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The purpose of this paper is to describe the new method for optimizing the topology of the control system frame for a canard missile to create its efficient model. Determining the minimum volume of the part risked losing some of the mechanical interfaces and functionality required of the frame. The proposed method must cope with these requirements and include a validation loop of the improved solution proposed by the software. The processing of the mathematical model to a printable form must take into account manufacturing technologies limitations and appropriate curvature continuities to avoid stress concentrations.

Real examples from the aerospace industry are presented and the process of determining a prototype is described. The optimization assumed leaving the largest volume of the domain. Strength analyses were performed on both the assembly fasteners and the robust prototype. Once all boundary conditions were validated, topological optimization was performed in the ANSYS environment. The algorithm of the optimization was presented.

Obtained fatigues showed the vast potential of topology optimization, efficient method of weight reduction in specific situations. It can be considered as an innovative approach to the manufacturing of products with a structure focused on the best possible correlation of weight and strength, for example of a canard rocket.

The paper introduces precise manufacturing technology of the inner frame for the missile’s control system, which ensures sufficient properties of the material, known as EBM.

The purpose of this paper is to create an assembly verification system that is capable of verifying complete assembly and torque for each individual fastener.

The 3D position of the tool used to torque the fastener and the assembly pallet will be tracked using an infrared (IR) tracking system. A set of retro‐reflective markers are attached to the tool and assembly while being tracked by multiple IR cameras. Software is used to triangulate the relative position of the tool in order to identify the fastener being torqued. The torque value is obtained from the tool controller device. By combining the location of the tool and the torque value from the tool controller, assembly of each individual fastener can be verified and its achieved torque recorded.

The IR tracking is capable of tracking within 2‐3 mm for each tracking ball, with a resulting practical resolution of 24 mm distance between fasteners while maintaining 99.9999 per cent reliability without false positive fastener identification.

This experiment was run under simulated assembly line lighting conditions.

By being able to verify assembly reliably, the need for manual torque check is eliminate and hence yield significant cost savings. This will also allow programming electric tools according in real time based on the fastener in proximity identification.

Currently, assembly verification is only done using the torque values. In automated assembly line, each process might involve fastening multiple fasteners. Using this system, a new level of assembly verification is achieved by recording the assembled fastener and its associated torque.

The purpose of this paper is to investigate the effectiveness of locking or staking of fasteners with epoxy material systems to prevent loss of preload in aerospace environments.

A quantitative experimental method is adopted to evaluate epoxy material systems for staking of fastener assemblies subjected to varying dynamic and thermal loads. A statistical design of experiments is employed to probe specific design parameters.

Results show that epoxy application can provide satisfactory fastener locking under a variety of service conditions. It is found that: Epon 828 epoxy provides superior fastener locking compared to 3M Scotch‐Weld Epoxy 2216; epoxy application around screw threads is more effective than application around screw head; and abrading the plate surfaces with 180 grit SiC paper is not an effective or useful surface preparation technique.

The paper is limited to two commercial epoxy material systems and does not consider important qualitative considerations for industrial use such as cure time and viscosity.

This and future paper may form the basis of new standards for epoxy staking in the global aerospace industry.

This paper is believed to be one of the very few original experimental studies of fastener staking available in the open literature.

It is a huge technical and engineering challenge to realize the precise assembly of thousands of large optics in high power solid-state laser system. Using the 400-mm aperture-sized transport mirror as a case, this paper aims to present an intelligent numerical computation methodology for mounting performance analysis and modeling of large optics in a high-power laser system for inertial confinement fusion (ICF).

Fundamental principles of modeling and analysis of the transport mirror surface distortion are proposed, and a genetic algorithm-based computation framework is proposed to evaluate and optimize the assembly and mounting performance of large laser optics.

