F-35 Program Information Non-Export Controlled Information Releasable to Foreign Persons Overview of the CTOL and STOVL Full Scale Static Tests on F-35 Lightning II Program Marguerite E. Christian Technical Lead, Full Scale Static Test F-35 Structures Development Lockheed Martin Aeronautics Company 2009 Aircraft Structural Integrity Program (ASIP) Conference December 1-3, 2009 Jacksonville, FL DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.
Acknowledgements Bob Burt, Director, F-35 Structures Development Team Phil Gross, Deputy Director and Chief Structures Engineer, F-35 Structures Development Team Joe Yates, Senior Manager, F-35 Structures Test Don Whiteley, STOVL Variant Chief, F-35 Full Scale Static Test John Bradley, CTOL Variant Chief, F-35 Full Scale Static Test Keith Jackson, Test Coordinator, F-35 Full Scale Component Tests 2
Tri-Variant Joint Strike Fighter (JSF) Conventional Take- Off and Landing Short Take- Off and Vertical Landing Carrier Variant F-35A CTOL Span........................ 35 ft / 10.67 m Length..................... 51.4 ft / 15.67 m Wing area.................. 460 ft 2 / 42.7 m 2 Combat radius (internal fuel) >590 n.mi / 1,093 km Range (internal fuel)..... ~1,200 n.mi / 2,222 km F-35B STOVL Span....................... 35 ft / 10.67 m Length.................... 51.2 ft / 15.61 m Wing area.................. 460 ft 2 / 42.7 m 2 Combat radius (internal fuel) >450 n.mi / 833 km Range (internal fuel)...... ~900 n.mi / 1,667 km F-35C CV Span........................ 43 ft / 13.11 m Length..................... 51.4 ft / 15.67 m Wing area.................. 668 ft 2 / 62.06 m 2 Combat radius (internal fuel) >600 n.mi / 1,111 km Range (internal fuel)..... >1,200 n.mi / 2,222 km 3
F-35 Full Scale Tests Locations & Fixture Sharing Lockheed Martin Fort Worth, US British Aerospace Systems Brough, UK STOVL Static STOVL Durability CTOL Static CV Durability CV Static CTOL Durability Vought Aircraft Industries, Grand Prairie TX, US CV Drop 4
Requirements Comparison of AG-1 and BG-1 AG-1 (CTOL) BG-1 (STOVL) 159 Load Rams 164 3335 Strain and Deflection Channels 3711 163 Test Runs 211 5
Full Airframe Test Conditions for AG-1 and BG-1 AG-1 (CTOL) No. Maneuver Description No. Maneuver Description BG-1 (STOVL) 1 9g Abrupt Pull-up, 0.60/SL 1-3g Right Trim WB Door Opening Event, 1.05/7K 2 1g Yaw Gust, 1.05/SL 2 5.6g Right Rolling Pull-Out, Full Command/Rate, 1.05/20K 3 4g 360 Deg Roll to Right, 1.50/40K 3-1g 180 Deg Roll To Left, 1.05/7K 4 1g 360 Deg Roll to Left, 1.05/SL 4-1g 180 Deg Roll To Right, 1.05/7K 5 7.2g 360 Deg Roll to Right, 0.60/5K 5 7g Abrupt Pull-Up, 1.05/7K 6-3g Push Over, 0.95/SL 6-3g Push-Over, 0.90/SL 7 7g Wind-up Turn, 1.20/20K 7 7g Wind-Up-Turn, WB Door Opening Event, 0.90/SL 8-3g Push Over, WB Door Opening Event, 0.90/SL 8-3g Push-Over, WB Door Opening Event, 0.95/SL 9 9g Wind-up Turn, 0.95/SL 9 7g Wind-Up-Turn, WB Door Opening Event, 0.95/10K 10 1g 180 Deg Roll to Left, 1.50/22K 10 7g Abrupt Pull-Up, 0.60/10K 11 9g Abrupt Pull-up, 0.80/SL 11 0g 180 Deg Roll To Left, 0.80/SL 12 9g Wind-up Turn, 0.90/SL 12 0g 180 Deg Roll To Right, 0.80/SL 13-3g Push-over, 1.05/SL 13 1g Steady Sideslip To Left, 0.95/SL 