Adt0619 PDF

Welcome to your Digital Edition of
Aerospace & Defense Technology and

Aerospace Manufacturing and Machining
Included in This June 2019 Edition:
Aerospace & Defense Technology Aerospace Manufacturing & Machining
www.aerodefensetech.com February
June 2019 June 2019
A new approach to
machining titanium
is high-feed side
milling, a process
characterized by low
radial engagement,
constant chip thickness,
and high feed rate and
speed. This solid-carbide
end mill features a unique
combination of geometry
and grade designed
specifically to work with
titanium alloys. (Photo
courtesy of Sandvik
Coromant)
Coating Technology Enables Effective Missile Countermeasures

The FACE™ of Military Modernization
Eyes in the Sky
Supplement to Aerospace & Defense Technology

From
From
the
the
Publishers
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Eyes in the Sky
From
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ofof
Ray optics simulation
for inertial navigation.
Visualization of counterpropagating light rays in a

counterclockwise rotating Sagnac interferometer.
Aircraft and spacecraft require highly accurate tools for attitude

detection and control.
control Many modern inertial navigation systems
include ring laser gyroscopes. To better understand how ring
laser gyros work, you can study the fundamental operating
principle of these devices: the Sagnac effect. This effect can be
demonstrated using ray optics simulation.
The COMSOL Multiphysics® software is used for simulating
designs, devices, and processes in all fields of engineering,
manufacturing, and scientific research. See how you can apply it
to ray optics simulation.
comsol.blog/ring-laser-gyros
Free Info at http://info.hotims.com/72994-797

June 2019

Eyes in the Sky
From
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the
the
Publishers
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ofof
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Aerospace & Defense Technology
Contents
FEATURES ________________________________________ DEPARTMENTS ___________________________________
Embedded Computing 36 Application Briefs
6 Eyes in the Sky 40 New Products
44 Advertisers Index
Lasers & Optics
10 Panoramic Thermal Imaging Technology AEROSPACE MANUFACTURING AND
Rotorcraft Technology MACHINING (Selected editions only) ____________________
14 Coating Technology Enables Effective Missile June 2019
IIa Machining Titanium Aero-Frames

Countermeasures
6a Getting the Most Out of Industrial CT
Digital Design Tools
A new approach to
Scanning
machining titanium
is high-feed side
milling, a process
radial engagement,
18 FACE™ - Future Airborne Capability Environment

10a Aerospace Work Platforms — More than

and grade designed
courtesy of Sandvik
Coromant)
Meets the Eye

RF & Microwave Technology
24 Broadband 1.2- and 2.4-mm Gallium Nitride (GaN) Power
Amplifier Designs
27 Multi-Agent RF Propagation Simulator
TECH BRIEFS _____________________________________ ON THE COVER ____________________

28 Electrical Characterization of Crystalline UO2, THO2 and A U.S. Army AH-64 Apache helicopter patrols at sun-
set. Because they often remain relatively stationary
U0.71TH0.29O2
in high risk areas for extended periods of time, heli-
29 ONR Short Pulse Research Evaluation and Non-SWaP copters are particularly vulnerable to attack by heat
Demonstration for C-sUAV Study seeking missiles. To counteract the threat, new opti-
32 Matrix-Free Assisted Laser Desorption Ionization Using Metal- cal thin film coatings are being incorporated into
countermeasure systems. To learn more, read the
Organic Frameworks
feature article on page 14.
(U.S. Army photo by 1st Lt. Ryan DeBooy)
2 Free Info at http://info.hotims.com/72994-772 Aerospace & Defense Technology, June 2019

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INSIDE STORY
Recent initiatives at Aitech include integrating Intel-based rugged PCs and GPGPUs into SFFs, incorpo-
rating inherent security features into the hardware platforms, and advancing power, processing and com-
munications in mission-critical systems. Doug Patterson, VP of Global Marketing, looks at how shrinking
system size and increasing computing density is impacting embedded computing design.
A&DT: SFFs are now enabling computing intelligence to be We always guide our customers to the proper hardware/soft-
placed on mobile systems and in remote locations. What are ware solution for their application, sometimes meaning advis-
some important things to consider when integrating these ing on options other than what we offer or can tailor from exist-
systems into an application? ing products.
Patterson: Testing, qualification, heritage, A&DT: What has SFF done for modularity in embedded com-
flexibility are vital to every mission. At the puting architectures?
system-level, the application always rules the
available options related to hardware and Patterson: SFFs have allowed systems engineers to realize the
software selections. Is there a processor or dream of true, distributed processing, putting computing resources
RTOS preference? Is the application Earth at the platform edge, closer to the sensors where the hard work is
terrain or Space (LEO, MEO, GEO or deep done. Pre-processed data can be passed back over the network to
space)? Are there specific mission endurance or environmental a smaller central mission computer that only decides the actions to
issues? What power is available? What is the mission inclination take. Large (heavy!), centralized mission computers are slowly tran-
as this can affect radiation-tolerance and, ultimately, reliability. sitioning to these smaller, lighter, stand-alone SFF systems weigh-
Everyone’s definition of “real time” is different and complete- ing only a few pounds and costing much less.
ly application-dependent. In a GPGPU-based system, is a 2-sec-
ond reaction to process, identify and perform a dependent A&DT: Have these new SFF systems impacted the use of
action on an image acceptable, or does it need to be quicker? industry standards, heading us towards similar problems
With over 1 TeraFLOP of processing performance, today’s the industry faced in terms of interoperability, proprietary
GPGPU-based systems can process, track and react to 100s of architectures, etc.?
images simultaneously, depending on processing/identification
levels needed. Patterson: The VITA standards organization has working
groups to study SFF standards (under VITA 73, 74 and 75), for
A&DT: Compare HPC computing a few years ago to what it both Earth- and Space-based applications. Like the military’s
looks like today, in terms of size-to-performance? ubiquitous ARINC-404 ATR standard developed during WWII to
define easily-installed, removable VHF radios, SFF chassis are
Patterson: By comparison, 3-5 years ago, modular, high per- being defined to match the application’s needs, not necessarily
formance 3U Intel VPX-based HPEC systems would take approx- the internal system’s functionality.
imately 400 in3, dissipate close to 75W, weigh over 13lbs and
provide 60-70 GFLOPs of processing performance, at best. A&DT: SFF subsystems are getting so small, it’s almost
Today’s high-performance, NVIDIA Jetson GPGPU-based sys- mindboggling. Where do you think the next leap will come
tems take up only 50 in3, dissipate less than 17W, weigh less from: in an even smaller enclosure size, a consolidation of
than 2.2lbs and provide 1 TFLOP, or ~14+ times HPEC system components and assemblies within, or maybe a combination?
performance at 1/3 the price. Do the math: the cost/perfor-
mance benefits of GPGPU-based systems performing similar Patterson: Although there aren’t any revolutionary, new compo-
applications are huge. nent physics or manufacturing lithographic technologies avail-
able to the general industry yet, current line widths and 3D stack-
A&DT: Describe the increasingly important role software ing are taking us quickly into the realm of sub-nanometer geome-
plays in SFF computing, and the need to integrate it with tries. This means smaller components with greater functionality,
the hardware. lower operating voltages and higher heat/power dissipations.
The next miniaturization issue is interface connectors.
Patterson: Software is the real cost-driver of any modern, Chassis size is not typically dictated by the electronics inside,
embedded computing system, dwarfing hardware development but by the physical size of the power and I/O connectors! While
and recurring costs more than 10x. Between maintenance and miniaturized, military-grade, MIL-C-38999 circular connectors
portability across multiple hardware upgrades that could make are now available, existing platforms desperately need a tech-
software incompatible, developing your application program in nology insertion upgrade: the internal harnesses all have the
a high-level programming language is now mandatory. larger, bulky 38999 connectors. However, this should be solved
Software must be considered carefully. Is a commercially- in a few short years, by companies like Aitech that have seen
available RTOS, Linux or another option preferred? Will you use the problems our customer are facing, up close and personal.
C/C++, Ada, native CPU assembly language or something else?
Do you need BIT, and to what levels of maintainability? For cyber- To learn more about Aitech, read the full-length version of this
security, what are available options to handle these concerns? interview at www.aerodefensetech.com/InsideStory0619.
4 www.aerodefensetech.com Aerospace & Defense Technology, June 2019

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Eyes in the Sky
Rugged High-Speed Cameras
Capture Critical Flight Test
Video Data
T
here is increasing demand for high-quality number of video frames that can be transmitted and
High Definition (HD) video for airborne ap- stored without additional conversion hardware, be-
plications such as Flight Test Instrumenta- cause of the sheer size of the data they generate.
tion (FTI). Ideally, such new camera solu- One approach for meeting the need for higher per-
tions can reduce the weight and difficultly of formance FTI cameras without adding complexity is
installing wiring, and enable data to be coherently to use IP cameras that utilize Ethernet wiring,
combined with image data. Ethernet cameras can switches and recorders. Ethernet IP cameras offer
address these needs with built-in compression and several key benefits when compared to traditional
multiple output streams. Additionally, as Ethernet- Composite Video Baseband Signal (CVBS), such as
based networks have become an attractive choice simplified installation, reduced system weight, and
for FTI applications, we see increased requirements high-quality images. Even better, the required infra-
for integrating Ethernet-based cameras with FTI structure is often already installed on the aircraft
data acquisition equipment, network recorders, and for other data acquisition purposes.
telemetry systems as this removes duplication of
wiring and devices. Using Cameras in Test Applications
Using an Ethernet camera that supports onboard Video is often used during a test campaign as a vir-
compression enables video compression to be re- tual “witness” to events (excluding high-speed video
moved from the FTI Data Acquisition System (DAS), which is used for applications such as time magnifi-
or it can eliminate a dedicated unit. The camera can cation and trajectory analysis). It is generally not
be connected via an Ethernet switch directly into used as a primary data source for measuring phe-
the system, like any other data acquisition unit. nomena about the aircraft, but it is a very useful tool
Even better, because there is no need for dedicated nonetheless. When the image data is properly corre-
hardware compression, SWaP is minimized and in- lated with data from other sensors, busses, etc., one
stallation wiring greatly simplified. can correlate the physical event with imagery. This is
As legacy airborne cameras are rapidly becoming especially useful for environments, like the cockpit,
obsolete, designers, systems integrators and end for example, where you can see how the pilots and op-
users have sought up-to-date digital video alterna- erators are interacting with instruments and controls
tives that offer higher quality images. Older cameras for user interface analysis and training (e.g. an organ-
typically use coaxial wiring, which while fairly im- ization may be looking at reaction times). Another
mune to noise and generally well understood, is heavy example is to check that the instruments are display-
and can create installation headaches. In addition, ing the same information as the bus to confirm the
the move to HD also adds complexity and limits the data the pilot is getting is accurate.

Embedded Computing
Many customers now want better qual-

ity video than older SD cameras offer.
They also want cameras that can cope Rolling Shutter Global Shutter
with being pointed into bright objects
(such as the sun). Older cameras tend to
use Charge-Coupled Device (CCD) sen-
sors that suffer from pixel bleed and be-
come washed out when encountering
bright objects. However, transmitting raw
HD video adds complexity and limits the
number of video frames that can be trans-
mitted and stored. Synchronizing this
video data with other flight test parame-
ters from a Data Acquisition System
(DAS) can also pose a challenge. Dedi-
cated compression cards can solve some
of these issues, but they have negative Figure 1. Global shutters capture the entire frame at the same time, avoiding the smearing effect rolling
implications for size, weight and power shutters can produce.
(SWaP) – all critical factors for FTI.
The extreme environmental condi- ters, which use simultaneous acquisition shortly afterwards at -30°C. Such ther-
tions typical of FTI applications require to capture the entire frame in a single in- mal differences can change electronic
highly reliable cameras ruggedized far stant of time, eliminate motion-induced component impedances as a result of
beyond the levels supported by most in- distortion. Rolling shutters are generally temperature or moisture condensation.
dustrial or commercial cameras. Today, cheaper, however, and can perform bet- FTI cameras should have rugged opti-
a typical FTI system designer uses sepa- ter at low light levels, so they can still be cal windows made of sapphire glass, for
rate camera and video compression sys- useful in some applications. example, to protect against scratches
tems, or stand-alone video cameras, The more modern CMOS sensors and breakage. And they should feature
with simple recording capability. The used in many HD cameras today are im- ruggedized connectors to maximize the
video is not usually synchronized to mune to pixel bleed that CCD sensors camera’s availability. To ensure that en-
other cameras or DAS data. For flight suffer from. They can also commonly vironmental requirements are met, the
test applications, camera data for utilize Wide Dynamic Range (WDR) camera should be qualified to DO-160,
telemetry needs to be coherently syn- techniques to enhance the illumination MIL-STD-461, MIL-STD-464, MIL-STD-
chronized and available for storage. Ide- of a scene. WDR techniques identify 810 and MIL-STD-704 at certified labo-
ally, the data in the telemetry stream particularly bright and dark portions of ratories. Manufacturer testing, quality
should be highly compressed to mini- images and control the saturation of management (ISO 9100, EN/AS 9100),
mize downlink bandwidth. Recorded pixels in those areas. WDR is important and other manufacturing standards
data, on the other hand, should be min- for achieving good image quality and is (IPC-A-610E, IPC-A-600, IPC J-STD-011,
imally compressed to provide maxi- becoming common in commercial elec- IPC/WHMAA-A-620) need to be ad-
mum quality for onboard and post tronics such as cameras and TVs (WDR dressed during the design stage.
flight analysis. is often referred to as HDR in these ap-
plications). Cameras in FTI Applications
Camera Functions and Features FTI camera data is typically sent to
Various image-processing functions Environmental Factors and ground via a telemetry device, and to a
are essential for delivering the appropri- Conditions in FTI recorder. Full HD video at 60 fps can take
ate image quality during test flights. During flight tests, the aircraft must up to 3 Gbps of bandwidth per channel.
Rolling shutter designs, common in execute maneuvers not often encoun- If several HD cameras are required the
consumer cameras, capture an image tered during typical operation. The air- bandwidth required for uncompressed
frame by rapidly scanning vertically or craft and its systems must be pushed to video can overload the data acquisition
horizontally, but the time difference be- their limits to prove the validity of the system. Also, the transmission bit rate
tween different parts of the frame can re- design assumptions and to record the will affect the video quality. Lowering
sult in the distortion of moving ele- safe operational limits. Cameras for FTI the bit rate will reduce the video quality
ments (such as spinning rotor blades) as must be designed to meet stringent and unless the frame rate is decreased.
shown in Figure 1. For flight tests, where harsh environmental requirements in To maintain video quality, changing
the subject being imaged is rotating or order to withstand the extreme vibra- the frame rate has a linear effect on the
moving with high velocity, a ‘global tion, shock, humidity and temperature. suggested bit rate. Video compression is
shutter’ is required to eliminate this For example, an FTI camera may need one method for overcoming some of
smearing effect (Figure 1). Global shut- to operate on a runway at 50°C, and these problems. Compressing HD video
Aerospace & Defense Technology, June 2019 www.aerodefensetech.com 7

