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July 22, 2020 | International, Aerospace

F-35 Propulsion Upgrade Moves Forward Despite Uncertainty

Steve Trimble July 21, 2020

An F-35B completed the first landing at sea on the USS Wasp in 2013. The Joint Program Office is considering thrust upgrades to increase the F-35B's “bring-back” payload to a carrier.

Credit: MCSN Michael T. Forbes II/U.S. Navy

Stabilizing the production system and securing a funded, long-term upgrade plan are now the main objectives for Pratt & Whitney's F135 propulsion system for the Lockheed Martin F-35.

Although first delivered for ground--testing 17 years ago, the F135 remains a lifeline in Pratt's combat aircraft engines portfolio for new-development funding. The U.S. military engines market is entering an era of transition with great uncertainty for the timing of the next major combat aircraft program.

  • Enhancement Package replaces “Growth Option”

  • New F-35 propulsion road map due in six months

The transition era begins with the likely pending delivery of Pratt's most secretive development project. In 2016, the U.S. Air Force named Pratt as one of seven major suppliers for the Northrop Grumman B-21 bomber. The Air Force also has set the first flight of the B-21 for around December 2021. That timing means Pratt is likely to have delivered the first engine for ground-testing. At some point within the next year, Pratt should be planning to deliver the first flight-worthy engine to Northrop's final assembly line in Palmdale, California, to support the Air Force's first B-21 flight schedule.

As the bomber engine development project winds down, the propulsion system for the next fighter aircraft continues to be developed, but without a clear schedule for transitioning to an operational system.

The Air Force Research Laboratory's Adaptive Engine Transition Program (AETP) is sponsoring a competition to develop an adaptive engine that can modulate the airflow into and around the core to improve fuel efficiency and increase range. The AETP competition is between Pratt's XA101 and GE's XA100 designs, with the first engines set to be delivered for ground-testing by the end of this year or early next year.

As 45,000-lb.-thrust-class engines, the first AETP designs are optimized for repowering the single-engine F-35, but the F-35 Joint Program Office (JPO) has established no requirement to replace the F135 for at least another five years. A follow-on effort within the AETP is developing a similar engine for a next-generation fighter, but neither the Air Force nor the Navy have committed to a schedule for transitioning the technology into an aircraft-development program. That leaves Pratt's F135 as the only feasible application for inserting new propulsion technology for a decade more.

After spending the last decade focused on completing development of the F-35 and upgrading the software, electronics and mission systems, the JPO is developing a road map to improve the propulsion system through 2035.

As the road map is being developed, program officials also are seeking to stabilize the engine production system. Pratt delivered about 600 F135s to Lockheed through the end of last year, including 150—or about 25%—in 2019 alone. The JPO signed a $7.3 billion contract with Pratt last year to deliver another 509 engines in 2020-22, or about 170 a year.

Although Pratt exceeded the delivery goal in 2019 by three engines, each shipment came an average of 10-15 days behind the schedule in the contract. The fan, low-pressure turbine and nozzle hardware drove the delivery delays, according to the Defense Department's latest annual Selected Acquisition Report on the F-35. Lockheed's production schedule allows more than two weeks before the engine is needed for the final assembly line, so Pratt's late deliveries did not hold up the overall F-35 schedule, says Matthew Bromberg, president of Pratt's Military Engines business.

F135 deliveries finally caught up to the contract delivery dates in the first quarter of this year, but the supply chain and productivity disruptions caused by the COVID-19 pandemic have set the program back. About five engines scheduled for delivery in the second quarter fell behind the contractual delivery date, Bromberg says. The pressure will grow as a loaded delivery schedule in the second half of the year adds pressure on deliveries, but Pratt's supply chain managers expect to be back within the contract dates in the first quarter of next year, he says.

The F-35 program's political nature also has caused program disruptions. The Defense Department's expulsion of Turkey from the F-35 program last year also banished the country's supply chain, which contributed 188 parts to the F135. In particular, Alp Aviation produces the Stage 2, 3, 4 and 5 integrally bladed rotors (IBR) for the F135.

As of early July, about 128 parts now made in Turkey are ready to transition to other suppliers, of which about 80% are based in the U.S., according to Bromberg. The new suppliers should be requalified to produce those parts in the first quarter of 2021 and ready to meet production rate targets for Lot 15 aircraft, which will begin deliveries in 2023.

“The overriding objective was to move with speed and diligence along the transition plan and ensure we are ready to be fully out of Turkey by about Lot 15,” Bromberg explains. “And we are on track for that.”