The stringent specifications of large ICF optics place very tight constraints upon the transport mirror’s assembly and mounts. The operational requirements on surface distortion [peak-to-valley and root mean square (RMS)] can be met as it is appropriately assembled by the close loop of assembly-inspection-optimization-fastening. In the end, the experimental study validates the reliability and effectiveness of the transport mirror mounting method.

In the assembly design and mounting performance evaluation of large laser optics, the whole study has the advantages of accurate evaluation and intelligent optimization on nano-level optical surface distortion, which provides a fundamental methodology for precise assembly and mounting of large ICF optics.

The purpose of this paper is to examine the performance of a fastener composite coating system, sherardized (SD) coating/zinc-aluminum (ZA) coating whether it has good performance in marine environment.

In this paper, SD coating was fabricated on fastener surface by solid-diffusion method. ZA coating was fabricated by thermal sintering method. Corrosion behaviours of the composite coating were investigated with potentiodynamic polarization curves, open circuit potential and electrochemical impedance spectroscopy methods.

Neutral salt spray (NSS) and deep sea exposure tests revealed that the composite coating had excellent corrosion resistance. Polarization curve tests showed that corrosion current density of the sample with composite coating was significantly decreased, indicating an effective corrosion protection of the composite coating. OCP measurement of the sample in NaCl solution demonstrated that the composite coating had the best cathodic protection effect. The good corrosion resistance of the composite coating was obtained by the synergy of SD and ZA coating.

SD/ZA coating can be used in marine environment to prolong the life of carbon steel fastener.

SD/ZA composite coating can reduce the risk and accident caused by failed fastener, avoid huge economic losses.

A new kind of composite coating was explored to protect the carbon steel fastener in marine environment. And the composite coating has the long-term anti-corrosion performance both in simulated and marine environment test.

D. Electrical Continuity and Lightening Strike Protection In metallic structure aircraft, much of the structure is often interconnected electrically via special grounding straps. One would think the grounding would be accomplished automatically via the aluminum rivets or titanium fasteners in the structure. Aluminum rivets, however, are anodized for corrosion protection and titanium fasteners are often coated with an aluminized paint as a barrier protection against galvanic corrosion of the structure. Both of these coatings are non‐conductive and other means such as periodic cadmium plated stainless steel fasteners or grounding straps are used. But why all the concern about electrical continuity? The reason is to avoid large differentials in electric potential between components when lightening strikes an airplane. If there is a large difference because there is no conductive flow path, the electricity will arc to the lower potential member and cause damage in the process. If this occurs within a fuel tank it could be catastrophic. Once the structure all has the same charge it proceeds to dissipate the charge back into the atmosphere.

Reports on the MSc group design project of students at the College of Aeronautics, aerospace vehicle design in 1995. The students worked on advanced short take‐off and vertical landing of a combat aircraft. Details the project showing aircraft dimensions and design. Full assessment of the results is pending, but outlines a number of problems faced by the students.

Threaded fasteners appear to be the best low cost option for applying a desired clamp load to assemble a joint, which can be disassembled, if necessary, at a low cost. A large number of joint failures are due to inadequate tension on the joint. Most conventional tightening methods only provide a vague indication of the bolt tension. In this paper we will discuss the development of the A‐BOLT™ system, which can measure the tension in the mechanical bolt to ±1 per cent accuracy of the proof load. The key element of the system is a specially designed mechanical bolt with a top‐mounted sensor to measure the bolt elongation. We will also describe the development of different generations of the A‐BOLT™ system and its industrial applications. Finally we will present an overview of research on the cluster based networking of wireless sensors to minimize energy consumption in a network of sensors.

Describes preliminary structural design work on a notional uninhabited tactical aircraft (UTA), carried out at Cranfield University. UTAs are seen as an important future element of military fleets. A notional baseline requirement was derived, leading to the evolution of a design solution. The basic requirements for such a UTA are naturally highly classified but, although industry has been hesitant to comment, the baseline requirements and design solution developed herein are believed to be reasonable.