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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
This study systematically evaluated the wear resilient performance of AZ61 magnesium alloy reinforced with 15 wt.% SiC and diverse amounts of multi-walled carbon nanotubes (MWCNTs) under dry sliding circumstances adopting pin-on-disc apparatus (ASTM G99). To identify the influence of factors like sliding speed (SS) (1-3 m/s), axial load (AL) (10-30 N), and MWCNT concentration (0-3 wt.%) that affect tribological performance, experiments were developed using a Central Composite Design (CCD) under Response Surface Methodology (RSM). SEM micrographs revealed a dispersion optimum near 2 wt.% MWCNT, where CNTs anchor to SiC and bridge the α-Mg matrix, while 3 wt.% shows agglomerates and micro-voids. Findings showed that wear loss (WL) and friction coefficient (CoF) was greatly amplified by increasing AL owing to localized heating and contact stresses. A compacted tribolayer was formed by increasing SS, which decreased WL but marginally raised the CoF. At low AL (10 N), SS (2.09 m/s), and
Senthilkumar, N.
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
Aircraft Maintenance, Repair, and Overhaul (MRO) operations are highly complex, involving coordination among multiple stakeholders including airlines, MRO providers, OEMs, and regulatory authorities. A significant challenge in this space is managing unplanned events such as Aircraft on Ground (AOG) conditions, where delays can lead to major financial losses to airlines and safety risks. Engineers must quickly diagnose the damage, evaluate compliance against regulatory limits, coordinate with OEMs, and make critical decisions—all while navigating a fragmented ecosystem of disconnected systems, diverse document types, and time-sensitive processes. This paper presents a real-world, intelligent MRO solution that addresses these challenges through the use of Agentic AI and context engineering. The system is designed to automate and augment key MRO workflows such as damage detection, repair pathway selection, compliance verification, and supplier coordination. At its core, the solution is
Abburu, SunithaG.V.V., Ravi KumarPoovalingam, SundaresanVaderahobli, Devaraja Holla
In the field of Aerospace, which has a long Life-Cycle process [20-30Years], Component Obsolescence has become a major problem as it prevents Maintenance & sustenance of a product with committed life-cycle period. Obsolescence Management plays a vital role by deriving strategic plans on proactive obsolescence where the system needs to be supported for several decades. This abstract analyzes the obsolescence challenges in the Aviation industry especially in Avionics System impacted by component obsolescence and present the possible proactive obsolescence management in terms of Engineering, Technology, and business/cost elements. The Obsolescence problem cannot be avoided but the impact of obsolescence and mitigate the risk can be minimized by planning and managing response. The obsolescence risk assessment for the Bill Of Materials (BOM) is a paramount activity to manage obsolescence proactively and cost-effectively. Digital Transformation of analyzing the component obsolescence status
Dharmananyala, RohithMunirathnam, KrishnaMarokeyfrancis, JoisyjoseSadashivaiah, NageshKondamari, Harshitha
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
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
The aviation industry contributes to around 2% of global carbon dioxide emissions. As various sectors of the economy look to reduce their global carbon footprint, the aviation industry is positively acknowledging alternatives to jet fuel. Hydrogen proves to be one such alternative having a high energy density and producing zero carbon emissions on combustion. Hydrogen when used in a jet engine produces water vapour and NOx emissions. In order to reduce the effect of GHGs, the current study aims to develop aircraft concepts suitable with hydrogen propulsion through fuel cells for a short-haul commercial mission profile. Aircrafts such as Metro-23 and Dornier 228-212 were referenced for the requirements of a utility turboprop aircraft. The weight estimation was done to obtain the take-off weight of 10,863 kg following the optimization of thrust to weight ratio and wing loading to calculate the initial dimensions. OpenVSP was used to model the initial structure of the aircraft. For the
Bhattacharya, AnishaSeetha Ramu, Sree ValliC N, Lakshmi ManasaRohit, Benjamin
Trajectory optimization for reusable launch vehicles is a critical challenge in space mission design, aiming to determine fuel-efficient paths for spacecraft during ascent, hover, and descent phases. Minimizing fuel consumption not only enhances cost-effectiveness but also improves mission sustainability. The optimization process is governed by nonlinear orbital mechanics, gravitational perturbations, atmospheric drag, and operational constraints such as thrust limits and collision avoidance. These factors make the problem highly non-convex and discontinuous, posing significant difficulties for classical gradient-based approaches, which often fail to identify global optima. In this work, we formulate the trajectory optimization problem for a reusable rocket executing an ascent–hover–descent cycle. The vehicle must ascend to a specified target altitude, maintain a stable hover for a given duration, and then return to the launch site. The primary decision variable is the throttle control
Eswara Sai Kumar, KandulaSingh, UtkarshPohankar, PritamA, AnoopMaharana, PriyabrataLineswala, Rut
This study presents a comprehensive methodology for optimizing critical UAV structural nodes—specifically Arm Clamps, Landing Gear, and Motor Mounts—using Generative Design (GD) tailored for Fused Filament Fabrication (FFF) with PLA+. Traditional “plate-and-standoff” UAV constructions often utilize orthogonal geometries that induce stress concentrations and fail to leverage the geometric freedom of additive manufacturing. Furthermore, reliance on expensive CNC machining or injection molding creates supply chain bottlenecks for custom or short-run UAV production. While FFF offers geometric freedom, applying it to structural airframe parts introduces challenges regarding anisotropy, layer adhesion, and material brittleness. This research optimizes these components for standard commercial 3D printers by strictly enforcing manufacturing constraints, including a 40-degree maximum overhang and a 0.4 mm nozzle size, to ensure printability without internal support structures. A significant