As Pratt transfers suppliers, the company also has to manage the effect on potential upgrade options. Alp Aviation, for example, had announced a research and development program to convert the finished titanium IBRs to a more resilient nickel material.

For several years, Pratt has sought to improve the performance of the F135 above the baseline level. In 2017, the company unveiled the Growth Option 1.0 upgrade, which is aimed at delivering modular improvements that would lead to a 5% or 6% fuel-burn improvement and a 6-10% increase in thrust across the flight envelope. The Marine Corps, in particular, was seeking additional thrust to increase payload mass for a vertical landing, but the proposed package did not go far enough to attract the JPO's interest.

“It missed the mark because we didn't focus our technologies on power and thermal management,” Bromberg says.

A year later, Pratt unveiled the Growth Option 2.0. In addition to providing more thrust at less fuel burn, the new package offered to generate more electrical power to support planned advances in the aircraft's electronics and sensors, with the ability to manage the additional heat without compromising the F-35's signature in the infrared spectrum.

Last fall, the JPO's propulsion management office teamed up with the Advanced Design Group at Naval Air Systems Command to analyze how planned F-35 mission systems upgrades will increase the load on the engine's thrust levels and power generation and thermal management capacity. In May, the JPO commissioned studies by Lockheed and Pratt to inform a 15-year technology-insertion road map for the propulsion system. The road map is due later this year or in early 2021, with the goal of informing the spending plan submitted with the Pentagon's fiscal 2023 budget request.

As the studies continue, a name change to Pratt's upgrade proposals reveals a fundamental shift in philosophy. Pratt's earlier “Growth Option” terminology is gone. The proposals are now called Engine Enhancement Packages (EEP). The goal of the rebranding is to show the upgrades no longer are optional for F-35 customers.

“As the engine provider and the [sustainment] provider, I'm very interested in keeping everything common,” Bromberg says. “The idea behind the Engine Enhancement Packages is they will migrate into the engines or upgrade over time. We don't have to do them all at once. The [digital engine controls] will understand which configuration. That allows us again to be seamless in production, where I would presumably cut over entirely, but also to upgrade fleets at regularly scheduled maintenance visits.”

Pratt has divided the capabilities from Growth Options 1 and 2 into a series of EEPs, with new capabilities packaged in increments of two years from 2025 to 2029.

“If you go all the way to the right, you get all the benefits of Growth Option 2, plus some that we've been able to create,” Bromberg says. “But if you need less than that and you're shorter on time or money, then you can take a subset of it.”

Meanwhile, the Air Force continues to fund AETP development as a potential F135 replacement. As the propulsion road map is finalized, the JPO will decide whether Pratt's F135 upgrade proposals support the requirement or if a new engine core is needed to support the F-35's thrust and power-generation needs over the long term.

Previously, Bromberg questioned the business case for reengining the F-35 by pointing out that a split fleet of F135- and AETP-powered jets erodes commonality and increases sustainment costs. Bromberg also noted it is not clear the third-stream technology required for the AETP can be accommodated within the roughly 4-ft.-dia. engine bay of the F-35B.

Now Bromberg says he is willing to support the JPO's decision if the road map determines a reengining is necessary. “If the road map indicates that they need significantly more out of the engine than the Engine Enhancement Packages can provide, we would be the first to say an AETP motor would be required,” Bromberg says. “But we think a lot of the AETP technologies will make those Engines Enhancement Packages viable.”

https://aviationweek.com/ad-week/f-35-propulsion-upgrade-moves-forward-despite-uncertainty

