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1 DSTO Support to Accident & Incident Investigations DSTO Melbourne

2 DSTO in Defence

3 DSTO structure

4 DSTO at a glance Budget : $440m 11 research divisions 2600 staff 7 sites across Australia

5 DSTO Support to Accident & Incident Investigations Impartial, independent scientific support to the ADF, and Directorate of Defence Aviation & Air Force Safety (DDAAFS). As a national resource, support civil agencies. Maintain a team of investigators, on-call 24/7. Forensic Engineering group AVD underpins incident and accident investigations. Can draw on the depth of scientific capability within DSTO

6 Divisional Structure Air Vehicles Division Aircraft Materials Propulsion Systems Aircraft Structures Flight Systems Applied Hypersonics Aircraft Forensic Engineering and Accident Investigation Engine Life Management Structural Mechanics Fatigue Methods Air Vehicles Systems Scramjet Development Advanced Metallic Airframe Technologies Propulsion Prognostics & Health Management Helicopter Structural Integrity Experimental Aerodynamics, Modelling & Simulation HiFire Flight Test Program Advanced Composite Technologies Infrared Signatures and Aerothermodynamics Structural Integrity Combat and Trainer Aircraft Fluid Mechanics Smart Structures and Advanced Diagnostics Mechanical & Combustion Experimentation Structural Testing, Transport & Surveillance and Aircraft Structural Integrity Fuels & Lubricants

7 DSTO Scientific Capability in Support to Accident Investigation Trajectory analysis Wreckage mapping Wreckage damage analysis Forensics Oxygen systems Wiring systems Composites damage assessment Aircraft Fuel Tank Safety Engine parts assessment Wear Debris analysis Flight path reconstruction Flight simulation Meteorological/aerodynamic modelling of terrain Instrument analysis Filament analysis Human factors Structural analysis and testing POL analysis

8 DSTO Invention Black Box Flight Data Recorder In the 1950s a number of Comet airliners crashed without explanation. DSTO Melbourne scientist Dr David Warren and his team subsequently developed a wire recorder to record pilot conversations and instrument readings at the time of a incident. Australia became the first country to make the device mandatory on all civil aircraft. The Black Box was developed further by the US and UK, and has since become one of the most valuable aids in aviation accident investigation history.

9 On-Site Scientific Investigation Other on-site images??

10 Site Mapping DSTO has a site mapping system consisting of a GPS unit, a handheld computer, and appropriate software for mapping items of interest at a crash site Sea King Accident Nias 8 April 2005 GPS Mapping System

11 GPS maps of IL76 accident in East Timor 2003 Wing parts Left hand wing Right hand wing Þ Tree000.shp #Y Mlg000.shp Engine parts.shp Þ Þ Ground marks - MLG Ground marks - fence impacts Þ #Y Generic line - fences Þ #0 Fuselage parts x Cockpit - lower #0 #0 Þ Þ #0 #0 #0 #Y x x ÞÞ Þ #0 #Y #0 #0 Þ #Y #Y Þ Þ #0 #0 Þ #0 #0 Þ #0 Þ #Y #0 ù Þ Þ Meters

12 3D laser mapping for rapid site recording

13 Examination and Analysis at DSTO Component Examination Furnace melting debris Microscopy Metallography NDI NDI Metrology Forensic examination of wreckage

14 Aircraft Forensic Engineering Direct support to Defence into the causes of accidents, defects and failures, and deterioration of ADF systems, equipment and materials. Largest group of scientific and technical failure specialists in Australia Support to Civil Agencies and Industry National Security Underpins: Aircraft/Helicopter Structural Integrity Full-scale fatigue tests Aircraft Accident Investigation damage

15 Forensic Scientific and Technical Capabilities Failure analysis of metallic, non-metallic and composite materials Corrosion investigations of materials and components Non-destructive testing (including evaluation and development) Aging Wiring and Systems Wear debris analysis Analysis of fuels and oils Metrology of components Identification of component and system problems Identification of materials and processing problems Oxygen system hazard analysis

16 Failure Analysis and Testing - Quantitative Fractography Determine the growth rates of cracks and apply this to fleet aircraft inspection intervals. Produce data that can be used to predict the life of aircraft structure Produce information about the loading/material interaction that may allow redesign and/or repairs to be more efficient F/A-18 Centre Barrel T56 Spin Rig P3 Orion Crack Depth mm Nov Jul-90 6-Jun-90 5-Aug Jul Sep Jul-88 3-Jul-89 5-Jul-88 6-Jan-88 5-Dec-88 4-Jul Flight Number 20 15

17 Full-Scale Fatigue Testing

18 Mechanical & Combustion Experimentation Combustion Testing Technical Support Engine tests Spin tests

19 Health Monitoring Rotation (Degs) 360 Phase-Energy: W1438b4.vib Log Amp (db) Vibration Diagnostics Advanced techniques for gears and bearings Engine fault diagnostics Engine Gas Path Analysis; Performance Modelling & Monitoring Wear Debris Analysis Novel Techniques Engine Torque Frequency (orders) :00:28. 1:00:37. 1:00:46. 1:00:54. 1:01:03. 1:01:12. 1:01:20. 1:01:29. 1:01:37. 1:01:46. 1:01: :00:00. 0:14:24. 0:28:48. 0:43:12. 0:57:36. 1:12:00. 1:26:24. 1:40:48. 1:55:12. 2:09:36. 2:24: :50: :53: :56: :59: :01: :04: :07: Eng01 Eng02

20 Fuels & Lubricants Condition Monitoring Fuels (contamination/degradation) Lubricants and hydraulic fluids Fuel from Incident Aircraft Normal Fuel

21 Wear Debris Analysis

22 Analysis of Aircrew Life Support Equipment

23 Helmet Damage Assessment Flash Thermography

24 Aircraft Wiring and Systems Investigations Fire Detector Air Multiplier

25 Oxygen System Analysis Investigate and analyse oxygen systems Failure Modes and Effect Analysis (FMEA) and Oxygen Hazards and Fire Risk Analysis (OHFRA) Specialist oxygen equipment advice Qualification testing of ADF Aircrew samples for operational units

26 Aircraft Performance & Modeling aircraft flight dynamic modeling

27 Aeroelasticity Stores separation & trajectories Flutter prediction Weapon vibration environment

28 Flexible Simulation capabilities Multiple laboratories throughout DSTO Reconfigurable components Fixed and rotary wing cockpits System models Display devices Scenario development tools Analysis tools Can model accident hypotheses

29 DSTO Developed Generic Graphical Replay Software HawkView and Graphical Replay Software (GRS) are general display programs used to replay: - Release of Stores from aircraft - Accidents & Incidents - Software/Hardware Failures - Debrief Tool Uses either on-board data recording systems and/or external data. Can make use of all available data eg Range Instrumentation, Camera Data, Radar Data, Voice Data, Witness data Airshow 2003

30 Animations to illustrate findings

31 Frequency Analysis - Cockpit Area Microphone The rotating machinery on a helicopters produce sounds at various frequencies. Frequency analysis of the ambient noise can identify and isolate the noise generated by rotating machinery such as engines, gearboxes, and pumps (A) Epicyclic gear mesh (B) Auxiliary pumps A B (C) Engine gas generator (once per rev). (D) Engine power turbine and Main rotor gearbox high-speed input shaft (once per rev). C D

32 Photogrammetry Photogrammetry is the Science/Engineering discipline of measuring object position using images. It can be used to reconstruct flights In this case: video footages used to determine ingress and impact conditions

33 Simulation from photogrammetry

34 Questions?

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