Welcome to
your Digital Edition of
Aerospace & Defense
Technology Next Generation FPGAs for
Electronic Warfare Systems
April 2016
Turbine Flow Meters
Designing a Power Generation
System for a More-Electric Aircraft
Managing the Impact of Nanomaterials
in Aerospace Manufacturing
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XPONENTIAL An AUVSI Experience
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The evolution of computational tools for COMSOL MULTIPHYSICS
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Contents
14
38
26
FEATURES ________________________________________
4 Electronic Warfare
4 Next Generation FPGAs for Electronic Warfare Systems
10 Materials: Composites
10 Managing the Impact of Nanomaterials in Aerospace
Manufacturing
14 Aerospace Materials/Manufacturing
14 Turbine Flow Meters
20 Alternative Power Sources
20 Designing a Power Generation System for a
More-Electric Aircraft
26 Show Preview
26 XPONENTIAL An AUVSI Experience
28 RF & Microwave Technology
28 International Microwave Symposium Preview
30 Developing an Auto-Synchronized Multi-Avionics Protocol Data
Bus Acquisition System
32 Tech Briefs
32 Creating Simulated LIDAR Images of Human Poses in a Virtual
Laboratory
33 Advanced Sensors for Traumatic Brain Injury (TBI)
34 Multifunctional Core-Shell and Nano-Channel Design for
Nano-Sized Thermosensor
36 Molecularly Imprinted Polymer (MIP)-Coated Microbeam
MEMS Sensor for Chemical Detection
DEPARTMENTS ___________________________________
38 Application Briefs
40 New Products
44 Advertisers Index
Intro Cov ToC + A
What dont we do for the US Military?
While we dont drive the armored vehicles or pilot the jet ghters,
EMCOR has plenty of boots on the ground to help keep our troops and
their facilities more efficient and ever ready. Below is just a sample of
how we help the military accomplish its missions
MISSIONS
ACCOMPLISHED
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Next Generation FPGAs for
Electronic Warfare Systems
D
esigners of virtually all elec- which countermeasure to deploy, and The choice of using an FPGA or a CPU
tronic warfare system applica- then transmitting the jamming signal at for a given task may be obvious because
tions exploit CPUs and FPGAs, the correct frequency and bandwidth, of its nature, but other times it could go
each offering unique strengths all must conform to an extremely strict either way. If so, the decision is often
and advantages for handling a wide time schedule. Thus, orchestrating the made for the CPU because a C program
range of tasks. This diversity arises from necessary FPGA and CPU resources be- is easier to develop, maintain and up-
fundamental differences in the devices. comes a critical design effort. grade. And, from a human resource per-
FPGAs consist of hardware logic, regis- High level decisions and complex data spective, it is often easier to hire a C
ters, memories, adders, multipliers and analysis are usually easier to implement in programmer than an FPGA designer.
interfaces connected together by the a CPU. If a complex signal processing task
user to perform a specific function. CPUs can be handled by the CPU, it is usually Next Generation SoC FPGAs
consist of ALUs, instruction execution easier to develop a C program for it in- Over the years, CPUs and FPGAs have
engines, cache memory, dedicated I/O stead of trying to develop IP for an FPGA. proven their effectiveness as team play-
and memory ports all connected in a An FPGA is typically much better at ers in electronic warfare systems. Be-
fixed architecture, whose resources are handling compute intensive signal pro- cause of this complementary relation-
driven by program execution. cessing or data crunching tasks because ship, many FPGA vendors now offer
Electronic warfare systems impose of its DSP blocks. Tasks like FFTs, matrix SoC (system-on-chip) devices combin-
some of the toughest restrictions on la- processing, and digital filtering can ex- ing CPU and FPGA resources within a
tency within the landscape of military ploit the benefits of thousands of DSP single monolithic silicon device. The in-
electronics. For example, systems to de- blocks operating in parallel. Further- dustry leaders in this market are Xilinx
feat RCIEDs (radio controlled impro- more, FPGA hardware surrounding and Altera.
vised explosive devices) must identify a these blocks can be tailored for each ap- Xilinx offers its Zynq family of SoCs
signal that could detonate the device, plication. This includes local data that combine ARM processors with Xilinx
and then immediately disable that com- buffers, specialized FIFOs, and opti- FPGA resources. Their most recent offer-
munication through countermeasures. mized interfaces to and from external ing is the Zynq UltraScale+ series, whose
Essential tasks in the chain from receiv- sensors, storage devices, networks, and CPU resources include a Quad-Core ARM
ing the signal, analyzing it, deciding system components. Cortex-A53 application processor, a Dual-
Core ARM Cortex-R5 real-time processor
and a Mali GPU (graphical processing
unit). The FPGA section includes a differ-
ent mix of 16 nm resources in each of the
eleven members of the series to cover a
wide range of complexity. The largest
member offers significant computational
power with nearly a million logic cells and
over 3,500 DSP slices.
A competing family of SoCs devices
from Altera is the Stratix 10 series, also
using the Quad-Core ARM Cortex-A53
Figure 1. Typical electronic warfare system task allocation for CPUs and FPGAs. CPU. Based on advanced 14 nm FPGA
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Electronic Warfare
Free Info at http://info.hotims.com/61060-768 www.aerodefensetech.com Aerospace & Defense Technology, April 2016
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Managing the Impact of
Nanomaterials in Aerospace
Manufacturing
A
s the aerospace industry con- (NIOSH), demonstrate that some nano- ability to commercialize nano-enabled
tinues to make improvements materials have the potential to cause ad- products and extend far beyond those
to safety, comfort and afford- verse human health effects. Occupa- that are normally associated with chem-
ability of aircraft, nanomateri- tional health risks associated with ical exposures in the workplace.
als are making their way into more ele- manufacturing and using nanomateri-
ments of aircraft structure, electronics, als have been under study for at least Developing a Risk Management
glass, textiles and other components. two decades and the understanding of Approach
While these materials provide tangible their impact is still evolving. For exam- An integrated, enterprise-wide risk
advantages in terms of weight, strength, ple, inhalation toxicology studies of management approach is essential to
speed and comfort, their effect on the nanomaterial composites have shown a ensure that occupational risk is con-
humans that come into contact with real possibility for lung inflammation trolled throughout the supply chain;
them is still being studied and debated. and fibrosis. from those that supply the nanomateri-
With dimensions between approxi- Workers handling nanomaterials or als, to the technology manufacturers
mately 1 and 100 nanometers about products containing them may be at using the materials, and on to those de-
the size of a virus nanomaterials have risk for inhaling fine dusts or aerosols, veloping and using the innovative
unusual physical, chemical and biologi- either during the production of the products this technology supports.
cal properties that can differ significantly nanomaterial or during the manufac- The first step is to establish a clear risk
from the properties of bulk materials, in- ture or use of products containing control policy. An executive positioning
cluding single atoms or molecules. nanomaterials. Published exposure as- statement addressing all activities, from
These differences enable the aerospace sessments, such as those conducted by procurement of the nanomaterial or in-
industry to do a number of things in- NIOSH, indicate the need for high-in- termediate product, to production, and
cluding: engineer aircraft structures that tegrity process containment and con- including distribution and use, clearly
are flexible and adaptive; develop inno- trols when handling nanoparticles. demonstrates managements commit-
vative energy generation and storage sys- However, the number of nanomateri- ment to ensuring worker health
tems for air travel; and manufacture sen- als already in commerce far exceeds throughout the supply chain. Worker
sors that monitor virtually every element NIOSHs ability to a) characterize the health and safety exposure controls
of air travel. However, these differences potential hazards associated with may not be considered during product,
also create challenges for ensuring that worker exposures and b) establish safe process, and facility design because reg-
an aerospace manufacturing workforce exposure levels. Organizations develop- ulations requiring the control of worker
and those supporting its supply chain are ing and using innovative nano-enabled exposures to nanomaterials do not yet
not inhaling unhealthy concentrations products must develop internal exist, and codes and standards to in-
of nanomaterials. processes to manage the potential risks clude appropriate engineering controls
Published research studies, such as to their enterprise. Such risks will not into the design of facilities, processes,
those conducted by the National Insti- only affect the health of their work- and equipment have not been estab-
tute for Occupational Safety and Health force, but also delay or impede their lished. However, a wealth of authorita-
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Free Info at http://info.hotims.com/61060-770
tive guidance is available, such as Cur- Protecting the health and safety of the
rent Strategies for Engineering Controls supply chain workers will also ensure
in Nanomaterial Production and Down- that preventable health and safety is-
stream Handling Processes (NIOSH Pub. sues wont disrupt the business flow.