Data & Memory Embedded Computing
Exchange Systems
data easily – any pain in terms of dis-

playing this data will be in the software,
We Handle the and this is relatively trivial as long as
you’re using the right formats. Latency
Data, you Focus Figure 2.
is an important issue for replaying data.
Currently, a software solution that can
The HDC-430
on the Mission from Curtiss-Wright is an
example of a new low SWaP IP
parse video from Ethernet data (such as
the widely used Video LAN Client
camera with onboard compression
(VLC)) may take a second or two to dis-
using an industry standard algorithm play what the camera has captured.
can reduce the bandwidth to a more While this is not a big problem for
reasonable amount without signifi- ground personnel who are looking at
cantly affecting the image quality. the feed, it can be an issue for those in
Today’s popular compression schemes the air. A pilot may be examining or try-
for flight test include MPEG2 (DVD ing to control an object in real-time and
videos), H.264 (Blu-ray video discs and the feedback delay between their actions
online streaming), JPEG 2000 (archiv- and the information on the screen can
ing, medical imagery and digital cam- be jarring. To achieve lower latencies,
eras). H.265 is a newer standard that is one needs to process data as quickly as
similar to H.264 but offers about double possible in the encoder and decoder.
the data compression ratio at the same This may have an impact on image qual-
level of video quality (or higher quality ity depending on the required bit rate
at the same bit rate). It is not yet com- and movement in the scene.
mon in airborne imaging due to its For example, if a high-quality repro-
higher processing requirements. duction of a complex moving scene is
Data Transfer Systems A camera that supports onboard required, the processing overhead is
compression and Ethernet packet-based going to be larger and more time con-
and Ruggedized transmission can easily output multiple suming than a lower bitrate stream of a
Memory Cards compression streams over one link. It static image. One way to reduce latency
can do this by creating two data significantly in most applications is to
streams, each of which stores video implement a hardware decoder, as op-
Over 50,000 Fielded Units data in Ethernet packets. One set of posed to software. This would likely re-
packets can contain high bit rate data, duce the time impact of decompression
Guaranteed Survival
the other low bit rate. This can be par- from approximately 1 second to 60 ms.
Hermetically Sealed ticularly useful for FTI. For example, A common requirement for airborne
Supports Declassification two compression rates can be defined displays is to show multiple camera
for the same channel over the same images on one screen. For traditional
Commands
Ethernet connection, enabling the user cameras, such displays require a multi-
Quick Data Erasure to set one data rate for the recorder and plexer to do the physical switching of
a second data rate for Pulse Code Mod- the signals. This means extra hardware
ulation (PCM) transmission. Having and a lot of wiring which increases sys-
Let us help you choose this multiple video output from the tem weight.
camera has the significant advantage of An advantage of IP cameras is that they
the best digital storage removing the need for separate video produce multiple streams and their data
system for compression devices. can be “logically” routed. Physical rout-
your application ing requires dedicated hardware to take
Video Transfer and Playback the signals and direct and/or combine
Moving from the more traditional them, whereas logical routing uses the
860.632.4634 analog camera data to a packetized for- existing Ethernet switch network to route
memory@kaman.com mat requires a paradigm shift. One is packets to a recorder, display, processing
now moving data, not video, so you’ll system, and transmitter as required.
kamanmemory.com
need something that can read the data This article was written by Russell C.
to display it. One tactic is to wrap indus- Moore, Director of Advanced Imaging &
try standard image data in such a way Video Systems, Teletronics – A Curtiss-
that it can be unwrapped into an easily Wright Company (Newtown, PA). For more
readable format for industry standard information, visit http://info.hotims.com/
displays. Recorders can store Ethernet 72994-500.
Free Info at http://info.hotims.com/72994-775 www.aerodefensetech.com Aerospace & Defense Technology, June 2019
Performance That
Powers Every Mission
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delivering value-added integration
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Panoramic Thermal
Imaging Technology
A New Concept in
Naval Defense
S
PYNEL sensors are passive wide discrimination over extremely wide SPYNEL systems have been selected
area surveillance systems with areas, at night and during the day, for their ability to maintain a high de-
automatic intrusion detection whatever the weather. The CYCLOPE tection rate without false positives, to
and tracking capabilities. The automatic tracking software ensures real resist all the vibrations that affect ships
360° thermal sensors offer 24/7 situa- time security against an unlimited and to be stabilized at very high sea
tional awareness by detecting and track- number of conventional and asymmet- state levels. When most ships rely on
ing an unlimited number of targets in rical threats. Hardly detectable targets radar and the use of night vision gog-
real time, on land, air and sea. HGH In- like crawling men, RHIBs, UAVs and gles, with which operators can be visu-
frared Systems recently won a multi- stealth aircraft are detected and their ally impaired in inclement weather,
million contract from a leading ship- distance & geolocation are indicated on SPYNEL provides high resolution imag-
yard, to equip three new warships with the same interface. ing regardless of fog and precipitation
the latest generation of SPYNEL pan - levels.
oramic thermal cameras. Infrared “Radar” Spynel sensors have proven to be ro-
SPYNEL IRST covers a wide range of bust and reliable, while being easy to in-
Real-Time Situational Awareness security & defense applications from tegrate and to maintain. It all began in
SPYNEL continuously rotates to pro- perimeter security at installations such the mid- 2000s, with SPYNEL’s first cus-
vide a full thermal panoramic view of as industrial sites, nuclear plants, dams, tomer: the US Army. As the first SPYNEL
the environment, with unlimited threat power stations, prisons, solar & wind cameras were intended for military ap-
detection capabilities. Each threat, once farms, to VIP events, the fight against plications, they were designed accord-
detected, can be automatically followed piracy and self-protection of ships, to ing to the appropriate military stan-
in a different zoom window, as if it were coastal and border passive surveillance, dards such as IEC 945 (maritime
tracked by multiple PTZ cameras. Algo- FOB protection, and UAV detection. standard), MIL-STD-810 (military stan-
rithms were optimized to distinguish The specific application determines dard), and MIL-STD-461 (EMC stan-
small boats from far-off waves. which SPYNEL system will perform the dard). SPYNEL cameras can be operated
The image quality provided by the IR best based on the required detection in a wide temperature range (from
sensor has a resolution of up to 120- and recognition ranges, the type of -40°C to +71°C) and have been field
Mpixels, at a rate of up to 2Hz. targets to be detected, the site’s tested in diverse environments. SPYNEL
Equipped with advanced Detection perimeter and building configuration, cameras are currently deployed in
Recognition & Tracking software called climatic constraints, and data storage deserts in the Middle East, in tropical re-
CYCLOPE, SPYNEL provides early target requirements. gions in Central America and the

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Lasers & Optics
Image 1. From left to

right : Spynel-M,
Spynel-U, Spynel-C,
Spynel-S, Spynel-X
Caribbean, in countries with very cold for SPYNEL’s maritime applications. sea, choppy conditions, and could effi-
winters in eastern Europe and, of With CYCLOPE's powerful image pro- ciently monitor the entire 360-degree
course, in maritime environments. cessing, the false alarm rate is very low perimeter while docked.
Regarding maritime applications, on- despite waves, vibrations and solar glare.
board surveillance equipment can be Challenges Faced in Developing
subjected to constant wind, temperature Maritime Applications Panoramic Thermal Imaging
changes, moisture and corrosive sea SPYNEL systems used for shipborne Technology
water exposure. The seas’ forceful move- applications can be installed on a mast SPYNEL cameras introduce a unique
ment creates structural vibrations that for the self-surveillance of ships, on off- concept with panoramic thermal imag-
can be harmful to delicate surveillance shore platforms, or on rooftops in port ing. The first and biggest challenge is to
technologies. SPYNEL systems were de- cities. Maritime applications can be explain this new approach to the mar-
signed to take these challenges into ac- both civil and military. Built up to mili- ket and make sure that the client does
count. Specific maritime cameras with tary standards, SPYNEL sensors have al- not assimilate SPYNEL to traditional
anti-corrosion painting and a water ready been chosen by several Navies PTZ (Pan Tilt Zoom) cameras, which are
sprinkler are delivered for these types of and installed on multiple war frigates intended for identification purposes.
applications. The water sprinkler can be and maritime platforms around the The second challenge is to present
controlled remotely to clean the seawa- world. Today, the SPYNEL cameras de- SPYNEL as an alternative to radar, which is
ter out of the lens of the camera. An in- livered to the French Navy almost ten a well-established technology in the mar-
novative optomechanical and digital years ago proved they could effectively itime sector. SPYNEL differs from radar in
stabilization system was also developed detect small wooden watercraft in open many ways. It is a passive system, which
means it is undetectable and cannot be
jammed. It offers a real-time panoramic vi-
sualization, enabling the management of
several detections & recognitions of differ-
ent targets simultaneously. That doesn’t
mean SPYNEL systems and radars are in-
compatible; SPYNEL systems are often in-
stalled in conjunction with radar to pro-
vide a double-layered surveillance system.
To facilitate surveillance, SPYNEL’s CYC-
LOPE software facilitates the merger of
data from radar and AIS (automatic iden-
tification systems).
Maritime Situational Awareness

In order to facilitate the identification
Image 2. Naval defense and security systems must operate in harsh sea environments under of threats as quickly as possible, the data
wartime conditions. from boats can be fused to CYCLOPE’s au-

Lasers & Optics
tomatic thermal detection, for an aug-

mented filtering of threats. CYCLOPE’s
AIS plugin displays AIS data of ships for an
immediate identification. CYCLOPE can
also sort out ships with AIS identification
from targets without AIS data, and detec-
tion can be set out only on targets with-
out AIS, in order to highlight them.
In conclusion, SPYNEL infrared systems
allow for an effective coverage of ultra-
wide areas on land, at sea, for civil, mili-
tary and private applications. Whether at
sea or along the coast, SPYNEL panoramic
cameras provide a constant surveillance,
day and night, even under the worst mar-
itime conditions. They are proven ship-
borne solutions, offering the best Image 3. SPYNEL cameras can effectively detect small wooden watercraft in open sea.
com bination of long-range detection,
panoramic video streaming, and low false
alarm rates. Entirely passive, the systems
operate while being protected from elec-
tronic jamming and camouflaging. The CYCLOPE’s AIS Plugin Displays AIS Data of Ships
cameras are rugged enough to operate For an Immediate Identification
under the harshest weather conditions,
and their innovative technology allows
for a unique optomechanical and digital
stabilization. Robust and compact,
SPYNEL systems are flexible enough to be
used both as a stand-alone surveillance
system or to be part of a complete surveil-
lance solution.
This article was written by Coline David,
Communications Officer, HGH Infrared Sys-
tems (Igny, France). For more information,
visit http://info.hotims.com/72994-501. Image 4. AIS Plugin Display
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Coating
Technology
Enables Effective
Missile Countermeasures
H
eat-seeking missiles have been in use against mentation has become increasingly sophisticated as each
both rotorcraft and fixed wing aircraft since the new generation of systems seek to overcome the counter-
mid-1950s, and countermeasures to deceive measures developed to thwart them. Simply stated, the
their guidance systems have been employed for heat seeking missile relies on the fact that an aircraft en-
nearly as long. Typically, countermeasures operate by gine is significantly hotter than anything else in the sur-
generating a strong infrared signature which confuses rounding environment. Therefore, it emits a strong mid-
the missile tracking system. At the heart of these sys- infrared signal which allows it to be easily identified. For
tems is some form of powerful infrared emitting source. helicopters, in particular, the primary sources of IR emis-
Often this source requires optical coating(s) to perform sion are the engine exhaust duct, any hot engine parts
wavelength filtering needed for optimum operation. How- that can be viewed externally (such as turbine blades),
ever, both the mechanical configuration of the thin film parts of the tail boom that are heated by the exhaust
filter coatings used and the operating extremes to which plume, and the exhaust plume itself.
they are subjected present challenges for the manufac- The peak of aircraft infrared emission is typically in the
turer. 4 μm – 5 μm wavelength range, which also happens to
correspond to the window of high atmospheric transmis-
Infrared Countermeasures sion which occurs in the 3 μm – 5 μm band. As a result,
Since their introduction, heat seeking missiles have a typical IR guided surface-to-air missile can lock on to an
been a particularly successful and deadly threat for mili- aircraft that is over 3 miles away. Additionally, heat-
tary aircraft. In fact, a report issued in 2009 estimated seeking guidance is passive. This stands in contrast to
that over the preceding 25 years, 90% of all US air com- radar, which sends out a signal that must be returned
bat losses had been caused by heat seeking missiles. (and which can therefore be detected by the target). As a
The basic operating principles of a heat seeking missile result, there is no way for an aircraft to know that it is
are relatively straightforward, although the actual imple- being targeted by a heat-seeking missile.

Rotorcraft Technology
The simplest and earliest IR counter-

measures were flares (hot sources) which A) Evaporative Deposition B) Water Absorption C) Magnetron Sputtering
could be dropped by an aircraft. The in- Water
tent is that the missile guidance system Coating
Material
will lock on to these, rather than the air-
craft engine, and thus be lead away from
the real target. However, flares only
burn for a short period of time, and an
Substrate Substrate Substrate
aircraft can only carry a limited number
of them. Furthermore, the pilot must be
aware of being targeted in order to de-
Figure 1. A) Evaporative deposition produces porous coatings which can B) absorb moisture, thus changing
ploy flares. Especially for helicopters, their spectral response. C) Sputtering produces much denser films which are largely impervious to water
which often remain relatively stationary absorption.
in high risk areas for extended periods, a
longer duration (always on) counter-
measure was required. Coating layer – deposition
As a result, heat-seeking missile coun- Optic
rate, and therefore coating
termeasures based on hot sources were thickness, depend upon
first introduced in the 1970s. Most the angle of the optical
commonly, these rely on a block of sili- surface relative to the
con carbide material which is heated material source
until it radiates a significant amount of
infrared energy, specifically in the 4 μm
– 5 μm band utilized by missile tracking
systems.
The first heat-seeking missiles utilized
a rotating reticle in their imaging sys-
tems which would sweep over the image Coating atoms travel in
of the target. When the target is off-cen- essentially a straight line
ter, this reticle movement causes a from the source to the optic
pulsed signal to be produced. When the
target is centered on the sensor, the sig- Material Source
nal becomes constant. This constant sig-
nal was required by these early missiles Figure 2. The long mean free path of coating material molecules in vacuum deposition techniques makes
in order to indicate that the target had layer thickness highly dependent upon the orientation of the optical surface relative to the material source.
been acquired, and thus allow a launch.
Typically, the countermeasures for While subsequent generations of perature range, typically around -55°C
these types of trackers employ a cylin- some missile guidance systems have to 600°C. It must be able to survive a
drical mechanical shutter that sur- moved past this simple reticle-based rapid rise in temperature (to around
rounds the hot source and modulates its technique, advances in the operation of 400°C) when the source is first powered
output. The resultant stream of infrared the countermeasure systems have con- on. In addition, throughout this entire
pulses is approximately synchronized tinued to maintain their effectiveness. temperature range, the coating trans-
with the rotation speed of the reticles, And, the basic concept of using a bright mission characteristics must remain rel-
thus producing a spurious signal that mid-IR source to jam or confuse the atively constant.
prevents the tracking system from lock- missile tracking remains unchanged. The second challenge is that of uni-
ing on to the target. Alternately, for a In some countermeasure systems, the formly coating a cylinder around its en-
missile already in flight, the IR pulses hot silicon carbide block is surrounded tire circumference. The specifics of both
from the countermeasure confuse the by a cylindrical tube, which is optically these issues, and solutions to them, are
targeting system causing it to veer off coated to modify the spectral output of examined in the following sections.
course. The countermeasure system can the source in order to further optimize
be either placed directly on the rotor- its effectiveness. The advantage of a Coating Densification for Stability
craft structure, or, in some cases, in a cylindrical tube is that it makes the Multilayer thin film coatings selectively
towed pod. The latter is employed be- angle of incidence on the coating uni- transmit and reflect different wavelengths
cause sometimes the bright infrared form (90°) in all cases. However, pro- based on the thickness and refractive
output of the countermeasure actually ducing such a coating presents two sig- index of the individual layers. The most
works to improve the lock of the missile nificant problems. First, the coating is widely utilized optical thin film coating
on the target. subjected to a very wide operating tem- technology is thermal evaporation, which

Rotorcraft Technology
at all) as surfaces which are perpendicular

to the material travel. The resultant spa-
tial variations in layer thickness across a
Tubes to be coated part caused by this situation lead directly
to unwanted variations in the wave-
length characteristics of the coating.
Because of this, uniformly coating
Part rotation
any kind of highly curved optic (domes,
steep aspheres, tubes, spheres, etc.)
using traditional deposition technology
Part holding rods is challenging. Traditional coating of a
shape like a cylindrical tube or full
sphere also requires first coating one
Chamber drum rotation half of the part, and then turning the
parts and performing a second coating
run. This essentially doubles produc-
Figure 3. Specialized tooling within the DSI MicroDyn® sputtering chamber causes continuous part rotation costs and time.
tion during coating, resulting in highly uniform deposition around the entire tube circumference. The circular symmetry of the tubes
that DSI coats for countermeasure appli-
uses either resistive heating or electron semiconductor) coating targets are cations provided an opportunity for the
beams to vaporize the source material(s). arranged around the circumference of the company to engineer customized tool-
Evaporation is popular because it is com- chamber. These targets are biased with a ing for the MicroDyn® sputtering sys-
patible with a wide range of source mate- negative voltage and immersed in a mag- tem that would enable production of a
rials, can be used to produce thin films netic field. Electrons leaving the target uniform coating around the entire cir-
from the deep ultraviolet through the far are contained in the vicinity due to this cumference of the cylinder in a single
infrared, and is highly cost effective. magnetic field. The electrons collide coating run. In this case, each individ-
However, evaporation is a relatively with the sputtering gas atoms and ionize ual tube is mounted on a rod within the
low energy process. As a result, the coat- them, and these ions are accelerated to- coating chamber, and this tooling is
ing material atoms or molecules don’t wards the target(s) because of their elec- configured so that the rods rotate
pack in tightly in the resultant thin film, trical potential. When these ions impact throughout the coating process in a way
making the layers somewhat porous. the target, they cause atoms or molecules that is synchronized with both chamber
This means the coating layers can subse- to be ejected (sputtered) and deposited motion and the sputtering deposition
quently absorb moisture, which changes on to the optics. Because the sputtered process. The result of this motion is
their effective refractive index, resulting target atoms are ejected with a large that every area on the outer surface of
in a shift in the coating’s transmission or amount of energy, they pack densely into the tube is exposed to the coating mate-
reflection properties. This problem is fre- the thin film. Thus, this approach en- rial source for the same amount of time,
quently of concern in military and aero- ables production of coatings that have producing uniform layer deposition
space applications, because the optic both the spectral performance character- around the entire tube circumference.
may be exposed to large swings in ambi- istics and the necessary environmental
ent temperature and humidity. stability essential for countermeasures Conclusion
Sputtering is a coating process which and other military applications. Coatings for military and aerospace ap-
increases the energy with which mole- plications often require performance over
cules impact the substrate surface. Con- Coating Highly Curved Surfaces a very wide range of ambient conditions,
sequently, the various forms of sputter- Another limitation of most thin film necessitating fabrication methods that
ing result in coatings that are coating techniques, including both evap- yield highly dense and stable thin films.
substantially more densified than is oration and sputtering, derives from the Plus, the size and weight constraints of
possible using evaporation. This makes fact that they are performed under mod- many of these applications also drive de-
sputtered coatings essentially impervi- erate to high vacuum conditions. This signers to use odd shaped components.
ous to water absorption and its atten- produces a relatively long mean free path Combining sputtering technology with
dant performance shifts. for the coating material molecules, mak- innovative tooling concepts can meet the
Deposition Sciences utilizes a propri- ing deposition occur essentially in a line challenges of providing thin film coat-
etary variant of magnetron sputtering, of sight to the material source. As a re- ings that meet these requirements.
called MicroDyn®, which is performed in sult, any surfaces that are “shadowed” by This article was written by Ryan Mc-
a chamber under low vacuum condi- others from the material source, or which Daniel, Material and Process Engineer Sr.,
tions. Here, parts for coating are held on don’t face perpendicular to the direction Deposition Sciences, Inc., (Santa Rosa,
a rotating drum within the chamber and of material travel, don’t experience depo- CA). For more information, visit http://
several electrically conductive (metal or sition at the same rate (or any deposition info.hotims.com/72994-502.

