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  • Maintainers Maintain Mission Readiness

    August 15, 2019 | International, Aerospace

    Maintainers Maintain Mission Readiness

    By Airman 1st Class Adriana Barrientos Fighter jets and heavies can rule the skies, but they need to get there first. It takes strict attention to detail from aircraft maintainers to service aircraft in order to launch them to the battlefield. Airmen from the 703rd Aircraft Maintenance Squadron identified and fixed a misplaced spoiler control rod on the E-3 Sentry during a Home Station Check at Joint Base Elmendorf-Richardson, June 3, 2019. Aircraft maintainers play a huge role when it comes to mission readiness. After all, they are responsible for the upkeep of aircraft that fly through the skies. It's imperative for these Airmen to be meticulous, confident and disciplined in order to carry out their mission— inspect aircraft and troubleshoot problems. The 703rd AMXS supports JBER's worldwide contingency and maintenance operations for the 3rd Wing, 11th Air Force, and the North American Aerospace Defense Command. They are responsible for the C-17 Globemaster III, E-3 Sentry, and C-130 Hercules. Crew chiefs assigned to the 703rd AMXS are assigned to either the 962nd or the 517th Aircraft Maintenance Units. One type of aircraft maintained by the 962nd AMU is the E-3 Sentry. As an airborne warning and control system or AWACS aircraft, it performs an essential mission, distinguishing between friendly and enemy activity. It also provides airborne command and control in addition to conducting all-altitude, all-weather surveillance. “I come to work and figure out what the flying and maintenance schedule is for the day,” said U.S. Air Force Staff Sgt. John Hays, 962nd AMU crew chief lead for two E-3B/C aircraft. “On a typical day, we launch one of the jets for a four to six-hour sortie and recover the jet towards the end of the shift. Once the jet lands, the other crew chiefs and I will perform a post-flight inspection and fix anything we find.” As a crew chief, Hays performs visual inspections of the entire structure of the aircraft. These include calendar inspections, which serve to provide constant observation of all components of the aircraft to ensure reliability. It was June 3rd when an issue with the jet's spoiler rod was identified during an in-depth calendar inspection, known as a Home Station Checks. “Calendar inspections vary, but a really important one is the Home Station Check that is completed every 180 days,” said U.S. Air Force Staff Sgt. Brandon Solomons, 962nd AMU crew chief. “One of the biggest things we look for during these inspections is irregular rubbing of moving components. During our mid-shift, Senior Airman Eric Goodholm noticed one of the rods was pushed up against another component in the wing called the flap track gearbox.” In this case, it was the spoiler control rod, which was not damaged but could have potentially caused a major problem during the flight. “A spoiler control rod basically helps lift the spoiler— a vital flight control surface that allows the jet to turn in flight, as well as a brake or slow down the jet during approach and landing,” said Solomon. “The pushrod is not supposed to rub on the gearbox, so myself and our production superintendent performed further investigations,” said Hays. “I identified that the two outboard spoilers follow up pushrods were connected incorrectly to the idler arm, therefore causing the pushrod to rub on the gearbox.” The total time to fix the issue was a combined eight hours, to include an operation check. “I led the fix of the malfunction along with Staff Sgt. Solomons,” said Hays. “We disconnected and reconnected the pushrods to the idler arm correctly, which provided the proper clearance from the gearbox.” These kinds of calendar inspections allow maintainers to identify defects before malfunctions cause serious danger or harm to the aircraft or personnel. In any case, a setback with the aircraft is a setback to the mission. “After ensuring the rod wasn't damaged, we got in touch with Tinker Air Force Base, and they found the same problem on three of their jets,” said Solomons. “This discovery drove a Time Change Technical Order, implemented to prevent flight binding across the fleet.” Time Change Technical Orders, or periodic updates to aircraft that authorize the modification of a system, were pushed to keep the operational tempo on track. As an air defense system, E-3s can detect, identify and track airborne enemy forces far from the boundaries of the United States or NATO countries. It can direct fighter-interceptor aircraft to these enemy targets. Thus being a vital component to the mission in day to day operations. “Something like this could have been easily overlooked, but Senior Airman Goodholm is very thorough and paid great attention to detail,” said Solomons. After the team made modifications and the pushrods were properly connected, a rig check was performed to verify if the spoilers were in the proper configuration. “I can say Senior Airman Goodholm, Staff Sgt. Hays and I contributed by identifying and planning a course of action to fix this issue, but it was an effort as an AMU that fixed the discrepancy,” said Solomons. “With the unit's team effort and strong leadership the problem was identified, fixed and the jet was able to go and perform the mission again.” General maintenance actions and inspections by not only the 703rd AMXS, but all maintainers require attention to detail day in and day out. The lives of the crew and mission success depend on it. https://www.jber.jb.mil/News/News-Articles/Article/1933112/maintainers-maintain-mission-readiness/source/GovD/

