Sunday, 7 September 2014

Contenders make final pitches for Polish helicopter deal

Contenders make final pitches for Polish helicopter deal

WARSAW
Source: Flightglobal.com
14:39 4 Sep 2014
All three contenders for Poland’s ongoing multirole helicopter procurement used this week’s MSPO defence show to mount a final push for the 70-unit deal, ahead of an end-September deadline for final submissions.
Warsaw is expected to select a preferred bidder by year-end ahead of a series of flight tests for the tri-service requirement, as it looks to retire its ageing fleet of mainly Russian types.
Although the simmering conflict in nearby Ukraine is causing alarm in Poland, defence minister Tomasz Siemoniak told reporters that the award of the contract was not being accelerated.
He describes 2014 as a “decisive year for the modernisation” of the country’s armed forces. “Everything is on track and is according to schedule. Owing to the [Ukraine] crisis we are strongly motivated to observe our deadlines,” he says.
The shortlist for the contest comprises the AgustaWestland AW149, Airbus Helicopters EC725 Caracal and Sikorsky S-70i Black Hawk, all three of which were on display outside MSPO’s exhibition hall in Kielce.
Although the bidders were largely unwilling to discuss the precise detail of Poland’s request for proposals, a large degree of local production and technology transfer is required.
asset image
Dominic Perry/Flightglobal
This could give AgustaWestland and Sikorsky an edge, due to their respective Polish subsidiaries PZL Swidnik and PZL Mielec. However, Airbus Helicopters is also promising substantial investment in the country, and suggests that it could become the “fifth pillar” of the Airbus Group, alongside France, Germany, Spain and the UK.
Although some of that investment will happen anyway, says Airbus Helicopters chief executive Guillaume Faury, winning the multirole contest – and a looming procurement of attack helicopters – would allow the manufacturer to accelerate its plans for the country.
“The level of investment I have in mind cannot be made in two to three years if we don’t have one or two big programmes to invest in,” he says. He estimates growth in the country would be around five times slower without the “catalyst” of the contract wins.
Faury is confident that the EC725 is the only one of the three helicopters on offer than can meet Poland’s wide-ranging requirements.
“We believe we are the only OEM to be able to offer a unique common platform for the different mission requirements that have been requested. The Caracal is today already available with the vast majority of systems, equipment and mission capabilities requested by Poland,” he says.
The company is already working through a similar tri-service contract for the EC725 in Brazil, he points out.
asset image
Dominic Perry/Flightglobal
Inevitably, AgustaWestland and PZL Swidnik see things a little differently. If Poland selects the AW149 it would be the first customer for the 8t rotorcraft, which only received military certification in July this year.
Danielle Romiti, AgustaWestland chief executive, says since its acquisition of PZL Swidnik in 2010, investments have transformed the company into the Anglo-Italian airframer’s “Polish industrial pillar”.
And Mieczyslaw Majewski, president of PZL Swidnik, is scathing of Airbus Helicopters’ proposals, noting that he is “not against the [PZL] Mielec people”.
He says: “Airbus Helicopters can say they will put jobs here, but how many? It will be 100 or 200 versus the 3,500 we employ. What does the government say to those people if they choose another company?”
Although PZL Swidnik has a long history of supplying helicopters for the Polish armed forces – most recently its W-3 Sokol and SW-4 Puszczyk – the very newness of the AW149 may count against it. Indeed, the company has sought, and been granted, an extension to develop the anti-submarine warfare (ASW) variant of the rotorcraft offered to the Polish navy, says project manager Zenon Witkowski.
“We succeeded in convincing the customer that the process of installing dedicated [mission] equipment on such a helicopter requires more time,” he says.
asset image
Dominic Perry/Flightglobal
Sikorsky, meanwhile, feels its offer of the S-70i – the international variant of the Black Hawk – is the most compelling. The helicopter is already assembled for the global market at PZL Mielec, with deliveries now “into the dozens”, says Bob Kokorda, vice-president defense systems and services at Sikorsky.
The S-70i is direct equivalent to the US-built UH-60M, says Kokorda, which he describes as “great proven product in demand by a lot of different countries”.
Although Polish analysts believe the Black Hawk may have the edge over its rivals thanks to support from the nation’s military, Sikorsky’s offer is not a simple one.
Poland’s requirement calls for one platform to be operated by all three services, and for those helicopters to be assembled locally.
However, to satisfy the ASW role, the US airframer can only pitch the S-70B, “a legacy version of the [SH-60] Seahawk” which will also not be built in Poland “because the quantities won’t be high enough”, says Kokorda. But he notes that “in the guts” of the two aircraft there is considerable commonality, which would reduce the “logistics and long-term life cycle costs”.

