid-infrared (MIR) region of the pointing accuracy, spectrum spanning 350 – 4000 cm-1 (ap- which is supported proximately 2.5 – 28 μm), which requires with optical en- optical materials that provide good trans- coder-based position mission in this waveband. sensors to provide high-resolution an- Risley Prism Scanner Design for gular measurement. Explosive Detection For example, 20,000 As shown in Figure 1, two identical count encoders are prisms rotating about a common optic easily obtained in prac- axis comprise a Risley prism pair. Maxi- tice and provide sub- mum deviation occurs when the prisms milliradian level point- are in alignment (a) and no net devia- ing resolution. tion occurs when they are in opposition In the MIR, a number of (c). As a result, any point in the conical material options exist for the Figure 4. field of view can be addressed by an in- prisms that provide high trans- Risley Prism Scanner Assembly termediate angle between the pair. mission and include zinc sulfide, (Photo: OPTRA, Inc.)

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optical axis that cannot be pointed longer integration times, the RP would bining scanning and step-stare opera- within) less than a milliradian. typically be used in a straightforward tion is the ideal approach for a Risley Prism systems can be used in step-stare configuration, tracing out a search/confirm operating scenario. either a steering or scanning configura- predetermined pattern. For techniques Constant prism rotation angles mini- tion, depending on the speed of the with shorter integration time require- mize system power requirements while spectroscopic technique being utilized. ments, the RP can be used in a scan- providing flexible scanning patterns. For spectroscopic techniques requiring ning configuration. Oftentimes com- Figure 3 shows the spiral pattern and rosette patterns that can be achieved in a scanning mode of operation: the spi- ral scan is accomplished by rotating the two prisms in the same direction with a small velocity difference be- tween the prism pair, while the rosette is accomplished by counter-rotating the prisms. Figure 4 shows a Risley Prism assembly that embodies this de- sign. The 50 mm clear aperture system measures 130 mm in diameter by 116 mm long and weighs 2.8 kg. Recently, a standoff DRS trace explosive detec- tion system used a Risley Prism scanner to achieve wide field of coverage in an overall compact package.

Conclusions OurO designerd friendly andd Laser based spectroscopic methods ¾I\MFPIXIGLRSPSK]GERWSPZIP have shown excellent potential for standoff detection of explosive materi- many of your application prob- als. The integration of a scanner with PIQWMRXLIHIWMKRTLEWI the spectrometer can provide wide field of coverage and extend these tra- ditional point sampling systems into two-dimensional field mapping sys- tems. A number of laser scanning sys- tems exist and include Risley Prisms along with gimbal, galvo, and fast scanning mirrors. Risley Prism scan- ning systems can be adapted for a wide variety of spectral ranges, field angles and scanning configurations to opti- mize performance based on the attrib- Dawn’sDawn advanced backplaneackplane utes of the selected spectroscopic ap- proach. Regardless of the specific Contact Dawn to ease topology customizationtion system parameters, the Risley Prism XLIHIWMKRXSTVSHYGXMSR tools now feature OVPXOpenVPX scanner’s inherent combination of transition and reduce Fabric Mapping Modules. large aperture, wide field of regard, HITPS]QIRXXMQIXSIREFPILMKL pointing accuracy, and fast beam de- You need it right. You want Dawn. performance, mission critical systems. flection in a compact opto-mechanical ;IPSSOJSV[EVHXSWTIEOMRK[MXL assembly that requires low-power to you soon. operate, make it uniquely suited for standoff detection applications. This article was written by Craig Schwarze, Principal Systems Engineer, (510) 657-4444 OPTRA, Inc. (Topsfield, MA). For more in- formation, visit http://info.hotims.com/ dawnvme.com 55590-501.

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Bruce Lund LLC Manager Lund and Company Invention, L.L.C.

The LVVWS (Lund Variable Velocity Weapon System) is a less-lethal weapon system. It is capable of adjusting the velocity of a projectile based on the distance to the target in order to have non-lethal impact energy. It uses an infrared range finder system to meter the distance to the target. It can launch up to three projectiles per second to a distance of 400 meters. The weapon uses a combustible gas to launch the projectiles — in many ways it is similar to a combustion engine.

“Entering the contest attracted interest that ultimately led to a SBIR contract to develop our technology into a less-lethal weapon system,” said Bruce Lund, LLC Manager, Lund and Company Invention, L.L.C.

Will you be next? THE

Your future starts here: www.createthefuturecontest.com DESIGN CONTEST 2015

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SPONSORS SPONSORS ➮ Intro Cov ToC + – A ➭ Getting It A composite wing spar undergoing inspection at GKN Aerospace. CAE and DFM simulation techniques are aimed at increasing the speed of manufacturing such Right with components. Composites With composites now a mainstay in most new aircraft designs, the engineering emphasis has switched from understanding if they work to thinking through the most efficient way to manufacture them, such as using design- for-manufacturing software. by Bruce Morey

omposite design and analysis is material type, fiber orientation, stack- Composites Design, Composite a highly integrated activity,” up order, balance, symmetry, drop-offs, Constraints said Chris Gear, Chief Technol- splices, and darts. John O’Connor, Director, Product and Cogy Officer & Senior Technical “DFM is a very important aspect on Market Strategy for Siemens PLM, “Fellow for GKN Aerospace. He noted that any composite design, where the manu- provider of the Fibersim tool for design how composite material is placed, how it facturing process and materials used with composites, noted that there are moves, how it cures, and the quality and will drive the final design solution and three areas where engineers can improve conformance of the product are all inter- are key to meeting our internal require- production rates for composites. One is related. All of these factors are consid- ments on weight, costs, and robustness to improve at the point of production it- ered in the final release of the data for of product,” said Gear. self, with faster machines or better tools. manufacturing, according to him, aided He explained that in the early stages The second is asking how to modify a by design-for-manufacturing (DFM). of a design, GKN will use their own or a design for faster manufacturing. Complicating manufacturing opti- customer’s design methods for compos- “The third step is the furthest upstream mization is the very nature of advanced ites within GKN’s own CAE toolset. This and that is how to optimize the design composites, requiring a unique design is to ensure they characterize and simu- for both its purpose, for example least process, unlike isotropic, homogenous late how the material will lay down into weight and maximum strength, while in- metal. Controlling fiber orientation and GKN’s double curvature tools, identify- corporating manufacturing constraints to number of layers of fiber embedded in a ing “hot spots where extra care is produce it as quickly as possible,” he said. plastic matrix is vital for its perform- needed in manufacturing and pinpoint An important element in this design ance. Initial CAD definitions that spec- where we need to validate an area that process, according to O’Connor, is to in- ify the outer and/or inner mold lines of is beyond the limitations of our existing corporate in the process the automated the part require further definition of methods,” he said. tool used to make the part, for example automated fiber placement (AFP) versus automated tape laying (ATL). Optimizing material also reduces weight. That was a goal of the new Multi- ply design feature in their latest Fibersim release. Unlike traditional ply-, zone-, or grid-based methods, the engineer places independent reinforcement regions on top of other regions, eliminating tedious zone or grid redefinition. With this Multi-ply approach, the design is updat- able between geometry and associated ply definitions, eliminating rework. “Multi-ply makes it easier and quicker to define a design, maintaining commu- nication between analysis and re- design,” he said. The unique workflow for advanced composites parts is different from metals, yet the end result must According to O'Connor, the Multi-ply remain the same—a part that meets the specification for the lowest cost. (Siemens PLM) function was developed through work-

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Free Info at http://info.hotims.com/555- ➮ Intro Cov ToC + – A ➭ Simulation/Manufacturing

ing with Siemens’ automotive cus- bench set of tools for designing and an- loop,” she said. While developed for the tomers. “The traditional zone- or grid- alyzing composite structures. automotive market, it provides a useful based design approaches were more She agrees that when it comes to help- tool to aerospace users as well. than automotive needed. But once our ing aerospace increase production rates, In fact, there are plenty of synergy op- aerospace customers saw [this feature], lessons learned from automotive will be portunities as composites and advanced they knew they could use it to their ad- a powerful tool. “One example of that is composites become more popular in vantage.” He predicts more automotive our new CATIA Composites Braiding many applications. For example, Richard- to aerospace spillover as the industry Designer tool,” she said, developed with son expects government funding of insti- continues to emphasize rate. a major European automotive OEM. tutes such as the Institute for Advanced “We need to ensure there is no dis- “With this, we simulate the actual Composites Manufacturing Innovation connect between the design engineer, braiding machine,” including parame- (IACMI), of which Dassault Systèmes is a the manufacturing engineer, and the ters like mandrel speed, carrier rotation, charter member, to also advance tools for shop floor,” said Rani Richardson, Com- and orientation. “We can do this all in better design for manufacture. posites Consultant for Dassault Sys- the design phase before we pass it to “Industries such as automotive, wind tèmes, providers of a full suite of Prod- CAE simulation. We are designing prop- energy, or compressed gas storage have uct Lifecycle Management (PLM) erly right from the start rather than the same goal [as aerospace] – develop software as well as the Composite Work- having to go through that iteration tools for building quality, robust com-

Siemens Fibersim Multi-ply combines a ply-based methodology with a zone-based methodology to Using software to tweak designs for best manufacturing is the goal of software like this from Coriolis. In assure a robust workflow accommodates changes this case, it adjusts ply contours to fill material strips most efficiently, creating faster, lighter designs as in design more easily. shown in this before and after picture.

20 www.aerodefensetech.com Aerospace & Defense Technology, June 2015 ➮ Intro Cov ToC + – A ➭ PALAIS DES CONGRÈS DE PARIS, FRANCE EUROPEAN MICROWAVE WEEK 2015 EuMW 2015 6 - 11 SEPTEMBER 2015 PALAIS DES CONGRÈS, PARIS, FRANCE FREEDOM THROUGH MICROWAVES 6 - 11 SEPTEMBER 2015 EUROPE’S PREMIER MICROWAVE, RF, WIRELESS AND RADAR EVENT

THE CONFERENCES (6 - 11 SEPTEMBER) s%UROPEAN-ICROWAVE)NTEGRATED#IRCUITS#ONFERENCE%U-)# 7th – 8th September 2015 s%UROPEAN-ICROWAVE#ONFERENCE%U-# THnTH3EPTEMBER s%UROPEAN2ADAR#ONFERENCE%U2!$ THnTH3EPTEMBER s0LUS7ORKSHOPSAND3HORT#OURSES&ROMTH3EPTEMBER s)NADDITION%U-7WILLINCLUDETHE@$EFENCE 3ECURITYAND3PACE&ORUM DISCOUNTED CONFERENCE RATES Discounted rates are available up to and including 6th August 2015. Register NOW and SAVE! THE FREE EXHIBITION (8 – 10 SEPTEMBER) %.4294/4(%%8()")4)/.)3&2%%
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posite parts faster and cheaper,” she tion or lack of chemical bonding that said. The materials and resins may be a will affect the lifecycle performance.” Design for little different, and certainly crashwor- Manufacturability thiness means different things between Machines and Design autos and airplanes, but the basic tools Richardson also noted that, with the Focus of July Webcast will be the same. increased emphasis in aerospace on Aerospace programs aren’t neces- An especially interesting new devel- DFM that a number of machine tool sarily unique in the need to minimize opment in CAE simulation is Dassault builders are working more closely with complexity and reduce overall part pro- Systèmes 2014 acquisition of Accelrys, software providers like Dassault Sys- duction cost, just as they aren’t unique now known as the Biovia brand within tèmes. Current partners include Fives, in the tendency toward cost overruns Dassault Systèmes. This software models Ingersoll Machine Tool, Mtorres, and and program delays. This webcast will molecular formation of resins and the Coriolis. This is important because how look at some processes, tools, and tech- resin curing cycle through chemical ki- a machine operates is best incorporated niques being used by engineers netics simulation. Optimizing the in the design for maximum manufac- throughout the industry to maximize chemistry through design of the plastics turing efficiency. the communication and collaboration used to bind composites could mean The final product of a design process skills between design and manufactur- ing so that better decisions are made stronger materials, and faster curing cy- involves using an advanced composites early in any development programs, no cles and manufacturing efficiencies. machine, such as an ATL or AFP, to matter how small the component, or “That brings a whole new element to make the part. Fives makes a number of how big the aircraft. our design for manufacturing that we such devices and provides software – During a one-hour free webcast on are starting to incorporate,” said the Advanced Composites Environment July 23, participants will be part of the Richardson. “We can predict delamina- Suite – that takes input such as CAD discussion with industry experts about recent advances engineers are utilizing to bring programs to fruition, and on time. Webcast attendees will be invited to interact with the experts during the Q&A portion of the webcast. To regis- ter, visit www.sae.org/webcasts.

models and ply contours from the CATIA Composites Designer or Siemens Fibersim and produces machine instruc- tions that are used to build the part.

