1. 11/16/98 NASA/AM 1 Aviation Safety Program dar Accident Mitigation NASA Research in Crashworthiness and Fire Prevention Douglas A. Rohn Element Manager NASA Lewis Research Center INTERNATIONAL AIRCRAFT FIRE AND CABIN SAFETY RESEARCH CONFERENCE November 16, 1998

2. 11/16/98 NASA/AM 2 Aviation Safety Program dar NASA Aviation Safety Program –Accident Mitigation Systems Approach to Crashworthiness –Background, Approach, Milestones, Status Fire Prevention –Background, Approach, Milestones, Status Resources Outline

3. 11/16/98 NASA/AM 3 Aviation Safety Program dar Air traffic is projected to triple over the next 20 yearsAir traffic is projected to triple over the next 20 years –Air travel may be the safest mode of travel, but even today’s low accident rate will be unacceptable NASA Enabling Technology GoalNASA Enabling Technology Goal –Reduce the aircraft accident rate by a factor of five within 10 years and by a factor of ten within 20 years Aviation Safety Program GoalAviation Safety Program Goal –Develop technologies that contribute to reduced aviation fatality and accident rates by 80% by 2007 and 90% by 2017 Aviation Safety Program ObjectivesAviation Safety Program Objectives –Eliminate Targeted Accident Categories –Strengthen Safety Technology Foundation –Increase Accident Survivability –Accelerate System Implementation to All Users & Vehicle Classes NASA Program Background

4. 11/16/98 NASA/AM 4 Aviation Safety Program dar Program Organization Aviation Safety Program Office Mike Lewis (LaRC) Deputies (ARC, DFRC, LaRC, LeRC) System-Wide Accident Prevention Dave Foyle (ARC) System-Wide Accident Prevention Dave Foyle (ARC) Single Aircraft Accident Prevention John White (LaRC) Single Aircraft Accident Prevention John White (LaRC) Weather Accident Prevention Ron Colantonio (LeRC) Weather Accident Prevention Ron Colantonio (LeRC) Aviation System Monitoring & Modeling Yuri Gawdiak (ARC) Aviation System Monitoring & Modeling Yuri Gawdiak (ARC) Accident Mitigation Doug Rohn (LeRC) Accident Mitigation Doug Rohn (LeRC) Safety Risk & Benefits Analysis Gov’t/Industry Program Leadership Team Office of Aero-Space Technology Lead Center (LaRC)

5. 11/16/98 NASA/AM 5 Aviation Safety Program dar Fire Prevention Limit Hazards Prevent In- Flight Fires Organizational Cultures Aircraft Class Unique Issues Manufacturer Liability Implications Reduce the Number of Fatalities Given that an Accident Occurs Prevent Post- Crash Fires Systems Approach to Crashworthiness Reduce In-flight Fires Increase Survivability of Post-Crash Fires Increase Survivability of Accidents Crashworthy Designs Adverse Economics GoalObjectivesChallengesApproachProjects Increase Human Survivability of Aviation Accidents Increase Human Survivability of Aviation Accidents Accident Mitigation

6. 11/16/98 NASA/AM 6 Aviation Safety Program dar Accident Mitigation Background Despite improvements, accidents still happen –For transports*: 43% involve serious injury/fatality; 45% of those are survivable –In-flight fires account for 5% of all fatalities* Technology needed to increase survivability –Reduce hazards (due to crash and/or fire) –Allow more time for escape –Eliminate/detect in-flight fires Focused to all aircraft classes –Fuel fire prevention to fires involving Jet-A * worldwide, 1959 - 1995 data, from Boeing/ASIST

7. 11/16/98 NASA/AM 7 Aviation Safety Program dar Accident Mitigation “Increase Human Survivability of Aviation Accidents” Systems Approach to Crashworthiness Systems Approach to Crashworthiness Fire Prevention Fire Prevention Prediction Methodologies Structures, Materials, Interiors, & Restraints Crash Resistant Fuel Systems Detection Suppression Inerting/Oxygen Fire-Safe Fuels Materials Accident Mitigation Sub-Elements

8. 11/16/98 NASA/AM 8 Aviation Safety Program dar NASA Aviation Safety Program Accident Mitigation Systems Approach to Crashworthiness –Background, Approach, Milestones, Status Fire Prevention –Background, Approach, Milestones, Status Resources

9. 11/16/98 NASA/AM 9 Aviation Safety Program dar Systems Approach to Crashworthiness Accident Data & Characteristics Transports, survivable accidents*: –23% of fatalities due to impact alone –50% of fatalities due to combination of impact injury and fire GA: low altitude, low airspeed Rotorcraft has made gains in crashworthiness * worldwide, 1959 - 1995 data, from Boeing/ASIST