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    AIR FORCE Space Vector Corp., Chatsworth, California (FA8818-19-D-0001); and OrbitalATK Inc., Chandler, Arizona (FA8818-19-D-0002), have been awarded a combined ceiling $424,000,000 multiple-award, indefinite-delivery/indefinite-quantity, cost-plus-incentive-fee, firm-fixed-price and cost-plus-fixed-fee for Sounding Rocket Program-4 (SRP-4). The SRP-4 contract provides suborbital launch services and launch support services necessary to accomplish the Rocket Systems Launch Program's suborbital mission. This contract will be used to meet Department of Defense and other government agency requirements for sub-orbital research, development, and test launch services, including prototype demonstrations and missile defense targets. Work will primarily be performed in Chatsworth, California; Chandler, Arizona, and a variety of government launch sites, depending on mission requirements. This award is the result of a competitive acquisition with a seven-year ordering period. 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Allison Transmission, Indianapolis, Indiana, has been awarded a maximum $20,781,402 firm-fixed-price contract for transmission overhaul kits. This was a sole-source acquisition using justification 10 U.S. Code 2304(c)(1), as stated in Federal Acquisition Regulation 6.302-1. This is a 13-month contract with no option periods. Location of performance is Indiana, with a Dec. 31, 2019, performance completion date. Using military service is Army. Type of appropriation is fiscal 2019 defense working capital funds. The contracting activity is the Defense Logistics Agency Land and Maritime, Warren, Michigan (SPRDL1-19-C-0057). Peckham Vocational Industries,** Lansing, Michigan, has been awarded an $8,609,660modification (P00003) exercising the first one-year option period of a one-year base contract (SPE1C1-18-D-N029) with two one-year option periods for drawers. This is a firm-fixed-price contract. Location of performance is Michigan, with a Nov. 21, 2019, performance completion date. Using military services are Army and Air Force. Type of appropriation is fiscal 2019 defense working capital funds. The contracting activity is the Defense Logistics Agency Troop Support, Philadelphia, Pennsylvania. NAVY Lockheed Martin Corp., Baltimore, Maryland, is awarded a $282,085,646 not-to-exceed undefinitized contract action modification to previously-awarded contract N00024-18-C-2301 for long-lead-time material and detail design in support of the construction of four Multi-Mission Surface Combatant ships (MMSC). The MMSC is a lethal and highly maneuverable surface combatant capable of littoral and open-ocean operation. This contract involves foreign military sales to the Kingdom of Saudi Arabia. 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The ordering period will begin March 2019 and is expected to be completed by February 2024. Fiscal 2019 operations and maintenance (Navy) funds in the amount of $100,000 will be obligated (approximately $33,333 on each of the three contracts to fund the contracts' minimum amounts) and funds will expire at the end of the current fiscal year. This contract was competitively procured for the award of multiple contracts pursuant to the authority set forth in Federal Acquisition Regulation 16.504. The requirement was posted to the Federal Business Opportunities website, with ten offers received. Naval Supply Systems Command Fleet Logistics Center Norfolk, Contracting Department Philadelphia, Pennsylvania, is the contracting activity. Kellogg Brown and Root Services Inc., Houston, Texas, is awarded $55,452,842 for task order A00011 under previously awarded firm-fixed-price, indefinite-delivery/indefinite-quantity contract (N62470-17-D-4012) to exercise the first option period for base operations support services at Camp Lemonnier, Djibouti, and other areas within Africa. The work to be performed provides for all management and administration, public safety, galley, ordnance, air operations, fire and emergency services, bachelor quarters, housing, pest control, integrated solid waste, base support vehicles and equipment, custodial, electrical, water, wastewater, port operations, supply, morale-welfare-recreation, facilities investment, and environmental services to provide base operations support services. After award of this option, the total cumulative contract value will be $122,263,227. Work will be performed at various installations in Territory of Djibouti, Africa and other areas within Africa, and work is expected to be completed November 2019. No funds will be obligated at time of award. The Naval Facilities Engineering Command, Europe Africa Southwest Asia, Naples, Italy, is the contracting activity. Lockheed Martin Space, Sunnyvale, California is being awarded a cost-plus-fixed-fee, cost-plus-incentive-fee $49,069,660 modification (P00002) to a previously awarded contract (N00030-18-C-0100) for Trident II (D5) missile production and deployed system support. 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Support includes removal of old and installation of new commercial-off-the-shelf precision approach radar; logistics and training support; remote landing site tower generator repair; tactical air navigation systems installation support; and Marine Air Traffic Control and Landing System, and Amphibious Assault Direction System sustainment support. This modification increases the estimated value of the contract from $19,226,946 to $30,846,043. This ceiling increase does not obligate funds. Funding will be obligated via task/delivery orders, which will be placed using operations and maintenance (Navy); and other procurement (Navy) funds. This modification is issued using other than full and open competition in accordance with Federal Acquisition Regulation Subpart 6.302-1 and 10 U.S. Code 2304(c)(1) - only one responsible source. Space and Naval Warfare Systems Center Pacific, San Diego, California, is the contracting