Companies like Coriolis Software are advancing the use of automatic design optimization to balance the “The engineer designing the part competing objectives of stress, engineering, and manufacturing constraints. The Coriolis optimization needs to know something about how framework captures design constraints, priorities, and rates solutions using criteria from the user. the machine will make the part,” said Robert Harper, Director, Technical Sales, Fives Cincinnati. Parameters include material width, minimum steering ra- dius for that width, material thickness, and the number of layers the machine can place. “They need to know these and limitations, such as minimum coarse length in an AFP and minimum cut length of the material, so when the engineer creates the design the machine is capable of creating that part. They need to know the machine’s capabilities in localized contours as well.” He said that they supply data to com- panies like Dassault Systèmes, such as minimum tow length, so that the de- signer has access to that in the CATIA Composites Workbench. While having access to such data is useful, educating CATIA Composites Braiding Designer is a role-based application, providing advanced braiding fiber simu- design engineers directly is just as im- lation. (Dassault Systèmes) portant. “Making parts using advanced

22 www.aerodefensetech.com Aerospace & Defense Technology, June 2015 ➮ Intro Cov ToC + – A ➭ Simulation/Manufacturing

composites is fairly new, especially com- simulation techniques available today. fectively. “[It] is assisting us in gaining a pared with the 100 years of experience “As more automation of manufacturing comprehensive understanding of our in metal cutting.” is being brought into our factories we products before we enter full scale pro- Coriolis Software also provides soft- need better methods to simulate and de- duction," he said. "More importantly, ware packages that specialize in com- fine our products in shorter lead times.” DFM has significantly reduced non-con- posites design and offline programming Using a DFM approach is helping formances and lowered waste in our solutions for various machines. The par- GKN establish how to do this more ef- manufacturing processes.” ent, Coriolis Composites, specializes in building AFP based on 6-axis robots for manufacturing composite parts. To pro- gram their own robots, they needed to develop software that could produce an optimized design for the system and produce a program off-line for the robot itself. The now independent Coriolis Software extended their capabilities to generalized CNC composite machines. The output from the company’s soft- ware is a design of the part optimized for manufacturing and a machine pro- gram that produces that part. They use FEM modeling to ensure the final model meets strength requirements. They offer a package integrated into CATIA Composites Designer, or a stand- alone package that can import data from either CATIA Composites Designer or Siemens Fibersim. “The objective of our software is to fill the ply contours with material strips in the most efficient way,” said Olivier Munaux, Software Manager, Coriolis Software. “An enriched data model serves the basis for running fast simula- tions at an early stage in the design process, giving engineers the opportu- nity to get feedback from the 'as built' as soon as possible.” This is a multi-objective optimization problem when accounting for all of the design drivers including cost, weight, and cycle time. Coriolis employs a genetic al- gorithm as an optimization engine, em- bedded in a framework to automate the process. Munaux believes his customers want built-in tools that are easy to use, that incorporate requirements and geom- etry, and compute a solution that is the best compromise between all of the com- peting requirements. “The aircraft industry recognizes both the benefits and the need [of simulation optimization] as aircraft production rates have increased,” said GKN's Gear. He believes the challenge relates to over- reliance on testing to validate solutions as opposed to using the full potential of

Aerospace & Defense Technology, June 2015 Free Info at http://info.hotims.com/55590-885 23 ➮ Intro Cov ToC + – A ➭ Bombardier Global 5000

Regional and Bizjets Refined and Redefined New engines power the difference. by Richard Gardner

here is definitely a degree of overlap in the regional and business jet sectors, both in Tterms of airframes and the en- gines that power them. At the high end of the market are aircraft such as the Boeing 737 BBJ and Airbus A319 Corpo- rate Jet, which typically carry up to a dozen VIP passengers in spacious lux- ury, but which in airline service carry around 130 passengers. Just below this in size come 70-100 seat regional jets from Bombardier and Embraer that are also available in VIP long-range executive jet formats. These are increasingly popular with heads of state and government departments as well as large corporate companies. Top-end purpose-built executive jets, Bombardier Challenger 350 such as the Dassault Falcon 5X, Bom- bardier Global 8000, Gulfstream G600, at a steady pace, but because customer structures and materials, and propul- and Cessna Citation X+, offer non-stop in- demand is relatively stable once again sion. So while the short-haul regional tercontinental connectivity and have de- (after a downturn in 2008) and require- jet aircraft and business jets may look veloped a premium market of their own, ments predictable, technology advances very similar in configuration and gen- an enviable niche where operators seem are following an evolutionary pattern, eral appearance to those of three largely immune to financial constraints. rather than offering any radical changes decades ago, beneath the surface they Smaller 30-50 seat jets provide regional in direction. incorporate the benefits of computer- shuttle services between major city hubs, aided design and manufacturing, as well as essential connections on lightly P&W’s Presence greatly enhanced aerodynamics with used routes, and are also available in well- What is driving product and perform- lower drag, new levels of connectivity appointed business jet versions. ance improvements, and thus sales, in and crew situational awareness, new Competition is intense right across these markets centers essentially in composite structures, and, now fast be- the sector, with new models emerging three areas—digital avionics, advanced coming the primary area of interest,

24 www.aerodefensetech.com Aerospace & Defense Technology, June 2015 ➮ Intro Cov ToC + – A ➭ Aircraft

highly efficient and environmentally friendly new-generation jet engines. Although global oil prices have crashed dramatically in recent times, improved fuel economy still has a direct and immediate beneficial impact on the bottom line for operators. There may be few all-new aircraft entering the regional market, such as the Mitsubishi MRJ fam- ily, but there is no shortage of new busi- ness jets. Many operators opt to order well-established and supported aircraft designs, such as the A319/320 and Em- braer EMB-170/190 families, that have been re-cast in new, attractively up- graded, re-engined versions, powered by the latest high-tech turbofans. At the top end of this market the new engines, such as the Pratt & Whitney Pure Power GTF (geared turbofan) and Snecma/GE CFM Leap, have been opti- mized, initially, as replacements for ex- isting engines such as the CFM-56 and Embraer E195 IAE V2500. The P&W GTF family has proven to be very scalable, expanding its range of thrust options from a maxi- mum of 35,000 lb for airline use, down to 16,000 lb for ultra-long-range execu- tive jets. The design philosophy for this engine is to introduce a speed-reduction gear- box between the low-pressure (LP) tur- bine and the fan, combined with a faster-running LP compressor. This opti- mization of the rotational rates of the moving parts is set to greatly reduce fuel burn and noise levels in aircraft that adopt it. Reductions in the noise foot- print have reached 75%, which equates to 20 dB below today’s strictest stan- dards, according to P&W. P&W also claims that fuel savings Cessna Citation-X compared to today’s generation of simi- lar thrust turbofans offer improvements for many years with the first flight now soon follow the MRJ’s planned entry of at least 15%. Reductions of 20% are two years late. As a result, its early po- into service. already in prospect, and could eventu- tential for market leadership, introduc- P&W is already looking ahead at a set ally go as high as 30% with further de- ing the GTF engine, has been eroded by of aerodynamic enhancements for the velopment, which might include higher the emergence of the second-generation GTF that will increase efficiency and bypass ratios, new materials, and new E2 series of regional jets, seating be- power to meet customer expectations combustor technologies. By the end of tween 75 and 130 passengers, which well into the next decade. 2014, the GTF had completed over will also be fitted with the Pure Power Also from P&W, and destined to be 26,500 cycles of testing, and the type engine. With a four figure sales tally for manufactured by P&WC in Canada, is has been initially certified for use on the the existing E-series jetliners and a well- the new PW800 that is based on the Airbus A320neo and the all-new Bom- established market position, it is little core of the Pure Power GTF, but without bardier C Series, with the MRJ and Em- surprise that new E2 models have a fan gear-drive system. It is intended to braer E2 series regional jets following. quickly overtaken the MRJ order book, cover a wide thrust range of between The MRJ program has been underway and the Brazilian program is likely to 10,000 lb and 20,000 lb and received a

Aerospace & Defense Technology, June 2015 www.aerodefensetech.com 25 ➮ Intro Cov ToC + – A ➭ Aircraft

bizjet market Snecma finds itself watch- ing its CFM-56 partner develop its own product in the form of GE’s new Pass- port engine. This has a higher thrust than the Silvercrest and is currently being developed in the 18,000-20,000 lb thrust range, for use aboard the new ultra-long range, large cabin, Bom- bardier Global Express variants, the Global 7000 and Global 8000. A Passport development engine flew for the first time aboard GE’s Boeing 747 flying test-bed aircraft in January and validated items such as the aircraft systems and instrument functionality, before undertaking further tests and evaluations that will lead up to certifica- tion later this year. After this it can be- come a key element in the certification program for the Global 7000, which is due for delivery in 2016, followed a year P&W geared turbofan demonstrator final assembly. later by the Global 8000. A new Pass- port assembly facility is being prepared bizjet market crashed following the eco- at its Strother manufacturing and sup- nomic downturn in 2008 was regarded port plant in Kansas. by many as a gamble, especially without a suitable launch aircraft signed up at Bizjets Taking Off the time, but the timing has proven to Independent market studies suggest be ideal for these two new aircraft as it that the total business jet market over now gives them a performance margin the next decade alone may top 10,000 over rivals. As an all-new engine it ben- aircraft, with a value of over $250 bil- efits from recent technology design lion. Nearly 70% of the total bizjet sec- progress in advanced fan design and tor is accounted for in value terms by weight reduction, and it is well-placed the top-end products, each costing be- with a thrust range of between 9500 lb tween $30 and $100 million. At present, and 11,400 lb to evolve into a bigger the market leaders in the large family. cabin/long-range market sector are Snecma, part of the Safran Group, is Gulfstream, Bombardier, and Dassault. P&W GTF fan drive gear system. an equal partner in CFM with GE and Gulfstream has always had a lead in co-produces the CFM-56 turbofan, the ultra-long range business jets and it still boost last year when it was selected to biggest selling commercial jet engine in offers customers the greatest global power the new Gulfstream G500 and history. Sharing manufacture and as- range with the G650ER, which can G600 jets. sembly of CFM-56 engines at facilities carry 16 passengers non-stop over 7500 in the U.S. and France, CFM has been nmi. This extended range version of the Passport to Fly continuously ramping up CFM-56 pro- best-selling G650 is also powered by Taking a big commercial risk almost a duction in the face of its share of a two Rolls-Royce BR725 turbofans and decade ago when it decided to look at a growing and massive 6300 backlog of has a ticket price of around $66 million. completely new turbofan engine sized orders for 737s and A320s. Last year Bombardier has always been a strong around super-mid-size business jets, 1500 CFM-56 engines were built, and player at the high end of the market. France’s Snecma pressed ahead with the this will be increased to 1800 per year Over the years its Challenger 600 series Silvercrest turbofan, which is now in by 2019, by which time the company’s has captured a significant proportion of production for use aboard two of the new Leap engine will be emerging in sales, benefiting from its large cabin vol- newest upmarket bizjets, the Dassault large numbers to power all the 737 Max ume and long range, but its larger Falcon 5X, and the Cessna Citation and some A320neo models. Global Express series (costing between Longitude. Both are in development This has provided enormous experi- $50 and $70 million) has expanded be- and are due to enter service in 2017. ence building and supporting turbofan yond the Global 5000 and newer Global Launching the Silvercrest just as the engines, but for the billionaire dollar 6000 to the two latest models, the