  • Four rocket companies are competing for Air Force funding, and it is war

    August 14, 2019 | International, Aerospace

    Four rocket companies are competing for Air Force funding, and it is war

    By ERIC BERGER Monday marked the deadline for four US rocket companies to submit bids for Air Force contracts, encompassing all national security launches from 2022 to 2026. This is a hugely consequential and much-contested bid process that has implications for the American aerospace industry for the next decade and beyond. The Air Force is seeking two providers for about two dozen launches. The prime contractor will receive 60% of the launches while the secondary contractor claims the remaining 40%. As the US military pays a premium for launch contracts to its nine reference orbits, this guaranteed revenue is extremely valuable to US companies aspiring to run a profitable launch business. The lead-up to Monday's deadline has included heavy political lobbying from the four companies: United Launch Alliance, SpaceX, Blue Origin, and Northrop Grumman. As a result of this, Congress is considering some changes to the Air Force's procurement policy, including an on-ramp for a third provider during the 2022 to 2026 period. But so far, the Air Force is resisting this. Here's a look at the four bidders and what is at stake for each of them. United Launch Alliance United Launch Alliance—a joint venture between Boeing and Lockheed Martin that enjoyed a monopoly on national security launches before the emergence of SpaceX—may be bidding for its life. To wean itself off its costly Delta boosters (as well as the Russian rocket engines that go with its workhorse Atlas V rocket), ULA has been developing the Vulcan rocket to cut costs while maintaining performance. The company says the Vulcan will be ready for its first flight in 2021. "Vulcan Centaur will provide higher performance and greater affordability while continuing to deliver our unmatched reliability and orbital accuracy precision from our treasured cryogenic Centaur upper stage," ULA's chief, Tory Bruno, said in a news release Monday. "ULA is the best partner for national security space launch, and we are the only provider to demonstrate experience flying to all orbits including the most challenging heavy-class missions, providing the bedrock foundation for the lowest risk portfolio of two launch service providers for the US Air Force." With increasing competition from SpaceX, Europe's Arianespace, Japan's Mitsubishi Heavy Industries, and Russian launch vehicles, ULA has been unable to capture much of the commercial market for satellite launches in the last decade. Therefore, it has largely been reliant on government business, mostly from the military. But ULA also relies on NASA through its science missions and lifting cargo and crew missions to the International Space Station. If the company does not emerge victorious from this competition, it faces an uncertain future unless Vulcan can become commercially viable. Moreover, ULA will lose out on hundreds of millions of dollars in government money to finalize Vulcan if it does not receive an award. Historically, Boeing and Lockheed have been stingy parents, and whether or not they would pay to complete Vulcan is unclear. One intriguing twist with ULA's bid is that its Vulcan rocket will use the BE-4 rocket engine, which is being developed and manufactured by Blue Origin—one of the four competitors in the Air Force bidding process. Blue Origin has said the Air Force competition was designed to unfairly benefit ULA. SpaceX The Hawthorne, California-based rocket company is the only bidder proposing to use rockets that are already flying—the Falcon 9 and Falcon Heavy boosters. This family of rockets has had a string of 49 successful launches since a static fire accident in September 2016, and according to SpaceX, it can meet all of the Air Force's desired orbits and payload specifications. "SpaceX means to serve as the Air Force's long-term provider for space launch, offering existing, certified, and proven launch systems capable of carrying out the full spectrum of national security space-launch missions and requirements," said the company's president and chief operating officer, Gwynne Shotwell. Since the Air Force agreed to admit SpaceX to the national security launch competition in 2015, the company has won several contracts for key missions and begun flying them for the military. These include the National Reconnaissance Office Launch 76, Orbital Test Vehicle 5, Global Positioning System III-2, and STP-2 flights. SpaceX also likely will offer the government the lowest price on service to orbit. However, in its criteria for awarding missions, the Air Force listed price among the last of its considerations. Due to its lower price point, especially with is reusable Falcon 9 rocket, SpaceX has considerable commercial business to offset the loss of Air Force contracts. But it would hurt financially, all the same. Blue Origin Jeff Bezos' rocket company has bid its very large New Glenn rocket for the Air Force missions. However, when this rocket will begin flying is not entirely clear, as there are questions about whether it will be ready by the beginning of the 2022 contracting period. What is clear is that Blue Origin does not believe the US Air Force has created a fair bidding process. Already, the company has filed a "pre-award" protest with the US Government Accountability Office. "The Air Force is pursuing a flawed acquisition strategy for the National Security Space Launch program," Blue Origin said, according to SpaceNews. The Air Force decision to award contracts to just two companies creates a "duopoly," Blue Origin says, and it limits commercial development of strategic US assets such as rocket engines and boosters. Bezos has been investing about $1 billion a year of his own money into Blue Origin, which has largely been used to support development of the BE-4 engine and New Glenn rocket. He is likely to continue development of the New Glenn rocket without Air Force funding, but company officials say it is not fair to hold their wealthy founder against their bid. Northrop Grumman Northrop has been developing the Omega rocket for this competition since at least 2016. The Omega vehicle differs from the other entrants in the competition as its first and second stages, as well as side-mounted boosters, are powered by solid-rocket motors rather than liquid-fueled engines. The bet by Northrop is that the US military, through its national security launch contract, would want to support one of the nation's most critical suppliers of solid-rocket motors for intercontinental ballistic missiles. Northrop officials have not said whether they would continue development of the Omega rocket if Northrop were to lose out on the Air Force contract. Northrop's bid suffered a setback in May when an "anomaly" occurred during test firing of its solid-propellant Castor 600 rocket motor, the Omega rocket's first stage. From a video provided by the company, a major part of the rocket's large nozzle appeared to break apart, blasting debris around the area. Afterward, a Northrop vice president, Kent Rominger, called the test a success. "It appears everything worked very, very well on this test," he said. "And at the very end when the engine was tailing off, we observed the aft exit cone, maybe a portion of it, doing something a little strange that we need to go further look into." Nevertheless, the test cannot have instilled absolute confidence in the Air Force. https://arstechnica.com/science/2019/08/four-rocket-companies-are-competing-for-air-force-funding-and-it-is-war/

