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Modern aircraft depend on extensive electrical wiring networks for power distribution, avionics, and control systems; however, these wiring systems are vulnerable to wear, insulation degradation, and arcing over time, leading to safety risks and costly unscheduled maintenance. This paper introduces an advanced Electric Health-Monitoring Wiring (E-Wiring) system that integrates temperature, current, insulation, vibration, and environmental sensors directly into aircraft wiring harnesses to enable continuous monitoring and intelligent fault detection. Data from these embedded sensors are processed through a distributed edge AI network, forming an Electrical Health Monitoring System (EHMS) capable of real-time diagnostics, predictive maintenance, and fault localization. The architecture comprises smart cable segments with sensor nodes, local harness gateways for edge processing, aircraft-level EHMS integration via AFDX/Ethernet, and cockpit or maintenance displays linked to ground-based
Tammana, Bala Sai Sri RohitMurthy, HarshaMendu, HarikaSivaniSunandha
It is a general practice to test aero engines to evaluate their performance in specially designed indoor test facilities after assembly, repaired or overhaul. Acoustic features are provided in the test facility to attenuate the noise level to a comfortable and acceptable level. Design of these features specially air intake and exhaust silencers are a challenging task in a flow field like aero-engine test facility considering the very high sound pressure level generated by them during test containing a very wide frequency band. Moreover, growing population and location of these facilities in the vicinity of residential areas has added this challenge in multifold. Also, the capital investment in building these facilities is huge due to their large size and longer construction time. Hence, the correct execution at first shot including design, fabrication and commissioning is very important. An attempt has been made to reduce design errors or improve the accuracy in the design stage by
Gouda, Bansidhar
The increasing demand for safety and reliability in aerospace applications necessitates rigorous testing of aircraft components, including light units, for explosion proofness. Traditional explosion proofness tests are destructive, expensive, and time-consuming, requiring significant resources for test setups and prototypes. To address these challenges, this research presents a numerical methodology using Computational Fluid Dynamics (CFD) simulations to investigate the explosion proofness for aircraft light units. The primary motivation of this study is to establish a computational framework that supports early-stage design screening, reduces the number of physical prototypes, and enhances understanding of explosion behavior before formal qualification testing. This work contributes to advancing engineering practices in the aerospace industry by demonstrating the efficacy of CFD simulations in evaluating and enhancing the explosion proofness of light units. The proposed CFD model
Selvaraj, SugumaranNataraja, Prabhu
Dynamic soaring is a flight technique that exploits wind shear for sustained flight. It is commonly observed in birds such as albatrosses and holds significant potential for unmanned aerial vehicle (UAV) missions. Previous research has primarily focused on trajectory generation using direct optimal control or differential flatness. This paper proposes an enhancement to the existing six-degree-of-freedom (6-DOF) trajectory generation method based on differential flatness. The proposed formulation includes sideslip and accounts for all stability and control derivatives. A Vortex Lattice Method (VLM) solver is then used to compute steady aerodynamic forces and moments, which are compared against the constant-derivative-based trajectories. To assess the validity of the constant-derivative assumption, a 6-DOF UAV model is simulated in a dynamic soaring orbit with stability augmentation provided by a Linear Quadratic Regulator (LQR). The observed divergence in this simulation highlights the
Swaminathan, Bharath
The study proposes the use of Carbon Fiber Reinforced Plastic (CFRP) sandwich composites configurations for structures interfacing cryogenic tankages. To address the design challenge posed by high thermal contractions in metallic tanks after cryogenic propellant filling, the study incorporates slits near the tank interfaces. Additionally, to minimize the transfer of cryogenic temperatures into these interfacing parts, the sandwich structure features interface end attachment made of thermally insulating Glass Fiber Reinforced Plastic (GFRP) material. Analytical and Finite Element (FE) studies were conducted on a typical cylindrical cryogenic intertank structure to demonstrate the proof of concept. These studies included analytical design using MATLAB based codes, parametric analyses with simplified shell element models and detailed 3D sector models using solid elements. The parametric studies assessed the effects of the number and dimensions of slits to achieve an optimal design, while
Bhalerao, Sandesh PopatGupta, Yogesh KumarMadhukumar, P.