Two Orbiters, One Comet Arriving At Mars Soon


Scientists and spacecraft controllers in Denver, Bangalore and many points in between are preparing for a rush of activity at the planet Mars, where two new spacecraft designed to study its atmosphere will arrive later this month, followed shortly thereafter by a rare Oort Cloud comet.
If all goes as planned, the two orbiters and the comet Siding Spring should add volumes to human knowledge about where most of the red planet’s water went, and perhaps about how it got there in the beginning.
NASA’s only Mars mission in the current launch window—the $671 million Mars Atmosphere and Volatile Evolution (Maven)—is expressly designed to investigate whether the water that once ran on the surface escaped into space. India’s Mangalyaan Mars Orbiter Mission (MOM)—its first flight to the red planet—can address some of the same questions (see page 42).
And Siding Spring’s flyby of Mars will be the equivalent of a free trip to the Oort Cloud, the mysterious realm of icy planetesimals 5 trillion miles from the Sun, which might have showered the inner Solar System with primordial water and perhaps even the building blocks of life.
Mars being Mars, there is also a risk of spacecraft failure, compounded by the danger posed by high-speed comet debris. At 34 mi./sec.—the closing speed as Siding Spring crosses the orbit of Mars—even a dust mote could damage or destroy a delicate instrument or critical piece of spacecraft hardware. So Maven and MOM will interrupt their planned checkout periods to hunker down as the comet passes only 80,000 mi. from the planet they, hopefully, will be orbiting.

Recent ground observations of Siding Spring’s path and coma suggest the comet will not pose as big a threat as originally feared, and mission scientists on all of the spacecraft at Mars are planning to take maximum advantage of the opportunity for observation that it represents (see page 42). But the guiding principle of spacecraft operation remains “safety first,” particularly after the programs have spent 10 months and plenty of money getting to their objective.
“Safety and health of the spacecraft and instruments absolutely come first,” says Bruce Jakosky, a planetary scientist at the University of Colorado’s Laboratory for Atmospheric and Space Physics (LASP) who is the Maven principal investigator. “There is no question about that. So if there is something that happens in the run-up to the comet, we’re going to make sure we’re safe. We want to survive and do our mission.”
Siding Spring will pass closest to Mars on Oct. 19. Maven will arrive there on Sept. 21, followed by MOM on Sept. 24. For Jakosky, who has managed the Scout-class mission from the beginning, the first order of business will be ensuring his spacecraft gets safely into orbit. Maven controllers have been in a 60-day “command moratorium” since the end of July that was designed into the Mars orbit-insertion (MOI) sequence to circumvent any action that might go wrong and cause problems.
“We just finished our last operational readiness test for orbit insertion,” he said Aug. 11. “It’s basically a rehearsal, and the team went through everything we’re going to be doing on MOI day to make sure we knew the procedures, knew what we had to do and were prepared. So we’re doing everything we can to be ready to ensure a success.”
With a 12.5-min. one-way speed-of-light delay in radio signals between the Maven spacecraft and its controllers at the Lockheed Martin facility near Denver, where it was built, the actual MOI will be completely autonomous.
Nominally, the MOI is a three-day sequence leading up to a 34-min. burn beginning a little before 10 p.m. EDT on the 21st—a Sunday—that will slow the spacecraft enough to enter orbit. But there is plenty of redundancy built into the flight-computer programming in case something goes wrong.
“If it goes correctly we go into orbit; if it doesn’t, we don’t,” says Jakosky. “In order to ensure it goes correctly, we have engine-out capability, so that if we lose one of the six thrusters we’re using, we can still get into orbit on five of them. We also have a computer-reboot capability, so if something happens during the burn, we designed it so that we could have a 13.5-min. outage, and that’s enough time for the computer to reboot, decide it still has a problem, swap sides, realize it’s supposed to be in the middle of its burn, reacquire attitude, resume the burn and get into orbit.”
Maven navigators are working with NASA’s Deep Space Network to track the spacecraft very precisely, and may decide to conduct one more trajectory correction maneuver (TCM) nine days before MOI. Jakosky says a course-correction burn planned for the end of July was canceled because it was not needed. The aim-point is a 100-by-200-km box in the sky, and so far Maven is inside the box if not headed straight for the bull’s-eye.
“Whether we do [the final TCM] will depend on what the tracking shows our trajectory to be, relative to our target point,” he says.
Mindful of the September 1999 loss of the Mars Climate Orbiter, the Maven MOI sequence also has provisions for an emergency orbit-raising maneuver at 24 hr. and then again at
6 hr. before insertion. The earlier spacecraft plunged too deeply into the atmosphere on arrival at the planet and disintegrated because of a mix-up between English and metric units of measurement (AW&ST Oct. 4, 1999, p. 40).