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Diminishing U.S. Combat Superiority Drives
New Software Development Requirements
U
.S. rival countries have Future Airborne Capability Environment The FACE Consortium membership ac-
been rapidly moderniz- (FACE) Consortium has established an complishes its function through sponsor-
ing their militaries, with open procurement environment that fa- ship and support by all the U.S. armed
publicized advances that cilitates reuse to meet four core goals: im- forces, primes such as Boeing, principal-
pose credible challenges prove affordability, speed, agility, and ex- level members such as Northrop Grum-
to U.S. supremacy in all cellence. The FACE™ Consortium is a man and over 80 associate-level members
aspects of warfare: air, land, sea, space government and industry partnership such as LDRA. All are working together on
and cyberspace. On January 19, 2018 dedicated to accomplish this using open the business and technology aspects of the
Secretary Mattis discussed the National industry standards, advanced integra- FACE Conformance process. Documents
Defense Strategy and emphasized the tion, and maintenance technologies. that include the FACE Technical Standard,
need to modernize key capabilities to FACE Business Guide, and FACE Confor-
address these threats. He stated: “To Capabilities Behind the FACE mance Verification Matrix are just a few ar-
keep pace with our times, the depart- Approach tifacts guiding suppliers towards the devel-
ment will transition to a culture of per- Since its inception in June 2010, the opment, release, and offering of FACE
formance and affordability that operates FACE Consortium has been addressing Certified Conformant Products. Members
at the speed of relevance. Success does the challenge confronted by next gener- like LDRA are incorporating solutions into
not go to the country that develops a ation Department of Defense (DoD) air- its offerings to remove implementation
new technology first, but rather, to the craft or military avionic systems in ac- ambiguity and to pave a path forward.
one that better integrates it and more quiring advanced capabilities while After a software package has been sub-
swiftly adapts its way of fighting. Our curbing the cost to procure and maintain mitted and received passing marks by
current bureaucratic processes are insuf- the platform over its intended lifecycle. the Verification Authority and the Con-
ficiently responsive to the department's Therefore, an ecosystem was created formance Verification Test tool suite, the
needs for new equipment. We will prior- where there is an open hardware, open software package or now unit of confor-
itize speed of delivery, continuous adap- operating system, open middleware, mance (UoC) can be released by the sup-
tation and frequent modular upgrades.” and open applications setting, which plier and registered in the FACE Certified
Avionic systems are a case in point. could be served by any supplier in the Product Registry, available for sale.
They have been on an unaffordable defense industry, large or small. As a re-
trend due to complexity and cost, partic- sult, any FACE software component can The FACE™ Technical Strategy
ularly in the evolution from hardware- be moved or ported from one DoD air- The FACE Technical Strategy is to pro-
defined systems to modern software-de- craft platform to any other relevant vide a software environment that enables
fined systems, where the costs to war-fighting platform with minimal in- moving FACE applications from one DoD
develop, integrate, and maintain soft- tegration complexity, on any desired aircraft or war-fighting platform to an-
ware continues to grow at an unsustain- hardware target, paving the path to a other with minimal software changes to
able rate. In response, The Open Group best-fit-for-the-cost solution. the FACE application. This software envi-

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ronment is referred to as the FACE Refer-

ence Architecture, which employs design
Next Military principles to enhance software portability
Vehicle such as providing a common set of inter-
Unaffordable!
faces to the portable FACE application.
F-35 This is all defined in the FACE Technical
~9.5 Million SLOC
Software ~17 yrs. Start->EIS Standard Edition 3.0, the most current re-
Hardware Integration
Dominant
GAO-12-437 page 18 6/2012
lease available.
Time/ Dominant The FACE Reference Architecture is
Cost B787 comprised of five layered segments
A380 where a FACE portable capability or
F-22 Unit of Portability (UoPs) may reside:
B-2 A380 • Operating System Segment (OSS)
• Portable Components Segment (PCS)
A340 B787 Next
F/A-18
B777 ~10 Million SLOC Military • Transport Services Segment (TSS)
F-16 ~7 yrs. start-> EIS Vehicle • Platform-Specific Services Segment
F-14 A320 Boeing quoted in
A-10 Possible!
NYC Aviation, 9/28/2011
(PSSS)
B737 A300/B747
Complexity/SLOC • I/O Services Segments (IOSS)
GE’s CCS, “open” IMA computing and tools reset “the curve” for Boeing 787 To manage variance and deliver porta-
“...Paradoxically, some of the most complex areas - such as the software-intensive common core system [CCS] at the bility, a common set of standardized in-
heart of the 787’s avionics and systems architecture - have proved robust and stable...CCs has been rock solid for us.”
Scott Fancher, Boeing 787 vice president and general manager, 02/15/2010 Aviation Week & Space Technology terfaces providing the connections be-
tween the FACE Architectural Segments
Figure 1. The Unaffordable Trend in Modern Systems (© GE Aviation) has been defined.
Operating System Segment

FACE The OSS UoPs provide typical POSIX,
Operating System Segment ARINC 653, or HMFM APIs as defined
Portable Components Segment by the FACE Technical Standard to
Common Services and Portable allow UoPs to move from one FACE
Components reside here
FACE defined
Conformant OS to another FACE Con-
TS
interface set formant OS.
Transport Services Segment
Portable Components Segment
All communication, including inter-UoP communication,
is achieved through message-based transport The PCS is where 80 to 90 percent of
middleware which resides in this segment
the typical software portable capabili-
TS FACE defined ties or UoPs exist. UoPs such as tracking
interface set
and navigation that are not tied to any
Platform-Specific Services Segment data transport or operating system im-
plementations live here. Consequently,
Standard UoP-level data products and indirect
hardware access are provided by this segment most portable capabilities between plat-
forms happen here. The UoPs in this
FACE defined
IO interface set segment can utilize two of the well-de-
fined interfaces in the FACE Technical
I/O Services Segment
Standardized, but indirect hardware Standard: the OS interface and the
access is provided by this segment Transport Services interface.
Hardware
Device Drivers
Transport Services Segment
The TSS contains UoPs that exist to
move data between the portable compo-
nents that reside in the PCS. This seg-
Interface Hardware ment removes the concern on how the
(i.e., MIL-STD-1553, Ethernet)
data is transported, freeing the devel-
oper from needing to deal with data
Platform Platform Platform User Input Platform Other conversion or any other transport detail.
Devices Sensors Displays Devices Radios Transports
TSS UoPs are also responsible for data
distribution between the PSSS UoPs. The
Figure 2. FACE Architectural Segments (© The Open Group) TSS also uses the OS interface.

Platform-Specific Services Segment

The PSSS is comprised of three sub-segments. The UoPs in
this segment are typically tied to a particular platform and
hence are less portable, such as UoPs that abstract the inter-
face to specific GPUs and other platform-unique interfaces.
The PSSS uses the OS interface, the I/O interface, and the TSS
interface.
I/O Services Segment

The IOSS lives to communicate with device drivers and pro-
vide the PSSS with access to I/O information. The IOSS UoPs
form abstractions to specific graphic displays, specific sensors,
or transport methodologies, such as CORBA, DDS, UDP, or TCP.
FACE Data Architecture

Because FACE applications need to exchange data, data-cen-
tric interfaces and common terminology have also been de-
fined. This allows integrators and subsystem developers to un-
derstand the data needs of all their UoPs; to describe the
things they want to communicate including the data going
into or coming out of a UoP; and to enable the integrator to
combine UoPs to provide a larger capability. The FACE Data
Model Language was defined to document this data exchange
and answer questions about the UoP, its relationships, and the
data types.
FACE Data Model Language

The FACE Data Model Language is specified by the open
and platform-independent Essential Metadata Object Facility
(EMOF) metamodel, raising the level of abstraction to help
manage complexity, where these models can be exported
from one application, imported into another, transported
across a network, stored in a repository, and then retrieved.
EMOF models can also be rendered into different formats
such as XML Metadata Interchange (XMITM) and the Unified
Modeling Language (UML). Additionally, the Object Con-
straint Language (OCL) can also be applied to the EMOF
model. This makes it more precise by associating assertions or
constraints that supply semantic rules to which the data
model content must adhere. OCL also provides object query
expressions that cannot otherwise be expressed by diagram-
matic notation.
FACE Conformance
The FACE Technical Standard is a robust document contain-
ing all requirements needed for a UoP to conform to, in order
to be certified. However, the FACE Consortium established a
FACE Conformance Program with associated conformance
criteria, process, and policy following the process or lifecycle
consisting of Verification, Certification and Registration of
the UoP. To assist with verification, a Conformance Verifica-
tion Matrix (CVM) was created. Though the CVM does not re-
place the FACE Technical Standard, it provides the Product
Standard and clarifies the Conformance Requirements that a
UoP must meet.
As shown in Figure 4, to expedite delivery of your UoP and
enable adoption, LDRA offers an integration package that sup-
Aerospace & Defense Technology, June 2019 Free Info at http://info.hotims.com/72994-781 21

the UoP has received a passing verdict,

the software supplier may submit the
Verification Results Package to the
Certification Authority (CA). The CA
then assesses the verification results
package, manages legal agreements,
and issues a FACE Conformance Cer-
tificate.
The final step is registration. The
software supplier submits the FACE
Conformance Certificate, the UoP de-
Figure 3. Example FACE Metamodel “face” Package and in XMI format (© The Open Group) scription, and metadata to the FACE Li-
brary Administrator who reviews and
confirms the FACE Conformance Cer-
tificate. Certified UoPs will maintain
certification as long as the software
product remains the same as defined by
the Conformance Statement and all
legal agreements are met. The Library
Administrator then updates the Reg-
istry with the UoP description, meta-
data, and FACE Conformance Certifi-
cate ID. Government stakeholders can
then search the FACE Library for FACE
Certified Products to procure.
Affordability, Speed, Agility and

Excellence
Figure 4. The LDRA tool suite imports the FACETM CVM, further enhancing and simplifying efforts in
achieving verification and UoP conformance The Army FACE Technical Inter-
change Meeting (TIM) was held on
ports all five segments of the FACE 2.1.1 dard. Furthermore, the test suite is used Tuesday, September 18th, 2018 at the
and version 3.0 reference architecture. by a FACE Verification Authority (VA), Von Braun Center in Huntsville Ala-
Once a software segment is selected, the which is an entity officially sanctioned bama. Keynote speaker Ms. Philomena
conformance verification matrix is im- by the Steering Committee to conduct Zimmerman, Deputy Director of Engi-
ported, and LDRA then guides the user or witness For-the-Record verification neering Tools and Environments, Of-
through its workflow, consisting of test- testing and verify adherence. Nonethe- fice of the Deputy Assistant Secretary of
ing activities, artifact placeholders, and less, the CTS is made available, so that Defense, Systems Engineering ad-
template documents. software suppliers who want to con- dressed the FACE Consortium and
form to the FACE Technical Standard Brigadier General Thomas H. Todd III,
Conformance Verification Matrix can self-verify to correct any undiscov- U.S. Army, Program Executive Officer,
The CVM has been implemented ered errors the tool suite may expose, Aviation delivered opening remarks.
within a spreadsheet that offers the abil- and obtain peace of mind before sub- The Open Group FACE Consortium
ity to filter content based on the FACE mitting the UoP to the VA. The CTS is members demonstrated how scalable
Architectural Segment the UoP is target- also hosted on Microsoft Windows, Red multi-domain operations are readily
ing, including all the requirements to be Hat Enterprise Linux, and CentOS. achieved through FACE Conformant
satisfied. The CVM supports each offi- Test summary results besides a applications. In this way, system-of-sys-
cial edition of the FACE Technical Stan- pass/fail verdict rendered by the CTS are tems integration is not only possible
dard and is used in conjunction with a captured and documented. It will con- but can be achieved in a rapid manner
corresponding version of the FACE tain a summary of each test case result, with safety and security built in, verify-
Conformance Test Suite, which tests test configuration settings, version of ing objectives in affordability, speed,
software adherence to the FACE Techni- the CTS used, date and time of the test agility and excellence.
cal Standard. run, edition of the FACE Technical Stan- This article was written by Ricardo Ca-
dard applied, and more. macho, Technical Product Marketing Man-
FACE Conformance Test Suite ager, LDRA (Wirral, UK). For more infor-
The FACE Conformance Test Suite FACE Certification and Registration mation, visit http://info.hotims.com/
(CTS) is used to test software and verify Once the Verification Authority 72994-503.
adherence to the FACE Technical Stan- completes its verification process and

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Figure 1. Microwave Office (MWO) schematic for the ideal power load and match (12 x 100-µm HEMT—nom-
band, gallium nitride (GaN) fabrication inal DC bias).
process and a process design kit (PDK)
that ARL used to design low-noise am- initial design was performed of an ideal, impedance and negative “CDS” normal-
plifiers, power amplifiers, and other cir- double, tuned, Q bandpass match for ized capacitance showed good broad-
cuits for future radar, communications, broadband operation centered around band performance. The ideal output
and sensor systems. After the first set of 4.5 GHz, with a goal of achieving 2 to 10 match is close to the ideal RLoad load
ARL and Raytheon designs was submit- GHz. A schematic of the ideal load as a line of a 1.2-mm HEMT from 3.5 to 6
ted for fabrication, test designs of resistor in parallel with a capacitor and GHz, while the MMIC output match un-
broadband Class A/B power amplifiers the ideal, double, tuned output match- dershoots the real part of the impedance
were developed. While these designs ing circuit is shown in Figure 1. but stays very close to 95% of RLoad
did not get fabricated in the initial ef- After designing a lumped-element over a broader range of 3 to 7 GHz. Since
fort, they serve to demonstrate the per- output match, the capacitors and induc- an ideal reactance equivalent to a nega-
formance, bandwidth, and capability of tors were replaced with monolithic mi- tive CDS capacitance can only be main-
this GaN process and could potentially crowave integrated circuit (MMIC) ele- tained over a finite bandwidth, the out-
be fabricated in the future. ments from Raytheon and retuned to put matching circuits match well over
achieve a broadband match. Then mi- the band, diverging at the low end of
Broadband Power Amplifier crostrip bends, tees, and decoupling ele- the frequency range (2 to 3 GHz).
The preliminary design of a single, ments for the DC bias were added to After designing the output match for
high-electron mobility transistor (HEMT) complete a layout of the MMIC output the broadband power amplifier, the S-
and 2-way parallel combined HEMT match. A simulation of the output parameters of the 12 × 100-µm (1.2-mm)
power amplifier was performed. These match showed a better than 20-dB re- HEMT are generated at the nominal DC
initial broadband power amplifiers are turn loss from 2.3 GHz to above 8.7 GHz bias. Initially, these S-parameters were
By Baiploo/Shutterstock.com
based on a 12 × 100-μm HEMT at a nom- versus the ideal lumped-element, double exported from Advanced Design System
inal recommended DC bias. This size tuned match with slightly less band- (ADS) and imported into Microwave Of-
HEMT had an optimal match provided width but an excellent match midband. fice (MWO) to perform an initial ampli-
by Raytheon as “RLoad” ohms in paral- Comparing the impedance match of fier design. Small-signal stability was an-
lel with a negative “CDS” pF in capaci- the ideal lumped-element output match alyzed and established with a shunt
tance. Since a negative reactance can to the lossy MMIC output match over resistor and a parallel series resistor and
only be matched over a limited band, an frequency to the ideal RLoad normalized capacitor on the gate of the HEMT.