2014-102), and General Safe Practices Monitoring supply chain activities, dis-
for Working with Engineered Nanoma- seminating new information about
terials in Research Laboratories (NIOSH nanomaterial hazards and appropriate
Pub. 2012-147). risk-based controls, and measuring
Next, allocate appropriately-skilled re- health and safety performance globally,
sources, such as industrial hygienists, that will create business value and ensure
can identify and characterize the nano- the health and safety of all the workers
materials hazards. Nanomaterial hazard potentially exposed to nanomaterials or
characterization is one of the most chal- nano-enabled products.
lenging tasks due to the unusual physical, Finally, the enterprise risk manage-
chemical, and biological properties that ment system must seek out opportuni-
can affect the toxicity of the material if it ties for continual improvement, an im-
enters the body through the lungs, by in- portant step due to the rapidly
Scanning electron microscopy image from a der-
gestion, or through the skin. mal sampling of skin showing a carbon nanotube. expanding number of nanoparticles
Assessing exposure risks to nanoma- (Bureau Veritas) and nano-enabled products, as well as
terials begins with the collection of data the publication of new toxicity data.
about the workplace, workforce, and
the nanomaterials and nano-enabled Third-Party Expertise
substances. The workplace is character- Manufacturers new to using nanoma-
ized by understanding the process terials in their construction process
equipment containment including: the should consider using experienced
ventilation system exchange rates and third-party industrial hygiene experts
filtration; the air, materials and people who can help design and implement a
movement throughout the facility; holistic risk management approach for
local exhaust ventilation and dust col- the handling of nanomaterials and
lection systems; the room finishes nano-enabled products. These experts
where nanomaterials will be handled; pride themselves on providing certified
and areas for workers to put on and re- and qualified risk management support
move personal protective equipment and services including: material charac-
and clothing. The workforce assessment High resolution transmission electron microscopy terization, exposure limit and analytical
must also define the tasks performed by image of a carbon nanotube. (Bureau Veritas) method development, exposure assess-
each worker and how they might be ment, exposure control, waste mini-
performed differently by various indi- ties to establish acceptable ranges of oc- mization and management, and supply
viduals, which will significantly impact cupational exposures, commonly re- chain assessment. Leveraging a third-
worker exposure risks. ferred to as occupational exposure party expert also gives manufacturers
The final contributor to the exposure bands (OEBs). Combined with the added assurance that they will be able
risk is the nanomaterial itself. Again, workplace and workforce characteriza- to protect workers from nanomaterial
identifying the presence of a nanomate- tion, these nanomaterial OELs and exposure to the very best of their ability.
rial or nano-enabled products may be OEBs allow the industrial hygienist to Supporting the aerospace industrys
difficult since hazard communication identify the job tasks for each job title leadership in using advanced materials
and labeling requirements are still in with potential exposure risks above the and advanced manufacturing methods
development, and health effects data OEL or OEB, or those that result in un- to achieve our vision of commercial air
on most nanomaterials are still lacking. certain assessment of risk. travel is both exciting and challenging.
In the absence of nanomaterial-spe- It is also vital that the enterprise risk It requires that risk be assessed and
cific data, progress is being made on de- management system include the orga- managed throughout the enterprise,
veloping a process for grouping these nizations manufacturing and distribu- keeping workers safe and healthy, and
un-studied nanomaterials with other tion supply chain. The unique hazards supporting a companys ability to bring
materials. They are categorized as either and rapid development of new informa- new technology to market.
nanomaterials with adequate toxicity tion about the toxicity of nanomaterials This article was written by Donna S.
information to develop occupational means the supply chain will look to the Heidel, CIH, FAIHA and John Baker,
exposure limits (OELs), or normal-size manufacturers organization for infor- CIH, Bureau Veritas (New York, NY). For
materials with a similar mode of action, mation on how to safely handle nano- more information, visit http://info.
toxicity, and physical-chemical proper- materials or nano-enabled products. hotims.com/61060-502.
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Free Info at http://info.hotims.com/61060-866
T
he aerospace industry has some Typical Flow Applications ufacturers can perform precise metering
of the most difficult operating From monitoring the fuel consump- of fuel flow in engine test cells, fuel and
conditions imaginable. Sensors tion of rotary and fixed wing aircraft, hydraulic fluid flow in component test
of all kinds used in this indus- missiles and drones, to evaluating the stands, and hydraulic fluid flow in hy-
try must stand up to the environment performance of hydraulic fluid and lu- draulic mules.
and be able to perform under harsh con- bricants, aerospace applications place Qualification and Acceptance Test-
ditions, fit in extremely tight spaces, high demands on flow sensing technol- ing: During the development process
and have electronics that can compen- ogy. Accurate and dependable flow me- for new flight-qualified components or
sate for variable conditions in order to ters are required for numerous fluid systems, turbine meters can be used to
provide precise, repeatable results. measurements on board aircraft and in validate compliance with performance
In particular, flight instruments meas- component test stands, such as: requirements over a wide range of oper-
uring fluid flow in aircraft fuel and hy- Fuel Management: Aerospace compa- ating conditions. In the process of ac-
draulic systems are required to operate nies rely on flow transducers to provide ceptance testing, the excellent accuracy
over extreme temperature ranges, while accurate, instantaneous fuel flow rate and achieved by turbine meters prevents
enduring heavy vibration and shock, and total fuel consumption data. Paired with manufacturers from narrowing the win-
withstand electromagnetic interference cockpit displays, flow meters must offer dow of acceptance due to the uncer-
and voltage transients. And, as aerospace easy installation and high reliability. tainty of the flow measurement. For ex-
test environments become more severe Fuel Ballast: As fuel is consumed, ample, a 100 pound per hour (PPH)
(higher temperature, greater vibration) there is a ballast issue that can be re- flow requirement can be narrowed to
and test application requirements for solved by fuel manipulation. This is 90 PPH by a flow measurement with
measurement devices grow more strin- often accomplished by pumping the 10 PPH uncertainty, thereby increasing
gent (smaller, lighter, more stable, higher fuel to different tanks, which requires the risk that a good part will be rejected.
accuracy), obtaining meaningful data can measurement of the fuel transferred to Performance Evaluation: Unmanned
be challenging. balance the aircraft. aerial vehicles (UAVs), drones and mis-
Hydraulic System Verification: siles are frequently called upon to stay in
Measuring hydraulic fluid leakage or dis- flight for extended periods of time, or
placement during a flight test requires a even loiter over an area. Aerospace de-
flow meter that is highly repeatable, ca- signers developing these and other ad-
pable of differential flow, and extremely vanced platforms seek instantaneous fuel
compact and rugged. Instrumentation flow rate data that can be used as feed-
suppliers are called upon to answer the back to control engine performance.
size, safety and durability requirements Maintenance, Repair, and Over-
of flight test engineers in a wide range of haul (MRO): When flow specifications
hydraulic system applications. are involved, turbine meters offer a
Product R&D: By pairing a flow precise tool to verify that fuel and hy-
Figure 1. The turbine flow meter is a popular meas- meter with a flow computer or smart draulic components meet the original
urement device among aerospace engineers. transmitter, aerospace equipment man- manufacturers specifications follow-
Intro Cov ToC + A
Famous last words:
Any calibration will do.
With Keysight calibrations, you can count on the
accuracy of your electronic measurement equipment
guaranteed. We test the actual performance of every
warranted specification and every installed option every
time. And if an instrument is out of spec, we zero in on
the problem and make all necessary adjustments. How
can you be sure? Because we provide a complete data
report so you know exactly what is done and why.