14 9g Wind-up Turn, Hammer Shock Event, 1.05/SL 14 4g Rolling Pull-Out To Left, 1.50/28K 15 2g Rolling Pull-out to Right, 0.90/SL 15 2g Rolling Pull-Out To Left, 1.50/40K 16 0g 180 Deg Roll to Right, 0.95/SL 16 0g 180 Deg Roll To Right, 0.95/5K 17 1g 360 Deg Roll to Left, 0.95/5K 17 1g Steady Sideslip To Right, 1.05/15K 18 1g 360 Deg Roll to Right, 0.95/5K 18 4.8g Abrupt Pull-Up, 0.60/SL 19 5g 360 Deg Roll to Right, 0.80/SL 19 2g Rolling Pull-Out To Right, 0.95/SL 20 0g 180 Deg Roll to Left, 0.95/SL 20 4.5g Rolling Pull-Out To Left, 1.05/12K 21 2g 360 Deg Roll to Left, 1.05/12K 21 2g Rolling Pull-Out To Right, 0.90/SL 22-1g 180 Deg Roll to Left, 1.50/22K 22 3.8g Rolling Pull-Out To Left, 0.90/SL 23 1g Steady State Sideslip, 1.05/SL 23 Brake Left 24 4g Rolling Pull-out to Left, 1.05/SL 24 Tiedown - Heavy Weather 25 9g Symmetric Trim with WBD Open, 1.05/SL 25 Tiedown - Moderate Weather 26 9g Symmetric Trim with WBD Open, 0.95/SL 26 0.5g Selective Stores Jettison, 0.95/SL 27 9g Abrupt Pull-up with Buffet, 0.60/5K 27 7g Wind-Up Turn, WB Door Opening Event, 1.05/7K 28 5.5g 360 Deg Roll to Right, 1.05/SL 28 Hybrid: 7g Right Pull-up, 0.60/15K + 7g Wind-Up Turn, Hammer Shock Event 29 Hybrid: Towing, Right Turn + 0g 180 Deg Roll, 1.50/22K 29 Hybrid: 7g Wind-Up-Turn, WB Door Opening Event + 7g Wind-Up Turn 30 Hybrid: Taxi + 9g Pull-up/Push-over 0.60/SL 30 Hybrid: 1g 180 Deg Roll To Right + 1g Steady Sideslip to Right, 1.05/7K 31 9g Wind-up Turn, 0.95/SL STRAIN SURVEY 32 9g Abrupt Pull-up, 0.80/SL STRAIN SURVEY 6
STOVL Local Static Tests Cockpit Pressure Nose Landing Gear (NLG) Doors Nose Landing Gear (NLG) Backup Structure Refuel Probe Back-up Structure and Mechanism Lift Fan Exhaust Vane Box Outboard Weapons Bay Door (WBD) Inboard WBD and Cradle Boarding Ladder Door Fwd Fuse Side Skin Lift Fan Mounts Lift Fan Inlet Aux Air Inlet Hoist Engine Mount-Fwd Upper * Weapons Bay Sta 8 Hardpoints Fwd Main Landing Gear (MLG) Door MLG Inboard Trunnion Support Structure MLG Drag Brace Interface at FS450 MLG Outboard Trunnion Support Structure RCN Door Attach Structure * Wing-Pylon Sta 9 * Wing-Pylon Sta 10 * Wing-Pylon Sta 11 Completed Tests Fuel Tank Pressure Jacking * Performed airframe capability testing at in support of future weapon systems * Sta 6 Engine Thrust Mount 102 Local Test Runs 50 Local-Global Test Runs 7
CTOL Local Static Tests Wing Pylon Sta 9 Wing Pylon Sta 10 Wing Pylon Sta 11 Airframe capability testing planned in support of future weapon systems Vertical Tail Shear Fitting Hoist Engine Mount, Fwd Upper In-Flight Refuel Receptacle Backup Structure Cockpit Pressure Vertical Tail Hinge 3 Weapons Bay Sta 8 Hardpoints Airframe capability testing planned in support of future weapon systems MLG Uplock Backup Structure Inboard WBD, Sta 5, and Backup Structure MLG Backup Structure Engine Thrust Mount Arresting Gear Backup Structure Engine Mount, Fwd Side Jacking Fuel Tank Pressure Outboard WBD and Backup Structure 53 Local Test Runs Completed Tests 43 Local-Global Test Runs 8
Non-Technical Information AG-1 s Journey Across the Atlantic Transport from FW to Houston, TX Reported UFO sighting in Dallas, TX Secured in hull of shipping vessel Ocean journey took 18 days Transfer to barge for trip down Humber River 9