After stabilizing the 1.2-mm HEMT,

the input impedance at midband (4.5
GHz) was simulated, resulting in a
higher Q matching impedance (Q = 2.4)
than the output, making it more diffi-
cult to broadband match the power am-
plifier input. An initial ideal input
match provided better than 10-dB re-
turn loss from 3.5 to 6 GHz but was lim-
iting the amplifier bandwidth com-
pared to the output matching circuit.
An ideal, coupled line provided a
broader frequency range for the input
match, while sacrificing additional loss.
A preliminary ideal transmission line
input matching circuit provided good
performance from 2 to 7 GHz. The ideal
input matching elements were replaced
with MMIC components resulting in
two relatively large inductors. Next, the
folded, spiral, coupled line required
electromagnetic (EM) simulation to ver-
ify its performance. A pseudo layout of
the full one-stage, 1.2-mm, 2- to 8-GHz Figure 2. Unfinished layout of the broadband (2- to 8-GHz) 1.2-mm GaN HEMT power amplifier.
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SINCE 1968

the power amplifier using the original for the MMIC 1.2-mm HEMT amplifier
ADS
lossless element input and output was within 85% (0.6 dB) of expected out-
matching circuits was simulated. Out- put power with 50% PAE at 4.5 GHz. In
put power and efficiency is slightly comparison, the ideal version of the 1.2-
hemt_DCIV..IDS.i
higher in comparison for the broad- mm power amplifier was 100% (0 dB) of
ts(I_IDS.i)
band, 1.2-mm HEMT power amplifier expected output power with 57% PAE. As
with lossless matching elements. expected, the 2-way combined ideal am-
In addition to the 1.2-mm broad- plifier has double the output power with
band power amplifier, a 2.4-mm similar bandwidth and efficiency, show-
power amplifier was implemented ing double the power of a single 1.2-mm
using two parallel combined 1.2-mm HEMT with 55% PAE at a comparable
ts(Vds) HEMTs. First, the ideal output match gain compression level.
hemt_DCIV..VDS
for a single 1.2-mm HEMT was trans-
Figure 3. ADS dynamic load line simulation of the formed from a 50-W output match to Conclusion
broadband (4.5-GHz) 1.2-mm HEMT power amplifier. 100 W so that two devices could be A preliminary design of a broadband,
easily paralleled into a 50-W load. This 1.2-mm HEMT power amplifier and a
power amplifier is shown in Figure 2; simple lossless combiner circuit would 2.4-mm HEMT power amplifier using
note the large area required for the need to be modified to supply DC Raytheon’s GaN process was performed.
broadband input match. bias, and there are a several easy ways The intent was to explore the band-
to modify it. The 2-way combiner out- width and performance of a Class A/B
Performing Simulations put matching circuit has the same biased 1.2-mm HEMT power amplifier
With a preliminary layout and broadband return loss, with a better designed to maximize bandwidth, out-
MWO simulations for a stable, broad- than 20-dB return loss match to the put power, and PAE over the 2- to 8-
band power amplifier from 2 to 8 GHz ideal load from 2.7 to 7.6 GHz. GHz band. Trying to increase the band
based on a 1.2-mm GaN HEMT, the ADS was used to simulate the per- to 2 to 10 GHz would certainly require
next step was to perform nonlinear formance of the broadband power am- more matching losses to extend the
simulations using the design kit and plifier as a 2-way combined (2.4 mm) bandwidth.
ADS. The nonlinear HEMT model HEMT power amplifier using the ideal A similar 2-way combined, 2.4-mm
within the ADS Raytheon design kit is output matching circuit. The input of HEMT power amplifier should achieve
needed to do performance simula- the 2-way combined amplifier was sim- comparable performance based on a
tions. MWO schematics for the MMIC ulated as two of the coupled line ideal preliminary design using ideal, lossless
input and output circuits were trans- input matching circuits into a 25- W matching elements. For the one-stage,
lated into ADS schematics. Ideal bias source. Output power would be ex- 1.2-mm HEMT design, a preliminary
tees were added to provide the DC bias pected to double (+3 dB), with similar layout was implemented, including EM
as a convenience to simulating the efficiency and bandwidth in compari- simulations of critical elements such as
ADS schematics, though the matching son to the single 1.2-mm HEMT power the folded coupled line for the broad-
circuits have the appropriate compo- amplifier. Performance simulation at band input match.
nents for DC and RF decoupling. This the frequency of 4.5 GHz, with output These designs illustrate broadband,
power amplifier design would still power equal to that expected and PAE Class A/B power amplifiers using a 1.2-
need design rule checks (DRCs), layout of 55% for a lossless matched broad- mm HEMT cell, which should provide
versus schematic (LVS), and final EM band, 2.4-mm HEMT single-stage power good efficiency with matching network
simulations. amplifier was performed. losses within 0.6 dB of ideal at these fre-
A dynamic load line simulation at Losses for the MMIC output match quencies at the recommended DC bias.
the center frequency of 4.5 GHz for the were calculated to be a reasonable 0.3 dB To get these designs ready for fabrication
one-stage power amplifier at nominal over most of the band, with up to a 0.5- would require additional steps to per-
DC bias is shown in Figure 3. As an ad- dB loss at the low end of the band — 2.5 form full EM simulations, simulate
ditional verification, ADS was used to to 3 GHz. Additional losses on the MMIC process variation effects, and perform
repeat the small-signal S-parameter input match would similarly affect small normalized determinant function stabil-
simulations but with the nonlinear signal gain and PAE. ity analyses. The Raytheon process is
HEMT model at the nominal DC bias. The performance data were typically 3 very capable for high-power RF ampli-
The gain seems a little higher than the to 4 dB compressed for the Class A/B, bi- fiers and robust low-noise amplifiers for
previous simulations in MWO but the ased power amplifier. For the ideal 2.4- receivers.
return loss and gain with frequency mm power amplifier, the input power This article was written by John E. Penn
has a similar shape, as expected. level is 3 dB higher, corresponding to a 3- of the Sensors and Electron Devices Direc-
To get a measure of the losses due to dB higher output power, with the same torate at the Army Research Laboratory,
the physical MMIC output, input, and large signal gain as the ideal 1.2-mm Adelphi, MD. For more information, visit
matching circuits, an ADS schematic of power amplifier. Nominal performance ARL at www.arl.army.mil.

Multi-Agent RF Propagation Simulator
A desirable interface between multi-

agents is through over-the-air RF
connections that include not only the
intended direct RF communications
paths but also highly variable multi-
ray propagation, range attenuation,
external RF influences, and near-earth
influence. These influences are all dif-
ficult to predict, control, and repeat
in an outdoor environment. This out-
door testing, as has traditionally been
done, is extremely expensive while si-
multaneously providing fewer data
points than more controlled events
and the testing events are generally
not repeatable.
Currently, in certain types of an-
tenna design fields, the correlation be-
tween model and simulations (M&S),
hardware-in-the-loop (HITL) testing,
and open-air range (OAR) testing is
minimal. Open-air test ranges intro-
duce many uncontrolled variables that
not only affect the performance of an
RF communications system but also
impact the quality of the test data.
Such variables include the ambient
electromagnetic environment (EME) Accurately modeling RF communication systems in the lab can better assure optimal functionality in the
that the RF system is operating in; an- field.
tenna placement and placement as
compared to other antennas; soil path control modules, spectrum ana- system. Relative signal strengths are
properties; physical terrain; multi-ray lyzer, EME generator, and device pairs modified not by physically moving
reflection signals; desirable, undesir- for sending and receiving RF signals. the RF devices or by changing the sig-
able, and hostile signals each disrupt- MARPS improves RF system designs, nals by adjusting the generating RF
ing functionality; and general system reduces the OAR testing time, saves device, but instead by manipulating
variability, among other factors. The money in the development of future the MARPS system paths to simulate
multiplicity of these variables impacts RF system technology, improves the such interactions.
the quality of the data gathered and correlation between models and sys- As a cellphone moves through an
makes it difficult to determine cause tem performance, increases test re- environment, the signal strength of
and effect. Basically, the results of the peatability of real environments, and the cellphone will vary based on a
open-air test are not repeatable and increases the ability to test new real- multitude of factors including ob-
the phenomenology is not clear. world complications that the RF sys- structions, other signals present, and
Navy scientists have developed a tem encounters. MARPS addresses even ground effects. A MARPS system
device to reproduce open-air, near- these needs by a variety of results/ef- can help create a more reliable cell-
earth effects in a lab setting. Known as fects including simulating an OAR test phone or cellphone system by provid-
the multi-agent radio frequency prop- scenario in a laboratory using a coming reproducible tests to developers
agation simulator (MARPS), the elec- puter, other RF equipment, and a set without incurring the great expense
tronics system reproduces real-world of digitally controlled RF paths. of open-air testing. Other examples of
effects and accounts for all donating The MARPS device and approach uses for a MARPS system would be in
signal competition. The signal propa- could be used to test a cellphone sys- designing more robust police scan-
gation simulator determines the per- tem in the presence of interfering signers, garage door openers, and other
formance of a communications sys- nals where the cellphone being tested RF systems.
tem prior to OAR testing. is directly plugged into the MARPS For more information on this technology,
The path simulator includes a sys- system and the interfering devices are contact Sean Patten at spatten@
tem controller, data sequencer, RF also directly plugged into the MARPS montana.edu; 406-994-7721.

Tech Briefs
Electrical Characterization of Crystalline UO2, THO2 and

U0.71TH0.29O2
Evaluating the suitability of advanced alloys for use in uranium-based neutron detectors.
Air Force Institute of Technology, Wright-Patterson Air Force Base, Ohio
trons than 238U in materials of

T racking and identifying radia-
tion sources in the age of nu-
clear proliferation and well- re-
Uranium Neutron Fission Cross Sections the same density. In comparison,
10B has a thermal neutron absorp-
104
sourced non-state actors is a tion cross section 6.55 greater
national priority. Current neu- than the thermal fission cross sec-
tron detection methods favor 10
tion for 235U. However, for neu-
Cross Section, barns
large detector volumes and long trons at 1.6 MeV, 235U has a 4×
-2
data collection times. Addition- 10
U-235 larger fission cross section and
ally, portable neutron detection 238U has a 2× larger fission cross
U-238
methods have persistent prob- 10-5 section than the 10B neutron ab-
lems with low signal-to-noise sorption cross section of approxi-
(small pulse height) and require 10-8 mately 0.5 barns. Therefore, for
large applied voltages. fast neutron detection, the ura-
Conventional neutron detec- 10-11 nium cross section is preferred.
tion usually employs scintillators, 10-11 10-9 10-7 10-5 10-3 0.1 10 A uranium-based neutron detec-
Neutron Energy, MeV
gas proportional tubes, or semi- tor has a substantial energy output
conductors with separate conver- The microscopic fission cross sections for 235U and 238U as a function advantage as compared to conven-
sion layers that convert neutrons of neutron energy. tional neutron detection devices
to charged reaction products. The that incorporate non-fissile or fis-
challenge in conversion-layer devices is conducting boron carbides have re- sionable neutron conversion materials.
to construct a layer of adequate thick- cently garnered interest because a high- The fission of uranium results in two or
ness for neutron capture that is also quality electronic material can be made more charged fission fragments with 168
thin enough to allow the resulting reac- that incorporates 10B as a component of MeV, having the potential of producing
tion products to interact with the the semiconductor material. more than 25 million electronic transi-
charge-sensitive areas. Standard conver- Another consideration in 10B based tions across the UO2 2.1 eV band gap. The
sion-layer devices typically employ 30 neutron detectors is the energy depend- resulting high-energy fission products
to 40 μm of enriched 10 B due to the ence of the capture cross section. For may, however, degrade the electronic
high thermal capture cross section of thermal neutrons (0.025 eV), the cap- properties of the UO2 either due to forma-
the isotope 10B and the ability for the ture cross section for 10B is about 3840 tion of point defects or because of subse-
energetic Li (0.84 MeV) and α (1.47 barns. However, for neutrons of 1.6 MeV quent decays and transmutations provid-
MeV) daughter particles to escape. The (the mean energy of prompt fission neu- ing a larger internal background noise
conversion layer thickness is thus a trons from 235U) the 10B absorption cross signal. A further consideration is that
compromise between the neutron inter- section is 0.2 barns. Therefore, to achieve uranium requires special handling pro-
action rate and the ability to capture the the highest detection efficiency for neu- cedures, especially if enriched, to take
charge in an electrically active medium. trons from fission, 10B based neutron de- advantage of the higher fission cross sec-
Some novel solid-state technologies tectors require neutron moderation, re- tion of 235U, as opposed to the more nat-
provide a thin-film neutron detector sulting in a loss of efficiency either due urally abundant 238U. Therefore, this re-
consisting of a (or a stack of) semicon- to scattering out or capture outside of the search will help to understand the
ductor diode(s), each surrounded by a detection medium. Similar arguments tradeoffs with uranium-based detectors
thin neutron-absorbing material. can be made for other conventional neu- made from UO 2 , UO 2 /ThO 2 , and
As an alternative to a conversion tron conversion materials. U 0.71 Th 0.29 O 2 using 238 U, before the
layer, the conversion atoms can also be For 235U, the thermal fission cross sec- complications of using and managing
incorporated into the detection me - tion is 585 barns and the fast neutron 235U are considered.
dium (gas, scintillator, or semiconduc- (1.6 MeV) fission cross section is 2 barns This work was done by Lieutenant
tor). This method has the advantage of as shown in the accompanying figure. Colonel Christina L. Dugan for the Air
a more efficient structure to capture the Also, the 238U thermal fission cross sec- Force Institute of Technology. For more in-
reaction products, but often results in a tion is 16.8 microbarns and its fast neu- formation, download the Technical
reduced electronic signature (or in the tron (1.6 MeV) fission cross section is 1.1 Support Package (free white paper) at
case of scintillators, reduced light out- barns. Therefore, 235U is approximately www.aerodefensetech.com/tsp under
put). As an example, icosahedral semi- 2× more likely to fission with fast neu- the Sensors category. AFRL-0272

Tech Briefs
ONR Short Pulse Research, Evaluation and non-SWaP

Demonstration for C-sUAV Study
Research project is designed to map small unmanned aerial vehicle (sUAV) effects space, empirically and by
simulation, as a function of high power microwave (HPM) waveform to develop effective countermeasures.
Office of Naval Research, Arlington, Virginia
T he OSPRES (ONR Short Pulse Research,

Evaluation and non-SWaP) program
performed fundamental work in the areas
of Silicon (Si) and Gallium Nitride (GaN) When it comes to
based photoconductive switch develop-
ment, measurement of HPM waveform protecting critical
dependent effects on small unmanned
aerial vehicle (sUAV), adaptive design of sensing equipment...
experiments, noise injection, RF coupling
to sUAV’s, minimally dispersive wave the-
ory, and positive feedback non-linear
transmission line (NLTL) development.
The photoconductive solid state
switch (PCSS) subgroup worked to de-
velop a fundamental understanding of
the limitations of Silicon and Gallium
Nitride based photoconductive switches
and their application to pulsed power.
With an estimated 2 megawatts (MW)
peak power generation (benchtop
equivalent), the Si-PCSS subgroup has
All’s weld that
succeeded in achieving one-third of the
peak power required for an individual
ends weld.
element in the envisioned phased array
required to meet mission needs.
Si-PCSSs have been integrated with a Zeus coated optical fiber for aerospace safety.
rapid charge capacitor system and pulse
forming transmission lines for pulse Ensuring the effectiveness of
testing. Si-PCSS hold-off voltage has composite welds is vital to structural
been pushed to >6 kV with 3 kV output health monitoring. Our coated
pulse moving closer to the project goal Visit us at the International
optical fiber extrusions are ideal for
of 10 kV hold-off. Currently, thermal Paris Air Show, Le Bourget,
sensing applications, including France, 17-23 June 2019
mitigation issues are the primary issue measurement of weld integrity
plaguing the Si- PCSS group. Cooling - Stand 3-AB118 to learn
during part validation. more about our coated
system designs are changing weekly and
optical fiber.
progressively moving towards a goal of Five decades of extrusion
500 W/cm2 cooling capacity. experience have made us a leader
The University of Missouri – Kansas in the aerospace industry. As we
City’s (UMKC’s) effects team has devel- continue our commitment to
oped a custom UAV model for RF ef- forming long-lasting partnerships,
fects testing, written code for the au- let’s see what we can develop
tomation of testing, and researched the together.
areas of an adaptive design of experi-
ments (DoE) and noise injection. The Visit zeusinc.com/McNair to learn
adaptive DoE was developed to re - how Zeus and McNair achieved this
fine/inform optimum source parame- AMERICAS: +1 803.268.9500
incredible fiber optic breakthrough EUROPE: +353 (0)74 9109700
ters that will result in known effects on and its impact for the aerospace ASIA/PACIFIC: +(86) 20-38254909
sUAV’s and further inform the require- industry. support@zeusinc.com | zeusinc.com
ments for a tunable HPM system with