  • Update: F-35 test fleet struggles with low readiness rates as key deadline approaches

    August 14, 2019 | International, Aerospace

    Update: F-35 test fleet struggles with low readiness rates as key deadline approaches

    Pat Host, Washington, DC Key Points The F-35 programme's test fleet has a fully mission-capable rating that is roughly 10% of its goal This could make it difficult for the Pentagon to make an educated decision on whether to enter full-rate production The Pentagon's Lockheed Martin F-35 Lightning II Joint Strike Fighter (JSF) test fleet has a fully mission-capable rate of 8.7% compared with an 80% goal, causing one watchdog to question whether the programme can accomplish all of its initial operational test and evaluation (IOT&E) test points before the phase ends. Dan Grazier, military fellow with the Project on Government Oversight (POGO) watchdog group in Washington, DC, said the Pentagon plans to make its full-rate production (FRP) decision by the rapidly approaching end of fiscal year 2019 (FY 2019) or early FY 2020. The fiscal year changes on 1 October. If the F-35 programme cannot accomplish all its IOT&E test points by this deadline, Grazier said the Pentagon cannot make an informed decision on FRP. The FY 2016 Director of Operational Test and Evaluation (DOT&E) report called for an 80% availability rate to conduct an efficient IOT&E and support sustained combat operations. According to an F-35 programme briefing slide provided by POGO and dated 19 July 2019, the 8.7% rate is an improvement from 4.7% in May. https://www.janes.com/article/90429/update-f-35-test-fleet-struggles-with-low-readiness-rates-as-key-deadline-approaches?from_rss=1

  • Big A&D Firms Seem To Be Merging Or Acquiring—Where’s Honeywell?

    August 14, 2019 | International, Aerospace

    Big A&D Firms Seem To Be Merging Or Acquiring—Where’s Honeywell?