AG-1 Arrival at BAES April 25, 2009 Largest crane in UK used to lift AG-1 from barge. Arrival at Brough at 6:30 AM Maneuvering around BAES site Delivered at BAES test facility 10
Achieved Unprecedented Test Rates 250 200 Legacy A Legacy C Legacy E - Less unit loads Legacy F - Less calibrations Legacy T F-35 BG-1 Orig Plan F-35 BG-1 Current Plan F-35 BG-1 Execution 150 Test Runs 100 50 0 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 Calendar Days Days from from Test Start Test Start 11
Still Improving Test Runs 225 200 175 150 125 100 75 50 25 0 Jan-08 Feb-08 Mar-08 Actual Baseline Plan Flight Clearance Dates Expanded Testing? Planned Delivery 01/11/08? Actual Delivery 05/28/08 Test Completion 11/12/09 Phase 0 NLG Door Apr-08 May-08 Phase 1 Jun-08 First Flight Jul-08 STOVL Static Test (BG-1) Phases 2 & 3 Aug-08 Sep-08 STOVL Doors Oct-08 Nov-08 Phase 4 Dec-08 Phase 5 Jan-09 Feb-09 Mar-09 AG-1 Schedule Revised Based Upon BG-1 Test Performance Testing Continues to Outpace Flight Test Need Dates Current Pace Indicates Test Completion 6 Months Ahead of Baseline Apr-09 Phases 6, 7 & 8 May-09 80%/64% Jun-09 Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 100%/80% Need Date 5/26/2011 Dec-09 Jan-10 Feb-10 Mar-10 Apr-10 May-10 Test Runs BG-1 Static Tests Remained Well Ahead of Flight Test Need Dates Completed Test Program Despite Delayed Test Start and Addition of 27 Expanded Capability Tests 225 200 175 150 125 100 75 50 25 0 Nov-08 Phase 0 Dec-08 Dec-08 Jan-09 Feb-09 Jan-09 Mar-09 Mar-09 Apr-09 May-09 Apr-09 CTOL Static Test (AG-1) AG-1 Actual AG-1 Baseline Plan AG-1 Revised Plan (BG-1 Rate Incorp) AG-1 Extended Tests Flight Clearance Dates AG-1 Extended Testing Phase 1 Transport May-09 Jun-09 Phase 3 Jun-09 Jul-09 Phase 2 Aug-09 Jul-09 Phase 4 Aug-09 Sep-09 Sep-09 Oct-09 Nov-09 Oct-09 Dec-09 Nov-09 First Flight Dec-09 Jan-10 Feb-10 Jan-10 Mar-10 Feb-10 Projected Test Completion Mar-10 Apr-10 80%/64% May-10 Apr-10 May-10 Jun-10 Jun-10 Jul-10 Aug-10 Jul-10 Sep-10 Aug-10 Sep-10 Oct-10 Nov-10 Oct-10 100%/80% Need date 01/26/201 1 Dec-10 Nov-10 Dec-10 Jan-11 Feb-11 Jan-11 Mar-11 Feb-11 12
Test Rate Enablers Well Organized and Documented Planning Efficiency of Test Fixture Required Minimal Set-up Changes Between Test Conditions Robustness in Data Acquisition System Eliminated Channel Swap-out Efficiency of Team Protocol for Test Preparation Tasks Flexibility to Adjust Test Sequence to Maximize Efficiency Inherent Structural Integrity of Test Article TCN 29966, Test Values vs. Strain Predictions at 150% DLL RHS Wingbox Rib - Vesette Test Value (micro strain). 12500 Reversal Above Prediction 7500 2500 Below Prediction -12500-7500 -2500 2500 7500 12500-2500 Below Prediction -7500 Measured strain @ 150% DLL Non-Linear FEM Prediction Above Prediction -12500 Strain Prediction (micro strain) Reversal Linear FEM Prediction Test Data Agrees Very Well With Predictions Full Correlation in Work 13