“The hooks are in there so we can do it if we need it,” Jakosky says. “We don’t expect to need it.”
Five orbital-adjustment maneuvers are planned to put Maven into its 6,200 X 150-km (3,850 X 93-mi.) science orbit. Instrument checkout will run until the end of October, when the spacecraft is scheduled to begin a year-long data-collection session designed to help scientists understand the interactions between the upper Martian atmosphere, the solar wind and other elements of the space environment.
A primary objective is to test the theory that the liquid water that once flowed on the planet’s surface was lost when the solar wind and ultraviolet radiation in sunlight stripped away the heavy, wet primordial atmosphere (AW&ST Aug. 26, 2013, p. 40).
The instrument suite designed for the job consists of the Solar Wind Electron Analyzer (SWEA) to measure solar winds and electrons in the Martian ionosphere; the Solar Wind Ion Analyzer (SWIA), to measure solar wind and ion density and velocity in the planet’s magnetosheath; the Suprathermal and Thermal Ion Composition (Static) instrument, which will measure ions in the atmosphere of Mars, including moderate energy escaping ions; and the Solar Energetic Particle (SEP) instrument to measure the impact of the solar wind on the planet’s upper atmosphere.
Also on board are the Langmuir Probe and Waves (LPW) instrument, which includes an extreme ultraviolet sensor, to measure properties of the ionosphere, wave-heating in the upper atmosphere and extreme ultraviolet inputs into the atmosphere from the Sun. Rounding out the package is a magnetometer, which will measure interplanetary solar wind and magnetic fields in the ionosphere; a Neutral Gas and Ion Mass Spectrometer to measure the composition and isotopes of ions and thermal neutrals in the atmosphere; and an Imaging Ultraviolet Spectrograph for global remote sensing of the upper atmosphere and ionosphere at Mars.
Maven scientists designed the instruments to work across the entire range of the spacecraft’s elliptical orbit, making in-situ measurements of the upper atmosphere at the lowest altitudes and then backing off for remote-sensing measurements that will allow researchers to extrapolate the low-altitude data out to global processes.
The arrival of a comet from the distant Oort Cloud, on a multimillion-year orbit that will reach its closest approach to the Sun five days after it passes Mars, is pure serendipity for comet experts. While the Maven team plans to switch off instruments that could be damaged if they are hit with debris while they are active, and to turn the spacecraft into the orientation that affords the greatest protection from any oncoming dust from Siding Spring, controllers also will interrupt instrument checkout and calibration to make observations of the event.
Still, safety comes first so at the point of greatest danger from the comet, plans call for Maven—and the other orbiters circling Mars that day—to be on the other side of the planet. Once its early orbital parameters are established, Jakosky says, controllers will adjust the orbit to minimize the danger by using Mars as a shield.
“We can get about 20 min. of hiding behind the planet, and the time of peak risk of the dust is thought to be between 30 and 60 min., so that is a significant risk reduction right there,” he says.
Jakosky’s counterparts at the Indian Space Research Organization are facing the same problems, and are considering the steps they can take to prepare the MOM spacecraft for the encounter. They are also working with Jakosky and his colleagues on possibly coordinating some scientific observations while the two orbiters are measuring the upper atmosphere.
“We’re going to meet with some of the Indian investigators before our science mission starts to talk about what’s possible,” Jakosky says. “There is a strong desire to collaborate, and I don’t know where it’s going to head.”
Of particular interest to the Maven scientists are the Lyman-alpha photometer and mass spectrometer on MOM. Maven, too, carries a mass spectrometer to measure chemical composition and coordinated observations at the same time from different locations which “allow you to separate out temporal and spatial variability,” Jakosky says.
However, because the Maven and MOM teams are just beginning detailed discussions, the most likely outcome will be joint data analysis at the end of the science missions, he says. Maven scientists have also been working with scientists on the European Space Agency’s Mars Express mission, which carries several instruments that can complement the Maven suite, so coordinated observations with that team are more likely. Joint data analysis with the Europeans is also in the cards, Jakosky says.
With the five-day delay in commissioning caused by the comet encounter, Maven probably will not be able to start its science mission until the second week in November. Jakosky says the annual American Geophysical Union meeting Dec. 15-19 in San Francisco is well timed for release of data on the comet encounter two months earlier.
“We think it is going to take about three months for us to come out with real, preliminary results about what Maven is telling us about Mars,” Jakosky says of the primary mission objectives. “Before that, we’re going to do everything we can to get data out and show people the types of things we’re measuring; but in terms of grand pronouncements of what it all means, at least [for the] preliminary pronouncements, we’re thinking about mid-to-late winter.” 