Tech Briefs
control over the policy desired levels- properties of GaN:C including the op- computationally quantify electromag-
of-lethality. The effects team has also tical and symmetric band structure of netic coupling and interference to
traveled to multiple test locations per- GaN:C, and obtained the software to UAV frames over the L-band and S-
forming over 1300 effects tests with the perform GaN-PCSS device level calcu- band and validated CMA coupling pre-
custom UAV. lations to model optical absorption, dictions using experimental measure-
UMKC’s GaN:C simulations/model- hold-off voltage, and thermal dissipa- ments. The RF coupling group also
ing subgroup has made progress in option relevant to determining the opti- reviewed the most common sUAV
timizing GaN:C for a high power, high mum design of a GaN:C based PCSS. shapes, sizes, material compositions,
repetition rate solid state switch. They The RF coupling subgroup used and electronics commercially available
have computed electronic structure Characteristic Mode Analysis (CMA) to and developed a table of occurrences
and frequency in sUAVs.
OSPRES 2017-2018 The Positive Feedback NLTL group
has developed a positive feedback
Accomplishments
Q1 Q2 Q3 Q4
power amplifier coupled with a nonlin-
Program Start Sept
DoE 0 test plan (May) Si PCSS improves ear transmission line generating ones-
Silicon PCSS holdoff recovery time w/
2017 Laser and RCC voltage 6kV irradiation of-kW power RF pulses in a closed-loop
GaN-PCSS Switch synchronization (Jan)
device cooling design Si-PCSS parameters
DoE 0 - 192 tests NRL
(May)
DoE 0 — 1282 tests
NSWCDD/NAWSCL network coupled with a 9-section 1200
Start (Nov) identified (Feb)
EHT RCC delivered
Bldg 71 renovation plan
(Apr-May)
(Sept)
GTEM installation (Aug)
V rated Schottky diode NLTL. Several
(DEC)
Review at UMKC (Sept) closed-loop experiments at low voltage
level within a frequency range of 5 to
70-MHz have been performed and con-
Sept Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sept tinuous RF signal outputs with positive
2017 2018
gain at different stages of the NLTL have
Notable achievements and progress of OSPRES program by quarter. been performed.
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Tech Briefs
Preliminary results of the Focused file, ultra-wideband micro-strip patch Doynov, A. Hassan, J. Lancaster, F. Khan, J.
Wave Mode (FWM) group suggest that antennas to demonstrate the potential of Verzella, J. Beaudin, L. Moler and A.N.
EM pulses with smaller rise times can ef- launching low dispersion EM waves with Caruso of the University of Missouri – Kansas
fectively launch electromagnetic waves results demonstrating the feasibility of City for the Naval Research Laboratory. For
whose time-average power density shows short EM pulses for c-sUAV ranges rele- more information, download the Techni-
minimal spatial decay contrary to the vant to the project. cal Support Package (free white paper) at
standard 1/r2 decay of EM waves. The This work was done by E.R. Myers, T. www.aerodefensetech.com/tsp under the
group designed and simulated low-pro- Fields, J.A. Crow, D. Chatterjee, P. Rulis, P. Research Lab category. NRL-0075
Matrix-Free Assisted Laser Desorption Ionization Using

Metal-Organic Frameworks
Army Research, Development and Engineering Command, Aberdeen Proving Ground, Maryland
M atrix-assisted laser desorption/ioniza-

tion (MALDI) is a soft ionization
technique that is widely applied in the
the deposition of an analyte solution onto
a metal substrate before the addition of a
matrix. The matrix/analyte dry spot is ex-
orption of the matrix and analyte mole-
cules in ionized form. The positive ions
are then accelerated through a vacuum
characterization of large biomolecules posed to a UV laser, and the laser energy into MS analyses.
using various mass spectrometry (MS) an- that is absorbed by the matrix/analyte is The MALDI process, however, lacks
alyzers, specifically, time-of-flight (TOF) converted into heat energy that initiates guiding systematic principles, which has
analyzers. The MALDI process involves charge transfer, which results in the des- resulted in mostly empirical work. For ex-
ample, there is no universal matrix that
can be used in the MALDI-MS analysis of
biomolecules. Hundreds of compounds
were assessed with several analytes and
Webinar were given qualitative ratings. These vari-

ables were the products of differences in
charge transfer efficiency between the
Available On Demand! matrix and analytes because of chemical
and structural factors.
OpenVPX Technology: Roadmap to This problem represents an urgent ana-
lytical need that can advance the MALDI
the Future
process toward mechanistic understand-
The U.S. Department of Defense and other users are ing. Metal-organic frameworks (MOFs)
demanding the implementation of open standards and are an emerging class of porous materials
interoperability. This one-hour Technical Webinar from that have been studied in multiple areas,
the editors of Tech Briefs Media will answer two including gas storage, sensing, air purifi-
important questions: Where is OpenVPX technology cation, and catalysis. MOFs are typically
today? And where is it going? synthesized from metal oxide secondary
building units (SBUs) connected by or-
Speakers: ganic linkers to form a reticulated, porous
Jerry Gipper network. MOFs are used because of their
Executive Director, VITA versatility and thermal stability.
The unique physical and chemical
properties of MOFs provide the potential
to serve as MALDI matrixes that are capa-
Rodger H. Hosking Ivan Straznicky, ble of ionizing a wide range of analytes.
Vice President and CTO, Advanced Packaging, However, because of their structural com-
Co-Founder, Curtiss-Wright Defense plexity, an attempt was made to deter-
Pentek, Inc. Solutions mine the existence of any interaction be-
tween the analytes and the MOFs when
they were mixed together. Low-frequency
Please visit www.techbriefs.com/webinar620 Raman spectroscopy (LFRS) was used to
determine the inter- and intramolecular
32 Aerospace & Defense Technology, June 2019

Tech Briefs
changes between free MOFs. In addition, gions, which are indicative of any po- Currently, there are two different
LFRS was used to investigate the reactions tential physical and chemical changes mechanisms that explain the ioniza-
that resulted from mixing analytes in an in a given analyte. In the case of MOFs, tion process in MALDI-MS analysis.
amorphous environment. LFRS can be used to investigate the The first mechanism is based on the
LFRS is a developing technique that binding properties of MOFs with the an- coupled chemical and physical dynam-
concurrently provides vibrational spec- alytes of interest and to determine the ics model, which involves charge
tra for tested compounds in the tera- nature of such binding. transfer during the excitation stage of a
hertz and normal Raman spectral re-
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Representative MOFs including HKUST-1 (named

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Tech Briefs
matrix/analyte mixture, resulting from perimental approach for MOF/analyte tures. This base knowledge will aid in
exposure to laser power. The second interaction during the MALDI process the development of efficient matrix-
mechanism is based on a cluster was designed to determine the ioniza- free desorption substrates for MS
model, which involves a combination tion model that governs the ionization analyses.
of proton and intracluster charge step and determine the basic elements MOF materials have demonstrated
transfer during the desolvation step of that contribute to the MALDI ioniza- superior homogenous and heteroge-
the MALDI process. Accordingly, an ex- tion process of the MOF/analyte mix- neous catalysis characteristics that will
be transcribed to the MALDI process.
Moreover, the diversity of MOFs can be
envisioned to act as a selective desorp-
tion surface for specific groups of ana-
High-Performance lytes without reliance on the addition
of external reagents.
Aircraft Need The overall goal of this project was to
study the mechanism of ionization and
High-Performance to determine the influence of factors
that affect the charge-transfer process
MPMs during the MALDI-MS ionization. It also
addressed the binding affinity issue be-
Meet the new dB-3756HE tween MOFs and analytes using the
LFRS technique to research inter- and in-
Microwave Power Module tramolecular changes between the MOF
÷ +LJKHτFLHQF\030 crystalline and amorphous states with
÷ *+]IUHTXHQF\UDQJH different analytes. These analytes were
classified as acidic or basic compounds.
• 1 kW pulsed output power
Once the basic properties of the
÷ PD[LPXPGXW\F\FOH
MOF/analyte mixture are understood, it
÷ /RZSRZHUFRQVXPSWLRQ will be possible to determine how to de-
÷ /LJKWZHLJKWDWOEV sign MOFs that can enhance the ioniza-
÷ )XOO0+]RIEDQGZLGWK tion efficiency for a wide range of com-
÷ 'HVLJQHGIRU8$9VDLUERUQH pounds during MALDI-MS analysis.
DSSOLFDWLRQVDQGUDGDU6$5 This research addressed the potential
V\VWHPV intra- and intermolecular changes for
MOF/analyte mixtures using LFRS and
MALDI-MS techniques. The MOFs used
in the LFRS technique were UiO-66-
COOH and UiO-66-NH2, and the ana-
lytes were pyridine, benzoic acid, cyti-
dine, lauric acid, and guanine. More
MOFs than those tested by the LFRS
technique were used for the MALDI-
MS analyses. Most of the MOFs were
obtained from internal sources, either
through synthesis or by leveraging
from already-funded projects that uti-
lize MOFs. The structures for some of
the MOFs and analytes are shown in
a HEICO company the accompanying figure.
Reliability by Design ® This work was done by Rabih E.Jabbour;
Gregory Peterson; Jared DeCoste (ECBC); and
)RUVSHFVFDOORU Yousef Jabaji (UMBC); for the Army Research,
YLVLWG%&RQWUROFRP()),&,(17 Development and Engineering Command.
)RUPRUHLQIRDERXWRXU For more information, download the
+LJK(τFLHQF\030VHPDLO Technical Support Package (free white
© 2019 dB Control Corp 0/HH#G%&RQWUROFRP paper) at www.aerodefensetech.com/tsp
under the Test & Measurement category.
ARDEC-0005

SIX DAYS THREE CONFERENCES ONE EXHIBITION
EUROPE’S PREMIER
MICROWAVE, RF, PORTE DE VERSAILLES
WIRELESS AND PARIS, FRANCE
29TH SEPT - 4TH OCT 2019
RADAR EVENT
EUROPE’S PREMIER
MICROWAVE, RF,
WIRELESS AND
RADAR EVENT
The European Microwave Exhibition
(1st-3rd October 2019)
• 10,000 sqm of gross exhibition space
• Around 5,000 attendees
• 1,700 - 2,000 Conference delegates
• In excess of 300 international exhibitors
(including Asia and US as well as Europe)
INTERESTED IN EXHIBITING?
For International Sales:
Richard Vaughan,
International Sales Manager
E: rvaughan@horizonhouse.co.uk
Tel: +44 20 7596 8742
or visit www.eumweek.com
Application Briefs
Counter-Drone Technology
Citadel Defense
San Diego, CA
760-224-3393
www.dronecitadel.com
C itadel Defense has developed a Counter-drone (CUAS)

technology called Titan that reliably detects, identifies,
and defeats unmanned aerial vehicles (UAV's or "drones") and
swarms threatening combat troops, critical infrastructure, or
information espionage. The company recently manufactured
a first-of-its-kind solution designed to protect troops, vehicles,
and permanent structures from threat drones.
Titan systems are software-programmable to provide an esca-
lating layer of protection against unwanted drones that are car-
rying device-triggering explosives or executing reconnaissance
missions to disrupt the military’s tactical operations. In an effort
to maintain technical superiority for servicemen and service- Titan is a next generation system that is high-powered,
women on the front lines of combat, Citadel Defense designed modular, programmable, multiband, and designed to deny
and developed the solution alongside warfighters and used arti- enemy use of threat drones. In less than 5 minutes, the en-
ficial intelligence (AI) and machine learning to constantly stay tire system can be set up, configured, and be ready to oper-
ahead of the changing threat. In environments where warfighter ate with a hemisphere of protection that extends beyond
communications are critical, Citadel's patented technology can the distances many drones can fly.
surgically defeat threat drones without taking down signals re- The Titan was designed to be operated by a user who has
quired for communication such as WiFi and Bluetooth. no signal expertise or training. By removing all cognitive
Through an open and extensible hardware and software ar- load across the user experience and offering warfighters the
chitecture, Citadel Defense created a solution that can adapt ability to set the system to “autonomous mode”, the Titan
to worldwide threats. Engineered for fixed, mobile, and dis- allows warfighters to focus on their mission without dis-
mounted operation, the system has been designed and engi- traction. According to Christopher Williams, CEO of
neered to meet rigorous testing requirements under MIL-STD Citadel Defense, the company’s goal in designing the Titan
810 to ensure that it is rugged enough for a variety of different system was to deliver technology that is as easy to operate
mission sets and can be successfully operated in even the as an iPhone.
harshest environments. For Free Info Visit http://info.hotims.com/72994-460
Modified USAF T-1A Aircraft

Field Aerospace
Oklahoma City, OK
405-219-3400
www.fieldaero.com
F ield Aerospace recently completed the first flight of a U.S.

Air Force (USAF) T-1A aircraft with a modernized flight
deck. The first fully modified Combat System Officer (CSO)
aircraft flew two successful consecutive check flights from
Field Aerospace’s Oklahoma City facility.
Last spring, the USAF awarded Field Aerospace a contract
to modernize the avionics on the entire T-1A trainer fleet
of 178 aircraft plus 30 training devices. The fleet comprises
CSO and Specialized Undergraduate Pilot Training (SUPT) Out, eliminating avionics obsolescence issues for the aging
aircraft. Working with subcontractors Nextant Aerospace, aircraft.
Collins Aerospace, HEBCO and FlightSafety International, The T-1A Jayhawk aircraft are medium-range, twin-engine
Field Aerospace served as the prime contractor for this jets used for advanced-phase training of airlift and tanker pi-
flight deck modification program. Field Aerospace’s mod- lots. It is also used to support navigator training for the U.S.
ernization included updating the avionics suite and adding Air Force, Navy, Marine Corps and international services. De-
Automatic Dependent Surveillance – Broadcast (ADS-B) signed and built by Raytheon Corp., the swept-wing T-1A is a

Application Briefs
military version of the Beech 400A. It has cockpit seating for AFB in Oklahoma; Randolph AFB in Texas, where it is used to
an instructor and two students and is powered by twin turbo- train instructor pilots; and at Naval Air Station Pensacola, in
fan engines capable of an operating speed of 538 mph. Most Florida where it is used for combat systems officer training.
of the USAF T-1A fleet supports SUPT, with the balance used The modernization includes updating the fleet to the Collins
for CSO training. The first T-1A was delivered to Reese Air Aerospace Pro Line 21TM system and enables the T-1A fleet to
Force Base, Texas, in 1992 and student training began in 1993. meet the FAA’s ADS-B Out mandate to support the trainer’s
They are currently stationed across five U.S. operating bases: standing requirement to access the National Airspace System.
Columbus AFB in Mississippi; Laughlin AFB in Texas; Vance For Free Info Visit http://info.hotims.com/72994-461
Video Graphics Modules fully tested and pronounced safe to fly within the National
WOLF Advanced Technology Airspace, the X-59 in late 2022 will begin making supersonic
Stouffville, Ontario, Canada flights over select communities to measure residents’ reac-
905-852-1163 tions to any noise they might hear.
https://wolfadvancedtechnology.com The chosen products, the XMC-E9171-VO (WOLF-3196)
and the XMC-FGX2-SDI-8IO (WOLF-3180), provide video
W OLF Advanced Technology ("WOLF") recently an-

nounced that NASA has chosen two WOLF video graph-
ics modules to take part in the development of NASA's X-59
capture, process, encode, and display capabilities to help en-
able NASA's "windowless cockpit display system", the eXternal
Vision System (XVS). NASA's XVS is designed to replace a
Quiet SuperSonic Technology (QueSST) aircraft. Now under front windshield with video display technology in NASA's
construction by Lockheed Martin Aeronautics Company at its Low-Boom Flight Demonstration mission.
famed Skunk Works plant in Palmdale, California, the X-59 is The XMC-E9171-VO features an AMD Radeon GPU, a chip-
designed to reduce the noise generated by a sonic boom. Once down rugged design that meets the MIL-810 specification and
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Application Briefs
can handle up to five 4K displays using Display Port 1.4, and

High Dynamic Range video with 10-bit color depth.
The XMC-FGX2-SDI-8IO is WOLF's second-generation Frame
Grabber eXtreme (FGX) which enables up to eight 3G/HD-SDI
or four 12G-SDI inputs and outputs, two analog inputs and out-
puts, a PCIe Gen4 interface that can handle up to 15.75 GB/s,
and ultra-low-latency H.265 encoding. It supports direct user
access to FPGA HDL logic for encryption, analysis, and image
recognition. A 10GigE LAN interface is also supported.
WOLF Advanced Technology designs, develops and manufac-
tures military grade rugged boards for video capture, process, en-
code and display. Their products are designed to operate in
harsh aerospace and defense environments without sacrificing
any of the processing power available from the latest generation
NVIDIA, AMD and Xilinx high-speed GPUs, APUs and FPGAs.
For Free Info Visit http://info.hotims.com/72994-463
Helicopter Load Sensor

Sensor Technology Ltd.
Banbury, Oxon, UK
01869 238400
www.torqsense.com
A newly developed intelligent wireless helicopter load sen-

sor has a choice of two displays, offering simple or com-
prehensive data read outs, so that users can select the best op-
tion for their operational needs.
The HeliNav LoadMaster’s simple sensor display is a small and
lightweight unit designed for easy mounting in the helicopter’s
cockpit or window. It displays the current load on its screen, a fig-
ure which is updated ten times a second and communicates with
the sensor on the cargo hook using a radio frequency wireless link.
The wireless nature of LoadMaster means that it can be fitted in a
matter of seconds. This makes it possible to share one unit among
a fleet of aircraft, since it is independent of the helicopter and its
system does not need official approval or certification.
For straightforward tasks, such as lifting loads from ship to
shore, the simple display gives adequate information. It uses
the license-free 2.4 GHz waveband to transmit load signals
from hook to display. It has a tare function to zero out fixed
loads and the units of measurement are user selectable. It also
has a reflective sunlight readable LCD display, optional ana-
log/digital readout, optional external antenna for maximizing
reception, and a ball mount with other base options available
on request. It is powered by a standard rechargeable battery
and is completely standalone and independent of the aircraft
The other option is a sunlight readable touch screen that
is preferred for duties such as crop spraying and compli-
cated point-to-point flight paths. This model can display
maps, charts data tables and other complex information.
Additionally, it will interface with Google Maps and other
functions to provide high level information and control.
This model operates from the aircraft’s 24V power supply.

