Transformative Use of Additive Technology in Design and Manufacture of Hydraulic Actuator for Fly-by-Wire System

In this paper, the results of research on additively manufactured aerospace parts made of maraging steel are presented. This state-of-the-art technology seems to have the highest potential for practical use in the field of ultra-light and high-performance aerospace hydraulic parts. The strength properties of representative specimens made with steel 1.2709 were investigated. The researchers conducted static tensile testing, fatigue tensile testing, and pressure impulse testing. A Goodman diagram was plotted to visualize the impact of the building orientation vs. load character on the fatigue strength of the additive manufacturing (AM) specimens. Based on the research carried out on the strength of the AM samples, an aircraft flight control actuator was designed to achieve the highest level of safety integrity along with the greatest simplicity and lowest weight relative to hydraulic actuators manufactured using classical methods. The entire design process was integrated with the manufacturing process to achieve this target.

Control design and state of the art for fly-by-wire systems

The report discusses the design and operation of electro-hydraulic servo-valves, illustrates a basic contol implementation design for an electro-hydraulic servo-valve controlled hydraulic actuator [for aircraft flight control actuation] and provides a survey of the state of the art of flight control of aircraft using fly-by-wire (FBW) architecture. The electro-hydraulic servo-valve figures prominently in typical FBW implementations and is an essential part of a modern aircraft flight control system. The scope of this report represents a large area of research, presented at a general level, and serves as a general summary of technologies and considerations for modern aircraft control. Fly-by-wire provides many advantages over traditional forms of aircraft flight control, and it represents both the state of the art in this area and also the future of almost all civilian and military aircraft flight control. The architecture, characteristics and control design relating to electro-hydraulic servo-valve controlled actuators is discussed in the report. The application of such actuators to fly-by-wire implementation is discussed in some depth, and the process by which fly-by-wire systems are developed is discussed.

Control design and state of the art for fly-by-wire systems

The report discusses the design and operation of electro-hydraulic servo-valves, illustrates a basic contol implementation design for an electro-hydraulic servo-valve controlled hydraulic actuator [for aircraft flight control actuation] and provides a survey of the state of the art of flight control of aircraft using fly-by-wire (FBW) architecture. The electro-hydraulic servo-valve figures prominently in typical FBW implementations and is an essential part of a modern aircraft flight control system. The scope of this report represents a large area of research, presented at a general level, and serves as a general summary of technologies and considerations for modern aircraft control. Fly-by-wire provides many advantages over traditional forms of aircraft flight control, and it represents both the state of the art in this area and also the future of almost all civilian and military aircraft flight control. The architecture, characteristics and control design relating to electro-hydraulic servo-valve controlled actuators is discussed in the report. The application of such actuators to fly-by-wire implementation is discussed in some depth, and the process by which fly-by-wire systems are developed is discussed.