Two Orbiters, One Comet Arriving At Mars Soon

A version of this article appears in the September 8 issue of Aviation Week & Space Technology.
Scientists and spacecraft controllers in Denver, Bangalore and many points in between are preparing for a rush of activity at the planet Mars, where two new spacecraft designed to study its atmosphere will arrive later this month, followed shortly thereafter by a rare Oort Cloud comet.
If all goes as planned, the two orbiters and the comet Siding Spring should add volumes to human knowledge about where most of the red planet’s water went, and perhaps about how it got there in the beginning.
NASA’s only Mars mission in the current launch window—the $671 million Mars Atmosphere and Volatile Evolution (Maven)—is expressly designed to investigate whether the water that once ran on the surface escaped into space. India’s Mangalyaan Mars Orbiter Mission (MOM)—its first flight to the red planet—can address some of the same questions (see page 42).
And Siding Spring’s flyby of Mars will be the equivalent of a free trip to the Oort Cloud, the mysterious realm of icy planetesimals 5 trillion miles from the Sun, which might have showered the inner Solar System with primordial water and perhaps even the building blocks of life.
Mars being Mars, there is also a risk of spacecraft failure, compounded by the danger posed by high-speed comet debris. At 34 mi./sec.—the closing speed as Siding Spring crosses the orbit of Mars—even a dust mote could damage or destroy a delicate instrument or critical piece of spacecraft hardware. So Maven and MOM will interrupt their planned checkout periods to hunker down as the comet passes only 80,000 mi. from the planet they, hopefully, will be orbiting.