Application Briefs
Active Protection System The IFL system is a lightweight APS, providing enhanced sur-
RADA Electronic Industries Ltd. vivability for armored and tactical platforms. RADA’s software
Netanya, Israel defined radars identify and precisely track incoming threats,
+972-9-892-1111 from any direction, in real time. The system then intercepts the
www.rada.com threat by launching a small warhead and activating it at a safe
distance from the protected platform at a precisely calculated
R ADA Electronic Industries

Ltd., a company that special-
izes in the development and pro-
moment, defeating the threat through a
shock-wave effect.
Manufactured by BAE Systems Land &
duction of tactical land radar for Armaments (formerly United Defense),
force and border protection, re- the Bradley Fighting Vehicle first entered
cently announced that following service in 1981. It is powered by a 600-hp
the announcement by General Cummins VTA-903T diesel engine that
Dynamics of a positive Army Re- gives it a top speed of 35 mph (56 km/h).
quirements’ Oversight Council It’s main armament currently consists of
(AROC) decision, Phase II of the a 25 mm M242 Bushmaster chain gun
Iron Fist Light (IFL) Active Pro- and BGM-71 TOW anti-tank missile. It
tection System (APS) for the also has a 7.62 mm M240 machine gun.
Bradley Fighting Vehicle is moving forward. The project is a In phase II of the IFL for Bradley project, RADA expects to
joint venture between General Dynamics’ subsidiary, General receive near-term orders for the supply of radars for qualifica-
Dynamics Ordnance and Tactical Systems, together with Israel tion testing, and the current potential is to equip one US army
Military Industries (IMI), which was recently acquired by Elbit brigade of Bradley armored vehicles. This phase is expected to
Systems. RADA is the provider of the radars to the Elbit/IMI continue into the years 2020 and 2021.
IFL system. For Free Info Visit http://info.hotims.com/72994-462
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©Copyright 2018 Gemstar Manufacturing

New Products
Lange Couplers Servo-Electric Presses

The construction and port orientation Beckwood Press Company (St.
of the Lange Coupler from SemiGen Louis, MO) announced the launch
(Londonderry, NH) makes it useful as of EVOx™, a complete line of
both a power combiner and splitter for servo-electric presses. With models
RF and microwave applications. It is a ranging from 1,000 lbf – 100,000
specific type of directional coupler, which allows passive cou- lbf (0.5 - 50 tons), EVOx™ presses are suitable for light-duty as-
pling of a defined amount of electromagnetic power. The sweet sembly applications including clamping, crimping, joining,
spot for Lange Couplers has traditionally been UHF to Q-band; press fitting, punching/blanking, riveting, spring testing, stak-
the limit becomes frequency. Substrate height and strip width ing, and swaging.
are inversely related to frequency, increasing loss due to the re- The EVOx™ line of presses is powered by Exlar® electric roller-
duced amount of metal available to act as a conductor. screw actuators from Curtiss-Wright, in lieu of hydraulic sys-
dB and frequency ranges in which Lange Couplers provide tems. Eliminating the hoses, pumps, and hydraulic oil improves
the biggest performance advantages, in terms of low loss, com- cleanliness, energy efficiency, and operator safety while lower-
pact layout and wide bandwidth are: < 0.4 dB on 10 GHz fre- ing operational and maintenance costs. The roller-screw tech-
quencies (low loss); as low as 10μm lines and spacing (layout); nology ensures Exlar® actuators last longer than traditional ball-
and 10-50 GHz bandwidth. screw actuators.
For Free Info Visit http://info.hotims.com/72994-470 VOx™ presses feature a programmable, intuitive controls sys-
tem that guarantees positional repeatability to within +/-0.0005"
Custom Microelectronics while offering force and positional feedback. Additionally, actu-
Mercury Systems, Inc. (Andover, ator size, frame style, dwell time, safety guarding, and other pa-
MA) announced the defense industry’s rameters are fully configurable.
first trusted custom microelectronics For Free Info Visit http://info.hotims.com/72994-477
capability targeting SWaP-constrained
intelligent sensors for military applica- Robotics Enclosures
tions. With tightly integrated design HEMCO (Independence, MO) enclosures
and manufacturing resources, the company has developed deep are designed to enclose robots and other lab
domain expertise spanning a broad of range of capabilities ide- automated processes by providing exhaust air
ally suited to custom microelectronics for defense applications systems or HEPA filtered clean workstations.
such as: advanced packaging technologies with surface-mount, Enclosures are built to protect robotic
flip chip, and wire bond; 2.5D and 3D packaging; thermal man- processes from contamination and personnel
agement; ruggedization; radio frequency (RF), microwave and from hazardous fumes. Utilizing a flexible,
mixed signal; scalable manufacturing; advanced testing proto- modular design, enclosures are engineered and built to exact cus-
cols; and a robust cybersecurity posture. tomer size and design requirements. HEMCO also offers a wide
For Free Info Visit http://info.hotims.com/72994-471 selection of standard sizes in vented or HEPA filtered models.
Horizontal Machining Center
Mitsui Seiki’s (Franklin Lakes, NJ) “Green” Graphene
new HU100-TS 100 tilt-spindle 5-axis Goodfellow (Coraopolis, PA) recently
horizontal machining center is built to announced the availability of ultra-
machine large, hard-metal workpieces pure “green” graphene, guaranteed
that are better suited for tilt-spindle metal-free and uniquely applicable in
processing than trunnion table opera- metal-sensitive processes. The graphene
tions. The horizontal table of the HU-100TS can accommodate is produced by means of a highly scalable process that involves
workpieces up to 1,900 mm (76") long and 1,250 mm (50") in di- breaking methane gas (CH4), a very potent greenhouse gas, into
ameter, weighing up to 2,000 kg (4,400 lbs.). X, Y and Z-axis trav- hydrogen and elemental carbon atoms in a plasma reactor. The
els are 1,300 mm (52"), 1,500 mm (60") and 1,400 mm (56") re- carbon atoms then recombine into graphene sheets in the hy-
spectively, with B-axis rotation of 360˚ and A-axis rotation of -30˚ drogen atmosphere. Elapsed time from the methane gas enter-
to +120˚. The machine’s compact 5,530 mm (221") x 8,431 mm ing the plasma reactor to the point when graphene is formed is
(337") footprint is similar to that of its 4-axis equivalent. less than a second.
The machine’s HSK-A100 taper spindle provides up to 150 The resulting graphene nanoplatelets are very thin and
kW (201 hp) power and 1508 N-m (1,112 lb-ft) torque. A stan- slightly crumpled and they do not stack (unlike exfoliated ma-
dard automatic tool changer has capacity for 60 tools (180 op- terials), ensuring optimal electrical, thermal and mechanical
tional), up to 500 mm (20") in length. Maximum tool diame- performance. These characteristics make this easy-to-use prod-
ter is 125 mm (5"); tools stored without adjacent tools can be uct an extremely good nanofiller suitable for electronic inks,
up to 216 mm (8.6") in diameter. polymers, metal composites and coating.
For Free Info Visit http://info.hotims.com/72994-495 For Free Info Visit http://info.hotims.com/72994-489

New Products Rod Ends and
Spherical
Bearings designed
and manufactured to
Aurora’s exacting
standards for quality
SPI to MIL-STD-1553 Interface
and durability.
Data Device Corporation (DDC)
(Bohemia, NY) has introduced the
Nano-ACE® BC/RT/MT MIL-STD-
1553 terminal, the latest evolution in its Enhanced Mini-ACE®
series, which has been in operation since 1999 with more than
800 million hours of in-service history. This new Nano-ACE® Registered and Certified
(BU-67833LC), which is an upgraded version of the BU- to ISO_9001 and AS9100.
67743LC Nano-ACE RT, offers complete BC/RT/MT functional-
ity, along with increased 32K ×17 RAM including parity capabil-
From economy commercial
ity, comprehensive autonomous built-in self-test, and the to aerospace approved,
option to auto-initialize from an external EEPROM. we’ve got it all!
The Nano-ACE® BC/RT/MT utilizes a fast 50 MHz Serial Pe-
ripheral Interface (SPI) to reduce pin count and package size,
enabling users to benefit from DDC’s market-leading 1553
functionality and reliability, in an ultra-small package that

provides the ability to create more compact and higher den-
sity boards. The BU-67833LC Nano-ACE’s highly efficient
+3.3V transceivers minimize power consumption and heat Aurora Bearing Company
dissipation, enabling further board miniaturization through 901 Aucutt Road
Montgomery IL. 60538
the use of smaller power and heat sinking components.
For Free Info Visit http://info.hotims.com/72994-475 complete library of CAD drawings and 3D models available at:
w w w. a u r o r a b e a r i n g . c o m
Solid State Power Amplifier
COMTECH PST (Melville, NY) has in-
troduced a new Gallium Nitride (GaN)
amplifier for applications in the X-Band
pulsed radar market. The AB linear design
operates from 9.0 to 9.9 GHz frequency
range over any instantaneous bandwidth of 500 MHz. Devel-
opment of this product is intended for use in ruggedized radar
applications. The amplifier design features Self Protection for
Load VSWR, Duty Factor, Pulse Width, Temperature, as well as
a graceful degradation in case of a RF power module failure.
Custom configurations and features are available as well as
specific power levels up to 16 kW.
2.4 kW Fuel Cell Module

Intelligent Energy (Loughbor-
ough, UK) launched a new 2.4 kW
fuel cell power product for the com-
mercial UAV market with first deliv-
eries planned for October 2019.
This latest product can achieve much longer flight times, for ex-
ample on a DJI M600 frame with an 11-liter 350Bar hydrogen
cylinder, a retrospectively fitted 2.4 kW FCPM could achieve a
flight time of over 2 hours compared to just 25 minutes with its
battery power pack.
Two 2.4 kW modules can also be linked in parallel to provide
up to 4.8 kW of power without the need for additional hard-
ware. The module provides the continuous power to the UAV
and is hybridized with a small battery to manage the peak loads.
The module can be fitted onto a number of off-the-shelf frames.
However, according to the manufacturer, efficiencies and flight
time can be optimized even further on a customized frame.

New Products
System Diagnostic Toolkit Single Board Computer

Abaco Systems (Huntsville, AL) Aitech (Chatsworth, CA) and Em-
recently announced the Health bedded Flight Systems, Inc. (EFSI) have
Toolkit, a unique and innovative partnered to integrate NASA’s cFS (core
solution designed to maximize Flight System) into Aitech’s modular,
system reliability and success in powerful and flexible SP0-S space SBC. NASA’s cFS is a platform-
mission critical environments such as electronic warfare, and project-independent, reusable software framework and set of
digital radar and flight control. Health Toolkit is a soft- reusable software applications. The cFS architecture is composed
ware/middleware tool, operating between the underlying of three key aspects—a dynamic run-time environment, layered
hardware and the application software, that interrogates all software and a component-based design—that combine to make
aspects of the hardware’s performance, optionally reports the cFS suitable for reuse on any number of NASA flight projects
on its health via an intuitive GUI and enables corrective and embedded software systems, at a significant cost savings.
measures to be taken if necessary. The Aitech SP0-S features multiple hardware I/O and software
The Health Toolkit is unique in that it not only analyzes options, including ample ECC-protected SDRAM. It also includes
and reports on Abaco VPX hardware within the system, but user Flash and EEPROM and auto-failover, redundant boot Flash,
also enables third party and custom hardware to be both in- in addition to two on-board GbE ports, serial ports, discrete I/O,
tegrated and interrogated and does so in a unified manner temperature sensors, three Watchdog timers, and more.
that makes the gathering and interpretation of data substan- For Free Info Visit http://info.hotims.com/72994-483
tially easier. The granular data provided by the Health Toolkit
can be used to identify patterns of behavior that can lead to Rugged COM Express Module
hardware malfunction, enabling corrective action to be taken The CB71C Rugged COM Express Mod-
to prevent system failure. It also reports on resource utiliza- ule from MEN (Nuremberg, Germany) is
tion, allowing resources to be reassigned if necessary. based on the AMD Ryzen Embedded fam-
For Free Info Visit http://info.hotims.com/72994-480 ily and can now be equipped with the
new Ryzen Embedded R1000 SoC in addition to the Ryzen Em-
bedded V1000 SoC. The new AMD Ryzen Embedded R1000 SoC
features a Radeon Vega graphics engine with three compute
units and support for up to three displays with a resolution of up
to 4k without additional graphics hardware. With up to four
powerful "Zen" processor cores, when using the AMD Ryzen Em-
bedded V1000 SoC, the CB71C is also suitable for virtualization.
The modules with AMD Ryzen Embedded V1000 provide pas-
sive cooling and a temperature range from -40°C to +85°C are pos-
sible with the low-power versions. The CB71C can be equipped
with up to 32 GB directly soldered DDR4 main memory and a 16
GB eMMC. PCI Express 3.0, DDI (DP, eDP, HDMI), SATA 3.0, Gi-
gabit Ethernet and USB 3.0 are available as high-speed interfaces.
2U MicroTCA Chassis
Pixus Technologies (Waterloo, On-
tario) now offers a 2U high rackmount
MicroTCA chassis holding a range of Ad-
vancedMCs. The 2U MicroTCA chassis comes with 1 MCH
(MicroTCA Carrier Hub) slot and 7 AdvancedMCs (AMCs)
standard. The backplane supports 40 GbE and PCIe Gen3
speed signals. Other backplane sizes and configurations are
available upon request.
The chassis platform has the card cage recessed within the en-
closure, providing protection for the AMCs and the cabling. The
left side of the card cage is raised slightly to allow for cabling to
be channeled to the rear of the enclosure. The rear of the chassis
is extra deep with a cavity for mounting various devices, includ-
ing RF modules. The pluggable power module slots are located se-
curely within the rear of the chassis and are cabled over to the
rear panel. Single or dual redundant power options are available.

Product Spotlight
New Products DISCOIDAL
FEEDTHROUGH
CERAMIC
CAPACITORS
API’s discoidal capacitors
are produced in our State College, PA (USA) facility
and provide great versatility in meeting varied volt-
age, capacitance, and dimensional requirements.
These nonpolar, multilayer capacitors are small, reli-
Integrated Measurement Assembly Platforms able, and high in dielectric strength. Low profile
RPI UK (Bath, UK) has supplied five integrated designs are also available in various OD, ID, and
measurement assembly platforms (iMAPs) to Rolls- thickness. These capacitors are ideal for high frequen-
cy applications and much more! https://www.apitech.
Royce and its approved MRO facilities. RPI’s iMAP, com/products/emi-filters-components-magnetics/
which can reduce inspection times by 90% and im- ceramic-capacitors/discoidal-capacitors/
prove gauge repeatability and reproducibility by up to
10-times, will be used by Rolls-Royce to measure and
API Technologies Corp.
assemble engine turbine rotors at its sites in Derby Free Info at http://info.hotims.com/72994-793
and Germany.
iMAP’s data acquisition software, AccuScan, en- MODEL & SIMULATE
ables manufacturers to measure up to 4,000 data points on up to eight surfaces si- DESIGNS, DEVICES,
multaneously per revolution, thereby significantly reducing process times com- AND PROCESSES
pared with other available methods. This inspection data is then used by COMSOL Multiphysics® is an inte-
grated software environment for
IntelliStack, iMAP’s Rotor Stacking Program, to solve the mathematical problem of
creating physics-based models and
how to best assemble a multi-stage rotor assembly to achieve minimum runout or simulation applications. Add-on
unbalance of the finished rotor. products expand the simulation platform for electro-
Specifically designed to inspect large and heavy components, RPI’s iMAP machines magnetics, structural, acoustics, fluid flow, heat trans-
fer, and chemical applications. Interfacing tools enable
combine a motorized high precision air bearing rotary axis, rigid column unit, anti-vi- the integration of COMSOL Multiphysics® simulations
bration granite base and AccuScan multi-channel circular geometry inspection software. with all major technical computing and CAD tools.
For Free Info Visit http://info.hotims.com/72994-482 Simulation experts rely on COMSOL Compiler™ and
COMSOL Server™ products to deploy applications to
their colleagues and customers worldwide.
Arbitrary Waveform Generator https://www.comsol.com/products
Tektronix, Inc., (Beaverton, OR) has launched the COMSOL, Inc.
AWG70000B Series Arbitrary Waveform Generator Free Info at http://info.hotims.com/72994-794
with new features that enable it to fully support the
testing of complex electronic warfare and wireless LOW
communications systems that require the ability to OUTGASSING
dynamically alter signal sequences during test scenarios. UV CURE
The Streaming Waveform ID feature provides users with immediate access to a ADHESIVE
total of 16,383 sequence steps through a direct Ethernet interface. For wireless com- Master Bond UV26 is a
munications research, engineers can now change modulation types on the fly to one part UV curable system featuring an exception-
simulate Doppler radars, building obstructions or other obstacles to improve orthog- ally high glass transition temperature (Tg) ranging
from 160 to 170°C. This NASA low outgassing certi-
onal frequency division multiplexing (OFDM) signal durability in real-world de-
fied compound offers strong adhesion to a wide vari-
ployments. The new AWG70000B Series also includes support for the Microsoft ety of substrates and it is capable of withstanding
Windows 10 operating system to meet IT security mandates for instrument opera- harsh chemicals as a coating and adhesive.
tion in government agencies and corporate IT departments. https://www.masterbond.com/tds/uv26
The AWG70000B Series provides up to 50 GSamples/s ,10-bit vertical resolution

and spurious-free dynamic range (SFDR) of up to -80 dBc. This enables generation of
Master Bond Inc.
highly precise RF signals and gives users high confidence in their measurement
stimulus system. The signal generator works with advanced SourceXpress PC-based
software to simplify and accelerate test signal creation. Free Info at http://info.hotims.com/72994-795