26 www.aerodefensetech.com Aerospace & Defense Technology, June 2015 ➮ Intro Cov ToC + – A ➭ Aircraft

Global 7000 and Global 8000, both to be powered by Passport turbofans, each with 16,500-lb thrust. High speed will be a major feature (cruise at up to Mach 0.9). The large cabin on this pair of air- craft will be 20% larger than on the Global 6000, which will give them an edge on the latest Gulfstream G650ER, combined with a similar ultra-long range of almost 8000 nmi. In Europe, Dassault’s Falcon family goes from strength to strength, incorpo- rating advanced avionics and display systems, fly-by-wire controls, and so- phisticated aerodynamics, with an in- tercontinental range combined with the ability to use relatively short runways with a slow approach speed and steep approach. This opens up the use of many airfields that are inaccessible to other large business or regional jets. Last year Dassault announced its new 8X model, an enlarged version of its pop- ular tri-jet 7X. Due to enter service in Dassault 7X 2016, the 8X will feature a bigger, more spacious cabin and refined wing shape, cluding a flaperon to provide even and is powered by Honeywell TFE731- and will also offer 6450-nmi range. It will shorter and steeper landing perform- 40BR engines. Next step up is the latest be powered by three PW307D engines, ance than the 7X or 8X. upgraded Challenger, the 350, powered each with 6720-lb thrust. But while all size categories are once by Honeywell HTF7350 turbofans. Dassault is also making rapid progress again growing, the superlight/mid-size Cessna is the leading supplier in this with the even more technically ad- market is the biggest in terms of aircraft size category and it has successfully de- vanced 5X. This is an all-new design, numbers. With new aircraft costing be- veloped a product line that offers much with a wider cabin and a range of 5200 tween $13 and $30 million, there are variety, from the Citation Sovereign and nmi, powered by Snecma’s new Silver- executive jets in this size to meet a wide Citation X to the new Latitude, pow- crest engines. It will feature a new range of requirements. At the lighter ered by PW306D engines, and the Lon- digital flight control system with fully end, the latest Learjet 75 from Bom- gitude, powered by Silvercrest engines. integrated moving control services, in- bardier is an upgrade of the model 45, The biggest potential threat to Bom- bardier and Cessna in this sector is com- ing in the shape of the all-new Embraer Legacy 450 and 500 models. Capable of carrying up to 10 passengers, and pow- ered by Honeywell HTF7500E engines, they offer many advanced features, such as fly-by-wire and advanced avion- ics, more common on larger business jets, and bridge the gap neatly between superlight and mid-size models. So, despite all the dire warnings a few years ago that the growth in business aviation was unsustainable, the facts have shown this worry to be un- founded, with more new aircraft ap- pearing on the market every year, and new generation engines helping to make the business case for modern re- placements and upgrades irresistible for Bombardier's Learjet 75 more and more customers.

Aerospace & Defense Technology, June 2015 www.aerodefensetech.com 27 ➮ Intro Cov ToC + – A ➭ Solutions for RF Power Amplifier Test

s wireless mobile devices grow are not uncommon. During RF PA pro- Typically, as test speed increases, re- in capability and complexity, duction test, manufacturers have to deal peatability decreases. Manufacturers the associated growth in with a number of critical issues; namely, must constantly struggle to balance these Apower demand is driving new speed, repeatability, cost, maintainability, issues, while also keeping an eye on cost approaches to battery utilization and and upgradability. Their biggest stress, and maintainability. Addressing the power efficiency. One of the single largest however, comes from trying to balance speed challenge is further complicated by power consumers in a wireless handset is speed and repeatability. the fact that PAs are being manufactured the RF Power Amplifier (PA) and as such, improved efficiency techniques like En- velope Tracking (ET) and Digital Pre-Dis- tortion (DPD) are being increasingly uti- lized. The key implication for test engineers — whether in design, charac- terization, or manufacturing test — is that testing these devices with this addi- tional capability can potentially drive up both test cost and overall test time. This Figure 1. System-level block diagram for a multi-DUT test. The RF PA power servo loop is a key requirement article discusses various approaches to in PA testing and must be performed at each test condition. maximizing test equipment utilization and reducing test times for such compo- nent RF PAs and front-end modules.

The Problem The demand for higher test speed spans from design validation to produc- tion test. As RF PAs support multiple modes, frequency ranges, and modula- Figure 2. Using the power servo loop approach in the tion formats, there is more to test during PXI VSG, amplitude changes can be achieved in less the validation phase. Thousands of tests than 200 µs.

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Free Info at http://info.hotims.com/55590-886 ➮ Intro Cov ToC + – A ➭ RF & Microwave Technology

Figure 3. The fastest technique for performing input power servo and measur- ing ACPR is to use FFT acquisition for both servo and ACPR.

in increasingly higher volumes to meet the demand for more and more wireless mobile devices, and have grown even more complex. Techniques like DPD and envelope tracking are often employed to help linearize the PA and increase its power effi- ciency, but these techniques only add to the testing that’s nec- essary during production, further slowing down the process. With PA manufacturers looking to reduce overall test times from 1.5 seconds to 500 ms or less, these slow-downs are simply no

Free Info at http://info.hotims.com/55590-892 longer acceptable. The Solution The key to addressing the challenges now facing PA valida- tion and manufacturing teams lies in finding a way to increase test speed while maintaining repeatability. Luckily, a number of test system techniques are now available to manufacturers for just such a task. The first technique involves speeding up the PA power servo loop (Figure 1). A power servo loop is essentially a “test and ad- just” process. The engineer sets the RF input power level to the Device-Under-Test (DUT), then checks the RF output of the DUT. If the RF output level is not within the required specifica- tion, the engineer changes the RF input level and checks again. This loop is continued until the correct output power level is achieved. Then, and only then, can the engineer start making measurements on the DUT. Getting this process done fast and allowing the engineer to quickly move on to making measure- ments is a key way to speed the overall RF PA test time. Since power servos are a non-deterministic process, list mode cannot be used to determine the power level difference from step one to step two. Instead, it must be determined in real time. And, because PAs are typically not operated in the linear region of the amplifier, a 3-dB change in input power, for exam- ple, will not equate to a 3-dB change in output power. This is where baseband tuning methods like that available with a PXI vector signal generator (VSG) come in, offering a way to speed up the tuning process and, therefore, the test process itself. The recommended PXI VSG approach for the power servo loop is to set the RF power level to the maximum level required from the source, then use the baseband power level to adjust the power level to the required input level. This is an iterative process that is performed until the output power reaches the re- quired level for testing. The method is fast and accurate, en-

30 Free Info at http://info.hotims.com/55590-893 Aerospace & Defense Technology, June 2015 ➮ Intro Cov ToC + – A ➭ RF & Microwave Technology

ber. The time required for this measure- ment is typically low – around 100 μs of overhead in addition to the acquisition time. In FFT mode, the data is run through a hardware FFT, and the result Figure 4. Using an external trigger with a short waveform is the ideal way to optimize repeatability and is a series of 64 to 512 spectrum bins. test time. The time required to perform the FFT is roughly equivalent to the time it takes abling power servos to converge very GHz, or a PXIe performance VSA, which to perform a single power measure- quickly. In fact, with this baseband tun- operates from 9 kHz to 27 GHz – both ment. Using these two test modes, there ing technology, amplitude changes of up with up to 160MHz analysis bandwidth are three basic methods for performing to 20 dB can be achieved in less than 200 – offer the ideal solution. With out- input power servo and measuring Adja- μs (Figure 2). It can also be used for fre- standing linearity, repeatability, and ab- cent Channel Power Ratio (ACPR). Test quency offsets within the bandwidth of solute amplitude accuracy, power servos times will vary depending on which the generator, making it especially useful can converge faster, thereby reducing method is selected. for measuring multiple channels within PA component test times. Moreover, the 1) Power Acquisition for Servo and a band. PXI VSA can be combined with the PXI ACPR. This method produces fast re- VSG for a fast, compact PA test solution. sults by using the same power acqui- Fast Signal Processing For power measurements, the PXI sition mode for both the servo and Once the power level is set correctly, VSA features two data acquisition ACPR measurement. First, it’s used the need for speed and accuracy modes: power acquisition and FFT (Fast for the servo loop, which normally switches to the analysis hardware. In Fourier Transform). Power acquisition converges between 2 and 3 steps. this case, a PXIe Vector Signal Analyzer mode takes a time record of IQ data and Once it converges, the input power (VSA), which operates from 1 MHz to 6 returns a single integrated power num- and gain are measured. Next, the

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Figure 5. When optimizing a short waveform length, getting too aggressive can actually increase the test time if the waveform is made too short, as shown on the left. Instead, the waveform should be set to just longer than the whole measurement cycle time, which includes the measurement time and processing time, as shown on the right.

ACPR is measured. This is performed form, and does not have to wait for an Since the engineer isn’t actually making 4 to 6 times to measure the 2 or 3 ad- external trigger; however, the measure- measurements during most of the wave- jacent channels. ment itself is often poor due to the sig- form, this is wasted time. 2) Power Acquisition for Servo, FFT for nificant variability throughout the An alternate approach involves short- ACPR. With this approach, the servo waveform. Variations in power level add ening up the waveform by cutting it to loop uses the power acquisition mode to the measurement uncertainty in just longer than the measurement acqui- as above, but the FFT mode is used for power and ACPR measurements. Re- sition time, and always measuring at the power measurements. The engineer peatability can be improved by increas- same point within the waveform. The simply makes one FFT measurement ing the measurement duration, but this test engineer measures at one point in instead of 4 to 6, and from that, cal- increases the test time. the waveform, and the delay to wait for culates the power for all adjacent Another option is to use an external an external trigger is half the total time channels. The method enables faster trigger to start the measurement. In this of the waveform, but since there is a measurements by simply reducing case, repeatability improves because the much shorter waveform, the wait time is the number of measurements needed engineer is always measuring at the significantly reduced. The result is im- to obtain the ACPR data. same time within the waveform, and proved repeatability and significantly 3) FFT Acquisition for Servo and ACPR. there is no variation in modulation sig- faster measurement time (Figure 4). With this approach, the FFT acquisi- nal during the measurement. Unfortu- When using this method, it’s important tion mode is used for both the servo nately, repeatability comes at the ex- to not get too aggressive with reducing and ACPR and because of this, when pense of measurement time. Only one the length of the waveform, otherwise it comes to making power measure- point in the waveform can be measured the next trigger might be missed and the ments, no further measurement for at any given time, and the delay to wait test time would increase. Ideally, to opti- ACPR is required. With no ACPR for an external trigger is, on average, mize waveform length, the waveform measurement necessary, this ap- half the total time of the waveform. should be set to just longer than the en- proach is by far the fastest of the three options (Figure 3).

Optimizing Repeatability and Test Time When it comes to optimizing repeatabil- ity and test time when making power measurements, there are a number of tech- niques available. One technique involves using an immediate trigger to start the measurement. This technique enables fast measurements be- cause the engineer can measure at any Figure 6. Shown here is a PA production test solution configuration with support for ET. This system is useful for testing PAs with time in the wave- ET and for dynamic EVM, commonly used for Wireless LANs to conserve power by turning the device off between packets.

