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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

J6924_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

Summary

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

J6924_F135_Propulsion_2012 - 2

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

F-35 AA-1 Flight Test

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 BF-1 Flight Test
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037

J6924_F135_Propulsion_2012 - 3

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

ISR Achieved
As of 10/15/12

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

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

J6924_F135_Propulsion_2012 - 4

F135 Propulsion System Characteristics


40K Thrust Class

Split Cases and


Stators

6 Stage
Compressor (HPC)

Nozzle

3 Stage Fan

3rd Stage
Turbine Blade

1st Stage Hollow IBR

Intermediate Case

Advanced Prognostics Health


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

J6924_F135_Propulsion_2012 - 5

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

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

J6924_F135_Propulsion_2012 - 6

Inlet Compatibility/Aeromechanical Testing


Risk Reduction Testing Verifies Compatibility
SI-05 Test Data 04 Dec 2003 Run47_Config_CTOL_BL_Wc357

Cruise
Bellmouth

Sea Level
Static Inlet

ITAR Technical Data


SI-05 Test Data:
Run47 Config CTOL BL Wc357

PT2/PT0
1.00
0.98
0.96
0.94
0.92
0.90
0.88
0.86
0.84
0.82
0.80

Wc2
Pt2Pt0
D2
DPCOPA
DPRPMX

=
=
=
=
=

357.484
0.96214
0.12071
0.02613
-0.02665

Lockheed Martin Aeronautics Company

FS 424.5
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. Public Release JSF12-1037

J6924_F135_Propulsion_2012 - 7

Main Engine Integration


Fan Duct Heat Exchangers

IPP System
Plumbing

Fan Duct
Heat Exchanger

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

J6924_F135_Propulsion_2012 - 8

F135 Propulsion System Characteristics


40K Thrust Class / Variable Cycle Engine
Modulated Exhaust Cooling
Fan Duct Blocker
2 Stage LPT

2 Stage
Lift Fan

Evolved F119 Core

Lift Fan Clutch


& Driveshaft

3 Stage Fan
F119 Based
Controls & Externals

Variable Area
Vane Box Nozzle

Roll Control Ducts and


Nozzles

3 Bearing Swivel
Module

Advanced Prognostics Health


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

J6924_F135_Propulsion_2012 - 9

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

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

J6924_F135_Propulsion_2012 - 10

Integrated Flight & Propulsion Control


Vehicle Management Computers Commands to Propulsion

Air Vehicle
Management
Computers

Thrust
Split

Pitch 3BSD

Thrust

Roll
Moment

Pitch Vane Box

YAW 3BSD

Lift System
FADECs

Main Engine
FADECs

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

PHAM

J6924_F135_Propulsion_2012 - 11

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

J6924_F135_Propulsion_2012 - 12

F135 SDD Program Review


Lift Fan Performance Recovery Verified for Flight Test

Block 3

Power Margin to
Achieve Thrust

Block 1/2

Block 1

Block 2
IFR

Block 3
FFR

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

J6924_F135_Propulsion_2012 - 13

Lift Fan Inlet Flow Angularity


Pre-Flight Test Configuration

Aero
Interface
Plane

First Rotor
Inlet Plane

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

J6924_F135_Propulsion_2012 - 14

Flow Angularity Improvements


Flight Test Fixes in Place

Door Angle

Inlet Modification

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

J6924_F135_Propulsion_2012 - 15

STOVL FFR Lift Fan Stability


Positive Stall Margin Demonstrated with Fixes

F35B Lift Fan


Inlet Test

C-14 Test Stand


Crosswind Set Up

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

J6924_F135_Propulsion_2012 - 16

STOVL Vane Box Integration


Vane Box Sidewalls Are Aircraft Structure
BF1-351-001sml

Releasable per JSF05-2781

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

J6924_F135_Propulsion_2012 - 17

Qualitative Assessment Weight Reduction


Lightweight Roll Post Duct

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

J6924_F135_Propulsion_2012 - 18