10. 11/16/98 NASA/AM 10 Aviation Safety Program dar Systems Approach to Crashworthiness Background NASA involvement –have been working other US government agencies and industry to improve crashworthiness for 20+ years Systems approach is required –Survivability in a crash is a function of >flight conditions at impact >impact surface >airframe response >seat response and restraint system performance >occupant response –Significant interaction between these contributing elements

11. 11/16/98 NASA/AM 11 Aviation Safety Program dar Systems Approach to Crashworthiness Approach Focus: Limit crash hazard –Analytic tools >Provide significant data on the injury mechanisms, injury criteria and crash criteria for typical crashes >Provide analysis methodology for optimizing crashworthiness system –Seats, restraints, energy absorption >Provide material handbooks and design guides >Work with industry to produce hardware and test Focus: Limit post-crash fire hazard –Crash Resistant Fuel Systems to reduce spillage >Transfer existing technology (example DoD Crash Resistant Fuel Systems )

12. 11/16/98 NASA/AM 12 Aviation Safety Program dar Systems Approach to Crashworthiness Present Validated Analysis Methodology Crash-Resistant Fuel Systems Advanced Restraints Energy-Absorbing Structural Concepts Increase human survivability Future Airbags FUEL SPILL

13. 11/16/98 NASA/AM 13 Aviation Safety Program dar AvSP Phase I 2.5.1 Roadmap L3 Milestone Decision Pt. m n L2 Milestone Comparison Modeling FY1998 1999 2000 2001 2002 2003 2004 Pre - AvSP Prediction Methodologies Structures, Materials Interiors, & Restraints Crash Resistant Fuel Systems Fuel System Evaluation New Concepts Testing Data Compilation for Transfer 4 Definition and Design New Fuel System Concepts 6 10 7 8 1 Test New Fuel System Concepts 11 9 7 Rotorcraft FEM GA-FEM Downselected Code Evaluation for Enhancement 1 Rotorcraft - FEMs GA -FEMs 2 GA - 2nd Gen. FEM Commuter FEM Iterative Code Validation and Enhancement 3 GA/Rotor Test GA - Test Crash System Evaluation Rotorcraft Test Code Validation Testing New Concepts Design Industry “Help” Materials 5 6 4 3 Blue - GA Red - Rotorcraft Yellow - Commuter/Transport Purple - GA and Rotorcraft Green - multiple categories Evaluate Codes & Downselect Validation of 1st Generation Codes/ Enhancement and Update input from Fire Prevention Concepts to Limit Fires Post-Crash Fire Mitigation Demo Structural Crash Analysis Tools Transport Crash Design Guide - Vol. 1 Advanced Protection Concepts Systems Approach to Crashworthiness

14. 11/16/98 NASA/AM 14 Aviation Safety Program dar Systems Approach to Crashworthiness Planned Milestones Proof-of-concept of technology & characteristics to limit fuel spill in post crash (4Q/FY01) Analysis tools for structural crashworthiness prediction (4Q/FY02) Advanced concepts to protect human body during crash (4Q/FY03) Demonstrate technology to eliminate/mitigate effects of post-crash fire (4Q/FY04) Transport Crash Design Guide (Vol. 1) (4Q/FY04)

15. 11/16/98 NASA/AM 15 Aviation Safety Program dar Systems Approach to Crashworthiness Current Status NASA Funded Research –Pre-AvSP begun –NASA/FAA co-funded activities in Crash Resistant Fuel Systems and analysis methodology work –NASA/AGATE alliance (GA) –Ongoing cooperation with Army at LaRC –GA/Rotorcraft/NASA have established relationships (no formal documents but lots of contacts)

16. 11/16/98 NASA/AM 16 Aviation Safety Program dar Systems Approach to Crashworthiness Challenges Technology Readiness –Dynamic analysis codes that can handle composite materials –Developing dynamic testing for components that are representative of the actual environment –Developing human injury criteria –Crash Resistant Fuel Systems technology that is not a weight penalty Implementation Readiness –Certification methods, regulations, and standards may be necessary –Affordability and retrofitability

17. 11/16/98 NASA/AM 17 Aviation Safety Program dar NASA Aviation Safety Program Accident Mitigation Systems Approach to Crashworthiness –Background, Approach, Milestones, Status Fire Prevention –Background, Approach, Milestones, Status Resources

18. 11/16/98 NASA/AM 18 Aviation Safety Program dar Fire Prevention Accident Data & Characteristics Survivable transport crashes *: –27% of fatalities due to fire and gases –50% of fatalities due to combination of impact injury and fire/gases In-flight fires account for 5% of all fatalities Ground maintenance mishaps * worldwide, 1959 - 1995 data, from Boeing/ASIST

19. 11/16/98 NASA/AM 19 Aviation Safety Program dar Fire Prevention Background NASA involvement –Combustion for propulsion systems –Micro-gravity combustion, detection, and suppression Two fire issues, both related to fuel or non-fuel combustion –Post-accident: overcome by smoke; fire itself –In-flight fire/explosion, including detection & suppression >Also ground maintenance mishaps