    Michael Bruno United Technologies (UTC) and Raytheon are working hard to convince shareholders to approve their mega-merger. L3 Harris Technologies is riding high after its heritage companies consolidated recently. Industry insiders are making bets on who is next. But Honeywell International has been conspicuously absent in all the major merger and acquisition (M&A) moves in recent years. Why? Honeywell Aerospace chief executive Tim Mahoney recently explained how his company still plans to take advantage of the wave of consolidation hitting aerospace and defense. “We've looked,” Mahoney told an Aug. 7 investor conference. “We've never thought—and we continue to not think—that scale is a major discriminator and a differentiator within our marketplace. Having said that, you need to be large enough to be relevant, and we have been at that point. But scale is not something that is attractive or makes you more attractive from an OEM perspective or from an aftermarket perspective. We've continued to differentiate ourselves relative to value-added offerings.” Mahoney spoke during a live interview with analyst Sheila Kahyaoglu at the Jefferies Global Industrials Conference. While Honeywell has remained active with bolt-on acquisitions—including the July 24 announcement it will buy autopilot specialist TruTrak Flight Systems for an undisclosed amount—the company has not consummated a prime- or OEM-level deal and even walked away from talks with UTC in 2016. That same year, Honeywell did buy warehouse automation specialist Intelligrated for $1.5 billion. And Honeywell leaders have long assured Wall Street that they keep their eyes open in A&D, as Mahoney reaffirmed. But they have complained that valuations were too rich to be conducive to dealmaking. Mahoney also indicated that Honeywell could take advantage of the consolidation trend in another way. “We've actually gone back and looked at when there has been very significant consolidations, or two companies coming together,” he explained. “That has actually helped us from a market share perspective, because typically when there's a large-scale integration of two companies, those two companies become inwardly focused, which is understandable. “As a result, we've been opportunistic relative to that,” he continued. “If you look at our cockpit systems business or some of those areas where we've competed with some of the companies that have consolidated, our auxiliary power unit business, you would see that we've actually grown disproportionately larger during those time periods.” One area Honeywell is now focusing on growing is its new big-data analytics software Forge, which the company recently rolled out for airlines and other industrial companies (Aviation DAILY, June 6). While the software expectedly looks to provide aircraft operators with predictive maintenance, fuel optimization and other flight operation benefits, Honeywell is looking to add ground operations through an expanding experiment with Swissport, one of the world's largest airport ground service providers. Last December, Honeywell and Swissport signed a five-year agreement initially to apply Honeywell's GoDirect Ground Handling product used across Swissport's global operation base. Ben Driggs, president of Honeywell Connected Aircraft, told the investor conference that the goal is to achieve faster airplane turnarounds in the 20-40% of the time the aircraft is on the ground. He said the partnership is first being implemented in Kansai International Airport (KIX) for Osaka, Japan, with Miami, Basel, Switzerland and “numerous” other Swissport airports planned. https://aviationweek.com/defense/big-ad-firms-seem-be-merging-or-acquiring-where-s-honeywell

  • Is this the first step to military passenger drones?

    August 14, 2019 | International, Aerospace

    Is this the first step to military passenger drones?