Test Findings STOVL Very Few Issues and No Real Structural Failures CTOL Only Test Finding Thus Far is Slight Damage to Rudder Blade Seals STOVL (BG-1) CTOL (AG-1) Cracks at Fwd Chevron Root on LHS and RHS Lift Fan Exhaust Doors Interference Between Inboard Weapon Bay Door and Fuselage at 50% DLL Aft Downlock Mechanism on LHS Auxiliary Air Intake (AAI) Door failed at 129% DLL of applied test loads TEF and Rudder Blade Seal damage during Control Proof of Operations Test Rudder Blade Seal damage during Control Proof of Operations Test Cracks occurred above 115% DLL; DUL test completed without failure Required door and fuselage trim Mechanism Redesigned - added door lock stops; replaced LHS AAI Door and Aft Downlock Mechanism; successfully completed DUL test without rupture Presented on following charts Presented on following charts 14
Blade Seals Damaged During BG-1 Control Proof of Operations Tests Trailing Edge Flap and Rudder Blade Seals Slipped off of Bullnose at Full Deployment and Were Damaged as Control Surface Returned to Faired Position Defined Trim for All Development Aircraft and Modified Seal Design for Production Aircraft RHS Vertical Tail and Rudder View Lkg Inbd & Fwd Bullnose Seal Cut-out for Rudder Hinge Bullnose Seal Blade Seal LHS Aft Door Hinge 15
AG-1 Control Proof of Operations Tests Incorporated Lessons Learned From BG-1 CPO Test Results Surface Deployment Angle Consistent with Expected Load Levels Bullnose Seals Trimmed Based Upon BG-1 Finding No Damage to Wingbox Control Surface Blade Seals Minor Damage to Rudder Blade Seals Study On-going View Looking Inboard and Down at RHS VT IML of Outboard Middle Blade Seal at Bullnose cut-out for RH VT Hinge 3 Middle Blade Seal Aft Lower Blade Seal Down Aft Surface delamination on IML of middle blade seal Chafing of upper edge on outboard lower blade seal 16
CTOL Horizontal Tail Component Test Testing Performed at BAES Test Facility in Brough, UK Seven Test Cases to 115% and 150% DLL 197 Channels of Strain/Deflection Data and 12 Load Rams Reduced Test Schedule by 40% and Completed Testing Approximately One Month Early Successfully Completed Maximum Up and Down Bending Tests to 200% Limit Load in May 2009 No Structural Failures Test Level Limited by Fixture Capability Note: STOVL Horizontal Tail Testing Completed in 2008 Ahead of Schedule Tested Specimen to Failure; Maximum Load Level Achieved 224% DLL Inbd Aft View of Upper Surface HT installed in fixture with upper surface facing downward. 17
Test Finding for CTOL Horizontal Tail Test Bearing Installed in Inboard Test Fixture Lug Migrated During 115% Limit Load Side Load Test Resulted in Modification to Bearing Design and Retention Method for Production Aircraft Installed Retainer Ring Upon Completion of 200% Limit Load Test and Successfully Completed 150% Limit Side Load Test Inbd Aft View Looking Up Fixture Inboard Lug Exposed Bearing Outer Race Horizontal Tail Hinge Spar Lower Cap 18