Recent ground observations of Siding Spring’s path and coma suggest the comet will not pose as big a threat as originally feared, and mission scientists on all of the spacecraft at Mars are planning to take maximum advantage of the opportunity for observation that it represents (see page 42). But the guiding principle of spacecraft operation remains “safety first,” particularly after the programs have spent 10 months and plenty of money getting to their objective.
“Safety and health of the spacecraft and instruments absolutely come first,” says Bruce Jakosky, a planetary scientist at the University of Colorado’s Laboratory for Atmospheric and Space Physics (LASP) who is the Maven principal investigator. “There is no question about that. So if there is something that happens in the run-up to the comet, we’re going to make sure we’re safe. We want to survive and do our mission.”
Siding Spring will pass closest to Mars on Oct. 19. Maven will arrive there on Sept. 21, followed by MOM on Sept. 24. For Jakosky, who has managed the Scout-class mission from the beginning, the first order of business will be ensuring his spacecraft gets safely into orbit. Maven controllers have been in a 60-day “command moratorium” since the end of July that was designed into the Mars orbit-insertion (MOI) sequence to circumvent any action that might go wrong and cause problems.
“We just finished our last operational readiness test for orbit insertion,” he said Aug. 11. “It’s basically a rehearsal, and the team went through everything we’re going to be doing on MOI day to make sure we knew the procedures, knew what we had to do and were prepared. So we’re doing everything we can to be ready to ensure a success.”
With a 12.5-min. one-way speed-of-light delay in radio signals between the Maven spacecraft and its controllers at the Lockheed Martin facility near Denver, where it was built, the actual MOI will be completely autonomous.
Nominally, the MOI is a three-day sequence leading up to a 34-min. burn beginning a little before 10 p.m. EDT on the 21st—a Sunday—that will slow the spacecraft enough to enter orbit. But there is plenty of redundancy built into the flight-computer programming in case something goes wrong.
“If it goes correctly we go into orbit; if it doesn’t, we don’t,” says Jakosky. “In order to ensure it goes correctly, we have engine-out capability, so that if we lose one of the six thrusters we’re using, we can still get into orbit on five of them. We also have a computer-reboot capability, so if something happens during the burn, we designed it so that we could have a 13.5-min. outage, and that’s enough time for the computer to reboot, decide it still has a problem, swap sides, realize it’s supposed to be in the middle of its burn, reacquire attitude, resume the burn and get into orbit.”
Maven navigators are working with NASA’s Deep Space Network to track the spacecraft very precisely, and may decide to conduct one more trajectory correction maneuver (TCM) nine days before MOI. Jakosky says a course-correction burn planned for the end of July was canceled because it was not needed. The aim-point is a 100-by-200-km box in the sky, and so far Maven is inside the box if not headed straight for the bull’s-eye.
“Whether we do [the final TCM] will depend on what the tracking shows our trajectory to be, relative to our target point,” he says.
Mindful of the September 1999 loss of the Mars Climate Orbiter, the Maven MOI sequence also has provisions for an emergency orbit-raising maneuver at 24 hr. and then again at
6 hr. before insertion. The earlier spacecraft plunged too deeply into the atmosphere on arrival at the planet and disintegrated because of a mix-up between English and metric units of measurement (AW&ST Oct. 4, 1999, p. 40).