    By: Kelsey D. Atherton The “passenger drone” is a flying contradiction. It is an autonomous vehicle, with a human inside. Current language has yet to capture this disparity — the weird balance between terms indicating that no human, not even a pilot, is onboard, and the fact that this is a robot people step inside and which then transports them. Regardless of the terminology, the whole category of machine is fascinating: what could people do with autonomous robots they can ride? On Aug. 4, 2019, Japan's NEC Corp demonstrated its autonomous flying passenger vehicle. With three wheels and four rotors, the craft is informally dubbed a flying car, though like most autonomous flying passenger vehicles it most closely resembles an oversized quadcopter. Long promised by science fiction and technologists alike, flying cars have yet to become a part of daily life. Yet there's something compelling about the drive, and modern attempts can inform what this new avenue for mobility might actually look like. While the vehicles are primarily designed for urban and commercial markets, any advance in vertical mobility in that space is worth watching for military planners. Taking advantage of commercially driven developments could subsidize new military machines, and it's not inconceivable that, if the technology becomes as prevalent as its designers hope, we could see versions modified like Hi-Luxes to become improvised weapons of future urban warfare. The most significant development in modern car-sized flying autonomous vehicles is the use of rotors or ducted fans for vertical takeoff and landing. Winged cars, a few of which have been developed, are clunky beasts, awkward on roads and in the air alike. VTOL, though, allows a vehicle like this to operate from helipads or even smaller areas, and to land where people might actually want to go. Freed from the runways and hassles of an airport, VTOL taxis could, for a certain set of extraordinarily well-off commuter, bypass rush-hour traffic. It's a promise that has attracted investment and development from companies like Uber and Bell, as well as multiple others. While the promise of carrying a person remains the distant dream of such machines, the easier-to-realize more immediate reality will be cargo and logistics, with the possibility of maybe evacuating a human in a pinch. The chief advantage offered by the car-sized vehicles over jetpacks, hoverbikes, jet bikes and flying boards is the stability and interior offered by the larger size. The technologies that enable vehicles like this are largely the same ones that enable drones at smaller and larger scales. Remote direction, autonomous stabilization, powerful batteries, the ability to maneuver in vertical space and potentially operate in cities, all of this could create a vehicle that provides a capability the commanders of the 2030s, who grew up with drones, might want in a machine. There is still much work to be done to transform the prototypes from experiments to useful machines. That there are multiple companies on multiple continents pursuing it should be a promising sign for the industry as a whole, and for any military designers looking to piggyback on a drone-like flying car into a new urban battle machine. https://www.c4isrnet.com/unmanned/2019/08/08/this-flying-taxi-drone-could-inspire-new-technicals/

  • What could a military do with this flying saucer?

    August 14, 2019 | International, Aerospace

    What could a military do with this flying saucer?

    By: Kelsey D. Atherton This may be a flying saucer, but don't call it a UFO. Carefully named, the All DIrections Flying Object, or ADIFO, is instead a saucer-like contraption, a flying prototype built at exploring the aerodynamic potential of an alien craft. It is, at its core, an omnidirectional flying wing built around a quadcopter with jets attached. Its designers see a future for the airframe as an unmanned combat aerial vehicle. In a video posted July 1, a narrator discusses the design process and aerodynamics of the craft. Like many VTOL tools built on a quadcopter frame, ducted fans provide initial lift and mobility at low altitudes and low speeds. The addition of vectored jets on the rear of the craft, combined with four vertical vents and four side-facing vents, promising greater maneuverability at high speeds. The ADIFO is the invention of Romanian engineer Razan Sabie in conjunction with Iosif Taposu, a scientist with a long career in aerospace research for the Romanian government. “The aerodynamics behind this aircraft is the result of more than two decades of work and is very well reasoned in hundreds of pages and confirmed by computer simulations and wind tunnel tests,” Sabie told Vice, in the pair's first American interview. That story explores both the specific nature of the ADIFO, and the long and mostly failed history of flying saucer design. Like many other ideas for the first decades of aviation, the possibility of operating the craft without a human on board opens up greater potential in what an airframe can actually do. Human pilots are subject to the limitations of a body and perception, and a flying disk changing directions suddenly at high speed is not the ideal place for a human to be. Uncrewed craft can take on novel forms, and execute turns and twists beyond those human limits. While maneuverability is likely the primary selling point for a future role as combat aircraft, the smooth and fin-free form could easily have stealth characteristics built in, and could be further adapted by a dedicated team to fully realizing that stealth flight. What might a military planner or designer do with such a machine? The proof-of-concept offers little in the way of information about storage space or sensors. With wide enough lenses, a handful of cameras could match the circular symmetry of the vehicle and provide and omnidirectional surveillance presence. The high speeds and potentially low radar profile suggest a role akin to earlier, Cold War spy planes, taking specific pictures in contested space and returning before anti-air systems can act. And as with any aircraft, the potential is likely there for it to release an explosive payload, taking the flying saucer from an extraterrestrial fear to a terrestrial threat. ADIFO might not be the future of anything. The project's home page says the team is still attracting partners, and aviation history is littered with proofs-of-concept that failed to materialize in a meaningful way. Yet there is something to the idea of a flying saucer working the moment it no longer has to transport a human. It is an old aviation frontier that likely warrants further exploration. https://www.c4isrnet.com/unmanned/2019/08/12/what-might-a-military-want-with-a-romanian-flying-saucer/

  • Will this hybrid drone give Russia a high-altitude advantage?

    August 14, 2019 | International, Aerospace

    Will this hybrid drone give Russia a high-altitude advantage?