activity. Data Intelligence LLC,* Marlton, New Jersey, is awarded a $11,314,171 indefinite-delivery/indefinite-quantity, cost-plus-fixed-fee, multiple-award contract to provide systems engineering support for Space and Naval Warfare Systems Center Pacific command, control, communications, computers, and intelligence programs. This is one of six contracts awarded. All awardees will have the opportunity to compete for task orders during the ordering period. This two-year contract includes three, one-year options which, if exercised, would bring the potential value of this contract to an estimated $28,840,430. Work will be performed at government facilities in San Diego, California (90 percent), and at contractor facilities in Marlton, New Jersey (10 percent). The period of performance of the base award is from Nov. 16, 2018 through Nov. 15, 2020. If the options are exercised, the period of performance would extend through Nov. 15, 2023. No funds will be obligated at the time of award. Funds will be obligated as task orders are issued using research, development, test and evaluation (Navy, Air Force and Defense Agency); operations and maintenance (Navy, Air Force and Defense Agency); other procurement (Navy and Air Force); foreign military sales; and Navy working capital funds. This contract was competitively procured via Request for Proposal N66001-16-R-0180 published on the Federal Business Opportunities and the SPAWAR e-Commerce Central website, with 21 offers received and six selected for award. Space and Naval Warfare Systems Center Pacific, San Diego, California, is the contracting activity (N66001-19-D-0006). Ratcliff Construction Inc.,* Orange Park, Florida, is awarded $9,990,000 for firm-fixed-price task order N6945019F0850 under a previously awarded multiple award construction contract (N69450-18-D-1315) for consolidation and repair of Aviation Hangar 600 at Naval Station Guantanamo Bay. The work to be performed provides for complete exterior and interior repairs consisting of underutilized space in the west “lean-to” two story structure. Remotely located areas will be consolidated into renovated spaces. This includes complete renovation of Aviation Hangar 600 to include demolition of structures and repair by replacement of mechanical, electrical, plumbing and fire protection systems. Work will be performed in Guantanamo Bay, Cuba, and is expected to be completed by August 2020. Fiscal 2019 operations and maintenance (Navy) contract funds in the amount of $9,990,000 are obligated on this award and will expire at the end of the current fiscal year. Six proposals were received for this task order. The Naval Facilities Engineering Command, Southeast, Jacksonville, Florida, is the contracting activity. ARMY DRS Sustainment Systems Inc., St. Louis, Missouri, was awarded a $30,439,974 firm-fixed-price contract for small enclosure kits to support production of the Chemical Biological Protective System. Bids were solicited via the internet with one received. Work locations and funding will be determined with each order, with an estimated completion date of Nov. 15, 2023. U.S. Army Contracting Command, Rock Island Arsenal, Illinois, is the contracting activity (W52P1J-19-D-3009). General Dynamics Ordnance and Tactical Systems, St. Petersburg, Florida, was awarded a $14,413,028 firm-fixed-price contract for Army Ground Mobility Vehicles and associated kits. Bids were solicited via the internet with three received. Work locations and funding will be determined with each order, with an estimated completion date of Nov. 16, 2019. U.S. Army Contracting Command, Warren, Michigan, is the contracting activity (W56HZV-19-F-0072). VSE Corp., Alexandria, Virginia, was awarded a $13,068,557 modification (P00014) to contract W911SA-16-C-0002 for labor, equipment and transportation necessary to provide logistics readiness support services to perform and assist with property accountability, vehicle operations and supporting functions, maintenance management services, field and sustainment level maintenance, storage site operations, hands-on-training mission support, and refurbishment support at various locations in Arizona, California, Texas, Oklahoma, Nevada, Arkansas and New Mexico. Work will be performed in Mountain View, California, with an estimated completion date of Aug. 29, 2019. Fiscal 2019 other funds in the amount of $11,715,802 were obligated at the time of the award. U.S. Army Mission and Installation Contracting Command, Fort McCoy, Wisconsin, is the contracting activity. *Small business **Mandatory source https://dod.defense.gov/News/Contracts/Contract-View/Article/1693147/source/GovDelivery/

  • U.S. Air Force Announces Tender to Procure 461 Engines for F-15EX Fighter Jets

    February 11, 2021 | International, Aerospace

    U.S. Air Force Announces Tender to Procure 461 Engines for F-15EX Fighter Jets

    The U.S. Air Force has announced plans to buy 461 engines to power their fleet of F-15EX jets. In a February 5 Federal Opportunities notice, U.S.A.F. Life Cycle Management Center (AFLCMC) said it wants to acquire up to 461 engines in order to meet propulsion and aircraft production delivery schedules using full and open competition. The engine delivery period is October 2023 through June 2031. Maiden flight of the F-15EX took place in earlier this month. The service awarded Boeing a contract to build the first lot of eight jets in July 2020. Future plans call for as many as 144 aircraft. The aircraft is an improvement over the F-15 C/D model in that it is a fly-by-wire, digital aircraft; has a powerful new processor; additional wing hardpoints; a new electronic warfare system; and an updated glass cockpit. It is based on the F-15QA, which Boeing is building for Qatar. Boeing said the EX can launch hypersonic weapons up to 22 feet long and weighing up to 7,000 pounds, which gives it an edge over the F-35. https://www.defenseworld.net/news/28934#.YCWomGhKiUk

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