32 www.aerodefensetech.com Aerospace & Defense Technology, June 2015 ➮ Intro Cov ToC + – A ➭ RF & Microwave Technology

tire cycle time, including the measure- turer with additional testing. ET is a and DPD. It also includes hardware ment time and processing time (Figure technique employed to improve the required for RF signal generation, en- 5). With the PXI VSA and VSG, roughly power efficiency of the amplifier by al- velope waveform generation, DUT, 500 to 600 μs is needed in addition to lowing the amplifier’s drain bias to track power, and RFFE control. the acquisition time to achieve the opti- the magnitude of the input signal enve- mum test time. lope. With this technique, a small re- Summary While this method works well for duction in gain enables the amplifier to Reducing validation or manufactur- constant signals like WCDMA and LTE- be more linear, to reach higher peak ing test time while maintaining repeata- FDD, it does not work for bursted powers, and to operate with greater effi- bility, especially in the face of emerging waveforms (e.g., GSM and LTE-TDD). ciency. DPD is a technique often em- technologies like ET and DPD, is ab- For these measurements, the engineer ployed to correct for the PA’s nonlinear- solutely essential to PA manufacturers. must maintain the duty cycle. Meas- ities caused by operating the PA in its Fortunately, this can be accomplished urement time is improved by adjusting region of high Power-Added Efficiency through a combination of real-time sig- the burst length to be slightly longer (PAE). With this technique, gain expan- nal processing, innovative baseband than the acquisition time. The off time sion is achieved, resulting in higher per- tuning technology, FFT acquisitions for is then used for calculations and the forming power amplifiers. Any new power servo and ACPR measurements, PXI VSG setting. tests required as a result of ET or DPD and use of shorter waveforms with an will run counter to engineers’ need to external trigger. Implications of Emerging reduce test time. This article was written by Jan R. Technologies A typical characterization and test Whitacre, Mainstream Wireless Technol- Emerging technologies such as ET solution for testing PAs with ET and ogy Lead, Global Programs Marketing, for and DPD are commonly used to im- DPD is shown in Figure 6. The solu- Keysight Technologies, Santa Rosa, CA. prove PA performance; however, their tion includes waveform generation For more information, visit http:// inclusion further burdens the manufac- software and PA test software for ET info.hotims.com/55590-541.

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Air-Ground Communications System Aims to Make Flying Safer

eliance on old-fashioned radio Rcontact by pilots and vulnerable tracking systems is still high, but satel- lites are set to change sky safety, thanks to international collaboration. The European Space Agency’s Iris pro- gram is looking to satellites to make aviation safer through modern com- munications. Worldwide digital data links via satellite, offering much higher capacity, will become the standard for cockpit crews, with voice communica- tions kept as backup. Iris is part of a much broader push to modernize how air traffic is managed in collaboration with the Single Euro- pean Sky effort of the European Com- mission, Eurocontrol, airport opera- tors, air navigation providers, and aerospace companies. An element of ESA’s Advanced Re- search in Telecommunications Systems (ARTES) program, Iris is developing a new satellite-based air–ground commu- Digital data links via satellite. nication system for Air Traffic Manage- ment (ATM). Controlling flight paths with 4D is Currently, aircraft are tracked by safer and more reliable. To help radar when over land and in coastal achieve this goal, ESA is developing a areas, and flight paths are negotiated new global standard for satcoms that by radio. However, once an aircraft can be adopted worldwide, and is de- heads out over the ocean, ATM is no signing infrastructure to make this longer possible until it reenters conti- service available in Europe. nental airspace. This means that flight To meet safety regulations, aircraft paths are difficult to adjust in response in European airspace fly an extra 42 to adverse weather and other factors, km on average than they would on and wide buffers must be maintained an optimal route, incurring unneces- between aircraft flying in a given sary costs and carbon dioxide emis- Some airlines already use satellite services oceanic corridor. sions. The 4D paths will enable precise Modernization on this scale demands tracking of flights and more efficient and affordability requires that costs be a long-term stepped approach, but it management of traffic. A key benefit kept to a minimum. promises to boost efficiency, capacity, of 4D is that it allows rapid rerout- High-capacity digital data links via and performance. Iris is divided into ing, meaning fewer flight cancella- satellite carrying this information to two phases, in line with Europe’s master tions and delays, and safer air travel – cockpit crews in continental and plan for managing future air traffic. possible partly because all aircraft will oceanic airspace are expected to become First, the Iris Precursor service will be continuously monitored and the norm, with voice communications provide air–ground communications for locations periodically reported to used only for specific operations. While initial 4D flight path control by 2018, control centers. the initial focus will be on Europe, the pinpointing an aircraft in four dimen- Airlines have accepted the need to capabilities developed will open oppor- sions: latitude, longitude, altitude, and switch to digital services, and some tunities for deployment in North Amer- time. Second, by 2028, the Iris long- satellite services are already in use over ica, Asia Pacific, and other regions, term service will enable full 4D manage- ocean airspace. The changes will take where the growth of air traffic is placing ment over airspaces across the globe, some time because manufacturing a strain on ground-based communica- and the data link will be the primary schedules for aircraft are set years in tions networks. means of communications between advance. Existing planes require mod- For more information, visit http:// controllers and cockpit crews. ifications to install the new hardware, info.hotims.com/55590-542.

34 www.aerodefensetech.com Aerospace & Defense Technology, June 2015 ➮ Intro Cov ToC + – A ➭ Technology Update

Altair Optimizes 3D-Printed Structures for Complex, Lightweight Designs ltair expects to better support the Ause of additive manufacturing (AM), or 3D printing, by releasing new OptiStruct solver capabilities for topol- ogy optimization. The company claims this new technology is the first tool de- veloped specifically for designers of lat- tice structures. 3D printing is capable of manufactur- ing hollow shapes with complex exter- nal geometry using lattice structures. OptiStruct now extends topology opti- mization to assist in the efficient blend- ing of solid-lattice structures with smooth transitional material volume, according to Altair. Lattice performance Topology optimization is particularly well-suited for 3D printing because it tends to create free-form, can be studied under tension, compres- organic structures that can be difficult to construct using traditional manufacturing methods. (Altair) sion, shear, flexion, torsion, and fatigue life. The technology provides CAE analyses for optimal and structurally ef- ficient material distribution. Topology optimization is particularly well-suited for 3D printing, according to Altair, because it tends to create free- form, organic structures that can be dif- ficult or impossible to construct using traditional manufacturing methods. “3D printing brings new structural freedom to product design, allowing more complexity in shapes and topol- ogy and the efficient production of cus- tomized products while accelerating the manufacturing process, since no tooling Altair OptiStruct enables designers to identify the best material placement and lattice structures. is needed,” said Uwe Schramm, Chief Technical Officer at Altair. “Topology the best material placement and lattice may need to consider buckling behav- optimization maximizes this design structures, according to Altair. Opti- ior, thermal performance, or dynamic freedom, enabling complex free-form mization identifies where material is characteristics. With OptiStruct, users structure development, seamless indi- needed in a design—and where it is not can manipulate material density based vidual designs, a shorter design process, required—prior to placing and optimiz- upon the result of an optimization and optimal 3D-printed structures.” ing lattice. process, comparing stronger vs. weaker, Altair is working with partners such OptiStruct optimizes lattices in two or solid vs. void vs. lattice designs. as Materialise NV, a Belgian provider of phases. First, it applies standard topol- “OptiStruct’s lattice capability repre- AM software and 3D printing services, ogy optimization, allowing more sents the first step towards integrating to enable more efficient data transfer. porous materials with intermediate den- smart materials with unique properties Lattice structures can contain hundreds sities to exist. Then, the porous zones in products,” said Ming Zhou, Vice Pres- of thousands of lattice cells, proving to are transformed into explicit lattice ident of Software Development at Altair. be a challenge for conventional STL file structures with varying material vol- “Continuing research and development transfer. Software packages like 3-Matic- ume. In the second phase, the dimen- will explore directional behavior and STL from Materialise focus on improve- sions of the lattice cells are optimized. smooth blending of varying lattice cell ments of a given lattice component to The result is a structure with solid parts layouts to take advantage of exotic ma- accommodate the various requirements plus lattice zones with varying volumes terial characteristics that could bring in- of the 3D printing process, creating sup- of material. novation to various applications.” port structures where necessary. Lattice zones could enable the suc- Part of the Altair HyperWorks CAE Instead of simply applying lattice cessful development of products that re- suite, OptiStruct is used for topology, to- structures to existing geometry, Op- quire characteristics beyond just stiff- pography, size, and shape optimization. tiStruct enables the designer to identify ness. Some applications, for example, Ryan Gehm

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MTU Develops New Turbine Blade Material in Record Time TU Aero Engines announced in fewer resources, burn less fuel, and are acting on turbine disks and shafts re- MMarch that its internal experts and cleaner and quieter than today’s engines. quired these components to be made industry partners have jointly developed MTU specialists have been thinking of from heavy nickel alloys to have suffi- a new class of intermetallic, high-tem- ways to tap the immense potential af- cient mass. Thanks to the use of TiAl perature materials for highly stressed en- forded by TiAl-based intermetallic mate- blades, these centrifugal forces are now gine components. Named titanium alu- rials for aero engine applications for much lower. As a result, the disk design minide (TiAl), this new lightweight many years. In terms of mechanical can be optimized for appreciably lighter material is designed for turbine blades properties, it is almost equivalent to the weight, and each reduction in weight and combines the advantages of metallic nickel alloys in use today, although its will assist in improving fuel economy and ceramic materials. density is much lower, but it has a high and CO2 emissions. According to MTU COO, Dr. Rainer melting point and a considerably higher The biggest hurdle that stood in the Martens, “While the introduction of a new creep strength than titanium alloys. way of the use of the lightweight mate- material used to take 20 years or so, we’ve These properties are attributable to the rial in the GTF was the fact that it is ex- succeeded in coming up with an entirely specific composition of the alloy and to tremely difficult to form. Previously, it new material class and maturing it for pro- the multiple heat treatments especially was impossible to forge turbine blades duction within a mere seven years.” developed for the purpose. using conventional, affordable methods. The hardware is already flight worthy Turbine blades in TiAl are about half “We performed thermodynamic calcu- and in late September 2014 a develop- the weight of comparable nickel-alloy lations to determine the optimum tem- ment Airbus A320neo was the first air- components but boast the same reliabil- perature range and phase configuration craft ever to take to the skies with cus- ity and durability. Also, the high alu- for forging,” said Prof. Dr. Helmut tom-made TiAl blades installed in its minum content makes the material re- Clemens, who leads the Department of engines–the new P&W Pure Power sistant to oxidation and corrosion. Physical Metallurgy and Materials Test- geared turbofans (GTFs), which subse- According to MTU, this is why TiAl is the ing at the University of Leoben in Aus- quently received certification in Decem- ideal candidate for applications under tria. Last year, Clemens, an MTU devel- ber. The blades in the new material are extreme conditions—high temperatures opment partner, was honored in Japan fitted to the third rotor stage of the and pressures—such as those to be found with the Honda Award for his ground- three-stage, high-speed low-pressure tur- in a high-speed low-pressure turbine. breaking research work. bine developed by MTU for the GTF en- “We’ve been mulling the use of tita- “With the TiAl alloy now developed, gine for the A320neo and other new and nium aluminides ever since we started forging can be carried out on con- re-engined aircraft. work on this unique low-pressure tur- ventional forming machines—that’s Continuing research is underway and bine for the geared turbofan,” said Dr. what makes things so radically differ- the company’s materials experts are busy Wilfried Smarsly, a specialist in advanced ent,” he said. developing an enhanced TiAl alloy aimed materials at MTU. It seems that TiAl is going to feature at manufacturing more turbine stages TiAls are seen as enablers to open up increasingly as new materials roll out of from the new material. An environmen- new horizons for design engineers, help- the realms of advanced R&D into pro- tal bonus of the new material is that TiAl ing to reduce the weight of other engine duction on new generation powerplants. allows engines to be built that use up components. The high centrifugal forces Richard Gardner