    By: Kelsey D. Atherton Is it still a tiltrotor aircraft if the whole body tilts? The new “Fixar” drone, set to be presented at Russia's MAKS-2019 airshow in late August, is a hybrid of sorts, a quadcopter with fixed wings. With limited moving parts and a flexible design, it's the kind of dual-use technology worth watching and, perhaps, even imitating. “Many companies and UAV manufacturers will present their aircraft, concepts and models” at the MAKS-2019 airshow, said Samuel Bendett, an adviser at the Center for Naval Analyses. “This Fixar UAV is a ‘self-initiated' project by the manufacturer, with the hope of getting attention from potential civilian and military customers at the air show.” Unlike the more eponymous tiltrotor craft, which switch distinctly from rotor-powered takeoff and landing to propeller-driven level flight, the Fixar instead has its four rotors in a permanently fixed position. The engines remain in position while the whole frame of the aircraft can lean backwards for more traditional vertical flights or stay level to operate as a fixed-wing machine. While the Fixar's marketing photos show it working in fields of crops, manufacturer IKS also bills it as designed specifically to operate in windy conditions and in mountains, suggesting that the whole machine might have a role in ISR and cargo transport. “What caught my attention in particular was that the drone can operate in ‘mountainous conditions' due to its unique design,” said Bendett. “In fact, Russian military has been practicing the operation of different UAVs at high altitudes and in high wind — so this Fixar UAV can prove useful right away.” Like all duel-use platforms, a drone is only as useful as the payloads put on it. Cameras and supply storage are likely options, though nothing yet suggests any new demand on the airframe. An ability to fly fast and from small patches of land without a runway is valuable, but it needs to have a certain range and speed to be a better choice than the baseline low cost and simplicity of civilian quadcopters. A large internal security market might support that and could easily lead to the Fixar in police roles, as well. “At present, there is no UAV in the Russian military that has characteristics similar to the Fixar, but given a steady rate of UAS acquisition by the MOD — at 300 UAVs per year for the next several years — it's safe to assume that the Russian military is looking to diversify its UAV fleet beyond the workhorses like Eleton or Orlan," said Bendett. https://www.c4isrnet.com/unmanned/2019/08/13/will-this-hybrid-drone-give-russia-a-high-altitude-advantage/

  • Red Arrows rock Gatineau-Ottawa

    August 14, 2019 | Local, Aerospace

    Red Arrows rock Gatineau-Ottawa

    by Eric Dumigan Under blue skies, the team wowed thousands in a special one-day edition of Aero Gatineau-Ottawa. The Red Arrows, who last performed in North America more than a decade ago, are conducting an 11-week North American tour that “aims to promote the best of British and deepen partnerships with close friends and allies.” The contingent includes 108 people, 12 Red Arrows Hawk T1 aircraft and one Atlas A400M RAF transport aircraft. In their 55th season, the Red Arrows will travel coast to coast across North America, conducting aerobatic displays, flypasts and ground engagements. The Red Arrows use a mix of red, white and blue smoke during their performances to enhance visual presentation. Eric Dumigan Photo The team's leader, Martin Pert, leads the nine-plane formation in a series of manoeuvres with formations that salute the 50th anniversary of the Apollo mission; the Concorde, the world's only supersonic commercial aircraft; the Second World War Lancaster bomber; and the Tornado, a multi-roll strike aircraft that was retired from the RAF in 2019. The team uses red, white and blue smoke to enhance its visual presentation. The Red Arrows were formed in 1965 and have performed over 5,000 displays in 57 countries around the world. The Folland Gnat was replaced in 1980 with their current aircraft, the BAE Systems Hawk T1 trainer. The Hawk is a standard military two-seat advanced trainer with a tweaked engine to allow for faster response times. The Red Arrows performed a flypast in Halifax this past weekend and will perform in Toronto on Labour Day weekend, and in Victoria and Vancouver between September 24 and 27. Aero Gatineau-Ottawa will host a full airshow from Sept. 6 to 8, featuring the U.S. Air Force F-35 Lightning II Demo Team. https://www.skiesmag.com/news/red-arrows-rock-gatineau-ottawa/