Intro Cov ToC + A
Aerospace Materials/Manufacturing
ing maintenance, repair, or overhaul. Why Turbine Meters? compact, lightweight packages with
As with qualification test procedure One of the preferred types of flow me- rugged materials of construction, tur-
(QTP) and acceptance test procedure ters among aerospace engineers is the bine meters are used to measure diverse
(ATP), the accuracy of these meters re- turbine meter (Figure1). It is widely fluids ranging from aircraft fuel to hy-
duces the chance that a conforming used for obtaining precise flow meas- draulic fluid, lubricant, cryogenic fluid
component will fall out of the accept- urements in clean, known liquids with and coolant. They also offer a versatile
ance window. relatively low viscosity. Available in metering solution that can be designed
and manufactured based on custom
specifications for packaging, end-fit-
tings, mounting, electronics, etc.
Turbine flow meters employ a
proven measurement technology,
which is digital in nature and provides
exceptionally reliable outputs. The
meter functions by sensing the linear
velocity of the fluid passing through
the known cross sectional area of its
housing to determine the volumetric
flow rate. The fluid, as it passes
through the meter, imparts an angular
velocity to the rotor, which is propor-
tional to the linear velocity of the
flowing fluid. Since the linear velocity
of the flowing fluid through a given
area is directly proportional to the vol-
umetric flow rate, it follows that the
speed of rotation of the rotor is directly
proportional to the volumetric rate.
maxon product range The meters turbine rotation produces a
train of electrical pulses sensed by an ex-
ternal pickoff mounted in close proximity
right combination.
Since the turbine flow meter is digital
in nature, the task of signal processing
is greatly simplified. The meter elec-
tronics are not subject to drift and elim-
inate the need for analog-to-digital con-
version. This is useful for monitoring
dynamic step-changes in flow for air-
If versatility and intelligent drive solutions As the worlds leading supplier of high-
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Free Info at http://info.hotims.com/61060-806
craft hydraulic systems, flight measure- have been successfully marketed. One
ments for telemetering flow rates, or version uses two rotors rotating in the
fast delivery fuel dispensing systems. It same direction. However, inlet swirl will
also allows linearizing and temperature affect both rotors, reducing or increas-
conditioning circuits to be adapted to ing the revolutions per minute (RPM)
military levels of temperature and elec- depending on the direction of the swirl,
tromagnetic interference (EMI) noise and shifting the accuracy of the meter
immunity, with all of the signal condi- output similar to that of a single-rotor
tioning electronics packaged in a com- device. An alternative approach uses
pact, rugged housing that is quiet to two closely coupled rotors, turning in
EMI susceptibility and emissions. opposite directions. The flow exiting
In addition, turbine flow meters can from the first rotor greatly affects the
withstand the extreme G forces encoun- inlet incidence angle on the rear rotor.
tered during the flight of high-perfor- The two rotors become hydraulically
Figure 3. Electronic processors can be packaged
mance or military aircraft. Their elec- coupled and their sum (or average) pro- with the turbine meter to meet any
tronics can operate in temperatures vides a cancelling effect on fluid swirl. installation requirement.
from -55C to 125C. The meters them- Therefore, flow straighteners are not re-
selves (when used with remote electron- quired in most applications, making it EMI/RFI and mismatching flow com-
ics) are used from cryogenic to 450F. possible to install the flow meter in puters to flow meters, and provides an
Safety and reliability considerations tight spaces where an added length of amplified signal for transmitting long
dictate the use of turbine flow meters in straight piping cannot be tolerated. distances. It also allows for meter inter-
some aerospace applications. The Another benefit of hydraulically-cou- changeability without the need for
meters in-line rotor configuration en- pled rotors is the RPM ratio can be mon- rescaling, and delivers multiple process
sures the presence of fluid flow (includ- itored to determine bearing integrity outputs for temperature, flow, and pres-
ing fuel, hydraulics and coolant) even if due to wear or particulates. Bearing di- sure (Figure 3).
its rotor is not rotating (locked). Other agnostics have many practical applica- Ceramic Bearings: In recent years,
flow sensing devices, such as positive tions in an aerospace environment (e.g., there have been major advancements
displacement meters, would not permit noting anomalies when securing test in turbine meter bearing technology.
the passage of fluid. The result would be data over long periods of time). Ceramic bearings have proven them-
engine overheating or fuel blockage. Helical Rotors: Additional turbine selves to be superior in wear and less
meter advantages are found in the use susceptible to particulates than stain-
Latest Technology Innovations of helical rotors, which optimize energy less steel bearings. Furthermore, ce-
Even though liquid turbine flow me- transfer over the entire surface of the ramic bearings can be used in water
ters have existed for decades, there have blade enhancing speed-of-response applications providing a low-fric-
been many design enhancements offer- to step changes in flow rate. Helical ro- tion bearing system with longer serv-
ing impressive flow performance. These tors also produce less pressure drop ice life than traditional journal bear-
improvements enable turbine meters to across the meter, as compared with the ings (Figure 4).
satisfy application requirements in ways traditional flat-bladed rotor design. Secured Internals: The repeatability
once considered infeasible. Advanced Electronics: Turbine flow of the turbine meter not only requires
Dual-Rotor Design: Turbine flow me- meters equipped with new, sophisti- high-quality bearing systems, but the
ters have traditionally offered a repeat- cated electronics provide total compen- rotor and supports (referred to as the in-
able flow range of approximately 100:1 sation to enhance flow measurement ternals) need to be rigidly mounted into
and a maximum linear flow range of accuracy, while extending linearity over the housing. In bi-directional applica-
30:1. This performance is adequate for their repeatable range. The electronics tions, it is important the method of se-
general-purpose applications, but may receive a signal from the rotor, temper- curing the internals prevents any move-
not be suitable for aerospace users. The ature sensor and, occasionally, a pres- ment changing the flow profile. This is
dual-rotor turbine design extends the sure sensor to correct for viscosity ef- best done with a rod-through clamping
lower flow range far below what has fects on the flow meter output. system that secures the internals on a
been possible before. These meters have Embedded Processors: Electronic machined step in the housing. This type
a wider turndown than single-rotor processors can be packaged with the of clamping system not only enhances
configurations, and offer a repeatable turbine meter for remote, direct, or em- bi-directional flow, but also provides a
flow range up to 500:1 and a universal bedded mounting to meet any installa- solution for high-shock applications.
viscosity curve (UVC) turndown range tion requirement. Modern meter de-
of 60:1 (Figure 2). signs generally employ embedded Finding the Right Solution
Hydraulically-Coupled Rotors: Al- electronic processor boards. This ap- Aerospace applications are among the
though several versions of dual-rotor proach allows for a small envelope, most rigorous for any type of measure-
technology are patented, only a few eliminates the problems associated with ment instrument; strict industry regula-
Intro Cov ToC + A
Aerospace Materials/Manufacturing
tions, extreme environments, and the ment solution. The right approach es- New or existing technology
ability to customize devices are just a tablishes a joint venture between the Environmental conditions
few of the demands placed on sensors flow meter supplier and customer, Performance criteria (e.g., accuracy,
in these applications. which is based on clearly defined speci- pressure drop, flow range)
Aerospace projects frequently call for fications, expectations and costs. The Certification requirements
a flow meter supplier with the resources project should start by identifying the Standards compliance
to provide a custom solution based on following key parameters: Delivery schedule
specific needs such as: Product cost
Ambient requirements
High/low temperature operation Long development cycles and high
Lightweight materials (aluminum, qualification costs require aerospace
titanium, etc.) companies to identify stable, reliable,
Bi-directional flow cost-effective partners. Such firms value
High-pressure capability speed in prototyping and development of
Extreme shock loads flow measurement devices in specialized
Custom physical dimensions packages. The precision output of these
Special end connections products helps reduce risk and cost in key
Material traceability applications while also minimizing the
Specialized testing requirements need for unscheduled maintenance.