The P&W Pure Power geared turbofan (GTF) is shown being assembled by an MTU technician. In late September 2014, a development Airbus A320neo was A cutaway of an actual GTF engine model. Turbine blades in TiAl are about half the first aircraft ever to take to the skies with custom-made titanium aluminide the weight of comparable nickel-alloy components but boast the same reliabil- (TiAl) blades installed in the GTF engines. (MTU) ity and durability. (Richard Gardner)

36 www.aerodefensetech.com Aerospace & Defense Technology, June 2015 ➮ Intro Cov ToC + – A ➭ Tech Briefs

Fabricating Transparent and Stretchable Supercapacitors Based on Wrinkled Graphene Electrodes Transparent and stretchable supercapacitors are used as portable energy sources for flexible electronics in biomedical, energy, and wearable systems. Air Force Research Laboratory, Wright-Patterson Air Force Base, Ohio

tretchable electronic devices, includ- Sing solar cells, light-emitting diodes, batteries, and textile supercapacitors, have been developed to retain their func- tions even when under large strains (up 2. CVD-growth to 40%). Some transparent solar cells, bat- 1. Make wrinkles graphene teries, and supercapacitors have also been Copper foil developed. However, most of the cur- rently developed electrodes and the asso- 3. Drop-coating of a layer PDMS on the as-grown graphene ciated supercapacitor cells cannot be both transparent and stretchable. It is highly desirable to integrate the 4. Remove Cu substrate in stretchable and transparent characteris- FeCl3 aqueous solution tics into a single device for aesthetically pleasing wearable electronics, and inte- grated energy conversion and storage sys- 5. Assemble device by pressing two wrinkled tems. However, it is still a challenge to graphene coated with polymer electrolyte together construct both stretchable and transpar- Electrolyte ent electronic devices because most of the PDMS substrate Wrinkled graphene existing electrodes are neither stretchable nor transparent. Highly transparent (up to 60% at 550 nm) and stretchable multilayer Schematic representation of the procedures for producing wrinkled graphene sheets for the fabrication of graphene sheets with a wrinkled structure transparent and stretchable supercapacitors. were synthesized, and after being trans- ferred onto a polydimethylsiloxane up to 95% for 2 nm thick film), the one- as the substrate for the graphene growth (PDMS) substrate, were used as both the atom-thick graphene sheet provides by CVD of methane as the carbon source current collector and active electrodes for an ideal electrode material for high-per- under the mixture carrier gas of argon the development of high-performance formance stretchable and transparent and hydrogen at 1000 °C in a tube fur- transparent (57%) and stretchable (up to optoelectronics. The first wrinkled nace, followed by coating a thin layer of 40% strain) all-solid supercapacitors with graphene sheet of a large area was syn- PDMS onto the top surface of the as- excellent stability, even over hundreds of thesized by chemical vapor deposition prepared graphene sheet, and thermally stretching cycles. (CVD) of methane with the carrier gas solidified at 75 °C for 1 hour. By remov- In spite of its excellent electrical, opti- of argon and hydrogen under 1000 °C. ing the Cu substrate in an aqueous solu- cal, and mechanical properties, graphene The wrinkled graphene sheet was then tion, a large piece of stretchable wrin- has rarely been discussed for applications transferred with its structural integrity kled graphene sheet on PDMS was as stretchable electrodes since stretching onto a PDMS substrate to exhibit high obtained. Finally, the transparent and often reduces its electrical conductivity transparency and stretchability. The re- stretchable all-solid-state supercapaci- dramatically. In addition, the process to sistance of the newly synthesized wrin- tors were assembled by pressing two of transfer a large-area graphene film from kled graphene sheet composited with the PDMS-supported graphene elec- the growth substrate to a pre-strained polyvinyl alcohol (PVA) to be used as a trodes together with a transparent layer elastic substrate (e.g., PDMS) often causes protecting layer and/or electrolyte ma- of polymer electrolyte between both the serious cracking or breakage of the trix increased by only 170%, even when electrolyte and separator. graphene sheet. As such, very limited ef- it was stretched up to 40% strain. Depending on the graphene growth fort has been made to develop transpar- As shown in the figure, a tweezer with durations, the PDMS-supported wrinkled ent and stretchable graphene electrodes, an appropriate wrinkled structure was graphene sheets exhibited an optical which is very difficult, if not impossible. used to produce a wrinkled copper (Cu) transmittance in the range of 50 to 60%, Owing to its high conductivity and foil by sliding it over the Cu foil. The re- which are comparable to the multilay- excellent transparency (transmittance sultant wrinkled Cu foil was then used ered planar graphene sheet prepared

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under the same condition. The wrinkled There should be a delicate balance be- more, these transparent and stretchable graphene sheets showed transparency tween the stretchability and trans- supercapacitors also showed an outstand- slightly lower than that of the planar parency for the graphene sheets to be ing stability as their CVs and capacitances graphene sheets synthesized at the same used in the high-performance stretch- did not vary over hundreds of cycles of condition, which can be attributed to able and transparent supercapacitors stretching up to 40% strain. These results the light diffuse reflectance and light- being developed. The high transmit- clearly indicate that the newly developed scattering effects associated with the tance of the resultant supercapacitors is transparent supercapacitors are highly wavy surface. evident, showing optical transmittances stretchable and stable. Indeed, the stretchability of both the in the range of 48 to 57%, depending This work was done by Ajit K. Roy of the planar and wrinkled graphene sheets on the growth time (i.e., the layer num- Air Force Research Laboratory; and Tao was improved significantly by PVA coat- ber) of the graphene sheets. Chen, Yuhua Xue, and Liming Dai of Case ing, which was used as both the protect- For supercapacitors based on both the Western Reserve University. For more in- ing layer and electrolyte matrix. Com- planar and wrinkled graphene sheets, formation, download the Technical pared with the PVA-coated planar their CVs and charging/discharging per- Support Package (free white paper) at graphene sheet, the PVA-coated wrin- formance, as well as their specific capaci- www.aerodefensetech.com/tsp under kled graphene sheet exhibited an even tance, was almost unchanged when they the Manufacturing & Prototyping cate- better stretchability. were stretched up to 40% strain. Further- gory. AFRL-0235

Modular Exhaust Design and Manufacturing Techniques for Build-to-Order Muffler Systems Mufflers for military vehicles can be made more cost effectively using analysis tools. U.S. Army TARDEC, Warren, Michigan

anaging the acoustic signature of fler. The second is back pressure, which the performance of the system can be Mmilitary vehicles can play a critical characterizes the restriction applied to found using the transfer matrix method role in the safety of soldiers. Low-fre- the engine. that involves representing each passive quency sounds propagate through the Once the models for the various ele- element in the muffler system as a two- atmosphere, resulting in unacceptable ments in a muffler system are defined, port element, and then finding a 2x2 acoustic vehicle detection ranges, requiring relatively large silencer structures to mitigate. Currently, these requirements are met by using a custom muffler that is Low Frequency: Mid Frequency: High Frequency: hand-assembled using low-vol- Helmholtz Tuner Expansion Chamber Absorbtion Chamber ume prototyping manufacturing techniques. This method results in significant engineering and manufacturing time. For the purposes of analysis, muffler systems may be broken up into acoustic elements that can be represented in a one-dimensional acoustic circuit analog. This circuit analog may then be solved to pre- dict the performance characteris- tics of the muffler. In the case of exhaust systems, the performance characteristics are usually com- posed of two separate fields. The first is transfer loss, or insertion loss, which characterizes the acoustic performance of the muf- A parametric model of the muffler concept.

38 www.aerodefensetech.com Aerospace & Defense Technology, June 2015 ➮ Intro Cov ToC + – A ➭ Tech Briefs

matrix, known as a transfer matrix, which describes the inter- action between elements. The transfer matrices describe the relationship between pressure and mass velocity through each Rod Ends and Spherical of the ports. In a muffler system, the circuit diagram is usually composed Bearings designed and of a source and source impedance, an n-element chain of ele- manufactured to Aurora's ments, and radiation impedance. In general, there are three exacting standards for quality different types of two-port elements. Distributed elements are and durability. long compared to the wavelengths being analyzed. This type Registered and Certified to of element is usually used to represent the piping in the muf- ISO-9001 and AS9100. fler system. Shunt elements are elements in which the pres- sure field is uniform across them, but which allow mass flow From economy commercial to to be diverted. Series elements have a constant mass flow aerospace approved, across the ports, but cause a pressure drop. we've got it all ! Once each transfer matrix is found, they can be used to cal- culate the pressure and mass flow. Similar to calculating pres- sure drop across a muffler system, the back pressure created by an element may be estimated using the transfer matrix Aurora Bearing Company method. Once the transfer matrices have been calculated, the 901 Aucutt Road same method used to estimate the acoustic performance of a Montgomery IL. 60538 muffler system may be used to calculate the flow resistance. Complete library of CAD drawings and 3D models available at: To be an effective product, the modular software needs to www.aurorabearing.com severely reduce the engineering time spent designing a muf- fler solution. The goal of the system is to automate the proce- Free Info at http://info.hotims.com/55590-890 dure enough to allow an acoustics layperson to develop a full muffler solution without the aid of a NVH engineer. A point of consideration in developing the acoustic model is that eventually a manufacturing model will need to be devel- oped from the solution. This means that care needs to be taken so that the algorithm does not find unmanufacturable solu- tions. Currently, it is anticipated that simple, conservative, geo- metric rules will need to be programmed into the system that take into account the entered space claim. However, because it will be difficult to prove that the constraints hold in all possible cases, a collision detection algorithm should be run when the manufacturing model is generated. If interference is detected, another solution will need to be found. Existing technology will be adapted to meet modular ex- haust design needs. Parametrically limited muffler designs that are established in this effort will be used to develop meaningful lists of muffler components for specific or broad applications. These component lists provide data necessary to optimize the shop layout plan, schedule, selection, and use of machinery/tooling, and the handling of inventory and mate- rials. Mufflers will be sized parametrically so that the manu- facturability of the muffler is controlled. Costs and lead times for modular mufflers will be signifi- cantly reduced due to several important factors. The compli- cated shapes, manufacturing challenges, and large amount of engineering required of custom exhaust systems has histori- cally driven the high costs and lead time. This work was done by Alan Hufnagel of the Army TARDEC; and Kevin Nelson, Greg Kangas, and Steve Mattson of Great Lakes Sound & Vibration. For more information, download the Tech- nical Support Package (free white paper) at www.aerode- fensetech.com/tsp under the Manufacturing & Prototyping category. ARL-0175

Aerospace & Defense Technology, June 2015 Free Info at http://info.hotims.com/55590-891 39 ➮ Intro Cov ToC + – A ➭ Tech Briefs

