F135 Propulsion Integration Topics for Symposium on Jet Engines Haifa, Israel

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1 F135 Propulsion Integration Topics for Symposium on Jet Engines Haifa, Israel Tom Johnson Program Chief Engineer Operational Military Engines 25 October 2012 J6924_F135_Propulsion_2012-1

2 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 J6924_F135_Propulsion_2012-2

3 F135 Qualification Program Milestones 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 F-35 AA-1 Flight Test F-35 BF-1 Flight Test J6924_F135_Propulsion_2012-3

4 F135 SDD Program Completed Over 23,700 Test Hours (Ground and Flight) CTOL / CV STOVL 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 ISR Achieved ISR Achieved As of 10/15/12 J6924_F135_Propulsion_2012-4

5 F135 Propulsion System Characteristics 40K Thrust Class Split Cases and Stators 6 Stage Compressor (HPC) Nozzle 3 Stage Fan 3 rd Stage Turbine Blade 1 st Stage Hollow IBR Intermediate Case Advanced Prognostics Health Management Features J6924_F135_Propulsion_2012-5

6 Main Engine Integration Mounts Interfaces Install Trailer Current A-1 F-35 FWD Upper Mount Design Top Forward Mount Aft Mounts Aft Side Link Forward Side Link Flight test Engine 6 in STOVL BF-1 J6924_F135_Propulsion_2012-6

7 Inlet Compatibility/Aeromechanical Testing Risk Reduction Testing Verifies Compatibility SI-05 Test Data 04 Dec 2003 Run47_Config_CTOL_BL_Wc357 ITAR Technical Data Cruise Bellmouth Sea Level Static Inlet SI-05 Test Data: Run47 Config CTOL BL Wc357 PT2/PT Wc2 = Pt2Pt0 = D2 = DPCOPA = DPRPMX = Lockheed Martin Aeronautics Company FS J6924_F135_Propulsion_2012-7

8 Main Engine Integration Fan Duct Heat Exchangers IPP System Plumbing Fan Duct Heat Exchanger J6924_F135_Propulsion_2012-8

9 F135 Propulsion System Characteristics 40K Thrust Class / Variable Cycle Engine 2 Stage LPT Modulated Exhaust Cooling Fan Duct Blocker 2 Stage Lift Fan Lift Fan Clutch & Driveshaft Evolved F119 Core 3 Stage Fan F119 Based Controls & Externals Variable Area Vane Box Nozzle Roll Control Ducts and Nozzles Advanced Prognostics Health Management Features 3 Bearing Swivel Module J6924_F135_Propulsion_2012-9

10 Integrated Flight & Propulsion Control Pilot Commands to Vehicle Management Computers Vehicle Management Computers Thrust Split Roll Rate Control Fore/Aft Acceleration Control Vertical Axis Control F-35B STOVL Unified Control J6924_F135_Propulsion_

11 Integrated Flight & Propulsion Control Vehicle Management Computers Commands to Propulsion Air Vehicle Management Computers Lift System FADECs Main Engine FADECs PHAM Thrust Split Pitch 3BSD Thrust Roll Moment Pitch - Vane Box YAW 3BSD J6924_F135_Propulsion_

12 Lift Fan Integration Development Insufficient Airflow Turning to Accommodate Forward Vane Box Offset Cg Vane Box Offset For Hover Optimization Thrust Thrust Turning Flow Vane Box Centerline Offset J6924_F135_Propulsion_

13 Power Margin to Achieve Thrust F135 SDD Program Review Lift Fan Performance Recovery Verified for Flight Test Block 1/2 Block 3 Block 1 Block 2 IFR Block 3 FFR J6924_F135_Propulsion_

14 Lift Fan Inlet Flow Angularity Pre-Flight Test Configuration Aero Interface Plane First Rotor Inlet Plane J6924_F135_Propulsion_

15 Flow Angularity Improvements Flight Test Fixes in Place Door Angle Inlet Modification J6924_F135_Propulsion_

16 STOVL FFR Lift Fan Stability Positive Stall Margin Demonstrated with Fixes F35B Lift Fan Inlet Test C-14 Test Stand Crosswind Set Up J6924_F135_Propulsion_

17 STOVL Vane Box Integration Vane Box Sidewalls Are Aircraft Structure BF sml Releasable per JSF J6924_F135_Propulsion_

18 Qualitative Assessment Weight Reduction Lightweight Roll Post Duct J6924_F135_Propulsion_

19

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