Krishna Bansal, Vaibhav
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
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
The aerospace industry is undergoing a significant digital transformation in the way system requirements are defined, communicated, and managed. Major OEMs are moving towards fully model-based development processes, with plans to deliver requirements exclusively in the form of models. It is no longer sufficient to manage requirements using traditional document-based approaches; instead, organizations must adopt tools and processes that enable the consumption, interpretation, and implementation of model-based requirements. However, MBSE itself does not ensure that the requirements defined within the model are complete or consistent. Without rigorous validation techniques, even well-structured models can carry forward poorly defined or conflicting requirements — leading to errors that propagate throughout the development lifecycle. This work proposes an approach that integrates formal methods into MBSE workflows by enabling completeness and consistency checks of SysML-based requirements
Gupta, ChandanNakkeeran, Rupashree
Unscheduled maintenance due to the failure of critical components, such as aero-engine rolling element bearings, is a leading cause of costly Aircraft-on-Ground (AOG) events; consequently, current time-based maintenance practices are inefficient and prone to risk. This paper develops a resource-efficient Hybrid Digital Twin (HDT) model for an engine bearing, focusing on the dynamic prediction of spall growth due to Rolling Contact Fatigue (RCF), thereby enabling a condition-based maintenance paradigm. The HDT architecture integrates two core models: (1) a physics-informed model that uses established life and fatigue theory to define initial degradation thresholds, and (2) a data-driven Recurrent Neural Network (RNN), specifically a Long Short-Term Memory (LSTM) network, for dynamic degradation rate modeling. The methodology utilizes a Monte Carlo simulation coupled with RCF progression equations to generate a large, high-fidelity synthetic run-to-failure dataset under varying
Mohamed, Abbas
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.
For brake and clutch components of aircraft vehicles which require higher mechanical strength and wear resilient, light-weight aluminium composites were developed infusing solid lubricant. In this study, hybrid composites were developed using powder metallurgy route with aluminum alloy AA356 and various amounts of zirconium oxide (ZrO2) (0, 5, 10, 15, and 20 wt.%) as reinforcements. A solid lubricant hexagonal boron nitride (hBN) at a fixed 5 wt.% is considered. Following the appropriate ASTM guidelines, the specimens were mechanically characterized by measuring their density, porosity, micro-hardness, compression strength, impact strength, and flexural strength, among other properties. The findings showed that the composites' mechanical and physical behaviour were greatly affected by the inclusion of ZrO2. Porosity increased as a result of particle clustering and interfacial voids, while density increased gradually as ceramic content increased. Consistently increasing ZrO2 addition
Senthilkumar, N.
Model-based development (MBD) and Model-based Testing are critical for airborne software compliance with DO-178C and its supplement DO-331, which specifically addresses model-based approaches for software levels A through D. Traditional manual methods increase the documentation and validation burden, leading to inconsistent implementations across the project, and raise the risk of missed defects or gaps in compliance. This paper presents an automation framework designed to align with DO-331 objectives by leveraging fine-tuned large language models (LLM) to automate the generation of high-level textual requirements and low-level model-based requirements. From these, comprehensive test cases are automatically derived, covering normal, edge, mutation based, and dynamic scenarios to ensure a thorough validation of model behavior. Utilizing AI agent, the framework extracts requirements and key parameters from documentation, enabling automated specification analysis and test script
Lalchandani, TusharPurushothaman, KalaivaniJeppu, YoganandaVijaya Kumar, Shree HarshaNatarajan, Akilandeswari
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
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
This paper presents an automated framework for security compliance and quality assurance in DevSecOps CI/CD pipelines, specifically designed for safety-critical avionics software. The framework integrates regulatory compliance checks, security validation, and robust verification directly into the software development lifecycle, supporting continuous integration and delivery for aerospace applications. Automated processes such as code compilation, coding standards compliance, Cyclomatic Complexity Measurement, Sources Line of Code and CRC validation on target hardware are seamlessly orchestrated to maintain consistency and reliability. The system generates comprehensive compliance reports, highlights coding standard violations and security issues, and notifies relevant stakeholders to facilitate timely resolution and corrective actions. As new code is checked in, the framework automatically initiates all verification and compliance tasks, ensuring that every software update is
Bhagwat, Shashank RaviChangappa, Naveen KumarNath, Sunny
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
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 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
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
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