A WORLD OF FIBER OPTIC
High-Speed End Launch Connectors
SOLUTIONS
Fairview Microwave Inc. (Irvine, CA) has introduced a
new extended series of mmWave, removable, end-launch,
PCB connectors that consists of 16 models operating in a
wide bandwidth that supports high data rates and VSWR as
• T1/E1 & T3/E3 Modems, WAN
low as 1.10:1. They are offered with four end launch connec-
• RS-232/422/485 Modems and Multiplexers
tor interface options: 1.0mm (110 GHz), 1.85mm (67 GHz), • Profibus-DP, Modbus
2.92mm (40 GHz) and 2.4mm (50 GHz). • Ethernet LANs
These high-performance, end launch connectors are reusable and don’t require any • Video/Audio/Hubs/Repeaters
• USB Modem and Hub
soldering. Some of the models in this line feature reduced profiles with a 0.350-inch • Highly shielded Ethernet, USB (Tempest Case)
mounting width, allowing for more launches to fit into the same PCB area. These con- • ISO-9001
nectors are offered in male and female versions and are constructed with an outer con- http://www.sitech-bitdriver.com
ductor made of stainless steel and a gold-plated beryllium copper center contact. S.I. Tech
For Free Info Visit http://info.hotims.com/72994-488 Free Info at http://info.hotims.com/72994-796

Publisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Joseph T. Pramberger
Ad Index
Editorial Director . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Linda L. Bell
Advertiser Page Web Link
Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bruce A. Bennett Aitech Defense Systems ........................................4-5......................................................................www.rugged.com
Digital Editorial Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Billy Hurley
Associate Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Edward Brown Amada Miyachi America ........................................7a ........................................................www.amadamiyachi.com
Managing Editor, Tech Briefs TV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kendra Smith API RF2M ......................................................................9 ........................................................................www.apitech.com
Production Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adam Santiago
Manufacturing Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kevin Coltrinari
API Technologies - EIS Div. ....................................43 ......................................................................www.apitech.com
Creative Director . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lois Erlacher Arnold Magnetic Technologies ............................30 ....................................................www.ArnoldMagnetics.com
Graphic Designer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Annette Murphy
Aurora Bearing Co. ..................................................41 ..........................................................www.aurorabearing.com
Marketing Director . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Debora Rothwell
Marketing Communications Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crystal Haylett Click Bond, Inc. ..........................................................21..........................................................www.clickbond.com/ad12
Marketing Assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dylan Legarda
Coilcraft CPS ..............................................................13 ..............................................................www.coilcraft-cps.com
Audience Development Director . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Christine Oldenbrook
Audience Development Coordinator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stacey Nelson COMSOL, Inc. ..............................................................43, Cover 4 ......................................................www.comsol.com
Subscription Changes/Cancellations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ADT@OMEDA.com
Concept Group, Inc. ................................................2 ................................................insulontech.com/aerospace#1
TECH BRIEFS MEDIA GROUP, AN SAE INTERNATIONAL COMPANY Create The Future Design Contest ......................31 ................................................CreateTheFutureContest.com
261 Fifth Avenue, Suite 1901, New York, NY 10016
(212) 490-3999 FAX (646) 829-0800
Crystal Group, Inc ....................................................19 ....................................................................crystalrugged.com
Chief Executive Officer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Domenic A. Mucchetti
Executive Vice-President . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Luke Schnirring dB Control Corp. ........................................................34 ............................................................................dBControl.com
Technology Director . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oliver Rockwell
Dynabrade Inc. ..........................................................1a ............................................................................dynabrade.com
Systems Administrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Vlad Gladoun
Digital Development Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Peter Bonavita European Microwave Week 2019 ..........................35 ..................................................................www.eumweek.com
Digital Production Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Howard Ng Fotofab..........................................................................33........................................................................www.fotofab.com
Digital Media Associate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Md Jaliluzzaman
Digital Production Associate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Jerry Aultz
GAGE BILT Inc. ............................................................14a ..............................................................................gagebilt.com
Digital Production Associate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Andrew Greenberg Gemstar Manufacturing..........................................39 ..........................................................www.gemstarcases.com
Digital Production Associate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Symba Wong
HandyTube Corporation..........................................1 ..................................................................www.HandyTube.com
Credit/Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Felecia Lahey
Accounting/Human Resources Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sylvia Bonilla Hawthorne Rubber Mfg. Corp. ..............................42 ..................................................www.HawthorneRubber.com
Office Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alfredo Vasquez
Helical Products Company, Inc. ..........................23........................................................................www.heli-cal.com
ADVERTISING ACCOUNT EXECUTIVES Infinite Electronics/Milestek..................................17 ................................................................................MilesTek.com
MA, NH, ME, VT, RI, Eastern Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ed Marecki
International Polymer Engineering ....................13a ................................................www.ipemanufacturing.com
(401) 351-0274
CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stan Greenfield Kaman Precision Products ....................................8 ....................................................................kamanmemory.com
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(203) 938-2418
NJ, PA, DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .John Murray
Master Bond Inc. ......................................................43..............................................................www.masterbond.com
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (973) 409-4685 Milpower Source........................................................37 ..............................................................................milpower.com
Southeast, TX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ray Tompkins
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(281) 313-1004 Mini-Systems, Inc. ....................................................25................................................................mini-systemsinc.com
NY, OH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ryan Beckman Orbel Corporation ....................................................41 ....................................................................................ORBEL.com
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(973) 409-4687
MI, IN, WI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chris Kennedy RAD Torque Systems ................................................3a ..................................................................www.radtorque.com
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(847) 498-4520 ext. 3008 Rohde & Schwarz GmbH & Co. KG ........................11 ..........................................................www.rohde-schwarz.com
MN, ND, SD, IL, KY, MO, KS, IA, NE, Central Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bob Casey
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(847) 223-5225 S.I. Tech ........................................................................43........................................................www.sitech-bitdriver.com
Northwest, N. Calif., Western Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Craig Pitcher
SRCTec, LLC..................................................................5a ................................................................www.srctecems.com
(408) 778-0300
S. Calif., AZ, NM, Rocky Mountain States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tim Powers Superior Tube Co. ....................................................3 ............................................................www.ametekmetals.com
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(424) 247-9207
Technologic Systems ..............................................14a ......................................................www.embeddedARM.com
Europe — Central & Eastern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sven Anacker
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49-202-27169-11 The Lee Company......................................................Cover 3 ........................................................www.TheLeeCo.com
Joseph Heeg
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49-621-841-5702
Volume Graphics........................................................9a ......................................................www.volumegraphics.com
Europe — Western . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Chris Shaw W.L. Gore & Associates ............................................Cover 2 ........................................................www.gore.com/test
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44-1270-522130
Integrated Media Consultants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Patrick Harvey Zeus, Inc. ....................................................................29 ................................................................................zeusinc.com
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (973) 409-4686
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Innovation in Miniature
WHEN IT COMES TO PERFORMANCE,

WE’RE YOUR WINGMAN.
PEACE OF MIND, SINCE 1948.

Count on The Lee Company for relentless support and
unsurpassed reliability. That’s been our approach for
SZIV]IEVW[LMGLLEWTPEGIHSYV½IPHTVSZIR
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¾]MRKXSHE]7S[LIXLIV]SYRIIHE
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The Lee Technical Hydraulic
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reference for hydraulic components.
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The Lee Company 860-399-6281 • www.TheLeeCo.com

WESTBROOK•LONDON•PARIS•FRANKFURT•MILAN•STOCKHOLM 53rd INTERNATIONAL
PARIS AIR SHOW
See us at the Paris Air Show, Hall 3, Stand A63 JUNE 17-23, 2019

Ray optics simulation
for inertial navigation.
Visualization of counterpropagating light rays in a

counterclockwise rotating Sagnac interferometer.
Aircraft and spacecraft require highly accurate tools for attitude

detection and control.
control Many modern inertial navigation systems
include ring laser gyroscopes. To better understand how ring
laser gyros work, you can study the fundamental operating
principle of these devices: the Sagnac effect. This effect can be
demonstrated using ray optics simulation.
The COMSOL Multiphysics® software is used for simulating
designs, devices, and processes in all fields of engineering,
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June 2019
A new approach to
machining titanium
is high-feed side
milling, a process
radial engagement,
and grade designed
courtesy of Sandvik
Coromant)

T
he rise of titanium for aerospace applications
has been well documented in recent years.
Machining
Equally, the challenges associated with the effi-
cient, productive and high-quality machining of this
popular material, have also been a topic of debate
and scrutiny. Of course, every machine shop wants
Titanium
optimized performance from its cutters when milling
titanium, but this can prove less than straightforward
without the right technology and know-how in place.
Today, however, thanks to a breakthrough in this area,
Aero-Frames things are beginning to change.

The aerospace segment is expected to demonstrate
impressive growth in the coming years as consumers
continue to drive demand for new routes and greater
flight frequency. Further drivers include global demo-
graphics and wealth creation in Asia and the Middle
East. In fact, according to Airbus, air traffic is set
IIa www.aerodefensetech.com Aerospace Manufacturing & Machining, June 2019

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Machining Titanium Aero-Frames
tion alone is needed to meet the require-
ments of modern machine shops faced
with the optimised production of titani-
um aero-frames. Sometimes it takes a
whole new strategy.
A New Approach
One such strategy is high-feed side
milling, which differs from traditional
machining approaches that utilize
large radial engagements and obligate
to low cutting speeds of 40-60 m/min.
Instead, high-feed side milling is char-
acterized by low radial engagement,
constant chip thickness, and high feed
rate and speed.
At Sandvik Coromant, the company’s
R&D team set about creating a cutting
Interior view of an aircraft fuselage tool that could leverage the benefits of
new milling strategies like high-feed
to double from its current levels over the tinue its transformation to reduce costs, side milling with the support of CAM
course of the next fifteen years. respond quicker and invest more heavily. programming, the thinking being that
With respect to aircraft structures, the elevated productivity and extended tool
More Aircraft Required demand for increasing levels of titanium life could be notable benefits. After two
All of these expectations point to one content in aircraft continues to rise, large- years of intensive development work,
outcome – the need for more aircraft. In ly as a result of its impressive strength-to- the result is the CoroMill® Plura HFS
turn, the challenge for aircraft OEMs weight performance. However, aero- solid-carbide end mill, a unique solu-
will be to accelerate production. frames are large components and there tion in geometry and grade that has
There is also a clear knock-on effect is often a considerable amount of mate- been specifically conceived for titanium
for the aerospace supply chain. Machine rial to machine away before the final alloys and, in particular, to work in
shops around the world serving this sec- component emerges ready for subse- combination with high-feed side
tor need to meet increasing require- quent assembly. With this in mind, it is milling strategies.
ments for capacity, output, quality, on- important for cutting-tool suppli-
time delivery and price. According ers to offer solutions that Cutting Speeds >100 m/min
to a recent survey by Deloitte, allow high productivi- Productivity has always been some-
the aerospace supply ty, and long and what of a stumbling block for machine
chain is expect- predictable tool shops producing titanium parts. The
ed to con- life. However, reason is that machinability is limited
more than by the high chemical reactivity, low
tooling thermal conductivity and work harden-
innova- ing properties of titanium. To combat
these issues, the latest end mill has
been designed to offer reliable per-
formance when machining titanium
alloys at cutting speed in excess of 100
m/min, while simultaneously demon-
strating long tool life.
The main wear mechanism during the
milling of titanium alloys is diffusion wear,
which is provoked by a chemical interac-
tion between titanium from the work-
piece material and chemical elements
from the tool coating and substrate. A
higher temperature in the cutting zone
intensifies the chemical reaction, so an
effective cooling system is especially
important for those looking to achieve
prolonged tool-life characteristics.
In order to improve heat transfer
from the cutting zone and use coolant in
a more efficient way, the latest solid-car-
Aircraft Fuselage Section bide end mill is equipped with a newly
2a www.aerodefensetech.com Aerospace Manufacturing & Machining, June 2019

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Machining Titanium Aero-Frames
developed internal coolant
solution. The coolant Landing Gear Beam
channels have exits
(one per each flute)
that are specifically
positioned to let the
fluid reach the
most thermally
loaded part of the
cutting zone. To
increase cooling
efficiency even fur-
ther, the tool is
equipped with the
exclusive Coolant
Booster (patent
pending), which fea-
tures coolant flow The Results was four times longer. As a result, the
grooves on the clear- By replacing the existing high-feed plant is witnessing annual savings of
ance side that are indexable insert cutter with the CoroMill® ⇔14,000 for the pocketing operation
designed to Plura HFS ISO S end mill, cutting data alone.
improve the heat could be suitably adjusted to make the This article was written by Corey Schwenke,
dispersion. required gains. For instance, cutting Product Manager - Solid Round Tools -
speed was raised from 50 to 110 m/min, Americas, Sandvik Coromant (Fair Lawn,
Defining the while axial depth of cut was increased NJ). For more information, visit http://
grade and the from 1 to 30 mm. At the same time, radial info.hotims.com/72994-520.
geometry depth of cut was reduced. The results
Sharp cutting proved particularly impressive.
edges are another Previously, the machining time for the
prerequisite when aero-frame pockets was recorded as 150
milling titanium minutes, with tool life of 37.5 minutes.
alloys as these help Using the CoroMill® Plura HFS ISO S
to decrease cutting end mill, machining time was
forces and mini- reduced by a factor of
mize the influence three, while tool life
of work hardening.
On the new tool,
sharp edges combine
Aerospace with a new (patent-
flap track -
standing pending) coating that
view features a TiAlN inner
layer and silicon-con-
taining outer layer. The outer layer
reacts with titanium alloys and forms a
thin sub-micron protective layer on
top of the original coating. During the
cutting process, the newly formed
chips glide on top of the protective
layer, preventing fast deterioration of
the original coating and prolonging
tool life.
The potential results of adopting the
new cutter in combination with high-
feed side milling strategies have
already been demonstrated at a
European plant operated by a major
aircraft OEM. Here, the company
wanted to increase production rates,
save time and keep costs under control
when machining pockets on aero-
frames made from Ti6Al4V using a
four-axis horizontal machining centre. High-Feed Side Milling

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Defense & Aerospace Manufacturing

Getting the Most Out of
Industrial CT Scanning
Industrial CT analysis software uncovers aerospace
manufacturing defects that scanning alone might miss.
Q
uality assurance and flight certifi-
cation of critical aerospace parts
and assemblies have reached new
levels of sophistication in recent years.
Leading aerospace and defense manu-
facturers worldwide now consider com-
puted tomography (CT) scanning to be
an essential part of their non-destructive
testing (NDT) toolkit. Far more power-
ful than the CT used to scan the human
body, industrial CT can penetrate almost
every material, from superalloys to lead,
revealing hidden details that previously
could only be found by cutting and
destroying finished parts. Figure 1. (Left) An additively manufactured aircraft cabin bracket with deliberately inserted discontinu-
However, because scanning is always ities. (Middle) Volume Graphics software generates a color-coded display of the locations of the weak
points directly on the scan of the real component. (Right) Part after destructive test shows component
performed after manufacturing, CT- failure in the exact spot predicted by the software. (Image courtesy of Airbus Emerging Technologies &
image inspection alone without further Concepts; software images courtesy of Volume Graphics; part manufactured by Concept Laser)
analysis can lead to over- or under-esti-
mation of the significance of visible microns), data-rich images. Advanced highlight internal and external geome-
anomalies. This can lead to high rejec- CT-scan analysis software transforms tries, detect voids and inclusions, con-
tion rates, time-consuming corrective this data directly from the CT file to a firm densities, and perform high-accu-
measures, or the addition of excess digital 3D image (as three-dimensional racy metrology for first-article dimen-
weight to designs — all negatives in voxels, rather than 2D pixels). The soft- sional inspection (such as for the
expensive aerospace projects. ware has various functionalities that AS9102 North American aerospace
The solution, widely used in Europe
but now increasingly being adopted in
the U.S., is advanced software that uses
CT-scan data to create a virtual three-
dimensional volume of a part, contain-
ing complete detailed information
about its geometry, both surface and
interior. This, in turn, can be compared
against the part’s master model and ana-
lyzed for a wide variety of performance
and durability metrics that, recorded
and categorized, can be used to support
qualification and flight certification.
Understanding Both the