This article was written by
Experience has shown project man- Mike McCoy, Senior Applications Engi-
agement for development and testing is neer, Badger Meter (Milwaukee, WI). For
Figure 4. Ceramic bearings are superior to stain-
essential to a successful outcome when less steel bearings in wear and less susceptible to more information, visit http://info.
devising a specialized flow measure- pitting due to particulates. hotims.com/61060-501.
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Designing a Power Generation
System for a More-Electric Aircraft
I
t is theorized that systems and equip- tween the propulsion system and elec- and the fuel for a heat sink is expected to
ment for an All Electric Aircraft (AEA) tric power system because an MEA inte- be a solution for the exhaust heat prob-
will be developed 20 years hence as a grates power management into the elec- lem of aircraft. Since the electric fuel sys-
More-Electric Aircraft (MEA) with no tric power generated by engines. In tem affects the engine thrust as the dis-
bleed system, which is a concept typi- addition, the MEE will also have to con- charge changes, a fault tolerant design in
fied by the Boeing 787, and electric pow- sider the importance for optimization of which the discharge does not change
ered propulsion (including electric dis- the aircraft in integrated management during a fault is necessary.
tributed thrust or electric hybrids by gas by advancing management of fuel burns A similar design concept must also
turbine power generation), which is ex- and the thermal control system, opti- be considered for the power supply of
pected to be realized after the 2040s. In mization of engine control and informa- the electric system. Although a
this trend, a More-Electric Engine (MEE) tion sharing with the entire aircraft, and starter/generator realized by the high
plays the roles shown in Table 1. the integration of flight control. power of the aircraft's generator con-
A conventional engine has two re- tributes to the reduction of the con-
sponsibilities: propulsion as a primary Low-Pressure Spool Power Generation ventional air starter and plumbing, it is
function, and a power plant for the sec- The conventional fuel control system considered a transfer mechanism that
ondary systems power source as a sub- wastes a lot of power because a fuel may become larger due to increased ex-
sidiary function. This article will focus pump driven by engine extraction power traction of power by a power take-off
on the expectation that MEE will be pro- through an accessory gear box delivers as the secondary power, which was
vided as a future key technology for the excessive fuel flow compared to the nec- bled of air, replaced with electrical
total energy management of MEA. essary fuel flow to acquire a specified power by an engine-driven generator,
Specifically, the engine will be an impor- thrust, which circulates in the bypass cir- disposal of the generated heat by the
tant factor not only for the conven- cuit of fuel metering. An electric fuel sys- enlarged starter/generator, and the lim-
tional role of high efficiency and low tem that eliminates excess flow improves itation of location and available space
emission, but also for optimization be- the unnecessary rise of fuel temperature, around an engine.
Intro Cov ToC + A
Alternative Power Sources
eration in the total energy manage- Integrated Propulsion Control energy management at normal times
ment system that consists of power The electric power management needs and provide safety and stability in an
generation, distribution, storage and to be linked with every status and situa- emergency (Table 3).
consumption. tion of the aircraft and requires a stable As described, the MEE shares a close
The power generation system is nec- power supply and quick response in an working relationship with the MEA and
essary for the engine system consider- emergency. A conventional fuel pump the AEA in every aspect. While the MEE,
ing the improvement of generating ef- driven by mechanical power needs to be especially the electric fuel system, is
ficiency for future increased power mounted on the engine AGB, but for the thought to play an important role in ther-
demand, stability of engine control, electric power system it needs to provide mal management and control of electric
and limits of mounting structures of flexibility upon being mounted on the aircraft in the future, it is also an essential
an extraction mechanism and genera- fuel pump, and fuel system integration system as well as a flight control system
tors. General aero-engines have a low- should be assumed from the point of a and requires high reliability and safety.
pressure (LP) spool and high-pressure holistic and optimized system.
(HP) spool in the compressor and the Tightening the information and com- Sufficient Emergency Power
turbine, respectively, and fans that ac- munication between the control system For the AEA, including an electric fuel
quire thrust are driven by a low-pres- of MEE and the aircraft system may en- control system, the electric power sys-
sure shaft and the generator and the able integrated control such as remov- tem is one of the crucial systems and re-
pumps are driven by the torque of a ing limiting conditions temporarily by quires high stability and fault tolerance
high-pressure shaft. The generator analysis of the information and the sta- that do not cause any power fluctua-
drive by the torque of a low-pressure tus in coordination with engine control tions or disruptions by a system fault.
shaft should be examined in consider- and aircraft control in an emergency. The authors propose electric bus designs
ation of weighing up the merits and Coexistence of aircraft control, electric such as a power interchange through
demerits of the high-/low-pressure power management and stability of en- the MEAAP (More- Electric Architecture
shafts shown in Table 2. gine operation must function as total for Aircraft and Propulsion) research.
Intro Cov ToC + A
Alternative Power Sources
Table 2. Merits and demerits of the extracting power shaft of the engine Table 3. Research targets of the integrated propulsion control
However, our targeting emergency ground operations, basically, the engine gines of a twin-engine aircraft are
power source capacity was merely as- generator provides power while the en- down in an emergency situation. If
sumed as a substitute of the power gine is turned over even if it is in a one or more engines work correctly,
source at normal times and has not ground idle condition. However, the sec- the capacity of the engine generators
mentioned the observation that the ondary power supply (for air condition- are thought to be designed to basi-
AEA is feasible under circumstances ing, starting avionics, galley, etc.) is nec- cally enable normal operation. In
such as generator failure and a disabled essary for ground operation before the these cases, the following need to be
bus, or while the engine is off. There- engine starts and generally electric power satisfied from the requirements of
fore, a backup or emergency power and compressed air are provided by the each certification.
source should be large and complicated. GPU or the APU. When the engine starts,
For example, the ram air turbine the air starter requires compressed air or The Control System can be Operated
(RAT) system has covered essential the starter/ generator requires electric and the Aircraft Can Fly and Land
power supply and the flight control power. A power supply source for them is Safely Even if Two Engines are Broken
drive for conventional aircraft in an required and the APU dedicates starter Applicable requirement;
emergency, but it may not be enough driving power to conventional aircraft. CFR(Code of Federal Regulation) Title
for the AEA due to increased power de- This power supply and demand needs to 14, Part25,
mand. The auxiliary power unit (APU) be met in order to consider the alterna- Subpart D - Design and Construction,
is also not sufficient to back up the AEA tive function of the APU. Those would be CONTROL SYSTEMS,
because it has a failure mode as com- considered normal operations. 25.671 General. (d)
mon as the engines, such as a disabled In terms of emergency and recovery In this condition, electric power must
fuel system. Therefore, alternative en- operations, first, it should be deter- be provided to the avionics, the flight
ergy sources such as batteries and fuel mined whether at least one or more control, a high lift device so that com-
cells (FC) will be required. In that case, engines work correctly, or if both en- munication, position and attitude, atti-
the problem is specific energy perform-
ance and it is difficult to mount those
batteries and fuel cells due to the
weight. Taking this into consideration,
weve focused on an LP power genera-
tion system as a high-performance
emergency source.
Intro Cov ToC + A
Alternative Power Sources
tude control and lighting is complete, maximum electric power by the forego- surface operation. Especially, when the
but not to the ECS, the galley, the fuel ing calculations. For the AEA, all actua- peak current is provided from the
pumps (the engines are already down), tors for flight control are electric and power supply, the capabilities of the
on-board entertainment, anti-icing sys- the electric power system is required to power system affect not only the gener-
tems (it was impossible for conven- provide peak current and absorb regen- ator capacity and size but also the wire
tional aircraft to provide the electric erated current repeating powering and capacity and weight to prevent a volt-
power while the engines were down be- regeneration according to the control age drop by line impedance.
cause bleed air was used).