The development of lightweight materials for use in aerospace and automotive applications is extremely significant. Magnesium (Mg)-based alloys and composites are good candidate materials from the perspective of low density, good specific strength, and abundance. The Mg-4Zn alloy is one such alloy, which is a lightweight, biocompatible, and eco-friendly Mg-based alloy. In spite of these advantages, there is a strong need and scope to improve its wear resistance and mechanical properties. Mg-4Zn nanocomposites with Si3N4 reinforcements (a biocompatible bioceramic) are hypothesized to possess superior properties. Microstructural analysis of the vacuum stir-cast nanocomposites confirms grain refinement and a consequent increase in microhardness with an increase in Si3N4 reinforcement wt.%. The addition of Si3N4 reinforcement to improve the properties of the Mg-4Zn alloy could introduce challenges in machining. To make products from the nanocomposites, machining them with minimal
N, AnandShaju, Tony MG, Nagamalleswara RaoD, BijulalK, Jayaprakash ReddyK, VijayanChaman, Joji J
Aerospace products operate within highly complex, safety-critical environments and endure extended lifecycles, often spanning decades. Sustaining their operational value requires rigorous management of Safety, Reliability, and Availability (SRA), while global Environmental, Social, and Governance (ESG) mandates demand parallel progress toward sustainability goals. This paper introduces an AI-driven strategy that integrates these dual imperatives—Sustenance Management and Sustainability Management—within a unified Product Lifecycle (PLC) framework. The proposed approach leverages Artificial Intelligence across five PLC phases: Generative Design, Detailed Design & Verification, Manufacturing & Industrialization, Operations & Maintenance, and End-of-Life Circularity. Anchored by a certified Digital Thread, this framework ensures seamless, auditable data flow from concept to disposal. Using Life-Limiting Parts (LLPs)—such as high-stress turbine discs—as a case study, the paper demonstrates
Srinivasan, KarthikG.V.V., Ravi KumarVaderahobli, Devaraja HollaBhate, UjwalVeluri, Sastry
Automatic Dependent Surveillance–Broadcast (ADS-B) has become a cornerstone of modern aviation, revolutionizing Air Traffic Management (ATM) through its ability to continuously transmit real-time flight data—including GPS-derived position, altitude, and velocity. Since its widespread operational deployment over the past decade, ADS-B has significantly enhanced situational awareness, improved safety, extended surveillance coverage into previously unmonitored airspace, and enabled more efficient aircraft routing and separation. However, despite its many advantages, the fundamental design of ADS-B introduces notable security vulnerabilities. Because ADS-B signals are unencrypted and unauthenticated, malicious actors can inject fraudulent broadcasts, creating the illusion of non-existent aircraft. Such spoofing attacks can trigger false cockpit alerts and distract pilots during critical phases of flight. The current ADS-B data format prioritizes simplicity to accommodate a broad range of
Chikkegowda, KanthaShetty, RameshKhan, KalimullaSahoo, Subhransu
This study presents a data-driven approach for strengthening aviation safety by integrating human factors assessment with modern predictive modeling techniques. The work focuses on understanding how human performance, operational conditions, and system-level interactions collectively influence safety risk, and how these interactions can be quantified to support improved design and decision-making. Unlike previous studies that address human factors or predictive modeling in isolation, this research offers a unified framework that links causal human factors indicators with statistical modeling, feature extraction, and machine learning based risk estimation. The novelty of this work lies in the structured pipeline that transforms raw categorical and narrative human factors information into measurable predictors that can be analyzed using structural modeling and machine learning. The methodology includes data preparation, dimensionality reduction, latent pattern discovery, dependence
Valiyaparambil, Praveen
Aerospace manufacturing operates within an intricate ecosystem where quality, compliance and traceability are critical to success. Conventional digital thread frameworks provide connectivity but remain largely passive, lacking the intelligence to autonomously manage complex non-conformities across the product lifecycle. This paper introduces an Agentic Digital Thread powered by Agentic AI, designed to transform non-conformity management into an adaptive, self-orchestrating system that actively drives decision-making and corrective actions [1, 4]. The proposed architecture employs a Master Agent to coordinate workflows and maintain end-to-end data continuity, while specialized Agents autonomously manage domain-specific tasks. In the pre-manufacturing phase, these agents proactively validate requirements, material conformity and process planning through integration with PLM, MES, ERP, QMS and supplier systems. In the post-manufacturing phase, the framework extends to concession