“The hooks are in there so we can do it if we need it,” Jakosky says. “We don’t expect to need it.”
Five orbital-adjustment maneuvers are planned to put Maven into its 6,200 X 150-km (3,850 X 93-mi.) science orbit. Instrument checkout will run until the end of October, when the spacecraft is scheduled to begin a year-long data-collection session designed to help scientists understand the interactions between the upper Martian atmosphere, the solar wind and other elements of the space environment.
A primary objective is to test the theory that the liquid water that once flowed on the planet’s surface was lost when the solar wind and ultraviolet radiation in sunlight stripped away the heavy, wet primordial atmosphere (AW&ST Aug. 26, 2013, p. 40).
The instrument suite designed for the job consists of the Solar Wind Electron Analyzer (SWEA) to measure solar winds and electrons in the Martian ionosphere; the Solar Wind Ion Analyzer (SWIA), to measure solar wind and ion density and velocity in the planet’s magnetosheath; the Suprathermal and Thermal Ion Composition (Static) instrument, which will measure ions in the atmosphere of Mars, including moderate energy escaping ions; and the Solar Energetic Particle (SEP) instrument to measure the impact of the solar wind on the planet’s upper atmosphere.
Also on board are the Langmuir Probe and Waves (LPW) instrument, which includes an extreme ultraviolet sensor, to measure properties of the ionosphere, wave-heating in the upper atmosphere and extreme ultraviolet inputs into the atmosphere from the Sun. Rounding out the package is a magnetometer, which will measure interplanetary solar wind and magnetic fields in the ionosphere; a Neutral Gas and Ion Mass Spectrometer to measure the composition and isotopes of ions and thermal neutrals in the atmosphere; and an Imaging Ultraviolet Spectrograph for global remote sensing of the upper atmosphere and ionosphere at Mars.
Maven scientists designed the instruments to work across the entire range of the spacecraft’s elliptical orbit, making in-situ measurements of the upper atmosphere at the lowest altitudes and then backing off for remote-sensing measurements that will allow researchers to extrapolate the low-altitude data out to global processes.
The arrival of a comet from the distant Oort Cloud, on a multimillion-year orbit that will reach its closest approach to the Sun five days after it passes Mars, is pure serendipity for comet experts. While the Maven team plans to switch off instruments that could be damaged if they are hit with debris while they are active, and to turn the spacecraft into the orientation that affords the greatest protection from any oncoming dust from Siding Spring, controllers also will interrupt instrument checkout and calibration to make observations of the event.
Still, safety comes first so at the point of greatest danger from the comet, plans call for Maven—and the other orbiters circling Mars that day—to be on the other side of the planet. Once its early orbital parameters are established, Jakosky says, controllers will adjust the orbit to minimize the danger by using Mars as a shield.
“We can get about 20 min. of hiding behind the planet, and the time of peak risk of the dust is thought to be between 30 and 60 min., so that is a significant risk reduction right there,” he says.
Jakosky’s counterparts at the Indian Space Research Organization are facing the same problems, and are considering the steps they can take to prepare the MOM spacecraft for the encounter. They are also working with Jakosky and his colleagues on possibly coordinating some scientific observations while the two orbiters are measuring the upper atmosphere.
“We’re going to meet with some of the Indian investigators before our science mission starts to talk about what’s possible,” Jakosky says. “There is a strong desire to collaborate, and I don’t know where it’s going to head.”
Of particular interest to the Maven scientists are the Lyman-alpha photometer and mass spectrometer on MOM. Maven, too, carries a mass spectrometer to measure chemical composition and coordinated observations at the same time from different locations which “allow you to separate out temporal and spatial variability,” Jakosky says.
However, because the Maven and MOM teams are just beginning detailed discussions, the most likely outcome will be joint data analysis at the end of the science missions, he says. Maven scientists have also been working with scientists on the European Space Agency’s Mars Express mission, which carries several instruments that can complement the Maven suite, so coordinated observations with that team are more likely. Joint data analysis with the Europeans is also in the cards, Jakosky says.
With the five-day delay in commissioning caused by the comet encounter, Maven probably will not be able to start its science mission until the second week in November. Jakosky says the annual American Geophysical Union meeting Dec. 15-19 in San Francisco is well timed for release of data on the comet encounter two months earlier.
“We think it is going to take about three months for us to come out with real, preliminary results about what Maven is telling us about Mars,” Jakosky says of the primary mission objectives. “Before that, we’re going to do everything we can to get data out and show people the types of things we’re measuring; but in terms of grand pronouncements of what it all means, at least [for the] preliminary pronouncements, we’re thinking about mid-to-late winter.” 

1971: DC-10 Pilot Report

Almost exactly 43 years ago this week, Aviation Week subscribers were settling down to enjoy a pilot’s report on the brand new McDonnell Douglas DC-10. The report, penned by Los Angeles bureau chief Robert Ropelewski, was an eye-opener to many who had yet to even see a widebodied jet, let alone fly in one. The era of the ‘jumbo’ jet was by this time less than two years old and the DC-10, which made its first flight at Long Beach, Calif, only a year before ‘Rope’ got his chance to fly one, was the world’s second twin-aisle commercial jet.

The eighth DC-10 was used for Aviation Week’s pilot’s report
The DC-10 was also the first widebody trijet, narrowly beating the competing Lockheed L-1011 TriStar into the air by less than three months in August 1970. It is a fair bet to imagine the interest with which Rope’s report was read by the Lockheed development team working on the TriStar project at Palmdale, a few minutes jet flight away from Long Beach across the San Gabriel Mountains. However, while the Aviation Week pilot report was published within days of the DC-10 entering service with American Airlines and United Airlines, Lockheed’s L-1011 had another eight months to await its debut. So sit back, and enjoy a trip down memory lane as Rope (accompanied by DC-10 chief project pilot and commander of the maiden flight, Cliff Stout) gives you a detailed firsthand account of handling one of the industry’s legendary big jets. 