Intro Cov ToC + A
Alternative Power Sources
As clarified by the typical current wave- generation and LP-SPOOL power gen- System Distribution
form, there is a big difference between eration. LP power generation is avail- The system distribution of a single
the maximum current, which is con- able to provide more electric power aisle aircraft with 180 seats is described.
sumed during acceleration and at maxi- than the HP power generation at the We assume 400kw electric power gener-
mum speed, and the average current. It time of the engine halting, which ation per engine through the combina-
means that the challenges regarding the means a windmill condition in flight. tion of two HP-SPOOL power genera-
increased capacity of the generator and It is expected that LP power genera- tions of 150kw 2 and one LP power
line impedance are solved for the entire tion can be used as an alternative generation of 100kw, considering the
power system by leveling the electric power generation system without function redundancy of the starter for
power with an accumulator and control- mounting the RAT by adding the same the conventional HP-SPOOL power gen-
ling the maximum current. We have pro- function as RAT to it. The FC (Fuel eration. Confirming the conformity by
posed electric accumulation and electric cell) is a part of the configuration as each condition, given that a windmill
peak-cut control using a flywheel battery an alternative system to the APU, but a power generation of the LP generator is
(FWB) as a countermeasure against the large weight disadvantage is caused 1/2 the rated capacity (assumed value),
above. A capacitor, which is superior in when the FC is requested to generate it is found that mounting an FC rated
the following points to an electro-chemi- the same volume of power as the APU. about 80kw enables operation.
cal battery, such as a lithium-ion battery, Therefore, the important point of this According to the current FC system for
is generally applied to the electric accu- study is to discuss how much the out- aviation, the weight is about 200kg per
mulator because: (a) it has a long life put of the FC can be reduced with the 25kw. Therefore, approximately 600kg-
(semi-permanent repetition), (b) it can be combination of LP power generation 800kg composition is assumed. Given
charged by a large current, (electricity can assuming the operational situation. that the RAT weighs 200kg including the
also be discharged by a large cur- structure and the APU weighs
rent), (c) it is an eco-friendly ma- 200kg (including fuel), the
terial and (d) it is able to accu- weight is increased by about
rately comprehend the residual 200kg-400kg. Since, on the
energy from terminal voltage. ground, the engines need to be
A capacitor, which saves elec- started only with the power
tric charge in the inductor, is from the FC, the FC must toler-
generally applied for the electric ate about twice the rating for
accumulator; however, FWB, power supply for a short time for
which saves the power by ki- engine starting, which should be
netic energy, is superior for an taken into consideration for the
application requiring both high thermal design of fuel cells.
power and energy. FWB is also There are several approaches
highly effective by being located to developing this power
close to the load whenever possi- source. The existing high-power
ble and therefore, superior to the ratio HEV lithium-ion battery
capacitor, which is inferior in (LIB) is 25 kg at a 30 kW rate
low temperature characteristics, (1.4Wh). If we assume a power
considering its mounting on a source capable of 150 kW, the
non-pressurized area. In addi- LIB system weight would be 125
tion, it is considered that both kg. This LIB would also incorpo-
the leveling and high reliability rate the engine starter current
of the electricity can be achieved design specifications. However,
by making use of the feature this LIB system limits the time
that FWB can transmit the elec- to operate the engine starter.
tricity and energy insulating The LIB system stores the
electrically through kinetic en- 7.0Wh at 150kW output power
ergy and configuring to distrib- and approximately 170-second
ute the electricity to multiple run times.
control surface actuators from
the multiplexed power system. Challenges of Generating
Power by a Low-Pressure
System Configuration Shaft
This system is comprised of The capacity of LP power
the combination of the con- Table 4. Considerations for the necessary electric power of a single aisle generation affects the feasibil-
ventional HP-SPOOL power aircraft with 180 seats. ity of the FC.The challenges of
Intro Cov ToC + A
Alternative Power Sources
generating power with the low-pressure eral aero-engines changes within the hand, the front-sump area is limited in
shaft as opposed to the more common range of 60-100%, but that of a low-pres- mounting space. The method to
high-pressure shaft, are: sure spool changes within the range of mount on the AGB is thought to be an
1. Type of generator 20-100%. For the generator of the high- extension of the conventional tech-
2. Location of the generator pressure shaft, a field winding-type syn- nique and has fewer challenges, but
3. Proposal for a new aircraft electric chronous type is broadly used, but it is the increased weight by larger PTO
power system not suitable for power generation by a (Power Take-Off) and the influence on
wide rotation speed range because a engine performance by the decreased
The specific difference between a gen- built-in permanent magnet generator is area for air flow in the engine need to
erator driven by a low-pressure spool used as a field power supply and output be examined.
and that driven by a high-pressure spool voltage is in proportion to the rotation The maximum rotation speed of the
is rotation speed range. The rotation speed cubed in principle. low-pressure spool is about 1/3 that of the
speed of a high-pressure spool for gen- The PM (Permanent Magnet motor) high-pressure spool. Since the constitu-
type and the SR (Switched tion of generators become larger as rated
Reluctance motor) type speed becomes lower if they have the
are considered to be same output/method, the generator of
prospects for the genera- the low-pressure spool will become larger
tor of the low-pressure than that of the high-pressure spool. Al-
shaft. The features of though it can be smaller by adding a gear
these types are shown in and accelerating, the acceleration is lim-
Table 6. The PM type has ited by the magnetic saturation character-
advantages in efficiency istic of the magnetic body and mechani-
and output density cal strength. In addition, since the
(weight/ volume), but it efficiency of the generator becomes lower,
has a drawback relating to the fluctuation range of the efficiency by
fault tolerance in which it the rotation speed becomes large for the
cannot stop excitation generator of the low-pressure shaft that
when it breaks down. The has a wide range of rotation speeds. Since
SR type is comprehen- the generator of the low-pressure spool is
sively potent in terms of inferior to that of the high-pressure spool
fault tolerance, although in performance and efficiency, it is practi-
it has drawbacks in cal to think this for the relatively low
weight and constitution. power. For a test calculation, the volume
The current generator is set based on an assumption that a
of the high-pressure 100kw generator is realistic.
spool is mounted on an
AGB (Accessory Gear Future Challenges
Box). The generator of Downsizing and lightening is the
Table 5. Electrical power system distribution the low-pressure spool is most challenging matter and downsiz-
considered to be embed- ing of power electronics using a fuel cell
ded and directly linked and wide band gap elements is an essen-
to the engine shaft in an tial technique. Downsizing and lighten-
aft-sump space or a ing of generators is also important. For
front-sump space, in ad- the future, since lightening is important
dition to mounting on to realize LP power generation, research
the AGB as well as that of is expected to move toward an electric
the high-pressure shaft, motor with high temperature tolerance
and considering the re- that can operate under temperatures of
duced mounting space more than 400C for LP power genera-
around a fan due to a tion, aiming at a composition to mount
high bypass ratio and the LP power generator on an AFT-sump
AGB-less for any future that does not require a PTO shaft.
plan. The aft-sump area This article is based on SAE Technical
(tail cone) has a large paper2015-01-2408 by Hitoshi Oyori, IHI
mounting space but has Aerospace Co. Ltd., and Noriko Morioka
a relatively high temper- and Tsuyoshi Fukuda, IHI Corporation,
Table 6. The features and types of generators ature. On the other doi:10.4271/2015-01-2408.
Intro Cov ToC + A
XPONENTIAL
An AUVSI Experience By Bruce A. Bennett
A
t AUVSIs Unmanned Sys- systems into countless aspects of our ting-edge research in unmanned vehicles
tems 2015 in Atlanta Geor- lifestyles, economies and national secu- and robotics; and something called Be-
gia, it was announced that rity paradigms. Listen to what they yond the Booth Showcase, which is a
the conference and trade have to say and stimulate your imagina- specially selected assortment of the best
show was being officially rebranded in tion before heading off each day to the products and partnership opportunities
2016 to XPONENTIAL An AUVSI Expe- exhibit hall or to one of the many edu- this years crop of exhibitors has to offer.
rience. The event, which runs from May cational sessions being offered. New to the Innovation Hub this year
2 May 5 at the Ernest N. Morial Con- are Discussion Groups, specialized gather-
vention Center in New Orleans, LA, will Exhibit Hall ings of individuals with similar interests
feature more than 180 speakers, 335- Speaking of the exhibit hall, there is where you can share ideas, trade informa-
plus educational sessions, and over 600 certainly plenty to see and do. For tion, brainstorm, solve problems, or net-
exhibitors representing more than 20 starters, over 600 exhibitors spread out work. Each Discussion Group will be
industries in the commercial, defense over 350,000 square feet of exhibit moderated by an industry expert to keep
and civil arenas. space will be showcasing the latest tech- the dialogue focused and productive.
