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July 28, 2020 | International, Aerospace

F-35 Propulsion Upgrade Moves Forward Despite Uncertainty

Steve Trimble

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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  • Contract Awards by US Department of Defense - November 21, 2019

    November 22, 2019 | International, Aerospace, Naval, Land, C4ISR, Security

    Contract Awards by US Department of Defense - November 21, 2019

    NAVY United Technologies Corp., Pratt and Whitney Engines, East Hartford, Connecticut, is awarded a $762,486,023 modification (P00014) to a previously awarded fixed-price-incentive-fee contract (N00019-18-C-1021). This modification exercises options for the Lot 14 production and delivery of 48 F135-PW-100 propulsion systems for the Air Force and 10 F135-PW-600 propulsion systems for the Marine Corps. Work will be performed in East Hartford, Connecticut (85.3%); Indianapolis, Indiana (11.8%); and Bristol, United Kingdom (2.9%), and is expected to be completed in April 2022. Fiscal 2020 aircraft procurement (Air Force and Marine Corps) funds in the amount of $762,486,023 will be obligated at the time of award, none of which will expire at the end of the current fiscal year. This modification combines purchases for the Air Force ($521,507,748; 68%); and the Marine Corps ($240,978,275; 32%). The Naval Air Systems Command, Patuxent River, Maryland, is the contracting activity. Cianbro Corp., Pittsfield, Maine, is awarded a $157,949,610 firm-fixed-price contract for construction of a super flood basin and extending portal crane rails for Dry Dock #1 located at the Portsmouth Naval Shipyard (PNS). Work will be performed in Kittery, Maine, and is expected to be completed by March 2022. Fiscal 2019 military construction, (Navy) contract funds in the amount of $157,949,610 are obligated on this award and will not expire at the end of the current fiscal year. This contract was competitively procured via the Navy Electronic Commerce Online website with one proposal received. The Naval Facilities Engineering Command, Mid-Atlantic, Norfolk, Virginia, is the contracting activity (N40085-20-C-8500). Huntington Ingalls Inc., Newport News, Virginia, was awarded a $136,000,000 cost-plus-fixed-fee modification to previously awarded contract N00024-15-C-4301 to continue performance of the repair, maintenance, upgrades and modernization efforts on the USS Columbus (SSN 762) Engineered Overhaul. Work will be performed in Newport News, Virginia, and is expected to be complete by November 2020. Fiscal 2020 operation and maintenance (Navy) funds in the amount of $136,000,000 will be obligated at time of award and will expire at the end of the current fiscal year. The Supervisor of Shipbuilding, Conversion and Repair, USN, Newport News, Virginia, is the contracting activity. (Awarded Nov. 20, 2019) J.F. Taylor Inc.,* Lexington Park, Maryland, is awarded an $83,563,471 cost-plus-fixed-fee, cost reimbursable, indefinite-delivery/indefinite-quantity contract. This contract will provide engineering, technical and project management support for developmental test and evaluation in the areas of test planning, test conduct, data analysis, test reporting, technical documentation, test project management and systems engineering through utilization of command and program test and evaluation toolsets. Work will be performed in Patuxent River, Maryland (96%); Point Mugu, California (2%); and China Lake, California (2%), and is expected to be completed in January 2025. No funds will be obligated at the time of award. Funds will be obligated on individual orders as they are issued. This contract was a small business set-aside competitively procured via an electronic request for proposal; one offer was received. The Naval Air Warfare Center Aircraft Division, Patuxent River, Maryland, is the contracting activity (N00421-20-D-0001). New Direction Technologies Inc.,* Ridgecrest, California, is awarded a $68,712,640 cost-plus-fixed-fee, cost reimbursable, indefinite-delivery/indefinite-quantity contract. This contract provides engineering, program, operational and maintenance support as well as technical administrative services to improve and maintain Airborne Threat Simulation Organization capabilities in a dynamic electronic warfare environment. Work will be performed in Point Mugu, California (87%); Victoria, British Columbia, Canada (10%); Halifax, Nova Scotia, Canada (3%), and is expected to be completed in November 2024. No funds will be obligated at the time of award. Funds will be obligated on individual orders as they are issued. This contract was a small business set-aside competitively procured via an electronic request for proposal; four offers were received. The Naval Air Warfare Center Weapons Division, China Lake, California, is the contracting activity (N68936-20-D-0005). The Boeing Co., St. Louis, Missouri, is awarded a $43,783,296 firm-fixed-incentive delivery order (N00019-19-F-2412) against a previously issued basic ordering agreement (N00019-16-G-0001). This order provides for the manufacture, test and delivery of 48 Trailing Edge Flap retrofit redesign