Veluri, SastryGopala Krishnan, Kannan
Initial weight estimation from Top Level Aircraft Requirements (TLAR) is a critical first step in aircraft design, yet existing empirical methods are inadequate for novel configurations such as those using Liquid Hydrogen (LH2) or Sustainable Aviation Fuels (SAF). This paper presents a hybrid methodology for top-level weight estimation of such unconventional aircraft. The approach is based on modifying a conventional baseline aircraft, integrating a new statistical model with component-specific weight estimations. A multivariate regression model to estimate the empty weight fraction (We/W0) was developed from a dataset of 44 conventional aircraft, yielding an R-squared value of 0.833. This statistical model was integrated with physics-based models for novel components, including cryogenic fuel tanks and fuel systems. The methodology accounts for iterative changes to fuselage structure and parasitic drag. Four configurations were analyzed: fuel types being Jet A1, SAF, LH2 with aft
Goyal, Tushar
Polymeric optical materials such as Cyclo Olefin Polymer (COP) are adopted in aerospace lighting systems due to their excellent optical clarity, dimensional stability, moldability and weight saving advantages over glass. However, their relatively low toughness and the presence of residual molding stress make them prone to crack initiation during mechanical fastening. During its installation, crack formation was consistently observed around self-tapping screw interfaces, raising concerns over reliability, maintainability, and compliance with durability requirements. A structured Design of Experiments (DOE) was performed to identify root causes and evaluate potential mitigation methods. The investigation revealed that residual stresses in the COP material, combined with localized stress concentrations during screw tightening, were the primary drivers of crack initiation. Two complementary process improvements were identified and validated as part of mitigation plan: (i) annealing of the
S, NikhilSingh, Abhimanyu KumarKatageri, PraveenSP, PradeepChandra, Praveen
To develop magnesium matrix composites, ceramic silicon nitride (Si3N4) particles are added to the magnesium (AZ31) matrix at 2 wt.%. The composite is produced via disintegrated melt deposition vacuum-stir-casting procedure. Microstructural studies reveal the presence of Si3N4 particles and their uniform spreading. An L9 orthogonal array, planned using Taguchi’s experimental design, is selected for three wear parameters; axial load (AL), rotational speed (RS), and time duration (TD) with trials as per the G99 standard in the pin-on-disc apparatus to assess the wear resilient of the composite. Experimental results show an increase in axial stress, and wear loss (WL) increases dramatically. Because the area of contact shrinks as RS increases, WL diminishes dramatically. When the AL is low, the friction coefficient (CoF) increases, and when the AL is large, CoF drops. When the RS is increased, CoF decreases. To optimize multiple responses effectively, the TOPSIS (Technique for Order
Senthilkumar, N.Dhinakar Raj, C K
Commercial and military aircraft increasingly rely on Integrated Vehicle Health Management (IVHM) as a critical enabler for predictive maintenance, operational efficiency, and mission availability. The evolution of IVHM data communication architecture- from legacy wire-based networks to more wireless based architecture involving onboard wireless sensor networks (WSN) and IP-based air to ground communication networks introduces multidomain cyber-physical attack surfaces that challenge both functional safety and continued airworthiness. DO-326A/ED-202A and DO-356A/ED-203A standards define aviation cybersecurity requirements within a safety-driven assurance context, and IEC 62443 standard offers a defense-in-depth, lifecycle-based control framework for industrial systems. A unified approach by mapping and harmonizing the complimentary aspects of these two standards has the potential to simplify and expedite the security assurance and certification process for the IVHM and other digital
Samudrala, RamakrishnaRamamurthy, Prasanna
The present paper reports preliminary requirement elicitation for Urban Air Mobility (UAM) from Indian perspective. A mission based approach has been adopted to identify the stakeholders and their respective requirements during different phases of the mission profile. Non adherence to the requirements emerge as possible risks for the mission and need mitigation planning. Three UAM operations for Bengaluru city viz. cargo delivery, organ delivery and passenger transport using UAM vehicle are elaborated. Stakeholders for these missions are identified and associated requirements are reported. For the cargo delivery mission, a detailed analysis is carried out to emphasis on how the India specific statutory restrictions of abiding by the red zone restrictions levied by DGCA impacts the de-tour factor and flight time. A qualitative assessment of the impact of these mission based requirements on the UAM vehicle design is presented.
