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June 17, 2019 | International, Aerospace

GE Sees Military as Driving Next-Gen Technology

PARIS - “Military is where the commercial business was 10 years ago,” says GE Aviation president and GEvice chairman David Joyce. With commercial now set after a decade of renewal (the CF6 replaced by the GEnx, GE90 by GE9X, CFM56 by Leap, CF34 by Passport, and the emergence of the Catalyst turboprop engine), hundreds of engineers and research and development resources are being tasked with creating future generations of military powerplants. Now that the commercial side has proved that new materials such as ceramic matrix composites and technologies such as additive manufacturing are viable, affordable and producible, the military has the confidence to lead the march into new territory.

Technologies developed for commercial engines have enabled new military capabilities; in turn, military research and development will enable even newer commercial engines decades into the future. It's a virtuous cycle, Joyce explains.

GE is on a roll: it has won the U.S. Army's ITEP competition to replace all T700 engines in Black Hawk and Apache helicopters with the ultra-fuel-efficient single-shaft ITEP next-gen helicopter engine, and it won contracts worth a billion dollars to develop its AETD three-stream adaptable fighter engine as far as demonstrating it on the ground in an F-35. Flight tests could follow, as could eventual reengining of the F-35 fleet. But in any case, GE will be ready with an engine for sixth-generation fighters.

In addition, the ubiquitous F404/F414 is being upgraded and continues to win new competitions, including the USAF's new Boeing-Saab T-X trainer and several foreign future fighter programs; the T408 turboshaft powers the new Sikorsky CH-53K King Stallion; and a team is working full time on competing to reengine the B-52 bomber. Business is growing “at really good rates” on both manned and unmanned “black” programs, says Joyce, and hybrid electric is being studied for future applications including UAVs, he adds.

He believes GE already has the enabling technologies for the next decade, “but industrializing them is a different thing.” The company has already invested “billions of dollars” in developing a manufacturing and supply chain of materials and technologies for its commercial engines, and this will continue,

“Additive manufacturing may be the most disruptive technology that I've seen in the industry in a long time,” says Joyce, “as it opens up a space for designers and for manufacturing that is on a different dimensional plane. It takes a long time to learn how to design with additive. It takes even longer to learn how to manufacture with additive at speed and high rate from a quality standpoint of view.

“We are jumping in with both feet because the results on the back end when you get it right are extraordinary,” he adds.

“It's going to pay off a whole load more in the next 20 years. This is going to be the best [real return on investment] that we've ever done.”

https://aviationweek.com/paris-airshow-2019/ge-sees-military-driving-next-gen-technology

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  • Enhancing Unmanned Operations in Extreme Conditions with the Power of Two-Stroke