Read the five page pilot report in the August 30, 1971 issue of Aviation Week & Space Technology

► Aviation Week is approaching its 100th anniversary in 2016. In a series of blogs, our editors highlight editorial content from the magazine's long and rich history, including viewpoints from the industry's most iconic names and stories that have helped change the shape of the industry.

F-35 Fire: In Search Of A Solution

The long-delayed operational debut for the Lockheed Martin F-35 Joint Strike Fighter is at risk of further slippage due to a safety-critical problem with its Pratt & Whitney F135engine for which no single root cause has yet been identified. Senior leaders initially dismissed the fire that damaged F-35 AF-27 at Eglin AFB, Florida, on June 23 as a “one-off incident,” as U.S. Marine Corps commandant Gen. James Amos called it in mid-July. However, Aviation Week has learned that at least five engines have been removed from F-35s after showing signs of premature wear.
The JSF flight-test team has until the end of this month to demonstrate and validate an operational work-around that will allow aircraft in the 21-strong systems development and demonstration (SDD) fleet to fly without the onerous flight restrictions that were imposed after the fire. If that is not done in time, the flight-test schedule that supports initial operational capability (IOC) dates will be in jeopardy, JSF Program Office Director Lt. Gen. Chris Bogdan said Sept. 3.
Meanwhile, Pratt & Whitney is working on redesigned engine components that are intended to prevent the problem from recurring, with the objective of lifting restrictions on the JSF training and tactics development fleet. While the investigation into the fire and related defects is ongoing, Bogdan says that 138 possible causes have been narrowed down to four. Pratt’s proposed design changes are planned on the assumption that further investigation will validate those findings and is intended to address any of the likely root causes.

No firm timelines or cost numbers have been established for redesign, production cut-in or retrofit, but Pentagon acquisition chief Frank Kendall said on Sept. 3: “I am getting more confident. I do not think it will be a huge cost [to fix the engine].”
The JSF program office declines to give details of the damage to AF-27 and says that it has not yet established whether the $205 million fighter (its program acquisition cost, according to the 2013 Selected Acquisition Report) can be restored to flyable condition. For Pratt & Whitney, the risk to the F-35 schedule emerges as another major test program—the Bombardier CSeries airliner—remains on hold due to a problem with a new P&W engine.
Five F135 engines have been pulled from F-35s after failing an inspection regime that was instituted after the June 23 fire. One of the failed engines was removed from F-35 CF-9 (the ninth production F-35C), an aircraft with fewer than 70 flight hours, according to a retired military officer and JSF program veteran. 
Bogdan says the problem was triggered by an event three weeks before the fire, when AF-27 was flown in a benign maneuver, well within the normal envelope, that involved a specific combination of yaw, roll and vertical g loads. The engine “flexed” to an unexpected degree during the 2-sec. maneuver, Bogdan says. This caused a “hard rub” of a fan stage stator against the engine rotor. Frictional heating resulted in estimated material temperatures of 1,900F compared with a design temperature of 1,000F.
This temperature overrun led to -micro-cracking in the neighboring third-stage fan blades, according to Bogdan. The cracks subsequently grew in normal operations and caused the blades to separate from the disk. The engine casing failed to contain one or more of the failed blades, which punctured the adjacent left-and-aft fuel cell. The resultant mixing of jet fuel and superheated air caused the fire.
Signs of stator-to-rotor wear of the kind that is believed to have caused the failure are apparent in images provided to Aviation Week by the former program official. The images are of the engine removed from CF-9, he says. Acquired with a borescope—comprising a camera and flexible fiber-optic probe—they show the inner ends of cantilevered stator blades in the engine’s fan stage, and a knife-edge-type seal on the interstage section of the rotor. Aviation Week asked the JSF Program Office to confirm that the images were from CF‑9, but the office declined to do so.
Investigation has narrowed the root causes down to four key suspects, according to Bogdan. An important factor in the investigation was that at least two of the failed F135s were not high-time engines. AF-27 made its first flight in late April 2013, and CF-9 flew three months later. According to information provided by the former military officer, when CF-9 was grounded in late July, it had accumulated 66.7 engine flight hours and 146.5 engine operating hours since delivery. It had passed two borescope inspections after July 13, with only 1.3 engine flight hours between the previous inspection and the check it failed.

