F135 Propulsion System:and Development Integration Challenges

F135 PropulsionIntegration TopicsforSymposium on Jet EnginesHaifa, IsraelTom JohnsonProgram Chief EngineerOperational Military Engines25 October 2012DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 1

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• SummaryDISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 2

F135 Qualification Program MilestonesPreliminary Design Review – May 02Critical Design Review – May 03CV/CTOL First Engine to Test – Oct 03STOVL First Engine to Test – Apr 04Post-Test CV/CTOL/STOVL CDR – Mar 05Flight Test Engines #1-3 – DeliveredCTOL Initial Flight Release – Oct 06CTOL First Flight – Dec 06LRIP Contract Awarded – Sep 07STOVL Roll-Out – Dec 07STOVL Flight Clearance Review – Mar 08STOVL Up & Away Flight Clearance – May 08STOVL First Flight – Jun 08STOVL Powered Lift Flight Release – Jan 09First STOVL Vertical Landing – March 10CV/CTOL Initial Service Release – Apr 09STOVL Initial Service Release – Dec 10F-35 AA-1 Flight TestF-35 BF-1 Flight TestDISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 3

F135 SDD ProgramCompleted Over 23,700 Test Hours (Ground and Flight)CTOL / CVSTOVL• 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 DeliveredISR AchievedISR AchievedAs of 10/15/12DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 4

F135 Propulsion System Characteristics40K Thrust ClassSplit Cases andStators6 StageCompressor (HPC)Nozzle3 Stage Fan3 rd StageTurbine Blade1 st Stage Hollow IBRIntermediate CaseAdvanced Prognostics HealthManagement FeaturesDISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 5

Main Engine Integration• Mounts• Interfaces• Install TrailerCurrent A-1 F-35 FWD UpperMount DesignTop ForwardMountAft MountsAft Side LinkForwardSide LinkFlight test Engine 6 in STOVL BF-1DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 6

Inlet Compatibility/Aeromechanical TestingRisk Reduction Testing Verifies CompatibilitySI-05 Test Data 04 Dec 2003 Run47_Config_CTOL_BL_Wc357ITAR Technical DataCruiseBellmouthSea LevelStatic InletSI-05 Test Data:Run47 Config CTOL BL Wc357PT2/PT01.000.980.960.940.920.900.880.860.840.820.80Wc2 = 357.484Pt2Pt0 = 0.96214D2 = 0.12071DPCOPA = 0.02613DPRPMX = -0.02665Lockheed Martin Aeronautics CompanyFS 424.5DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 7

Main Engine IntegrationFan Duct Heat ExchangersIPP SystemPlumbingFan DuctHeat ExchangerDISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 8

F135 Propulsion System Characteristics40K Thrust Class / Variable Cycle Engine2 Stage LPTModulated Exhaust CoolingFan Duct Blocker2 StageLift FanLift Fan Clutch& DriveshaftEvolved F119 Core3 Stage FanF119 BasedControls & ExternalsVariable AreaVane Box NozzleRoll Control Ducts andNozzlesAdvanced Prognostics HealthManagement Features3 Bearing SwivelModuleDISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 9

Integrated Flight & Propulsion ControlPilot Commands to Vehicle Management ComputersVehicleManagementComputersThrustSplitRoll Rate ControlFore/AftAccelerationControlVertical Axis ControlF-35B STOVL Unified ControlDISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 10

Integrated Flight & Propulsion ControlVehicle Management Computers Commands to PropulsionAir VehicleManagementComputersLift SystemFADECsMain EngineFADECsPHAMThrustSplitPitch – 3BSDThrustRollMomentPitch -Vane BoxYAW – 3BSDDISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 11

Lift Fan Integration – DevelopmentInsufficient Airflow Turning to Accommodate Forward VaneBox OffsetCgVane Box OffsetFor Hover OptimizationThrustThrustTurning FlowVane BoxCenterline OffsetDISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 12

Power Margin toAchieve ThrustF135 SDD Program ReviewLift Fan Performance Recovery Verified for Flight TestBlock 1/2Block 3Block 1 Block 2IFRBlock 3FFRDISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 13

Lift Fan Inlet Flow AngularityPre-Flight Test ConfigurationAeroInterfacePlaneFirst RotorInlet PlaneDISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 14

Flow Angularity ImprovementsFlight Test Fixes in Place• Door Angle• Inlet ModificationDISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 15

STOVL FFR Lift Fan StabilityPositive Stall Margin Demonstrated with FixesF35B Lift FanInlet TestC-14 Test StandCrosswind Set UpDISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 16

STOVL Vane Box IntegrationVane Box Sidewalls Are Aircraft StructureBF1-351-001smlReleasable per JSF05-2781DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 17

Qualitative Assessment Weight ReductionLightweight Roll Post DuctDISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037J6924_F135_Propulsion_2012 - 18