DE, Manabendra M.Hebbar, ArchanaHenry, Devanandham
Global Navigation Satellite System (GNSS) receivers are widely being used in aerospace as well as automotive applications primarily for navigation applications. ISRO uses indigenously developed GNSS receivers in its Launch vehicles (LV) mainly for POD (Preliminary Orbit Determination) and for INS aiding in long duration missions. Advanced GNSS receivers are being developed and used in ISRO’s new generation launch vehicles for closed loop guidance (CLG) applications. Being used in CLG, continuous solution availability and robustness of GNSS solutions are of paramount importance. From April 2023 onwards, GNSS receivers on-board ISRO’s LV missions have shown degraded performance in terms of reduction in no. of satellites tracked and in some cases loss of GNSS solution as well. This was seen in multiple missions and was analyzed in detail. It was observed that there is nearly 3-4dB reduction in carrier to noise density (C/No) ratio and corresponding change in RF AGC gain is also observed
A, Mohammed BasimO T, Anand ShankaraV S, BijuV Gopal, BijuV S, VinojK, BalanC, Radhakrishna Pillai
Acoustic-induced vibrations pose a significant risk to launch vehicle hardware and payload reliability during critical phases such as lift-off and transonic phase. Reducing such vibrations is especially challenging when the hardware has already been fabricated, limiting the possibility of structural redesign. This study demonstrates a practical post-fabrication solution using a thin viscoelastic polymer coating applied externally to fully assembled hardware. Comprehensive evaluations were conducted using both acoustic testing and Experimental Modal Analysis (EMA) before and after coating application. During acoustic test, a substantial decrease in structure response from 150Hz to 2000Hz, with a reduction of approximately 50% in the grms values was observed for the coated structure demonstrating significant vibration mitigation over a wide frequency range. In contrast, EMA measurements using impact excitation revealed that the response transfer functions did not show a significant
Avirah, Nohin KPanda, Ajay KumarShaikh, Altafhusen
This paper investigates the energy consumption characteristics of series hybrid aircraft with a focus on comparing conventional energy management approaches against an AI-powered optimization framework. The study comprehensively models the energy demands of a series hybrid aircraft across all major flight phases, including Idle & Ground Operations, Taxi, Takeoff, Climb, Cruise, Descent, Approach, Landing, and Rollout & Taxi. For each phase, detailed mathematical formulations are developed to capture power requirements and energy flow, incorporating real-time operational parameters to enhance the accuracy of the energy consumption estimations measured in kilowatt-hours (kWh). The AI-based optimization leverages advanced control strategies, specifically Model Predictive Control (MPC) and Reinforcement Learning (RL) algorithms, to dynamically manage the aircraft’s energy systems. MPC is employed to predict and optimize future energy usage by solving constrained optimization problems over
Kanchagar, Amogha
Grid fins are non-conventional aerodynamic lifting and control surfaces which are made of a frame supporting lifting surfaces positioned in the form of a lattice structure. Grid fins are also called as lattice fins and are used as control surfaces in launch vehicles, crew escape systems, missiles etc. to achieve static stability. Each panel of the grid fin acts as fin and it produces force which increases stability of the vehicle. For a crew escape system module, grid fins are used as a passive aerodynamic control surfaces to achieve static stability. Grid fins are positioned at the end of crew escape system module to provide required static margin by increasing moment arm. In contrast to conventional fins, grid fins incorporate a distinctive waffle-like pattern or grid pattern configuration, offering superior aerodynamic performance in supersonic regimes and enabling compact storage in stowed position during launch followed by deployment at the time of exigency. In case of an
Mali, Somanath NanduSundar Raj, RSundaresan, MKR, Suresh
Digital engineering practices in aerospace increasingly require closely connected and traceable analysis workflows rather than isolated finite element tasks. Traditional FEA methods remain effective, but they involve considerable manual effort during pre- processing and post-processing, making rapid iteration difficult. Finite Element Analysis of STructures (FEAST), an indigenous finite element analysis software developed by Vikram Sarabhai Space Centre (VSSC) ISRO, offers structural analysis capabilities through a command-based architecture, yet its manual operation limits its use in automated studies. This work develops a flexible scripting-driven framework that links geometry creation, load-case definition, solver execution, and result interpretation within a unified digital engineering pipeline. The framework automates repetitive tasks, incorporates Design of Experiments (DoE) for systematic parameter variation, and supports sensitivity and automation studies. Its performance is
