F135 Propulsion Integration Topics · 2014-11-13 · J6924_F135_Propulsion_2012 - 1 F135 Propulsion...

J6924_F135_Propulsion_2012 - 1

F135 Propulsion Integration Topics

for Symposium on Jet Engines

Haifa, Israel

Tom Johnson Program Chief Engineer

Operational Military Engines

25 October 2012

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037


Agenda

• F135 Development Program History

• CTOL/CV Propulsion Integration Challenges

– Engine Mounts / Interfaces

– Aircraft Inlet / Fan Compatibility

– Fan Duct Heat Exchanger / IPP Integration

• STOVL Unique Propulsion Integration Challenges

– Integrated Control System & Software

– Lift Fan Performance / Vane Box Integration Effect

– Lift Fan Operability

– Roll Post Weight Reduction

• Summary



Preliminary Design Review – May 02 Critical Design Review – May 03 CV/CTOL First Engine to Test – Oct 03 STOVL First Engine to Test – Apr 04 Post-Test CV/CTOL/STOVL CDR – Mar 05 Flight Test Engines #1-3 – Delivered CTOL Initial Flight Release – Oct 06 CTOL First Flight – Dec 06 LRIP Contract Awarded – Sep 07 STOVL Roll-Out – Dec 07 STOVL Flight Clearance Review – Mar 08 STOVL Up & Away Flight Clearance – May 08 STOVL First Flight – Jun 08 STOVL Powered Lift Flight Release – Jan 09 First STOVL Vertical Landing – March 10 CV/CTOL Initial Service Release – Apr 09 STOVL Initial Service Release – Dec 10

F135 Qualification Program Milestones

F-35 AA-1 Flight Test

F-35 BF-1 Flight Test



CTOL / CV STOVL

ISR Achieved ISR Achieved

Completed Over 23,700 Test Hours (Ground and Flight)

• 11,788 Test Hours Achieved

• 5 Ground Test Engines

• 11 Flight Test Engines Delivered

- 8 CTOL, 3 CV

• 11,964 Test Hours Achieved

• 3,402 Hours Powered Lift

• 8,821 Clutch Engagements

• 6 Ground Test Engines

• 7 Flight Test Engines Delivered

F135 SDD Program

As of 10/15/12 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037


F135 Propulsion System Characteristics

40K Thrust Class

Advanced Prognostics Health Management Features

3 Stage Fan

1st Stage Hollow IBR

Nozzle 6 Stage

Compressor (HPC) Split Cases and

Stators

Intermediate Case

3rd Stage

Turbine Blade



Main Engine Integration

Current A-1 F-35 FWD Upper

Mount Design

Top Forward

Mount

Forward

Side Link

Aft Mounts

Aft Side Link

Current A-1 F-35 FWD Upper

Mount Design

Top Forward

Mount

Forward

Side Link

Aft Mounts

Aft Side Link

• Mounts

• Interfaces

• Install Trailer

Flight test Engine 6 in STOVL BF-1



FS 424.5

Cruise

Bellmouth

Inlet Compatibility/Aeromechanical Testing

Sea Level

Static Inlet

PT2/PT0

1.00

0.98

0.96

0.94

0.92

0.90

0.88

0.86

0.84

0.82

0.80

SI-05 Test Data:Run47 Config CTOL BL Wc357

Wc2 = 357.484Pt2Pt0 = 0.96214D2 = 0.12071DPCOPA = 0.02613DPRPMX = -0.02665

ITAR Technical Data

Lockheed Martin Aeronautics Company

SI-05 Test Data 04 Dec 2003 Run47_Config_CTOL_BL_Wc357

Risk Reduction Testing Verifies Compatibility



Main Engine Integration

Fan Duct Heat Exchangers

Fan Duct

Heat Exchanger

IPP System

Plumbing



F135 Propulsion System Characteristics

40K Thrust Class / Variable Cycle Engine

Lift Fan Clutch

& Driveshaft

F119 Based

Controls & Externals

3 Stage Fan

Evolved F119 Core

2 Stage LPT

3 Bearing Swivel

Module Roll Control Ducts and

Nozzles

Modulated Exhaust Cooling

Fan Duct Blocker

2 Stage

Lift Fan

Variable Area

Vane Box Nozzle

Advanced Prognostics Health Management Features


J6924_F135_Propulsion_2012 - 10

Vehicle

Management

Computers

Integrated Flight & Propulsion Control

Fore/Aft

Acceleration

Control

Roll Rate Control

Vertical Axis Control

F-35B STOVL Unified Control

Thrust

Split

Pilot Commands to Vehicle Management Computers


J6924_F135_Propulsion_2012 - 11

Integrated Flight & Propulsion Control

Air Vehicle

Management

Computers

PHAM Main Engine

FADECs

Vehicle Management Computers Commands to Propulsion

Lift System

FADECs

Thrust

Split

Thrust

Pitch -

Vane Box

Pitch – 3BSD

Roll

Moment

YAW – 3BSD


J6924_F135_Propulsion_2012 - 12

Lift Fan Integration – Development

Insufficient Airflow Turning to Accommodate Forward Vane

Box Offset

Thrust Thrust

Vane Box Offset

For Hover Optimization

Cg

Turning Flow

Vane Box

Centerline Offset


J6924_F135_Propulsion_2012 - 13

Lift Fan Performance Recovery Verified for Flight Test

Block 1 Block 2

IFR Block 3

FFR Po

we

r M

arg

in

to

Ach

ieve

Th

rust

Block 3 Block 1/2

F135 SDD Program Review


J6924_F135_Propulsion_2012 - 14

Lift Fan Inlet Flow Angularity

Pre-Flight Test Configuration

Aero

Interface

Plane

First Rotor

Inlet Plane


J6924_F135_Propulsion_2012 - 15

Flight Test Fixes in Place

• Door Angle

Flow Angularity Improvements

• Inlet Modification


J6924_F135_Propulsion_2012 - 16

STOVL FFR Lift Fan Stability

Positive Stall Margin Demonstrated with Fixes

C-14 Test Stand

Crosswind Set Up

F35B Lift Fan

Inlet Test


J6924_F135_Propulsion_2012 - 17

STOVL Vane Box Integration

BF1-351-001sml Releasable per JSF05-2781

Vane Box Sidewalls Are Aircraft Structure


J6924_F135_Propulsion_2012 - 18

Qualitative Assessment Weight Reduction

Lightweight Roll Post Duct


F135 Propulsion Integration Topics · 2014-11-13 · J6924_F135_Propulsion_2012 - 1 F135 Propulsion...

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