So, what can attendees expect nology and solutions in all aspects of Another popular attraction located
to find at XPONENTIAL 2016? unmanned vehicle and robotics design, on the show floor is Robots in Action, a
The event kicks off on Monday after- manufacturing and use including air, special area where exhibitors can show
noon, May 2, with educational program- ground, surface, subsurface, space sys- off their small unmanned vehicle and
ming and workshops from 1:30 to 4:30 tems, weapons systems, security sys- robotics technology by demonstrating
pm, followed by welcome receptions in tems, engineering and R&D, propulsion it live. Some of the companies who
the early evening. These receptions are a systems, sensors, electronics, fabrica- demonstrated their expertise during last
great venue for first-time attendees and tion, imaging and communications sys- years show were Aurora Flight Sciences.
veterans alike to mingle and network in tems, and much, much more. Lockheed Martin, Detroit Aircraft LLC,
an informal relaxed atmosphere. Centrally located in the exhibit hall is and Unmanned Cowboys LLC.
Tuesday, May 3, kicks off with the the Innovation Hub, a unique area The exhibit hall will also play host to
first of three General Sessions planned where attendees can avail themselves of a number of special interest and tech-
for that week. According to AUVSI, the a variety of resources such as panel dis- nology pavilions. For example, the Air
General Sessions bring together a host cussions, workshops and special interest pavilion will highlight products and
of industry leaders who are deter- sessions; technical poster presentations services specifically targeted to the UAS
mined to reshape our world with the where attendees can interact face-to-face market such as engines, guidance sys-
spread and integration of unmanned with people doing some of the latest cut- tems, cameras, flight testing, and regu-
Attendees can evaluate the latest unmanned vehicle and robotics technology AUVSIs educational sessions tend to attract standing-room only crowds. (Photo:
up close in the exhibition hall. (Photo: AUVSI/Robb Cohen) AUVSI/Robb Cohen)
Intro Cov ToC + A
AUVSI Show Preview
Intro Cov ToC + A
INTERNATIONAL
MICROWAVE
SYMPOSIUM PREVIEW
T
he 2016 International Mi- tains that, al- Next-Generation 5G RF and Microwave
crowave Symposium (IMS2016), though the Systems. His keynote will explore the
organized by the IEEE Mi- phone con- vital role of a software-based approach
crowave Theory and Technique tains amazing to enable the explosion of wireless com-
Society (MTT-S), is the annual interna- semiconduc- munications for high-data-rate voice,
tional meeting for technologists in- tor and other data, and video applications, from early
volved in all aspects of microwave the- technologies, prototyping and research, all the way to
ory and practice. Held in San Francisco the phone is fully deployed systems.
from May 22-27, IMS is part of Mi- still in its in- Some of most compelling applica-
crowave Week, which incorporates fancy. Per- tion domains of the Internet of Things
technical symposia and an exhibition sonal wireless and Swarm concepts relate to how hu-
Dr. James Truchard
focused on RF, microwave, millimeter- connectivity mans interact with the world around
wave, and THz frequencies. has the potential to revolutionize them and the cyberworld beyond.
Heres a preview of some of the healthcare and education; the health- While the proliferation of communi-
keynotes, sessions, and other special care revolution has already begun. But cation and
events taking place during Microwave the biggest contribution of wireless will data process-
Week. To learn more and to register, be in improving the very concept of col- ing devices
visit www.ims2016.org. laboration. has pro-
In his keynote address, The Birth foundly al-
Keynote Speakers and Death of the Cell Phone, Dr. tered our in-
The hand- Cooper will point out the irony that the teraction
held cell- ability to solve the problems associated patterns, lit-
phone was with these revolutions may well be en- tle has been
introduced hanced by collaborative tools that use changed in
42 years ago, wireless technology to improve itself. the way we
but the mod- Dr. Cooper conceived, and led the effort process in- Professor Jan M. Rabaey
ern smart- to develop, a personal, portable cellular puts (sen-
phone is less radio handset. The result was the intro- sory) and outputs (actuation). The
than 10 years duction of the first truly mobile tele- combination of IoT (Swarms) and
old. Dr. Mar- phone in 1973. wearable devices offers the potential
tin Cooper, Dr. James Truchard, President, CEO, for changing all of this.
referred to as Dr. Martin Cooper and Co-Founder of National Instru- Professor Jan M. Rabaey of the Uni-
the founder of the cell phone, main- ments, will discuss Softwares Role in versity of California Berkeleys keynote,
Intro Cov ToC + A
RF & Microwave Technology
"The Human Intranet Where Swarms data; ultra-low-power CMOS, and en- The Exhibition
and Humans Meet," will discuss the ergy-scavenging and energy-harvest- The Exhibition consists of over 600
Human Intranet, an open, scalable plat- ing designs; new materials, metamate- exhibiting companies who represent
form that seamlessly integrates an ever- rials, and 3D printing applications for the state-of-the-art when it comes to
increasing number of sensor, actuation, RF/microwave; low-cost, personal materials, devices, components, and
computation, storage, communication, satellites and technologies; and next- subsystems, as well as design and simu-
and energy nodes located on, in, or generation 5G, 100+ GBPS wireless, lation software and test and measure-
around the human body acting in sym- and Internet of Things (IoT). ment equipment. The Exhibition also
biosis with the functions provided by Panel Sessions are an hour and 20 includes Microwave Application Semi-
the body itself. minutes long and focus on topics such nars, or MicroApps 20-minute techni-
as software-defined radio, RF MEMS, cal seminars presented by exhibitors ad-
Sessions and Workshops system-on-a-chip, microwave photon- dressing state-of-the-art products,
Focus Sessions highlight emerging ics, and other subjects. processes, and applications of interest
new technical topics that are gaining Workshops and short courses in- to the microwave community. Visit
importance and may be of significant clude emerging topics such as terahertz www.ims2016.org/exhibition for a full
interest to the microwave community. technology, carbon-based electronics, exhibitor list.
The sessions encompass a wide range green microwave technologies, and
of topics, and may involve a specific flexible/wearable electronics, as well as
emerging technology or cover several 5G wireless systems, technologies for
technologies relevant to a common low-cost phased arrays, RF technolo-
application. Some of these areas in- gies and applications for autonomous
clude RF technologies for smart vehi- and distributed vehicles and drones,
cles and drones; personalized health- and the latest developments in test and
care through wireless sensing and big measurement systems.
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RF & Microwave Technology
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RF & Microwave Technology
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Intro Cov ToC + A
Tech Briefs
Intro Cov ToC + A
Tech Briefs
This hybrid experimental/virtual ap- tion capture system, which tracks a set
proach enables us to generate partial of 68 retro-reflective markers affixed to
surface point clouds with a complete a tight-fitting garment worn by the vol-
spherical coverage of viewing angles unteer, based on a modified Helen
along different azimuths and eleva- Hayes type marker set. Marker trajecto-
tions. We can also create the same point ries are captured during the subjects ac-
clouds at different scales to simulated tivity trials using 18 cameras. The sub-
LIDAR images of distant human targets. jects performed a variety of specified
Unlike many common avatar anima- actions within the capture volume in-
tions produced by artists, each of our cluding digging, picking up and putting
action simulations is individualized down an object, throwing, limping with
with respect to one of the human test a weighted ankle brace, and running.
subjects. The accompanying figure The motion capture volume is approxi-
shows two examples of such point mately 20 feet long, 15 feet wide, and
cloud patches. eight feet high.