Silicon Microsphere Fabrication Silicon microspheres are used for optical devices. SPAWAR Systems Center Pacific, San Diego, California

he efficiency and methodology of tical fiber, followed by the slow heating The program has a 2-second wait period Tcoupling light into microcavities has and stretching of this exposed area until at this stage to soften the cladding and improved exponentially in the last the taper is the desired diameter. A fiber- core further so the fiber would be less decade. One such advancement is cou- optic tapering setup was used to create ta- likely to fracture when stretched. pling light onto silicon microspheres. pered fiber. This tapering setup consisted The right and left stages move indi- The material, size, and shape of a silicon of two motorized clamps and a torch. vidually to stretch the fiber one side at a microsphere are ideal for optical devices. Motorized clamps pull the fiber apart time. This step controls the taper diam- Silicon microspheres are not the primary as the gas torch, which a separate motor eter by augmenting the number of material used to fabricate microspheres controls, moves slowly vertically while stretches in the program. At the end of for optical coupling because current the two clamp stages move laterally. A the stretching, an additional post-heat- methods used for microsphere fabrica- small fiber about 5 to 6" was placed be- ing process begins. The post-heating tion cannot produce single-crystal silicon tween the two clamp stages. First, with phase added extra gravitational sag to in the 16-μm scale, which is best for cur- the single mode fiber (SMF) clamped in the tapered fiber. If the fiber was not rent optical technology. place, researchers manually moved the post-heated, the tapered fiber would The pulsed laser ablation method can torch such that the SMF was directly have cooled at a higher tension because now produce silicon microspheres that above it. The distance between the preset the stretching procedure would make are ideal for optical use. This is a process location and the set torch z-axis position removal of the tapered fiber far more in which the surface of a silicon substrate was recorded for automation. difficult as it would have a high ten- is super-heated by a high-power laser In the pre-stretching phase, the two dency to break. until molten, and a second laser pulse clamp stages were moved in phase to This work was done by B.N.L. Pascoguin, hits the molten silicon, ejecting micron- place the stripped fiber into the pre-heat R.P. Lu, J.M. Kvavle, and A.D. Ramirez of sized spherical particles. Furthermore, sil- phase for further cleaning. The pre-heat- SPAWAR Systems Center Pacific. For more icon is naturally abundant, which further ing removes the excess debris left on the information, download the Technical enables the large-scale production of op- cladding strip by burning off the buffer Support Package (free white paper) at tically compatible microspheres. and jacket residue. After the pre-heating www.aerodefensetech.com/tsp under the Processes for forming spherical struc- phase, the program returned the torch Manufacturing & Prototyping category. tures exist in nature. The most com- and the fiber to the alignment position. SPAWAR-004 monly known example of a micros- phere that nature provides is a rain droplet. Rain droplets form a spherical Right Fiber Stage structure while falling in air because of Fiber aligners Clamp the surface tension in the water mole- cules taking advantage of this shape, OPEN Left Fiber Stage which has the smallest surface-area-to- Clamp volume ratio. Thus, a raindrop has a CLOSED nearly perfect spherical shape as it trav- Torch els in space. The approach used in this Right Fiber Mount Stage work is to fabricate a single-crystal sili- Left Fiber Mount Stage con microsphere as inspired by this nat- ural process of raindrop formation. As with the microspherical liquid water droplets, ablation of a silicon wafer mo- mentarily makes liquid silicon droplets in space, allowing these droplets to form spheres and cool to a solid state before settling onto the silicon wafer surface. This process allows a reproducible large- scale production of silicon microspheres in the 100-μm size scale. The procedure for fabrication first re- quires stripping off the jacket and buffer The fiber-optic tapering setup. Top view: The left and right boxes are the clamp and the stages that stretch from a short section at the end of an op- the fiber. Side view: The center is the torch.

40 www.aerodefensetech.com Aerospace & Defense Technology, June 2015 ➮ Intro Cov ToC + – A ➭ Tech Briefs

Designing and Fabricating a Multiple-Decade Battery These long-life batteries can be used to power unattended sensors in harsh and remote environments. Army Research Laboratory, Adelphi, Maryland

here is a great need for energy sources Indirect power conversion is used for low light conditions. By bandgap- Tthat can power unattended sensors the commercial off-the-shelf (COTS) matching the PV to the optical phos- for more than a decade. Unattended sen- iBAT. The conversion process is based on phor output and identifying fabrication sors can be located in harsh and remote a two-step process converting nuclear process effects on PV efficiency, the locations that are often dangerous for decay to optical energy, then optical to total device efficiency could be opti- personnel maintenance and power electrical energy. The isotope is encapsu- mized. Silicon (Si) solar cells such as source replacement. The power source lated inside a phosphor. The beta decay amorphous Si are the most available must last the lifetime of the sensor. Un- excites the phosphor generating photon and inexpensive in the market. The like chemical batteries, the higher energy emission, usually at a narrow frequency highest conversion efficiency and spe- densities of radioisotopes allow the sen- bandwidth. Photovoltaics (PVs) sur- cific power density was found in the in- sors to operate for infrastructure lifetimes rounding the phosphor platelets convert dium gallium phosphide (InGaP). (~150 years). Isotope batteries (iBATs) the optical energy into usable direct cur- The components used were: have the potential to become reliable, ro- rent (DC) electrical energy. There are in- 1. GaAs thin-film/InGaP solar cells. The bust, and maintenance-free power efficiencies inherent in the two-step con- PV cells convert photons to usable sources for remote, long-term, low- version processes. electrical energy, which trickle charges power sensors. iBATs are different from The most difficult part of the design onboard backup batteries. chemical batteries because they are self- of the battery was selecting a solar cell 2. Phosphor platelets. contained energy sources using radioiso- that is sufficiently efficient when ex- 3. ABS cassette and enclosure case. The tope decay. posed to narrowband wavelengths and cassette adds additional mechanical

Present, Exhibit, Sponsor, Attend, Network Topics include: Join us 16 - 19 November 2015 at the Pacific Palms Resort in City • Advanced Coatings & Films of Industry, CA for the Nano for Defense Conference (NT4D). NT4D is • Advanced Manufacturing/Nanomanufacturing the premier event addressing emerging nanoenabled technologies • Biomaterials for Defense Applications • Nanostructured Materials: 1-D, 2-D, and that enhance or revolutionize U.S. defense programs and missions. Metamaterials The event addresses the most critical issues in real and emerging • Next Generation Electronics needs for defense, identifies exciting nano & emerging technology • Power & Energy Generation advances primed for development, forges connections to facilitate • Safety & Health and accelerate the development process, and identifies obstacles to • Nano-Enabled Advances in Sensing the accelerated transition of emerging technology innovations. • Tech Insertion Success Stories • Sustainment & Sustainability For more information and to register, please visit: usasymposium.com/nano

Aerospace & Defense Technology, June 2015 Free Info at http://info.hotims.com/55590-888 41 ➮ Intro Cov ToC + – A ➭ Tech Briefs

The assembly includes all of the materi- als listed, along with additional required tools for handling, safety, and precision. The GaAs solar cells are placed on a vac- uum table so they can lay flat. Five cells are soldered in series, which makes up a single layer. Optical adhesive is applied on the PV surface using a tiny paintbrush. Using plas- tic tweezers, platelets are placed on the sur- face. After the platelets cover the surface, the layer cures underneath a UV lamp for 40 seconds. Another solar cell array of five cells is placed on top of the platelet layer. Figure 1 shows the two layers before they are wired and glued together. The two layers are connected in series, which is considered a single sandwich. Optical adhesive is applied to the edges of the PV layers, which physically attaches them together after a 40-second cure. Double-side Kapton tape is placed on the other side of the sandwich. This process is Figure 1. The GaAs arrays before the layers are wired and glued together to make a single sandwich repeated throughout the entire assembly. to surround the platelets. Each sandwich is attached to each other and connected in parallel. Four sand- wiches make up one cassette. The first adhesive is applied to the en- tire surface of the cassette and allowed to cure. Then a thin layer of the second is applied to the surface. After curing, the sandwich is slid into an ABS cassette. Connecters are soldered to plus and minus wire leads. The process is repeated 6-10 more times, depending on the nec- essary power needed. The individual cas- settes are inserted into the enclosure, starting from the bottom to the top. The female connector is secured into the en- closure cover. The energy harvester cir- cuit board is screwed into the cover stand-offs and platforms. Lastly, the cover Figure 2. The iBAT GaAs cassette (left) and the 3D CAD of the iBAT assembly (right). is aligned and screwed onto the enclo- sure. The connectors are aligned to the support for the vital components. the COTS iBAT to directly power sen- leads protruding from each cassette, and The shape and features of the cassette sors. The iBAT trickle charges the bat- electrically and mechanically connected allow the user to individually slide tery array. By definition, it is an energy with the enclosure’s cover being screwed the cases into the enclosure. The en- harvesting system when coupled with and pressed in place. Figure 2 shows a 3D closure is the case for all of the cas- any type of energy transducer. CAD view of the COTS iBAT assembly, its settes, the female connector, and the Two different types of epoxies are used components, and the actual cassette. energy harvester circuit. This adds ad- in the iBAT design. The first layer of This work was done by Johnny Russo, ditional mechanical support and epoxy is a flexible, translucent epoxy Marc S. Litz, and Dimos Katsis of the Army other environmental resistance. . with a 90-minute work life and a high Research Laboratory. For more informa- 4. Board-to-board electrical connectors shear and peel strength. After that layer tion, download the Technical Support that electrically and mechanically con- cures, another epoxy is applied. This is a Package (free white paper) at www. nect the components together. high-impact-resistant epoxy that is a aerodefensetech.com/tsp under the 5. A thin-film battery that provides on- white, low-viscosity liquid that when Manufacturing & Prototyping category. board backup and energy storage for applied, hardens in 20 minutes. ARL-0177

42 www.aerodefensetech.com Aerospace & Defense Technology, June 2015 ➮ Intro Cov ToC + – A ➭ Application Briefs

Flight Management System Software Thales Paris La Défense Cedex, France +33 (0)1 57 77 86 26 www.thalesgroup.com

hales was recently selected by Northrop Grumman Corpo- Tration to have its state-of-the-art Flight Management Sys- tem software, i-FMS200, embedded in the avionics mission equipment package that Northrop Grumman will provide to upgrade the US Army’s UH-60L Black Hawk helicopters. The upgraded version of the Black Hawk helicopter will be known as UH-60V. Thales has been working closely with Northrop Grumman Corporation over the past three years to provide a proven, scalable and modular Flight Management System (FMS) soft- ware design that meets the requirements for the UH-60V pro- gram. Thales’ FMS software has proven its ability to be inte- grated by Northrop Grumman into its newest equipment during a flight demonstration on-board a UH-60L helicopter. AH-1Z and UH-1Y helicopters and U.S. Navy E-2D Advanced Moreover, hosting the Thales’ FMS software directly on Hawkeye programs. Additional benefits to be derived from Northrop Grumman’s mission computer will provide architec- their scalable, fully integrated mission equipment package in- ture weight and cost optimization on the UH-60V aircraft, clude enhanced pilot situational awareness and mission eliminating the need for standalone FMS hardware. safety, decreased workload and life cycle cost, and a common Northrop Grumman is the digital cockpit supplier and inte- training environment. grator for the U.S. Army’s UH-60V program, which replaces Built by Sikorsky Aircraft, the twin-engine UH-60 Black analog gauges in UH-60L helicopters with electronic instru- Hawk has served the U.S. military since 1979 when it first ment displays. The upgraded helicopter will replicate the UH- entered service with the U.S. Army. Since then, modified 60M pilot-vehicle interface and provide interoperability. The versions have been developed for the U.S. Navy, Air Force, new upgrades are expected to extend the life and mission ca- and Coast Guard. More than 750 aircraft are expected to be pabilities of the UH-60 platform. Northrop Grumman’s ap- modified under the UH-60V program. Northrop Grumman proach to the design and implementation of the UH-60V in- has also selected Thales to provide the civilian certified TOP tegrated mission equipment package is based on their Star 200 GPS system. experience with similar upgrades for the U.S. Marine Corps For Free Info Visit http://info.hotims.com/55590-571

COTS Rugged Systems NAI’s Sensor Interface Unit (SIU35) offers modularity and adds distributed interfaces over Ethernet for custom solu- North Atlantic Industries tions using commercial-off-the-shelf (COTS) products. As Bohemia, NY part of the Data Acquisition Unit (DAU) system, the SIU35 631-567-1100 enables population of each board with function-specific www.naii.com modules. As part of NAI’s modular COSA architecture, a selection of up to 15 different functions can be selected orth Atlantic Industries (NAI) recently received an initial from a broad assortment of low-power, high-density mod- Ncontract from L-3 Maritime Systems for Custom-on-Stan- ules. Functions include programmable discrete analog dard Architecture™ (COSA™) COTS rugged systems for the I/O (A/D, D/A & RTD), communications (RS-232/422/485 & Ship to Shore Connector (SSC) Data Acquisition Unit. The ad- ARINC-429), LVDT measurement, RVDT simulation and vanced, rugged intelligent I/O and communications subsystem LVDT/RVDT AC excitation. delivers significant advantages for data acquisition and control The Space, Weight and Power-Cost (SWaP-C) optimized solutions for the U.S. Navy’s new SSC program. The SSC is the design increases packaging density, saves enclosure slots, successor to the Navy’s versatile Landing Craft Air Cushion and reduces power consumption, resulting in easy integra- (LCAC) vehicle, which is nearing its expected service life. Prime tion, cost savings and no NRE. In addition, the SIU35 incor- contractor for the detail design and construction of the Ship to porates automatic background Built-in-Test (BIT) testing Shore Connector, awarded under Naval Sea Systems Command that is always enabled and continually checks the health of (NAVSEA) Contract N00024-12-C-2401, is Textron Systems. each channel.