    July 9, 2019 | International, Aerospace

    Enhancing Unmanned Operations in Extreme Conditions with the Power of Two-Stroke

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UAVs will play a crucial role in this future considering the need for operators to monitor harsh environments and difficult to reach terrains, especially rotary UAVs. Reaching inhospitable locations can present a variety of logistical challenges, not least of which is the cost of sending land-based patrols or manned aircraft often from navy ships or other maritime vessels. This is where UAVs can enable operators to safely monitor terrains in a cost-effective and efficient way to better understand complex habitats. Carrying out monitoring exercises in areas such as the Artic where there is a real risk to life can be a major challenge. Through the use of well-engineered rotary UAVs, organisations are able to perform a variety of tasks with ease. The responsibility to advance the endurance capabilities of UAVs falls on engine manufacturers. For this reason, we must continue to innovate to increase performance. Over the last few years, rotary UAVs have grown in complexity, not only in terms of the platforms themselves but also the robustness and performance of the engines they run on. As the operational requirements for UAVs grows, engine manufacturers must continually innovate to improve power-to-weight ratios, reduce emissions, and accelerate capabilities in harsh environments. For a long time, fixed-wing UAVs were considered the optimal choice for endurance and speed over their rotary counterparts. However, this is changing rapidly thanks to enhancements in engine design. Rotary UAVs are now becoming a platform of choice due to their reduced logistical footprint and the ability to take off and land in a confined or limited space, especially in maritime environments such as on-board navy ships and coastguard cutters for example. The requirement for rotary UAVs to operate in extreme temperatures such as the cold of the Arctic or the severe heat of warmer climates is essential for operators. This is where two-stroke propulsion engines play a vital role. Two-stroke applications present rotary UAV manufacturers with a range of benefits, including ease of maintenance due to less moving parts and the ability to operate on heavy fuels which are a must for corrosive marine environments. Alongside this, two-stroke powered rotary UAVs are often capable of flying missions with a full payload in extreme conditions for more than five hours without overhaul. With this as a backdrop, it is vital for UAV and engine manufacturers to accelerate the development of propulsion systems capable of operating in extreme locations around the globe. As the industry moves towards hybrid and electric propulsion new challenges will arise and it is crucial that OEMs raise the bar to power the next generation of UAVs. In order to advance the endurance and capabilities of rotary UAVs, engine manufactures must look to innovate the propulsion technology used. Electric is an increasingly popular option for commercial drones. However, electric comes with its own challenges and limitations, such as operational endurance and increased weight of the electrical motors. Considering the performance of batteries in extreme temperatures in comparison to their fuel-based counterparts, there is a long way to go before pure electric UAVs will be capable of flying extended missions in harsh terrains. Hybrid applications that utilise both a combustion engine and electric propulsion systems will provide a bridge toward the future of pure electric flight. A clear advantage for hybrid applications is improving power to weight ratios to enable increased payload capacities. Hybrid UAV applications can be used in various functions, such as: electrically powered take-off and landing with conventional engines powering horizontal flight; or powering flight using only electrical motors whilst the combustion engine acts solely as a generator. In addition, safety is a key purpose behind the pursuit of hybrid applications. For UAV manufacturers, having the ability to convert to an electric battery should the combustion engine fail could make all the difference in enabling a safe landing. Operating UAVs in extreme weather conditions reduces the chances of potential health and safety issues associated with deploying staff or manned systems into harsh environments. In addition, a further key benefit of using UAVs is enabling the deployment of cost-effective systems that perform safely in extreme locations. Ultimately, developing UAVs that can fly farther and for longer in harsh environments will require engine manufacturers to consider alternative fuel and power systems such as heavy fuel two-stroke applications. Heavy fuel is widely considered a must in the maritime industry when dealing with complex environments due to its resistance to extreme temperatures. At Hirth, pairing a robust heavy fuel combustion engine with electrical propulsion is something we are pursuing to advance the future capabilities of unmanned systems and bridge the gap to pure electric flight. For further information about Hirth's portfolio of engines, visit: http://hirthengines.com/ About Hirth Hirth Engines GmbH, based near Stuttgart, with global sales operated from Vienna, has a long pedigree in the development of propulsion systems, stretching back to The innovative company was founded by German aviation pioneer and World War I ace Helmuth Hirth, a student of US inventor Thomas Edison, and collaborator with the Wright Brothers and Zeppelin. The company has set its sights on consolidating its leading role in the development of two-stroke engines for a range of diverse sectors including:  Unmanned and manned light and experimental aircraft (fixed wing and helicopters)  Hovercraft Next generation R&D will focus on hybrid engines, based on the company's winning formula of providing easy to maintain power to weight ratio propulsion technology across civilian and military applications. https://dronescrunch.com/enhancing-unmanned-operations-in-extreme-conditions-with-the-power-of-two-stroke/

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  • How Much Does It Cost To Insure A Russian-Made Stealth Drone?

    June 8, 2020 | International, Aerospace

    How Much Does It Cost To Insure A Russian-Made Stealth Drone?

    David Axe The Russian defense ministry has insured its new stealth drone and its control station for 1.4 billion rubles. That's $20 million. And it's probably worth every ruble. The S-70 Hunter-B, a jet-powered flying-wing drone, perhaps is the most significant new warplane to emerge in Russia since the Su-57 stealth fighter that first flew in 2010 and now is in low-rate production. The Hunter-B first appeared in January 2019 on the ground at an airfield in Novosibirsk in southern Russia. It flew for the first time on Aug. 3, 2019. The Sukhoi-designed drone zoomed over the airfield for more than 20 minutes at a maximum altitude of around 2,000 feet, according to TASS, the state news organization that also reported the value of the robot's insurance. It's easy to dismiss the Hunter-B as a developmental dead-end, owing to Russia's poor track record when it comes to fielding unmanned aerial vehicles and the satellite infrastructure that helps controllers on the ground direct a UAV's flight. But the likelihood of Hunter-B eventually entering front-line service with the Russian air force is "big," said Tom Cooper, an author and independent expert on Russian military. "The Russian military is running multiple UAV-related projects," Cooper said. "Thus the emergence of this project is perfectly normal." "At this point, it is going to be the heaviest and fastest UAV [in Russian service] if and when fielded,” said Samuel Bendett, an analyst with the Center for a New American Security in Washington, D.C. Bendett estimated the Hunter-B's weight at around 20 tons and its top speed at more than 600 miles per hour. The drone is in the same class as a manned lighter fighter. The Russian air force reportedly is considering assigning Hunter-Bs as robotic wingmen for Su-57 pilots, extending the coverage of an Su-57 flight's sensors and adding to the manned pilots' firepower. On Sept. 27, the sole Hunter-B prototype flew in formation with an Su-57. The U.S., Japanese and Australian air forces are developing their own wingman drones. But Sukhoi has its work cut out for it completing the Hunter-B. “A a host of aerodynamic, electronic and high-tech issues need to be worked out,” Bendett said. And to be stealthy, the drone needs a new engine layout. In its current configuration, the Hunter-B's AL-31F motor projects from the rear of the airframe, creating a major source of radar reflectivity. Sukhoi has tinkered with a new version of Hunter-B that buries that engine deep inside the airframe, in the same way that Western firms do with their own stealth drones. As the high-stakes development continues, Sukhoi at least can take comfort that its drone is fully insured. https://www.forbes.com/sites/davidaxe/2020/06/05/how-much-does-it-cost-to-insure-your-russian-made-stealth-drone/#5a88c68023aa

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