Sixty-eight human subjects whose Using 3D scans of the human
data were used for SLI generation were shapes to create mesh models, fol-
scanned and motions captured in the lowed by animating the models with
AFRL 711th HPW/RHXB 3DHSL facility. motion capture data, could yield con-
The raw data collection process consists sistent and repeatable digital human
of two parts whole-body scans and op- avatars. Coupled with an automatic
tical marker-based motion capture. A orthogonal ray- tracing script, the vir-
whole body scanner photometric sys- tual laboratory allows simulating
Precision Metal Stamping
(High and Low Volume)
tem with nine camera pods was used to LIDAR point clouds of human actions
capture the subjects shape in a standing quickly and consistently for different Welded & Mechanical Assemblies
pose. Each pod wa comprised of two viewing angles and scales, as well as
Complex CNC Machining
black and white cameras, one color for a large number of subjects. The
camera, and one (or two) speckle pat- simulated data can then be used in re- Close Tolerance Grinding
tern projectors. search on human pose shape retrieval
Tooling, Fixtures and Gages
The data from each individual pod is and action recognition from single-
used to generate one continuous 3D view 3D point clouds. Laser Cutting and Welding
point cloud, which is then merged with This work was done by Jeanne Smith and
Rapid Prototyping
the data from the other camera pods to Iaiah Davenport of Infoscitex Corp., and
create a textured high-resolution 3D Huaining Cheng of the Air Force Research Wire EDM
whole-body image. The subjects wear Laboratory for the Air Force Materiel Com-
tight-fitting, stretchy clothing for a true mand. For more information, download
body shape during scanning. the Technical Support Package (free white
The three-dimensional mocap data paper) at www.aerodefensetech.com/tsp
are gathered using a passive-optical mo- under the Sensors category. AFRL-0241.
Aerospace & Defense Technology, April 2016 www.aerodefensetech.com Free Info at http://info.hotims.com/61060-779
Intro Cov ToC + A
Tech Briefs
sors have an ultra-thin form factor The first closed-diaphragm wafer sen-
(thickness 90 m prior to packaging, sors were received from LLNL and imme-
and 130 m after final packaging). The diately tested. Static calibration produced
new sensors were designed to measure a linear relationship between 5 and 25
absolute pressure by modifying the PSI with an R2 = 0.986. The closed-di-
original contact stress sensor design to aphragm sensor is 90 microns thick, and
create a reference cavity a trapped vol- the final product with Kapton packaging
ume of gas that is hermetically sealed is 130 microns thick. Dynamic compari-
within the device. The new sensors pre- son of the new sensor with the existing
define the pressure sensors reference fluid percussion pressure transducer pro-
cavity within the silicon-on-insulator vided close tracking of pressure events.
(SOI) wafer. Initial testing revealed the need for
Close-up of the sensor showing the diaphragm (A) Five new sensors with diaphragm di- shielding of cables and power supply for
and four connector contact strips (B). ameters of 200, 400, 600, 800, and 1000 subsequent applications.
m (see figure) underwent testing and This work was done by Bruce Lyeth,
biologic ICP and impact pressure tran- calibration to determine the optimum Ph.D., of the Regents of the University of
sients. diaphragm diameter for subsequent in- California, Davis, for the Army Medical
Test-ready sensors were produced animal testing. The new sensors were Research and Materiel Command. For
with a range of diaphragm diameters packaged with an encapsulating layer of more information, download the Tech-
(200 - 1000 m). Diaphragm diameter Kapton to protect the sensor diaphragm nical Support Package (free white
should affect sensitivity of the sensors. and electrical connections from body paper) at www.aerodefensetech.com/tsp
These wafer-scale, absolute pressure sen- fluids. under the Sensors category. ARL-0190
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Tech Briefs
Intro Cov ToC + A
ITAR-Registered Tech Briefs
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onitoring trace gases is of great importance in a wide range
ITAR/DFAR & ISO 9001 Registered Engineering Design & Analysis Services of applications. Detecting a diverse range of chemical
Sensor Class Magnetics for Critical Applications Indexing Features for Alignment & Orientation
agents requires an adaptable sensor platform capable of identi-
fying threats before they cause harm. Research and develop-
ment in hazardous-materials detection technology focuses on
increasing speed, sensitivity, and selectivity while reducing size
and cost. Although the current state-of-the-art vapor detector
eMail: Sales@MagnetUS.com (Joint Chemical Agent Detector) is lightweight, handheld, and
(800) 437-8890 magnetapplications.com easily attaches to a belt, it still provides added bulk to a soldier
on foot. Recently, microcantilever-based technology has
emerged as a viable platform due to its many advantages such
Free Info at http://info.hotims.com/61060-782
as small size, high sensitivity, and low cost. However, microcan-
tilevers lack the inherent ability to selectively identify chemi-
cals of interest. The key to overcoming this challenge is to func-
tionalize the top surface of the microcantilever with a sorbent
layer (i.e., polymer) that allows for selective binding between
the microbeam and analyte(s) of interest.
Molecular imprinting involves arranging polymerizable func-
tional monomers around a template, followed by polymeriza-
tion and template removal (see figure). Arrangement is generally
achieved by noncovalent or reversible covalent interactions. In
both types of molecular imprinting, once the template is re-
moved, three-dimensional cavities are generated within the
final materials that are complementary to the template molecule
Rod Ends and Spherical
in size, shape, and functionality. Essentially, one creates a molec-
Bearings designed and ular memory within the imprinted polymer matrix. This al-
manufactured to Aurora's lows preparation of polymers that are selective for the adsorp-
exacting standards for quality tion of the target molecule of interest. Other advantages of this
and durability. technique include robustness and stability under a wide range of
Registered and Certified to chemical and physical conditions, and an ability to easily design
recognition sites for a plethora of target chemicals (e.g., pesti-
ISO-9001 and AS9100.
cides, energetic materials, pharmaceuticals, and proteins).
From economy commercial to The polymer materials of interest are sol-gel-derived xero-
aerospace approved, gels, which have been used as a platform for MIP-based sensor
we've got it all ! development. These materials are attractive because their
physicochemical properties can be adjusted by choice of pre-
cursor(s) and the processing protocol. Precursors were chosen
based on potential interactions with the explosive 2,4,6-trini-
Aurora Bearing Company trotoluene (TNT). These specific interactions allow for in-
901 Aucutt Road creased target recognition.
Montgomery IL. 60538 A MIP alone does not meet the requirements for a sensor
without some form of a transducer to convert the analyte in-
Complete library of CAD drawings and 3D models available at:
teraction into a measureable signal. There is evidence of a va-
w w w . a u r o r a b e a r i n g . c o m riety of gravimetrical detection techniques applied to convert
Intro Cov ToC + A
Tech Briefs
a MIP into a sensor. Low-mass, high- tion of explosive compounds and warfare agents of interest to the Army. A
frequency, and low-cost micro/nano CWAs. To date, this is one of the only successful MIP-coated microbeam
sensors utilizing mass loading of micro- demonstrations of a MIP-coated mi- MEMS sensing format could reduce sen-
cantilevers have drawn increasing atten- crobeam MEMS sensing platform for sor cost and size, while maintaining the
tion in the area of gravimetric sensing, these targets. Although preliminary, the high sensitivity, selectivity, and porta-
and MIPs have become an attractive data suggests that this combination is bility needed for military applications.
thin film coating for many microelectro- an effective and robust chemical This work was done by Ellen L. Holthoff
mechanical systems (MEMS)-based sen- nanosensing scheme. Further investiga- of the Army Research Laboratory and Lily
sors. In this work, molecularly im- tions will focus on refinement of the Li, Tobias Hiller, and Kimberly L. Turner of
printed xerogel thin films have MIP (i.e., xerogel formulation) for im- the University of California Santa Barbara.
demonstrated selectivity and stability in proved selectivity. Finally, the MIP- For more information, download the
combination with a fixed-fixed beam coated microcantilever sensor platform Technical Support Package (free white
MEMS cantilever. evaluation should be expanded to in- paper) at www.aerodefensetech.com/tsp
The sensors are fixed-fixed beams of clude other explosives and chemical under the Sensors category. ARL-0191
varied lengths and widths. The beam
thickness was 2 m. The values were cho-
sen so that the natural frequencies of the
beams were less than half the natural fre-
quency of the shear piezo actuator (330
kHz) used to drive the device. The mi-
crobeams were fabricated using a standard
silicon on insulator (SOI) process. The SOI
wafer used was 2 m silicon (Si) device
layer with 1 m buried oxide and 520 m
Si handle. First, oxide was grown on both
sides of the wafer. Silicon nitride (Si3N4)
was deposited on the backside on top of
silicon oxide; together they serve as masks
to protect the backside for potassium hy-
droxide (KOH) etch in a later step. After
front side oxide removal, it was then spun
with photoresist and pattern was trans-
ferred. Then a deep reactive-ion etching
was used to define the device features.
