Unmanned Aircraft Systems Roadmap 2005-2030 - Federation of ...

UAS ROADMAP 2005
techniques, unique component designs, and multi-use applicability. Advanced manufacturing techniques
can greatly reduce tooling cost and fabrication time. For example, resin-transfer molding for outer mold
casing components can reduce production cost up to 40% over conventional lay-up techniques. JETEC is
pursuing this and several other fabrication concepts including gang milling, high-speed milling, bonded
castings, bonded disks, metal-injected moldings and inertial welding.
Unique component designs must be pursued to allow UA engines to provide a high level of sophistication
while minimizing cost. Since part count is a major determinant of production cost, design features such
as drum turbo-machinery, slinger combustors, threaded casings, and integral blisks can reduce part count
by an order of magnitude. Low cost seals such as brush and finger designs have shown great promise for
replacing large, expensive labyrinth-type seals.
FIGURE D-2. JETEC COST GOAL IN COMPARISON TO EXISTING SYSTEMS.
Development costs can inhibit a buyer from pursing a new engine design. This leaves only off-the-shelf
systems that typically have less than optimal performance and/or cost for UA. These penalties can come
in the form of increased maintenance, decreased range or speed, increased production costs, or decreased
low observable (LO). To counter this and minimize development costs, industry must examine multi-use
concepts where a common-core can be incorporated into UA and commercial propulsion systems such as
general aviation, business jet, and helicopter gas generators. The payoffs are enormous for both
communities – decreased cost to the military and increased technology for the civilian sector.
� Versatile Affordable Advanced Turbine Engines (VAATE). As currently planned, the
DoD/NASA/DOE VAATE initiative is ramping up over the next several years, and will follow and
build upon the IHPTET effort. Unlike IHPTET, which focused heavily on performance, VAATE will
build upon the technology advances of IHPTET, and concentrate on improving aviation, marine and
even ground-power turbine engine affordability, which proponents define as capability divided by
cost. VAATE's affordability orientation will look at technologies cutting engine development,
production and maintenance costs. The balance of the VAATE affordability improvements will come
from performance capabilities--technologies associated with boosting thrust and cutting weight and
APPENDIX D – TECHNOLOGIES
Page D-2