HiFi- Manufacturing high fidelity full-scale wind tunnel model for next-generation air vehicle development

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Advanced Materials The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Applicants must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with the Announcement. Applicants are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. OBJECTIVE: This topic seeks to develop and demonstrate design and manufacturing technology capable of building a full-scale wind tunnel model for developing next-generation aircraft using new structures and manufacturing technologies. The structural model must be light and easy to assemble/disassemble to store and transfer to the test facility. This effort will explore state-of-the-art technologies in new lightweight structure concepts, new assembly concepts, and low-cost manufacturing technologies to build large wind tunnel models for full-size testing. DESCRIPTION: The Department of the Air Force is exploring designing and manufacturing full-scale wind tunnel models to test next-generation air vehicles. Air Force Research Laboratory (AFRL) is currently assessing emerging air vehicle concepts to address warfighter needs and their use for quickly testing full-scale vehicles eliminating the uncertainty associated with testing scaled models in a small wind tunnel. Developing a scaled model is often another challenge since the other components, such as the actuator, test rig, material, etc, are not scaled as structures. The process for obtaining accurate aerodynamic data from a scaled model may require a similar workload as designing and fabricating a full-scale model, and most importantly, the analysis and test result may not agree well due to the uncertainty of the scaled model and test environment. This effort aims to explore new structural concepts and low-cost manufacturing technology to build a high fidelity lightweight, and compact full-scale wind tunnel model. Among new structural ideas, lattice structures, origami structures, compliant mechanisms, Lego-like structures, or topology-optimized structures are concepts that might satisfy the weight, rigidity, assembly time, and volume requirements critical for the success of this program. It is unlikely that a simple foam construction will meet volume requirements unless there is a novel concept that satisfies stiffness and compaction requirements. The outer mold line (OML) of the assembled model should match the design within a yet to be determined tolerance and the skin should be stiff enough to maintain the OML under aerodynamic loads and smooth enough to meet the surface roughness requirements. The model should not deform under the aero loads expected in the wind tunnel and its components should be robust enough to endure 25 assembly/disassembly cycles. The disassembled part should be compact enough to fit in a standard 20 foot ISO dry storage shipping container for easy transfer to the wind tunnel facility. The focus of this topic is on evaluating new structural concepts and low-cost manufacturing technologies and selecting feasible concepts considering the wind tunnel model's weight, rigidity, assembly time, and volume requirements. In a future project, the design and manufacturing concepts demonstrated through this topic will be used to design and fabricate a full-size air vehicle model (F-16 equivalent size). The main deliverables for this topic are a full-size section of wind tunnel model for a relevant vehicle. The contractor should perform analysis to validate a full vehicle can be transported within the 20 foot ISO shipping container. The applicant should demonstrate through analysis and testing that the fabricated structure will meet anticipated wind tunnel loads. The applicant also should demonstrate the capability that one to four people can assemble and disassemble within a couple of hours. PHASE I: This topic is intended for technology proven ready to move directly into Phase II. Therefore, a Phase I award is not required. The applicant is required to provide detail and documentation in the Direct to Phase II proposal which demonstrates accomplishment of a Phase I-like effort, including a feasibility study. This includes determining, insofar as possible, the scientific and technical merit and feasibility of ideas appearing to have commercial potential. It must have validated the product-market fit between the proposed solution and a potential AF stakeholder. The applicant should have defined a clear, immediately actionable plan with the proposed solution. Relevant areas of demonstrated experience and success include: modeling and simulation, concept development, concept demonstration, concept evaluation, and field testing. Phase I type efforts include the assessment of the structural concept and the potential for fast assembly/disassembly. PHASE II: Eligibility for a Direct to Phase Two (D2P2) is predicated on the applicant having performed a Phase I-like effort predominantly separate from the SBIR/STTR Programs. These efforts will include modeling and simulation of prototype concepts, concept development, concept demonstration, concept evaluation, and field testing. Phase II efforts shall conduct analysis, experimentation, and fabrication of prototype systems to address unique requirements that may not be otherwise met by conventional wind tunnel models. PHASE III DUAL USE APPLICATIONS: Phase III shall include fabrication of more complex prototypes such as full sections of a wind tunnel model. REFERENCES: 1. Mobile augmented reality to support fuselage assembly, Lu s Fernando de Souza Cardoso, Fl via Cristina Martins Queiroz Mariano, E. R. Zorzal, 1 Oct2020, Business Comput. Ind. En. KEYWORDS: Quick assembly; quick disassembly; full scale wind tunnel models