Back side mask features were defined
using photolithography and inductively
coupled plasma. The front side was spun
with a ProTEK coating to protect features
during back side release etch. The back
side was opened by anisotropic KOH etch
and stopped at the buried oxide. The de-
vice was then finished with removal of
ProTEK and buried oxide layer.
The work reported here validates the CONTACT US:
MIP-coated microcantilever sensing
1.207.892.8899
concept and demonstrates the feasibil-
ity of this MEMS sensor for the detec- TUBEHOLLOWS.COM
Intro Cov ToC + A
Application Briefs
Design Software
Collier Research Corporation
Newport News, VA
757-825-0000
http://hypersizer.com
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Intro Cov ToC + A
Co-located with
//
for 2016
E>Pasadena world-class,
E
E&,
E
EK
who attends
Engineers Program Managers
R&D D
W Academia
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Publisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Joseph T. Pramberger
Ad Index
Editorial Director TBMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Linda L. Bell For free product literature, enter advertisers reader service num-
Editorial Director SAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .William Visnic bers at www.techbriefs.com/rs, or visit the Web site beneath their
Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bruce A. Bennett ad in this issue.
Associate Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Billy Hurley
Managing Editor, Tech Briefs TV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kendra Smith Reader Service
Associate Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ryan Gehm Company Number Page
Production Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adam Santiago
Assistant Production Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kevin Coltrinari ACCES I/O Products . . . . . . . . . . . . . . . . . .775 . . . . . . . . . . . .23
Creative Director . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lois Erlacher Aurora Bearing Co. . . . . . . . . . . . . . . . . . . .783 . . . . . . . . . . . .36
Senior Designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ayinde Frederick
Global Field Sales Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Marcie L. Hineman
C.R. Onsrud, Inc. . . . . . . . . . . . . . . . . . . . . .770 . . . . . . . . . . . . .11
Marketing Director . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Debora Rothwell Coilcraft CPS . . . . . . . . . . . . . . . . . . . . . . . .769 . . . . . . . . . . . . .9
Marketing Communications Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Monica Bond
COMSOL, Inc. . . . . . . . . . . . . . . . . . . .790, 799 . . . .42, COV IV
Digital Marketing Coordinator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kaitlyn Sommer
Audience Development Director . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Marilyn Samuelsen CST of America, Inc. . . . . . . . . . . . . . . . . . .798 . . . . . . . .COV III
Audience Development Coordinator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stacey Nelson EMCOR Government Services . . . . . . . . .765 . . . . . . . . . . . . .3
Subscription Changes/Cancellations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .nasa@omeda.com
ESTECH 2016 . . . . . . . . . . . . . . . . . . . . . . .806 . . . . . . . . . . . .17
TECH BRIEFS MEDIA GROUP, AN SAE INTERNATIONAL COMPANY Gage Bilt Inc. . . . . . . . . . . . . . . . . . . . . . . . .780 . . . . . . . . . . . .35
261 Fifth Avenue, Suite 1901, New York, NY 10016
(212) 490-3999 FAX (646) 829-0800 Hawthorne Rubber Mfg. Corp. . . . . . . . . . .791 . . . . . . . . . . . .42
Chief Executive Officer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Domenic A. Mucchetti
Hunter Products, Inc. . . . . . . . . . . . . . . . . .787 . . . . . . . . . . .40
Executive Vice-President . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Luke Schnirring
Technology Director . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oliver Rockwell Imagineering, Inc. . . . . . . . . . . . . . . . . . . . .763 . . . . . . . . . . . . .1
Systems Administrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vlad Gladoun Interstate Connecting Components . . . . .792 . . . . . . . . . . . .42
Web Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Karina Carter
Digital Media Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Peter Bonavita
John Evans' Sons, Inc. . . . . . . . . . . . . . . . .764 . . . . . . . . . . . . .2
Digital Media Assistants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Keith McKellar, Peter Weiland, Anel Guerrero, Maria Sevilla Kaman Precision Products . . . . . . . . . . . .777 . . . . . . . . . . . .31
Digital Media Audience Coordinator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Jamil Barrett Keysight Technologies . . . . . . . . . . . . . . . .771 . . . . . . . . . . . .15
Credit/Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Felecia Lahey
Accounting/Human Resources Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sylvia Bonilla Lemos International Co., Inc. . . . . . . . . . .793 . . . . . . . . . . . .42
Office Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alfredo Vasquez Lyons Tool & Die Co. . . . . . . . . . . . . . . . . . .779 . . . . . . . . . . . .33
Receptionist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Elizabeth Brache-Torres
Magnet Applications . . . . . . . . . . . . . . . . .782 . . . . . . . . . . . .36
ADVERTISING ACCOUNT EXECUTIVES Magnetic Component Engineering, Inc. . . . . .778 . . . . . . . . . . . .31
MA, NH, ME, VT, RI, Eastern Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ed Marecki Master Bond Inc. . . . . . . . . . . . . . . . .785, 794 . . . . . . . .39, 42
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tatiana Marshall
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(401) 351-0274
maxon precision motors, Inc. . . . . . . . . . .772 . . . . . . . . . . . .16
CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stan Greenfield Mfg4 2016 . . . . . . . . . . . . . . . . . . . . . . . . . .788 . . . . . . . . . . . .41
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(203) 938-2418 Mini-Systems, Inc. . . . . . . . . . . . . . . . . . . . .776 . . . . . . . . . . . .29
NJ, PA, DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .John Murray
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (973) 409-4685 MPL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .781 . . . . . . . . . . . .35
Southeast, TX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ray Tompkins New England Wire Technologies . . . . . . .774 . . . . . . . . . . . .21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(281) 313-1004
OFS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .786 . . . . . . . . . . . .39
NY, OH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ryan Beckman
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(973) 409-4687 Otek Corporation . . . . . . . . . . . . . . . . . . . .795 . . . . . . . . . . . .42
MI, IN, WI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chris Kennedy PI (Physik Instrumente) LP . . . . . . . . . . . .768 . . . . . . . . . . . . .8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(847) 498-4520 ext. 3008
MN, ND, SD, IL, KY, MO, KS, IA, NE, Central Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bob Casey
Proto Labs, Inc. . . . . . . . . . . . . . . . . . . . . . .766 . . . . . . . . . . . . .5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(847) 223-5225 Remcom . . . . . . . . . . . . . . . . . . . . . . . . . . . .796 . . . . . . . . . . . .42
Northwest, N. Calif., Western Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Craig Pitcher S.I. Tech . . . . . . . . . . . . . . . . . . . . . . . . . . . .797 . . . . . . . . . . . .42
(408) 778-0300
CO, UT, MT, WY, ID, NM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tim Powers
Space Tech Expo . . . . . . . . . . . . . . . . . . . . .789 . . . . . . . . . . . .43
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(973) 409-4762 Superior Tube Co. . . . . . . . . . . . . . . . . . . . .762 . . . . . . . .COV II
S. Calif. , AZ, NV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tom Boris
TRENTON Systems . . . . . . . . . . . . . . . . . . .767 . . . . . . . . . . . . .7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (949) 715-7779
Europe Central & Eastern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sven Anacker Tube Hollows International . . . . . . . . . . . .784 . . . . . . . . . . . .37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49-202-27169-11 Ulbrich Stainless Steels &
Joseph Heeg Special Metals, Inc. . . . . . . . . . . . . . . . . . . .773 . . . . . . . . . . . .19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49-621-841-5702
Europe Western . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chris Shaw
W.L. Gore & Associates . . . . . . . . . . . . . . .866 . . . . . . . . . . . .13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44-1270-522130
Integrated Media Consultants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Patrick Harvey
Aerospace & Defense Technology, ISSN - pending, USPS Application to Mail at Periodicals
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