Gupta, ShivangiT J, Raj ThilakP, Deepak
Submarine-launched missiles with domed nose cones are highly vulnerable to cavitation erosion as they travel at high speed through an underwater launch tube and then into the air from the sea surface. The collapse of vapour cavities crystallizes intense damage on the vehicle surfaces so that the vehicle structure and aerodynamic performance are threatened. In this work, we show the full 3D numerical and analytical analysis of surface protection concepts for the reduction of cavitation damage on such an axisymmetric dome-shaped body. A computational methodology was developed by importing a complex computer-aided design (CAD) model of a dome and the connecting tubular structure into a high-fidelity simulation environment. The geometry was simplified by omitting non-essential details to facilitate the generation of quality mesh for CFD analysis. Simulations have been carried out to analyze the flow field and pressure distribution under two critical stages, at two angles of attack of 0
Velayudhan, GauthamP S, PremkumarS, Suhail AhmedP, KrishnakumarVasantharaj, C
Dynamic responses at critical locations of a spacecraft due to excitations expected during the ascent phase of a launch vehicle mission are usually estimated through a Coupled Loads Analysis (CLA) using the structural dynamic finite element model of the launch vehicle coupled with that of the spacecraft. Generally, the full physical structural dynamic model of a spacecraft has lakhs of degrees-of-freedom (DOFs). Coupling such a model with a similar model for the launch vehicle results in exorbitantly high computational costs for CLA. Hence, dynamic analysis of such large and complex structural assemblies usually employ sub-structure coupling or Component Mode Synthesis (CMS) methods. The most widely used CMS method for dynamic analyses is the Craig-Bampton (CB) method. Conventionally, a full launch vehicle CLA involves one level of CB-reduction wherein a reduced-order dynamic model of the spacecraft is first generated using the fixed-interface CB-method. This reduced-order model is
Ramachandran, Nirmal
This research investigates the fabrication and evaluation of Delrin (polyoxymethylene, POM) composites reinforcing 5-20 wt.% chopped ramie fiber (RF). The polymer composites were fabricated via the injection moulding technique. Glass transition temperature (Tg), thermal conductivity, Vicat softening temperature (VST), heat deflection temperature (HDT), melt flow index (MFI), and coefficient of linear thermal expansion (CLTE) were the various thermal characteristics of the sustainable composites that were systematically evaluated as per the ASTM standards. The addition of RF drastically altered the Delrin matrix's performance. Among the formulations, the composite with 15 wt.% RF had the best combination of properties: higher VST and HDT values, which provide greater dimensional stability at high temperatures; lower CLTE, resulting in less thermal expansion; comparatively better thermal conductivity; and improved heat dissipation. Eventually, there was a moderate drop in the MFI
S, ThirumalvalavanSenthilkumar, N.Selvarasu, S
Worldwide, engineers are exploring the possibility of using polymer composites in their quest for lightweight materials. In this study, injection moulding was used to develop a biodegradable polymer PLA composite containing 20 wt.% vetiver fibers (VFs) and 2 wt.% nano-silica (nSiO2) obtained from pearl millet, which is sustainable. Materials need machining as secondary operation that required joining. Desirability analysis was used to examine and optimize machining (drilling) studies that were designed with Taguchi's design (L9 orthogonal array). Surface roughness (SR) and delamination factor (Fd) were taken as outputs, while spindle speed (SS), feed rate (FR), and drill diameter (DD) were the inputs. Drilling studies were performed on a single vertical machining center (VMC). ANOVA identifies that the FR had the most decisive influence on SR (F=559.24, p=0.001785), followed by DD and SS. FR is the dominant contributor to Fd (F=379, p=0.00263), followed by SS and DD. At low SS and high
Senthilkumar, N.
Strap-on boosters play a crucial role in heavy launch vehicles by providing additional liftoff thrust without major changes to the baseline design, enabling launch with existing propulsion systems. However, strap-on boosters introduce additional pressure drag and alter the overall aerodynamics of the vehicle. While efforts have been previously made to derive empirical relationships to predict the aerodynamics of different strap-on configurations, most are case-specific and primarily limited to estimating drag coefficients (CD). The present study focuses on geometric parameters of strap-on such as length, diameter and radial gap between strap-on and core. The results are used to derive an empirical relationship which can be applied during preliminary design stage of a launch vehicle to predict axial force coefficient (CA), normal force coefficient (CN) and pitching moment coefficient (CPM), which are required for mission design and structural load estimation. In the current study
Muraleedharan, Archana P.G, Ramana BharathiS, Gnanasekar