Geometry and the Physics of a
Part
Today’s advanced industrial CT
Figure 2. CT analysis software shows the fiber orientation within a helicopter rotor blade made of light-
machines produce extremely high-reso- weight, fiber-reinforced plastic composites (GRP). (Scanning courtesy of TPW Prüfzentrum; image
lution (generally between 1 and 400 courtesy of Volume Graphics)

Figure 3a. (left). Regular orthogonal CT slice of a weld seam; only a small portion of the existing pores are visible. Figure 3b. (middle). Analysis software pro-
vides an “unrolled” view of the same weld seam; pores and cracks are clearly visible along the entire seam. Figure 3c. (right). 3D rendering of the tank show-
ing the path (green) used to unroll the weld seam. (Images courtesy of Volume Graphics)
standard). Measurement templates pres- multiphysics capabilities). This capabili- casting, a composite layup, or is additively
ent data, such as the geometry of every ty predicts part stability, strength, and manufactured (AM) using aluminum,
individual void detected in a part, in for- performance with accuracy, speed, and titanium, Inconel, carbon fiber, or ceram-
mats that can be included in the product ease-of-use that has become transforma- ic composites, CT scanning power can be
manufacturing information (PMI) data- tive for those aerospace manufacturers adjusted to penetrate almost every mate-
base for the product. who’ve adopted it. rial, and the analysis software can then be
Also integrated within the software is An integrated CT data-analysis software put to work on the resulting data.
finite element analysis (FEA) functional- package reproduces the exact geometry In every case, deviation from the part’s
ity (much more sophisticated than in the and behavior of an individual part or master CAD model, as well as failure
90s and empowered by high-perfor- component, from a single bracket to a potential under a wide range of multi-
mance computing, automated “mesh- full engine block, no matter how it was physics conditions such as stress, vibra-
less” solver algorithms, and sophisticated made or what it’s made of. Whether it’s a tion, heat, electromagnetics, etc., can be
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INDUSTRIAL CT SCANNING
Airbus is using AM widely; the 3D-
Wall thickness [mm]
printed titanium cabin brackets used
3.00 throughout the A380 weigh 30 percent
less than the traditionally milled pieces
2.70 used in previous aircraft. The structural
mechanics simulation module in the
2.40
Volume Graphics (Heidelberg, Ge-
2.10 rmany) software the company employed
was verified on this part (Figure 1). As
1.80
lighter, yet more costly, superalloys are
1.50
increasingly being employed for weight
reduction in aerospace, CT-based evalu-
1.20 ation of the performance of these mate-
rials is becoming a valuable part of the
0.90
aircraft manufacturer’s toolkit.
0.60
The complex internal details made
possible through AM, such as lattice
0.30 structures and cooling channels, can
only be fully evaluated through CT data-
0.00
analysis. The software works directly on
the voxel data of the scan, overlapping
Figure 4. A wall thickness module in CT analysis software automatically localizes and color codes areas the part and its CAD master model for
with an insufficient or excessive thickness or gap width directly within a voxel, point cloud, mesh, or
CAD data set. In this example, the module was used to examine the wall thickness of a Lycoming IO- direct comparison. When there are devi-
540-E1B5 aircraft engine. (Scan courtesy of YXLON US; image courtesy of Volume Graphics) ations between these, automatic manu-
facturing geometry correction calculates
automatically identified. This helps man- Additive Manufacturing suggested changes to the geometries of
ufacturers evaluate whether defects are AM is proving its worth in safety-crit- 3D-printed parts.
above or below tolerance criteria, and ical aerospace components. With pro- There can be unpredictable side-
supports critical go/no-go decisions that duction parts in the air (GE took an effects from laser sparks and floating
can have significant economic impact. early AM lead with their Leap engine powder occurring inside a 3D-printing
What’s more, quick feedback on as-man- and, more recently, the Catalyst machine, particularly during metal-AM
ufactured parts can inform design deci- engine for their advanced turboprop), builds of aerospace components. CT-
sions, guide adjustments to mold dimen- this technology has become an impor- scan analysis software provides visual
sions, and help direct changes to manu- tant option for lightweighting structur- confirmation of porosity, voids, inclu-
facturing equipment settings that will al as well as non-structural air and sions, blocked cooling channels (very
optimize the final product. spacecraft components. important to control in AM-produced
turbine blades), surface dimensional
and thickness variations, and warping.
A Look Back at the Development Virtual (simulation-based) stress testing
of Industrial CT Analysis assesses the impact of such discontinu-
ities on part stability — including direct-
Not surprisingly, physics-department engineers at Boeing were among the
ed force, torque, and pressure analysis
early enthusiasts for the use of CT to assess aerospace part quality, writing a
chapter for the Review of Progress in Quantitative Nondestructive Evaluation in of static loads — and calculates the Von
1991 about “a new inspection capability for aircraft hardware.” Mises stresses to identify the most likely
locations of failure.
“We believe that the most beneficial application of CT will be in using CT data
for component acceptance by engineering criteria rather than inspection stan-
dards,” noted the authors.
Composites
Today’s newer, larger aircraft contain
At that time, the more sophisticated analysis tools that would be needed to a significant proportion of composite
take full advantage of scan data were in the early stages of development. The materials, which provide stiffness and
authors described CT scanning of an aircraft drum casting that revealed a defect structural strength exceeding that of tra-
in the outside wall. To predict the potential impact such a defect might have on
ditional metals and also deliver the value
the component’s performance, the scan data was converted to a 2D digital model
of the part and then transferred to a finite element analysis (FEA) code. FEA was of weight savings and decreased fuel
a nascent tool at the time, not yet widely used; while the effect on performance consumption. There are a number of
was predicted quite accurately, the analysis itself involved expert setup and long issues that arise in composite manufac-
run times, and the images were low in resolution. turing that can be addressed in greater
depth through CT-scan data analysis.
By 1997, German physicists at Volume Graphics had developed the first soft-
ware able to directly process CT slice-image stacks on standard PC hardware. A • Proper orientation of fibers is critical
year later, the application did away with the need to analyze data slice-by-slice, to robust performance of composite
covering a volume in all three dimensions. wings, blades, fuselages, and bulk-
heads. Fiber-composite material analy-
sis software provides insights into car-

bon fiber reinforced polymer (CFRP) Welds analysis are increasingly being
and glass-reinforced plastic (GRP), vi- The art of welding in aerospace is as old employed by the aerospace industry,
sualizing both local and global fiber as the first commercial aircraft. The including commercial, defense, and
orientations (Figure 2), and aiding integrity of welds is obviously of critical NASA, to ensure product integrity
comparison of nominal and actual val- importance: last year the International and meet certification requirements.
ues of the orientation tensors of indi- Space Station detected a loss of oxygen Other applications of the methodol-
vidual components; these values can that was a direct result of a weld-pore issue. ogy include engine wall-thickness
be fed into simulation software to as- A variety of processes have been devel- evaluation (Figure 4), injection-
sess stress and durability. oped to join both traditional and newer molded part geometry correction,
• Part delamination is a major flaw that metals such as titanium, aluminum, and soldering inspection of circuit
can be challenging to fully evaluate in magnesium. Weld seams of all types have boards, evaluation of hot-formed air-
composite components made up of restrictions on thickness and can con- craft parts, reverse engineering of
multiple layers; visualization of CT tain porosities and cracks for which CT older aircraft, crash forensics, and
scans makes delaminations visible so analysis software can be an extremely more.
their causes can be addressed. valuable identification tool. Scanning a A growing trend in aerospace
• Undulations arising from process er- typical S-shaped weld for defects using manufacturing is at-line, or even in-
rors — such as inadequate material, CT alone requires inspecting individual line, use of CT scanning plus analy-
errors in layering technique, excess image slices one at a time. Viewed this sis software implementation right on
application of resin — can be uncov- way, the full effect of a crack or porosity the production floor. Accurate and
ered quickly, and remedial steps taken can remain undetected. Using analysis complete understanding of how
to correct manufacturing methodol- software, however, the S-shape of the changes in manufacturing parame-
ogy flaws. weld can be defined as a straight path ters can affect the final product is
• Gluing of components is of particu- that more clearly displays the full extent essential when the goal is the level of
lar importance with composites. of the discontinuity (Figure 3 a – c). quality that flight-critical products
Analysis software helps visualize how require.
well glue was dispersed, how big the A Methodology with Broad This article was written by By Kamil
contact zone is between glue and ma- Applications in Aerospace Szepanski, Volume Graphics (Heidelberg,
terial, and whether any breaks have These are just some of the many Germany). For more information, visit
occurred. ways that CT-scanning plus software http://info.hotims.com/72994-522.
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Aerospace Work Platforms —
More than
Meets the Eye
Today’s work platforms
are far more complex
than the simple
designs of the past.
F
or maintenance personnel in
the aerospace industry to do
their jobs effectively, they need
to be able to get physically close to the
equipment they are working on. This
statement sounds obvious, but in
order to meet this requirement, it is
very important to utilize quality work
platforms. Although most people are
familiar with the basic uses of work
platforms, there is not always much
thought given to everything that goes
into their design and fabrication.
In years past, simple platforms were
widely used for a variety of different
work applications, however, much
more is demanded of them in modern
facilities. These increased demands
have forced the work platform fabrica-
tion industry to evolve. The design
and fabrication of today’s platforms
require manufacturers with expertise,
experience, and skill. Fabricators and
designers must incorporate special-
ized features in many areas never
before seen or even considered.
Safety, configurability, mobility, mate-
rial selection, worker access, and utili-
ties are all requirements that need to
be considered.

Handrails and guardrails protect against falls.
This one incorporates padding to protect nearby
product.
Safety
The first and most critical element of
the modern work platform is that it has
to be fully OSHA-compliant. Many older
platforms that are still in use today do
not meet OSHA standards. It could be
that the stairways are too steep or the
platform lacks sufficient handrails. So,
the first step to ensuring safety is to
adhere to OSHA guidelines. This re-
quires a sophisticated level of communi-
cation between the end user, the fabrica-
tor, and the designer. Every element of
the work platform must be compliant.
One piece of the safety puzzle that’s
been gaining more and more attention
in recent years is the non-slip walking
surface. Proper, reliable traction for per-
sonnel on a work platform is one of the
most effective ways to protect against
injuries. Traditionally, common tread
plate was a standard feature, however
when this kind of surface encounters
some moisture, it can become very slip-
pery. Beyond tread plate, slip-resistant
roll-on, brush-on, spray-on coatings
have become more popular choices.
Another strategy, which utilizes engi-
neered wood installed over corrugated
metal decking, has recently emerged.
With this approach, a sandpaper grit is
formed on a fiberglass sheet and then
bonded to wood.
Finally, more end-users are requiring a
metallic grit substrate that can be
applied to the platform surface. This is
done through a thermal spray process,
shot at a very high temperature. As it
Aerospace Manufacturing & Machining, June 2019 www.aerodefensetech.com 11a

Aerospace Work Platforms
This non-slip surface starts as a rolled-on prod- A “FOD Slide” installed under stairs catches any
uct. Note the foam on the edge to protect the object dropped on stairs and directs it towards a Air casters allow a heavy platform to move
product “FOD Collection Tray” at the bottom effortlessly on a cushion of air
cools, it melts and creates a non-slip sur- maintenance, personnel often need to users want one platform that does a
face that essentially never wears out. get to challenging areas and an extra number of different things. This means
The next box to check in the safety level of safety is needed to accommodate it needs to be configurable both hori-
category is load certification. Cal - this. By utilizing fall-restraint tie-off zontally and vertically, as it must sit at
culations must be made based on the points, the operator can tie into a hook several different levels off the ground.
load requirements of the actual job, and get to the dangerous edge of the Furthermore, sometimes, the end user
and the platform must be proof-tested platform safely. may not know exactly what height the
to ensure it meets those needs. Load Foam features are designed to protect platform will need to be used at. This
certification may be required for the workers and product. There can be ma- means the platform must be designed to
entire platform or just a specific sec- ny protruding shapes on a work plat- accommodate this unknown. Features
tion. form (I-beams, elbows, etc.) By adding a such as slider decks, removable panels,
Some smaller, while still critical, ele- foam feature on these shapes, personnel and flop boards can help make the plat-
ments to the safety of a work platform, are less likely to injure themselves by form adjustable enough to meet most
are fall-restraint tie-off points, foam fea- mistakenly walking into them. configurability needs.
tures, and foreign object debris (FOD) FOD (foreign object damage – stray Platforms can now be designed to be
containment features. In aerospace parts or debris that could damage a jet height-adjustable and also include related
engine if ingested) containment is a cur- features such as adjustable-angle stairs.
rent focus of attention. When an opera- Even more specialized, there are times
tor finds a piece of FOD, a containment when a work platform must be designed
feature provides a place to put it so it to have piecemeal assembly and disassem-
doesn’t end up somewhere that it bly capabilities. Situations can arise where
shouldn’t. This helps maintain the an end user must squeeze a work platform
integrity of the job being worked on. through a very confined portal, and then
Finally, explosion-proof components “open it up” once inside in order to per-
must be considered when designing form a specific task. In this instance, the
and fabricating a work platform. De- platform must be able to be carried in
pending on where the platform will pieces and then be easily reassembled.
ultimately be used, there may need to
be special illumination incorporated Mobility
into the design that won’t accidentally One of the most important consider-
produce a spark that could ignite flam- ations when designing a work platform
mable gases and liquids. is its mobility. Work platforms are gen-
erally heavy and moving them around a
Configurability plant or facility can be a daunting task.
The physical requirements of the Traditionally, the platform is designed
modern-day work platform can be com- to roll on casters. This can be challeng-
plex. First and foremost, end users are ing, however with the old technology.
Hinged flop doors give access to key locations
when needed, but fold down offering fall protec- looking for multi-level platforms. As Luckily, caster technology has advanced
tion when not everyone is trying to keep costs low, so that, although they can hold just as

Material Selection example, salty environments along the
Considerations coastline.
In addition to safety considerations Some materials may be prohibited.
and configurability requirements, The end user may not be able to use a
material selection is important to particular type of metal in the same
understand. First, what type of envi- environment as their product — chem-
ronmental or chemical considerations icals may degrade the platform.
(corrosion resistance) must be incor- Another consideration for material is
porated into the design? Platforms electrostatic discharge (ESD) control
need to be able to withstand their features. Walking around on a platform
intended operating conditions — for can generate static electricity that will
PROFOUND
The in-depth insights of our non-destructive
fiber composite material analysis
The Fiber Composite Material Analysis Module for VGSTUDIO MAX gives
you profound insights into fiber-reinforced materials such as carbon-
Utilities of all types are common on today’s fiber-reinforced plastics (CFRP) or glass-fiber-reinforced plastics (GRP)—
platforms, in this case, electric and com- completely non-destructively, thanks to CT.
pressed air, and lights
Determine fiber orientations, fiber volume fractions, and fiber orientation
much weight, it only requires a fraction distributions; visualize the results clearly; and export the material properties
of the force to push them. This is for further use in your simulation software.
accomplished by incorporating multi-
ple wheels on one caster, reducing fric-
tion. Incorporating an air caster im- Meet us at Amerimold 2019, in hall F, booth 1127 or
proves the mobility of work platforms
learn more at www.volumegraphics.com.
even more. This technology creates a
cushion of air, allowing an operator to
move 2,000 pound-plus work platforms
by themselves.
Work platforms can also incorporate
linear rails. This could be anything
from built-in lifts to boards that extend
out. These functions enable linear mo-
tion and are critical when an operator
must position a heavy part of the plat-
form.
Aerospace Work Platforms
This platform
is covered with
non-slip engi-
neered wood
supported by
corrugated
metal decking
underneath
discharge when a ground is made. If there are sensitive elec-

tronics, grounding jacks should be installed throughout the
TS-7553-V2 platform.
Finally, weight considerations must be addressed when
Industrial IoT Gateway selecting the material. The platform may need to be under a
NXP i.MX6UL 698MHz ARM Cortex-A7 CPU certain weight in order to keep it mobile.
4 GB MLC eMMC Flash
Systems and Utilities
The modern work platform needs to be equipped with a
variety of utilities to satisfy the operator. For example, general
and task lighting must be present, and their controls should
be right at the operator’s fingertips. The electrical capabili-
ties may need to be single phase, multiphase, or low voltage.
There could be hydraulic, pneumatic, or vacuum require-
ments. An operator may need a lab-quality vacuum with low
pressure for a certain task.
Finally, with today’s plugged-in world, there are data re-
quirements for work platforms. Data cables need to be run in
order to accommodate computer workstations.
The simple work platform is being swallowed by time. The
modern-day facility is looking for a platform that meets spe-
cific material and safety requirements and can perform a
number of different functions. By utilizing these specialized
pieces of industrial equipment, facility managers can be con-
Nine-Axis MEMS MotionTracking Device fident their maintenance personnel have every advantage
Industrial Temp Range -40 °C to 85 °C available to do an effective job.
This article was written by Ken Wasiuta, Vice President of WB
Industries (O’Fallon, MO). For more information, visit http://
www.embeddedARM.com info.hotims.com/72994-521.
14a Free Info at http://info.hotims.com/72994-805 Aerospace Manufacturing & Machining, June 2019

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Welcome to your Digital Edition of

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