20. 11/16/98 NASA/AM 20 Aviation Safety Program dar Fire Prevention Approach Focus: Limit fire hazards –Fire-safe fuels >Evaluate concepts & develop fuel additives/mods for tank flammability –Materials >Evaluate low heat release materials for cabin interiors Focus: Prevent in-flight/non-crash fires –Fuel mods or inerting >Evaluate concepts & develop fuel additives/mods for post-crash fires >Develop on-board inert gas/oxygen generation systems for commercial applications of tank inerting & on-demand (stored & generated) oxygen –Low-false-alarm detection >Develop design criteria for low false-alarm detection –Suppression >Leverage Halon replacement technology as available; consider other suppression concepts

21. 11/16/98 NASA/AM 21 Aviation Safety Program dar Low Heat-Release Materials On-Board Inert Gas Generation DetectionSuppressionSuppression FALSE ALARM MICRO-FAB GAS DETECTORS LEVERAGE NON-HALON APPLICATIONS Fire-Safe Fuels Increase accident survivability & prevent in-flight fires Fire Prevention

22. 11/16/98 NASA/AM 22 Aviation Safety Program dar AvSP Phase I 2.5.2 FY1998 1999 2000 2001 2002 2003 2004 Pre - AvSP Fire Prevention Identify & evaluate concepts Roadmap L3 Milestone Decision Pt.L2 Milestone Eval. OBIGGS/ OBOGS Concept Detection Inerting/ Oxygen Experimental characterization of fuels, mods, & additives Fire-Safe Fuels Materials Suppression Evaluate system design concepts Evaluate low false alarms in representative fire conditions Des./Dev prototypes: combined system and/or separate Define requirements Prototype demonstration in post-crash environment Experiments for database & scale-up characteristics. System demo in simulated in-flight conditions Demonstrate non-Halon effectiveness Assess Halon-replacements Evaluate alternate methods for commercial appl. Evaluate thermally-stable polymer samples Breadboard & screen sensors Ground tests & transfer concepts to ind. 2 4 Des. prototype. concepts m 1 3 7 65 9 B 8 10 11 5 6 2 1 n input from Crashworthiness Note: OBIGGS/OBOGS = On-board inert-gas/oxygen generation system Design Criteria for Low False-Alarm Concepts to Limit Fires In-Flight Fuel Flammability Reduction Demo Post-Crash Fire Mitigation Demo Detection Design Concepts

23. 11/16/98 NASA/AM 23 Aviation Safety Program dar Fire Prevention Planned Milestones Proof-of-concept of technology & characteristics to limit fuel flammability in post crash (4Q/FY01) Design criteria for reliable, low-false-alarm fire detection systems (4Q/FY01) Demonstrate technology to prevent in-flight fuel- related fire/explosion (4Q/FY04) Demonstrate technology to eliminate/mitigate effects of post-crash fire (4Q/FY04)

24. 11/16/98 NASA/AM 24 Aviation Safety Program dar Fire Prevention Current Status NASA Funded Research –Pre-AvSP begun –NASA: leverage & expand ongoing research >Combustion ¤Propulsion & Fuels ¤Micro-gravity >Materials development ¤Structural ¤High-temperature –FAA Participation: detection; inerting; fuels –Industry: plan to get involved with active vendors

25. 11/16/98 NASA/AM 25 Aviation Safety Program dar Fire Prevention Challenges Technology Readiness –Detection discrimination between fire and non-fire sources –Practical products to prevent fuel explosions/fires –Light-weight, high volume on-board inert gas/oxygen generation systems –Low heat-release materials in economic, large quantities –Effective, light-weight alternate suppression systems Implementation Readiness –Economic barriers: cost, weight, infrastructure

26. 11/16/98 NASA/AM 26 Aviation Safety Program dar Resources NASA funds: $36.8M –Cost-share assumed for some activities >Industry: in-kind (hardware) for crash tests >FAA R&D: co-funded fuel system crash tests & in-kind fire prevention test support Facilities –NASA-LaRC Impact Dynamics Research Facility –NASA-LeRC Combustion Labs –FAA-Tech Center Crash & Fire Facilities Partnerships –Strong participation of FAA Tech Center –AGATE cooperation for early products in GA Crashworthiness –Working on industry partners; leverage with DoD –International ? Planning & Rationale

27. 11/16/98 NASA/AM 27 Aviation Safety Program dar Systems Approach to Crashworthiness and Fire Prevention contribute to NASA safety goal Technical content focused to reduce accident effects in order to enhance survivability; plus prevention –Crash dynamics, human protection, post-crash fire, in- flight fire Technical & implementation hurdles recognized Preparing to execute –Finalizing plans ; e stablishing cooperation Summary