Aerospace & Defense Technology, June 2015 www.aerodefensetech.com 43 ➮ Intro Cov ToC + – A ➭ Application Briefs

SSC craft will serve as the evolutionary replacement for the Navy’s existing fleet of LCACs, which are nearing the end of their service life. Their mission is to land surface assault ele- ments in support of operational maneuvers from the sea, at over-the-horizon distances, while operating from the Navy’s amphibious ships and mobile landing platforms. Like earlier LCACs, these craft also will be used for humanitarian and dis- aster relief missions. The new air cushion vehicles, offering increased reliability and availability, are designed for a 30-year service life. They will use more corrosion-resistant aluminum in the hull than current LCAC, as well as composites in the propeller shroud assembly and shafting to increase craft availability and lower life-cycle maintenance costs. These craft also will incorporate an advanced skirt, a pilot/co-pilot arrangement, a cargo deck to accommodate a 74 short ton payload (up to M1A1 Tank), and more powerful, fuel efficient Rolls-Royce engines. For Free Info Visit http://info.hotims.com/55590-509

Embedded Computing Subsystems

GE Intelligent Platforms Huntsville, AL 1-800-433-2682 www.geautomation.com

E’s Intelligent Platforms division recently secured orders Gfrom General Dynamics UK valued at £64 million (~$100 million) to provide a range of embedded computing subsys- tems that will be deployed onboard the British Army’s SCOUT Specialist Vehicle (SV) platforms. The scalable, open architec- ture subsystems – which include Ethernet switches, gateway processors, data servers and video servers – will allow SCOUT SV platforms to be easily upgraded during their lifetime as new requirements and technologies emerge. The subsystems being supplied by GE Intelligent Platforms will provide the backbone of the vehicle electronics architec- British Army SCOUT Specialist Vehicle ture. The Ethernet switch connects all the networked ele- ments of the vehicle together; the gateway processor provides The SCOUT SV program includes six variants: SCOUT Re- all the processing capability for the General Dynamics UK connaissance, Protected Mobility Reconnaissance Support software to run the platform; and the data and video servers (PMRS), Command and Control, Engineering Reconnais- allow the vehicle to store and distribute vehicle and scenario sance, Repair, and Recovery. Each SCOUT SV platform variant data and video around the platform and on into the wider will be a highly-agile, tracked, medium-weight armored fight- connected battlefield. ing vehicle, providing British troops with state-of-the-art best- GE also proposed the use of its OpenWare switch software, in-class protection. which allowed the operation of the vehicle’s network to be SCOUT SV vehicles are developed upon a highly-adaptable optimized to the specific requirements of the platform. and capable Common Base Platform, maximizing commonal- The SCOUT SV platforms replace the British Army’s CVR(T) ity in mobility, electronic architecture and survivability that vehicles and are all-new, heavily protected, high mobility, ensures the British Army has a family of world-class platforms. fully digital platforms featuring state of the art ISTAR (intelli- Each SCOUT SV platform variant has extensive capabilities, gence, surveillance, target acquisition and reconnaissance) ca- including acoustic detectors, a laser warning system, a local pabilities. According to General Dynamics UK, who have been situational awareness system, an electronic countermeasure chosen to deliver 589 of the new platforms, the SCOUT Spe- system, a route marking system, an advanced electronic archi- cialist Vehicle provides a step-change in the armored fighting tecture and a high performance power pack. vehicle capability being delivered to the British Army. For Free Info Visit http://info.hotims.com/55590-507

44 www.aerodefensetech.com Aerospace & Defense Technology, June 2015 ➮ Intro Cov ToC + – A ➭ Application Briefs Lightning Strike Protection for Composite Aircraft

Emergency Locator Transmitter ® (ELT) Shipsets MicroGrid McMurdo Group Lanham, MD 240-790-0600 www.mcmurdogroup.com

cMurdo Group, a company that specializes in end-to-end Msearch and rescue (SAR) and maritime domain awareness (MDA) solutions, was recently selected by Embraer to provide complete Emergency Locator Transmitter (ELT) shipsets for its E Jets second generation of aircraft, known as the E Jets E2. The Precision-Expanded Foils contract will include McMurdo Group’s Kannad Integra ELTs with its new ARINC GPS Interface fitted on the aircraft, and Kan- nad 406 MHz Survival ELTs for use by crewmembers in the cabin. 203/294-4440 www.dexmetmaterial.com

Free Info at http://info.hotims.com/55590-894

The ELTs will be installed in various Embraer E Jets E2s, in- cluding the E175 E2, E190 E2, and E195 E2 versions, starting in 2018. Kannad Aviation ELTs are already integrated into Open Your Designs Embraer’s existing Phenom 100, Phenom 300, Legacy 450 and Legacy 500 business jet aircrafts, and are used by some of the to Flexible, world’s largest aircraft and airline brands including Airbus, Boeing, Bombardier, Pilatus, British Airways, China Airlines Precision and United Airlines. The Kannad Aviation ELTs are currently the only ELTs with a dual positioning source: the GPS receiver on board the air- Maintenance craft and an internal GPS receiver integrated into the beacon. The Kannad Integra ARINC e-Nav interface allows the GPS po- High Precision, sition of an aircraft to be transmitted continuously from the Mechanical onboard GPS to the beacon. This allows the ELT to store and Torque Wrenches record the aircraft's position information in real time. In addi- & tion, the ELT also has an internal GPS receiver. Multipliers The Kannad Integra-AF provides several performance advan- tages due to its redundant antenna and GPS interface designs. Unlike traditional ELTs, Integra Kannad ELTs have a secondary built-in antenna that will continue to transmit distress signals ‡DFFXUDF\ reduced calibration in the event the primary external antenna is non-functional ‡/LJKWZHLJKWHUJRQRPLFVPDOOIRRWSULQW during a crash. A dual GPS design includes a built in GPS an- ‡$OOPHFKDQLFDOQRH[WHUQDOSRZHUUHTXLUHG tenna and a connection to standard onboard GPS systems to ‡'LJLWDOFRQWURO,QWHUQDWLRQDOPHDVXUHPHQW further facilitate emergency location positioning. Other Kan- &XVWRPHUVLQFOXGH nad benefits, such as its compact, lightweight design and easy ‡86$UP\‡861DY\‡860DULQHV programming, also factored into Embraer’s decision. Pratt &:KLWQH\‡6LNRUVN\‡/RFNKHHG0DUWLQ‡+RQH\ZHOO In a typical search and rescue scenario, an emergency signal Drop-in replacement for many Powerdyne®† wrenches from an ELT or distress beacon is relayed via satellite to Mission $9HWHUDQ2ZQHG&RPSDQ\ Control Centers and Rescue Coordination Centers for eventual res- ZZZDGYDQFHGWRUTXHFRP cue team deployment. This search and rescue ecosystem (known as [email protected] COSPAS ARSAT) has helped to save over 37,000 lives since 1982. 860.828.1523 *Patent # 5,203,239 l Patent Pending For Free Info Visit http://info.hotims.com/55590-508 †Powerdyne® is a registered trademark of Bidwell Corporation

Aerospace & Defense Technology, June 2015 Free Info at http://info.hotims.com/55590-895 45 ➮ Intro Cov ToC + – A ➭ New Products

Portable Fluid Chiller FPGA Chip and Protocol A low temperature fluid chiller, suit- MEN Micro Inc. (Blue Bell, PA) has released the CS1, able for labs and plants, has been intro- an FPGA chip with an integrated AFDX protocol that duced by Thermonics Corp. (Mansfield, provides a flexible alternative for communication in MA). The portable chiller recirculates airplanes. The customizable CS1 enables users to build heat-transfer fluids at precise tempera- AFDX-based communication systems independent of tures needed to support industrial a form factor. Specifically designed for the demands of applications in chemical, energy, and safety-critical avionic applications, the new chip is a electronics. The DO-254-compliant FPGA, certifiable up to DAL-A, with DAL-D certification support two-stage, cas- package available in March 2015. Developed according to ARINC 664P7-1, and in con- cade refrigera- sideration of the specific Airbus and Boeing AFDX requirements, the CS1 can be used tion chiller in applications of both airplane suppliers. is capable of The CS1 is also offered in MEN Micro’s P522 PMC I/O mezzanine card–available as a reaching –80°C. COTS product—that can be used as an alternative to PMCs already on the market, or Designed for re- for evaluation purposes. liability during The CS1 supports two full duplex AFDX networks based on standard IEEE 802.3 Eth- 24/7 tempera- ernet and applies protocol stack implementation. With up to 255 receive VLs (Virtual ture control, Links) and 64 transmit VLs, the chip ensures safe and deterministic data transfer the fluid chiller through determined bandwidths. is equipped For Free Info Visit http://info.hotims.com/55590-510 with on-board diagnostics that M-PHY® Multi-Lead Probe help predict The Teledyne LeCroy M-PHY Multi-lead chiller health Probe allows developers using an embedded M- and avoid un- PHY bus in their PCB designs to tap into the sig- expected down- nal traces directly and capture bus traffic for time. An intuitive touch-screen inter- protocol analysis and debugging. The probe al- face allows for set up of thermal lows for individual connection to each separate profiles, viewing data and trends, and transmit-pair and receive- pair of each serial lane, allowing flexibility to connect to logging diagnostics. Communications any accessible points on the surface of the PCB. Each connection uses a high-imped- interfaces (IEEE, RS232, Ethernet, USB) ance electrical probe to minimize perturbation of the M-PHY bus signals, while pro- for remote chiller control. viding reliable capture of all M-PHY traffic. For Free Info Visit The probe will connect to a Teledyne LeCroy Eclipse X34 M-PHY Protocol Ana- http://info.hotims.com/55590-513 lyzer via a multi-lead probe pod. Support is provided for M-PHY data rates of GEAR1, GEAR2 and GEAR3, and at lane widths from x1 to x4. Each individual lane connec- tion is made by using two 294 mm (11.6") extender coax cables connecting into 71 mm (2.8”) flextip connectors which each are attached to an individual transmit-pair or receive-pair on the surface of the PCB. For Free Info Visit http://info.hotims.com/55590-511

VMEbus 4th Generation Intel® Core™ i7/i5 Processor Board Concurrent Technologies (Colchester, UK) has announced VP B1x/msd, a 6U VME board based on a 4th generation Intel® Core™ i7/i5 proces- sor. The headline variant of VP B1x/msd uses the quad-core i7-4700EQ processor that features new instructions to enhance vector processing and secu- rity along with improved graphics capability. Variants are also offered based on i5-4410E and i5-4422E processors for dual core based performance and power optimized solutions. All processor variants include Intel HD Graphics 4600 which has 20 execution units and can sup- port three simultaneous display outputs. A front or rear VGA port is provided for backwards compatibility with previous boards. Up to two DVI-D interfaces and a DisplayPort connection are available as options for applications needing high resolution digital display support. A 2.5-inch drive can be accommodated on-board for mass storage. For Free Info Visit http://info.hotims.com/55590-512