  • Precooler Technology Could Bring Advantages To Fighter Engines

    August 14, 2019 | International, Aerospace

    Precooler Technology Could Bring Advantages To Fighter Engines

    By Tony Osborne Technology developed by Britain's Reaction Engines for its SABRE (Synergistic Air-Breathing Rocket Engine) hypersonic powerplant is to be fitted on the Eurojet EJ200 engine from a Eurofighter Typhoon to understand if the technology can help transform the powerplant's operating envelope. The £10 million ($12 million) project announced by the Royal Air Force (RAF) Rapid Capability Office (RCO) in July will see BAE Systems, Reaction Engines and Rolls-Royce engineers work to better comprehend Reaction's precooler technology and how it could be integrated for use on a jet engine—perhaps even the powerplant for Britain's future combat aircraft, the Tempest. Two-year project will scope integration to better understand precooler potential benefits Heat exchanger is an enabler for Reaction Engines' SABRE technology The trials represent the first acknowledged application of the precooler technology At high speed, jet engines struggle with a thermal challenge as air entering the intake becomes too hot, reducing thrust and limiting the ability to reach speeds beyond Mach 3. Reaction's precooler, essentially a highly efficient heat exchanger, already has proven its ability to quench megawatts of heat energy from the incoming air. Trials in the U.S. have shown the precooler technology to cool intake airflow from more than 800F (426C) to around 212F in just 1/20th of a second, helping to maximize performance. Applied to a fighter engine, the precooler could allow it to work more efficiently at high speeds but also enable manufacturers to be less reliant on exotic, expensive and heat-resistant materials such as titanium. This could lead to lower costs in terms of purchase and maintenance, which are both key focuses of Britain's Future Combat Air System Technology Initiative (FCAS TI). The goal of the FCAS TI is to research and develop new technologies that can be spiraled into Britain's Eurofighter Typhoons and Lockheed Martin F-35s, but also potentially featured in a combat aircraft to replace the Typhoon in the 2030s. “This is Phase 1 of something more,” Air Vice Marshal, Simon “Rocky” Rochelle, chief of staff for capability and the brainchild behind the RAF's RCO, said at the Royal International Air Tattoo, where the contract was signed. “There is something here that needs to be explored, investigated, tested and tried.” Over the next two years, engineers will study how the precooler can be integrated onto the EJ200. Once this is established, the engine and precooler will be ground-tested together. “This isn't about a new market for EJ200. We are using existing assets to try and address that heat challenge,” Conrad Banks, Rolls-Royce's chief engineer for future defense programs, tells Aviation Week. “If you can cool the intake air down, suddenly you can expand the flight envelope of your gas turbine and it introduces some exciting supersonic and hypersonic applications.” There is no suggestion the UK is looking for a hypersonic fighter, especially with the high costs associated with the airframe alone. Nonetheless, the technology could enable higher supercruise performance—sustained supersonic flight without the use of afterburner, or more simply better fuel economy. “What we will do on the testbed is assess the drop in temperature and then see how that affects the core of the engine, that then validates our model. . . . This is not about massively changing the engine,” Banks explains. How the precooler could be fitted to the engine is also part of the scope of the study. One option could be a donut-like configuration around the intake, Banks suggests. The work also will consider how the introduction of a precooler affects the rest of the airframe and whether such an installation is affordable. The precooler fitted to the EJ200 will be “designed and scaled to the engine to match its performance,” says Banks. As Banks describes it, the technology will not change the low-observability aspects of the platform such as the engine's infrared signature, pointing out that will depend on what is done on the back end of the engine. However, officials note such a heat exchanger also could be mounted to the rear of the engine. For Reaction Engines, the trials build on its lightweight heat exchanger (HTX) experiments, which were conducted in Colorado and used a J79 engine from an F-4 Phantom to feed the precooler. The technology is key to the company's SABRE concept, which is targeted at air-breathing hypersonic and space access vehicles. In this role, the engine is designed to efficiently extract oxygen from the atmosphere for rocket combustion. In the fully integrated SABRE, the chilled air will be passed from the HTX to a turbo-compressor and into the rocket thrust chamber, where it will be burned with sub-cooled liquid hydrogen fuel. Reaction Engines has raised over £100 million in the last three years from public and private sources. In addition, the UK government in 2013 announced a £60 million commitment to assist with the demonstrator engines. Strategic investments also have been made at BAE Systems in 2015 and more recently in 2018 by Rolls-Royce and by Boeing's capital venture arm, HorizonX. https://aviationweek.com/defense/precooler-technology-could-bring-advantages-fighter-engines

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