BG-1 Testing Supports Flight Test Envelope Expansion BG-1 Phase 0 1 st Flt & Out-of-fixture Conditions NLG Door Open & VAVBN Vane Loads Cockpit & Fuel Tank Pressure Tests to DUL Test Completion Jun 08 Clearance Event NLG Test Supports BF-1 Initial Flight Clearance BF-1 1st Flight BG-1 Phase 1 Initial STOVL Mode & Air Refuel LFI, LFE, AAI Doors Air Refuel Probe Backup Structure, Lift Fan Mounts BG-1 Phase 2 Doors / 115 & 150% DLL NLG Doors & FF Side Skin Hammershock BG-1 Phase 3 CPO and Doors/115 & 150% DLL Control Proof of Operations Tests AAI Doors w/ Hammershock & Weapons Bay Doors BG-1 Phase 4 Initial Full AF Conditions to 115% DLL 7 FAF Test Conditions (Includes Engine Hammershock) BG-1 Phase 5 Full AF Conditions to 150% DLL Wing Up/Down Bending, Max/Min Fuselage Bending 7g Maneuver w/ Hammershock Pressure BG-1 Phase 6 Local Tests #1 Fwd MLG Door & RCN Door & Backup Sep 08 Oct 09 Dec 09 Feb 09 May 09 Jun 09 CTOL Flight w/ open STOVL Doors Hover Pit Entry Limited STOVL Mode Clearance Air Refuel 80/64% Allowable Load Envelope Flight Clearance Support 100% Allowable Load Envelope Pursuit for Loads Aircraft BG-1 Phase 7 Local & Global/Local Tests MLG Backup, Taxi & Tow, Wing Hardpoints* & Ladder Door Weapons Bay Hardpoints* & Sta 5/7 ASRAAM Hangfire Oct 09 Weapons Separation BG-1 Phase 8 Final Tests Engine & Lift Fan Mounts, Jacking, Hoist & Tie-down, Sta 6* Nov 09 Ship Suitability & Final Certification * Includes Extended Capability Tests 19
AG-1 Test Phases & Flight Test Support Test Completion Clearance Event AF-1 1st Flight AG-1 Phase 0 1 st Flight Cockpit/Canopy and Fuel Tank Pressure Tests to DUL AG-1 Phase 1 In-Flight Opening of WBD WBD Open and Closed Tests to 150% DLL AG-1 Phase 2 In-Flight Refuel and CPoO In-Flight Refuel Receptacle Tests to DUL Control Proof of Operations Tests AG-1 Phase 3 Initial Full Airframe Conditions to 115% DLL 6 FAF Test Conditions (Including Hammershock) AG-1 Phase 4 Full Airframe Conditions to 150% DLL Wing Up/Down Bending, Fuselage Up/Down Bending Hammershock w/ 9g Maneuver Control Surface Max Hinge Moments AG-1 Phase 5 Local and Local/Global Tests to 150% DLL NLG Backup, MLG Trunnions, Jacking, Hoisting Engine Mounts Backup, Arrestor Gear Backup Weapons Stations Expanded Capability Feb 09 Aug 09 Oct 09 Oct 09 Dec 09 May 10 Supports Initial Flight Clearance In-Flight Opening Door Clearance Aerial Refueling 80/64% Allowable Load Envelope Flight Clearance 100/80% Allowable Load Envelope Flight Clearance Support 100/80% ALE Flight Clearance Weapons Separation Arresting Gear 100% Max Take-Off Gross Weight 46% of Testing Completed to Date 20
Summary Test Progress Unprecedented BG-1 Completed Per Baseline Schedule Despite Delayed Test Start and Limited Number of Test Anomalies/Findings Schedule Savings Allowed Incorporation of Expanded Capability Tests Without Impact to Flight Clearance Support CTOL and STOVL Horizontal Tail Component Tests Completed One Month Ahead of Schedule; Reduction of About 40% Demonstrated Strength Capacity Above 150% Limit Load for CTOL and STOVL Horizontal Tails and STOVL Weapons Hardpoints Lessons Learned Implemented for Remaining Static and Durability Test Articles CTOL Test In-Progress and Keeping Pace with BG-1 Performance AG-1 Test Started per Baseline and Expected to Finish 6 Months Earlier Than Planned What s Next? CV Drop Test to Begin in Jan. 2009 First Full Scale Durability Test (CTOL) to Begin in Feb. 2010 CV Full Scale Static Test Scheduled to Begin Sept. 2010 Static Test Results Verifying Outstanding Structural Integrity of F-35 Lightning II Design 21
Questions? 22