kits in support of the F/A-18E/F aircraft. Work will be performed in St. Louis, Missouri (72%); Lucerne, Switzerland (20%); Paramount, California (5%); and Hot Springs, Arkansas (3%), and is expected to be completed in June 2022. Fiscal 2020 aircraft procurement (Navy) funds in the amount of $43,783,296 will be obligated at time of award, none of which will expire at the end of the current fiscal year. The Naval Air Systems Command, Patuxent River, Maryland, is the contracting activity. The Boeing Co., St. Louis, Missouri, is awarded a $24,068,180 modification to a firm-fixed-price delivery order (N00019-20-F-0331) against a previously issued basic ordering agreement (N00019-16-G-0001). This order exercises the option to procure 34 Group A-1 retrofit kits, 34 Group A-2 retrofit kits, and 34 Group B retrofit kits for incorporation of the Distributed Targeting Processor-Network into the EA-18G aircraft for the Navy. Work will be performed in St. Louis, Missouri (99%); China Lake, California (0.5%); and Whidbey Island, Washington (0.5%), and is expected to be completed in June 2022. Fiscal 2020 aircraft procurement (Navy) funds in the amount of $24,068,180 will be obligated at time of award, none of which will expire at the end of the current fiscal year. The Naval Air Systems Command, Patuxent River, Maryland, is the contracting activity. IAP Worldwide Services Inc., Cape Canaveral, Florida, is awarded an $18,301,899 recurring/non-recurring services type contract for base operating services at Naval Support Activity, Annapolis. The work to be performed provides for all management, supervision, labor hours, training, equipment and supplies necessary to perform base operating services to include, but not limited to, facility investment, service calls, pest control, operation of utility plants, refuse collection, special events and snow and ice removal. Work will be performed in Annapolis, Maryland, with the contract period of Dec. 1, 2019, to May 31, 2020. No funds will be obligated at time of award. Fiscal 2020 operation and maintenance in the amount of $12,025,901 for recurring work will be obligated on individual task orders issued during the contract period. The Naval Facilities Engineering Command, Washington, Washington, District of Columbia, is the contracting activity (N40080-20-D-0500). Sikorsky Aircraft Corp., a Lockheed Martin Co., Stratford, Connecticut, is awarded a $15,387,971 cost, cost-plus-fixed-fee, firm-fixed-price task order (N00019-20-F-0429) against a previously awarded indefinite-delivery/indefinite quantity contract (N00019-16-D-1000). This task order provides for security, project engineering, integrated logistics support, material support, sustainment engineering, training and program support for the VH-3D/VH-60N executive helicopter special progressive aircraft rework. Work will be performed in Stratford, Connecticut (88%); and Quantico, Virginia (12%), and is expected to be completed in November 2020. Fiscal 2020 operation and maintenance (Navy) funds in the amount of $3,846,993 will be obligated at time of award, all of which will expire at the end of the current fiscal year. The Naval Air Systems Command, Patuxent River, Maryland, is the contracting activity. Bell Boeing Joint Project Office, Amarillo, Texas, is awarded a $14,323,100 firm-fixed-price order (N61340-20-F-7000) against a previously issued basic ordering agreement (N00019-17-G-0002). This order provides for the design, fabrication, installation, test and delivery of four Navy CMV-22 flight training devices. Work will be performed in Chantilly, Virginia (64.29%); and Hurst, Texas (35.71%), and is expected to be completed in November 2021. Fiscal 2019 aircraft procurement (Navy) funds in the amount of $14,323,100 will be obligated at time of award, none of which will expire at the end of the current fiscal year. The Naval Air Warfare Center Training Systems Division, Orlando, Florida, is the contracting activity. L3 Harris Corp., Van Nuys, California, is awarded a $9,630,900 modification (P00008) to a previously awarded firm-fixed-price, indefinite-delivery/indefinite-quantity contract (N68335-16-D-0019). This modification increases the ceiling of the contract to procure additional lightening protection, Moving Target Indicator (MTI) reflectors, refurbished MTI feedhorns, and operator workstations for Precision Approach Radar systems in support of all Navy, Air Force and Marine Corps manned aircraft. Work will be performed in Van Nuys, California, and is expected to be completed in May 2024. No funds are being obligated at time of award, funds will be obligated on individual orders as they are issued. The Naval Air Warfare Center Aircraft Division, Lakehurst, New Jersey, is the contracting activity. Iridium Satellite LLC, Tempe, Arizona, is awarded a $9,378,867 cost-plus-fixed-fee option to support commercial satellite-based network services for the Department of Defense in the areas of satellite, ground node, user equipment/terminal software and hardware development, integration and testing. 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  • Air Force rolls out Advanced Battle Management System devices in COVID-19 fight