Free Info at http://info.hotims.com/55590-896 www.aerodefensetech.com Aerospace & Defense Technology, June 2015 ➮ Intro Cov ToC + – A ➭ New Products

Low-Profile AC-DC Power Supplies Schaefer Inc. (Hopkinton, MA) recently intro- Ultra-Miniature | High Reliability duced the new low-profile TERa Series of Advanced Quartz Crystals, Oscillators Thermal Technology AC-DC power supplies. The and Sensors TERa family offers three output power classes of 700, 1200 and 2000 Watts that are uniquely sealed Military Grade Crystals and Oscillators in a heat conducting potting material. Featuring an ultra-wide temperature range of –50°C to 85°C, these units are designed for easy-to-connect paral- lel/series operation if higher power or redundancy is needed. Other features include high power density, Power Factor Correction (PFC), 100- 242 VAC universal inputs, galvanic isolation, high efficiency, full complement of protections, single or multi-output operation, output voltage adjustment and com- pliance to EN55022 Class A (Class B with filter). Optional copper case and termi- nal block connections are available. For Free Info Visit http://info.hotims.com/55590-514

600W Programmable Power Supplies TDK Corporation (Tokyo, Japan) recently added 600W high voltage models to TDK-Lambda’s Z+ series of programmable DC power supplies. This series is now available with output voltages of 0-10, 0-20, 0-36, 0-60, 0-160, 0-320 or 0-650 VDC and with output powers of 200, 400, 600 and 800W. The TDK-Lambda Z+ 600W high voltage models have the same features and compact dimensions (2U high and 2.76" wide) as the existing models and achieve efficiencies of up to 89%. The units can operate in either constant cur- rent or constant voltage modes and accept a universal 85- 265 VAC input. Up to 6 units can be connected in parallel (master-slave configuration), or 2 identical units in series with external diodes. All the Z+ series can be programmed via the front panel controls or remotely using the USB, RS232/485 or analog control interfaces. Optional LAN, GPIB (IEEE488) and isolated analog programming inter- faces are also available. For Free Info Visit http://info.hotims.com/55590-515 UNSURPASSED QUALITY THAT Additive Manufacturing THE DEFENSE INDUSTRY The NanoSteel® Company (Providence, RI) has announced the expansion of its additive manu- COUNTS ON facturing (AM) material capabilities to support metal 3D printing of complex high-hardness • Highest mechanical shock survivability parts and the ability to customize properties in the industry layer-by-layer through gradient material design. • Military Temperature Range and Beyond The company leveraged its 2014 breakthrough in • Low Acceleration Sensitivity AM wear materials to print a bearing and impeller using the powder bed fusion process. These parts were • Swept Quartz Capability measured to be fully dense and crack-free, with hardness • Designed and Manufactured levels >1000 HV. in the USA Building on this milestone, the company used a combination of high-hardness and ductile alloys to create a part featuring a gradient design. NanoSteel worked AS9100C with Connecticut Center for Advanced Technology to generate part samples using ISO 9001:2008 freeform direct laser deposition. This single additive manufacturing process achieved a seamless transition between the hard and ductile properties without sub- STATEK CORPORATION sequent heat treatment. These gradient material designs offer the equivalent of “dig- 512 N. Main St., Orange, CA 92868 ital case hardening™” —delivering impact resistance and overall robustness in ad- dition to high hardness and wear resistance in a single part. Tel. 714-639-7810 | Fax 714-997-1256 For Free Info Visit http://info.hotims.com/55590-516 www.STATEK.com

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Free Info at http://info.hotims.com/55590-898 high-speed signal processing radiation-tolerant FPGA family. The RTG4’s reprogramma- ble flash technology offers complete immunity to radiation-induced configuration up- EPOXY sets in the harshest radiation environments, requiring no configuration scrubbing, un- PASSES like SRAM FPGA technology. RTG4 supports space applications requiring up to 150,000 logic elements and up to 300 MHz of system performance. VERTICAL Key product features include: up to 150,000 logic elements, each with a four-input BURN TEST combinatorial look-up table (LUT4) and a flip-flop with built-in single event upset Master Bond (SEU) and single event transient (SET) mitigation; system perform- EP90FR-V is a two component flame retardant epoxy system for ance up to 300 MHz; 24 serial transceivers with operation from bonding, sealing, coating and potting. It has been 1 Gb/sec to 3.125 Gb/sec; 16 SEU- and SET-protected tested to the FAR standard 14 CFR 25.853(a) and SpaceWire clock and data recovery circuits; 462 SEU- and fully complies with the rigorous vertical burn test specification. This allows it to be considered for SET-protected multiply-accumulate mathblocks; more than 5 use in highly specialized aviation applications. Mbits of onboard SEU-protected SRAM; single event latch-up http://www.masterbond.com/tds/ep90fr-v (SEL) and configuration memory upset immunity; total ionizing dose (TID) beyond 100 Krad. Master Bond For Free Info Visit http://info.hotims.com/55590-518

Free Info at http://info.hotims.com/55590-899 Chemical Agent Resistant Coating Sherwin-Williams (Cleveland, OH) recently announced A WORLD OF FIBER OPTIC that MIL-DTL-64159 Type III Chemical Agent Resistant Coat- SOLUTIONS ing (CARC) Aerosol is now available for touch ups or other small job applications on military vehicles, ground support equipment and rotocraft. The coating provides vital CARC protection for military vehicles in the field, where a scratched or damaged finish coat – or a repair made with a non-CARC coating – may compromise the integrity of a ve- • T1/E1 & T3/E3 Modems, WAN hicle’s protection and put military personnel at risk. • RS-232/422/485 Modems and Multiplexers A specially-designed aerosol can allows military personnel to mix the two-part • Profibus-DP, Modbus • Ethernet LANs coating through a simple procedure that includes shaking the can, depressing a • Video/Audio/Hubs/Repeaters plunger to mix the coating and shaking once more prior to application, saving time • USB Modem and Hub and allowing rapid field recoating. The water-reducible topcoat is Qualified Products • Highly shielded Ethernet, USB (Tempest Case) • ISO-9001 Database (QPD) approved and it is available in multiple CARC colors. The topcoat http://www.sitech-bitdriver.com/ combines superior corrosion resistance in a CARC coating, and it is easily portable S.I. Tech in 250 mL and 400 mL sizes. Free Info at http://info.hotims.com/55590-900 For Free Info Visit http://info.hotims.com/55590-519

48 www.aerodefensetech.com Aerospace & Defense Technology, June 2015 ➮ Intro Cov ToC + – A ➭ Ad Index Publisher ...... Joseph T. Pramberger Editorial Director – TBMG ...... Linda L. Bell For free product literature, enter advertisers’ reader service num- Editorial Director – SAE ...... Kevin Jost bers at www.techbriefs.com/rs, or visit the Web site beneath their Editor ...... Bruce A. Bennett ad in this issue. Managing Editor ...... Jean L. Broge Managing Editor, Tech Briefs TV ...... Kendra Smith Reader Service Associate Editor ...... Billy Hurley Company Number Page Associate Editor ...... Ryan Gehm Production Manager ...... Adam Santiago Assistant Production Manager ...... Kevin Coltrinari ACCES I/O Products ...... 885 ...... 23 Creative Director ...... Lois Erlacher Designer ...... Bernadette Torres Advanced Torque Products LLC ...... 895 ...... 45 Global Field Sales Manager ...... Marcie L. Hineman Marketing Director ...... Debora Rothwell Aerotech, Inc...... 871 . . . . .COV IA-IB Marketing Communications Manager ...... Monica Bond Digital Marketing Coordinator ...... Kaitlyn Sommer Aurora Bearing Co...... 890 ...... 39 Audience Development Director ...... Marilyn Samuelsen Audience Development Coordinator ...... Stacey Nelson Subscription Changes/Cancellations ...... [email protected] C.R. Onsrud, Inc...... 883 ...... 19

TECH BRIEFS MEDIA GROUP, AN SAE INTERNATIONAL COMPANY 261 Fifth Avenue, Suite 1901, New York, NY 10016 Coilcraft CPS ...... 875 ...... 3 (212) 490-3999 FAX (212) 986-7864 Chief Executive Officer ...... Domenic A. Mucchetti COMSOL, Inc...... 897, 902 . . . .48, COV IV Executive Vice-President ...... Luke Schnirring Technology Director ...... Oliver Rockwell Systems Administrator ...... Vlad Gladoun Create The Future Design Contest ...... 17 Web Developer ...... Karina Carter Digital Media Manager ...... Peter Bonavita CST of America, Inc...... 901 ...... COV III Digital Media Assistants ...... Keith McKellar, Peter Weiland, Anel Guerrero Digital Media Audience Coordinator ...... Jamil Barrett DARcorporation ...... 896 ...... 46 Credit/Collection ...... Felecia Lahey Accounting/Human Resources Manager ...... Sylvia Bonilla Accounting Assistant ...... Martha Saunders Dawn VME Products ...... 882 ...... 16 Office Manager ...... Alfredo Vasquez Receptionist ...... Elizabeth Brache-Torres Dexmet Corporation ...... 894 ...... 45

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Aerospace & Defense Technology, June 2015 49 ➮ Intro Cov ToC + – A ➭ What’s Online

Most-Viewed Articles From Other SAE Magazines The following are the top 4 most- Following are recent articles from other magazines by SAE International, covering viewed aerospace-related articles of the automotive, off-highway, and truck & bus industries. More articles can be found the month as of early April. Additional at http://articles.sae.org/. aerospace articles can be read at http://articles.sae.org/aerospace/. The Quest for the Self-Cleaning Car New water-rejecting coating explored Counterfeit Electronic Parts: by chemists at University College London 1 Manufacture of and Avoidance and other universities makes for tough http://articles.sae.org/13923/ self-cleaning surfaces that might work on motor vehicles. In tests, the resilient coat- ing worked even after being wiped, scratched with a knife, and scuffed with sandpaper forty times. The coating—a thin layer of titanium dioxide nanoparti- cles covered with a waterproof veneer that can be applied to steel, glass, and other surfaces with spray adhesives—may eventually find application as automotive paint, glass and lighting coatings, even as a protectant for the surfaces of solar cell panels. More development work will Flight Vision System for Rotary- be needed to determine if the paint can meet the industry’s requirement for a 2Wing Aircraft glossy surface and other needs, the researchers said, but the likes of Magna Inter- http://articles.sae.org/13936/ national and Land Rover have already inquired about their studies. Read more at http://articles.sae.org/13981/.

Thermoplastic Technology Offers Impact Protection Across Automotive, Sports, and Defense The Oakwood Group and its technology licensee companies are designing engi- neered thermoplastic solutions to help protect vehicle occupants, sports players, Automatic Collision Avoidance and soldiers from severe impact injuries. 3Added to Inspection Software The supplier claims a market-leading share http://articles.sae.org/13930/ for its polypropylene head impact energy absorbers used for headliner applications, and its technology licensee companies, Viconic Sporting LLC and Viconic Defense LLC, are making application inroads with the infinitely tunable plastic energy ab- sorbers. Read more at http://articles.sae.org/13988/.

Military Technologies Aid the Fight for Improved Off-Highway Efficiencies There is a never-ending need for tech- nologies that can improve the efficiency of off-highway equipment, while enhanc- ing safety for both operator and the ma- NASA Embraces CFD to Replace chine. The defense sector of the industry 4Cancelled Flight Tests has an upper hand in the investment and http://articles.sae.org/13906/ invention of such technologies, some of which could, and probably should, find their way into equipment used for agricul- ture, construction, forestry, and mining. Radar is one such example of technology that was once used just in combat applications, and was very costly, but is now being widely used in vehicles for various applications. Short-wave infrared (SWIR) works in wavelengths from 0.9 to 1.7 μm, which is not visible to the human eye. In the military, SWIR is used for surveillance, reconnaissance, and night imaging. This technology can find many applications in off-highway equipment. Read more at http://articles.sae.org/14015/.

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