    May 8, 2020 | International, Aerospace

    Air Force rolls out Advanced Battle Management System devices in COVID-19 fight

    Nathan Strout The U.S. Air Force has begun deploying thousands of personal devices to military personnel and health care providers that allow them to access classified information from home or outside of the office, even though the devices themselves are unclassified. The devices were supposed to be demonstrated during a test of the Air Force's Advanced Battle Management System in April, which was delayed to August or September due to the ongoing COVID-19 situation. With the test pushed back, the Air Force decided to begin rolling out the devices to support the fight against COVID-19. “Even in a virtual, COVID environment, the team pulled together very rapidly to do something that we were going to demonstrate in April as a prototype,” said Air Force Chief Architect Preston Dunlap during a virtual Mitchell Institute event May 7. The devices are loaded with SecureView, a software architecture built on an “unclassified at rest” model. “(The software has) the ability to process classified information on a device that's unclassified when you're not using it. So you could literally throw it on the street—no problem. I wouldn't recommend it, but no problem. But then when you use it, you actually can operate and access the information you need much like you would in your office,” explained Dunlap. “We're deploying about 1,000 of those in about three week sort of cycles now to get them out to the force,” said Dunlap. In addition, the Northern Command ABMS team was able to deploy unclassified tablets with SecureView to healthcare workers in New York City and aboard the hospital ship previously deployed to New York City, the USNS Comfort. The team is also pushing out data and applications to those devices to give users real time awareness of patients' health status, Dunlap said. He also said they were using artificial intelligence algorithms to predict how COVID-19 will spread. The software was developed by the Air Force Research Laboratory as part of DeviceOne, a line of effort under the Air Force's ABMS family of systems. ABMS is the Air Force's contribution to the Department of Defense's Joint All-Domain Command and Control concept, an ongoing effort to ensure connectivity between the services. Under JADC2, the Department's leaders want sensors to feed data to shooters in near-real time, regardless of domain. As envisioned, JADC2 systems should enable National Reconnaissance Office satellites to feed data to U.S. Army shooters, or U.S. Navy sensors to feed data to Air Force shooters. Dunlap noted that the use of DeviceONE to fight COVID-19 represented a real world on ramp of ABMS. “So from both a classified and unclassified world, seamless devices, mobility, data and applications where you need it, when you need it, are actually being demonstrated before our eyes in a real world current operation,” said Dunlap. “In some sense, you could call that we're actually doing a current ops on ramp to be able to support people and keep people safe.” The Air Force is largely agnostic towards which hardware is used for DeviceONE, said Dunlap. The program utilizes off-the-shelf consumer devices, enabling easy upgrades and keeping costs low compared to other DoD technology efforts. “For DeviceONE, all of the work that the team did was software-based and software security-based, and the hardware piece of that (we) are procuring and competing across the vendors that can provide the laptops, the tablets, the servers in the backend and so forth,” said Dunlap. While the system can be used to access any classification level, the configuration rolled out for COVID-19 support was limited to just the secret level. However, Dunlap said the software can be used for any classification level and was currently in use around the world by several combatant commanders. “It's incumbent for us to be able to provide the security and software on top of (the hardware) that enables our operators to be on that island, on that aircraft, in that Humvee, in the tents, and be able to get the information they need,” said Dunlap. And Dunlap added that the delayed ABMS test will be expanded when it does occur, incorporating Strategic Command and Space Command. Dunlap also hinted that the ABMS test after the August/September test will include Indo-Pacific Command, bringing the on ramp to the operational edge. “There's going to be a variety of key adjustments there,” said Dunlap. “Before, in December, it was mostly a Northern Command focus. We now have a Space Command and a Space Force, and so the predominant thing here is we're going to have the U.S. Space Command Commander, Gen. (John) Raymond, actually be the supported commander for the first time as opposed to a supporting commander.” https://www.c4isrnet.com/air/2020/05/07/air-force-rolls-out-advanced-battle-management-system-devices-in-covid-19-fight/

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