The F135 features seals at the tips of both static and rotating airfoils, with abradable material (“teeth”) on the blades and a knife-edge on the outside of the rotor (for stators) and on the inside of the case (for rotor blades). In a high-performance engine where each stage has a high pressure ratio, close tip sealing is essential to minimize air leakage from the rear of the engine to the front, which reduces performance and efficiency. The knife-edge cuts a channel when the engine is first run, but according to an engine industry source, “knife-edge seals in a fan are designed to take no rub or a very limited rub in normal operation.”
The reason why moderate-g maneuvers would be related to the “hard rub” and overheating has not been definitively identified, but a causal linkage between maneuver loads and clearances inside the engine points to distortion or displacement of engine components. The F135 is the heaviest high-performance fighter engine ever built, weighing 70% more than the P&W F100 and measuring 24% larger in diameter, with consequently larger inertial and gyroscopic forces. The Pegasus engine in the AV-8B Harrier II, with a similar diameter to the F135, suffered from blade rubbing in the event of departures from normal flight, and those engines had to be removed for inspection and overhaul.
Remedial work is proceeding along two tracks. The SDD fleet is conducting flight tests to develop and validate a “burn-in” procedure, comprising a prescribed sequence of maneuvers, which is intended to wear down the abradable materials in the seal gradually, without reaching off-design temperatures. The initial goal is to clear the SDD aircraft for a larger flight envelope in order to keep testing on schedule. It is possible, Bogdan says, that the burn-in procedure will suffice to prevent a recurrence of the problem.

Next month, however, Pratt & Whitney is due to start testing a modified fan section with a deeper abradable rub strip that should mitigate the effects of the sort of blade rub encountered in June, independent of the root cause of the rubbing. “The final fix is intended to meet the full specified life,” the manufacturer says. “We hope to be able to share more details at the conclusion of our tests.”
P&W will pick up the tab for fixes to the 156 engines already delivered. “Pratt and Whitney’s reaction to this problem, in my opinion, has been very, very good,” Bogdan says. “From a technical standpoint, they have put their A team on this. From a business standpoint, they realize this is a problem they need to solve.” Bogdan says the most critical item in meeting the Marine Corps’ IOC date is the need to modify aircraft to IOC standard. 
Under the return-to-flight program that followed the July 3 grounding, borescope inspections were mandated at every three flight hours, maximum speed was limited to Mach 0.9, and aircraft were restricted to -1 g to +3 g. The fleet was also limited to 18-deg. angle of attack and half-stick deflection rolls. Test aircraft are now cleared to Mach 1.6 and 3.2 g, and can fly up to 6 hr. between inspections if engaged in air refueling missions or on transits to ranges for weapons testing. F-35 BF-3, which is instrumented for loads testing, is being used to help clear the flight envelope. Aircraft outside the test force are still subject to the original restrictions.
Neither the program office nor Pratt & Whitney have responded to a query concerning the reasons the F135’s diagnostic and prognostic systems failed to detect the incipient failure of AF-27’s engine or the excessive rubbing found on borescope inspections of other engines. During its campaign to advocate termination of General Electric’s F136 alternate engine, P&W stated that prognostic systems could detect problems early and “mitigate their potential impact on flight operations.” 

Flight Carrying 100 Americans Forced To Land In Iran, Kept For Hours

(CNN) -- A charter airplane carrying military contractors, including Americans, took off early Saturday from Iran, hours after its pilots were ordered to land because the flight plan was out of date, a U.S. State Department spokeswoman said.

The Fly Dubai charter landed in Dubai a short time later, spokeswoman Marie Harf said.

The news brought to an end an incident that began late Friday when the charter plane en route to the United Arab Emirates was told by Iran that it needed to return to Afghanistan, a number of U.S. officials said.

The pilots said they did not have enough fuel to return to Afghanistan, and the Iranians ordered it to land or be "intercepted," the officials said.

It landed in Bandar Abbas in southern Iran near the Persian Gulf, the officials said. The plane was then inspected by Iranian authorities, they said.

There were 140 passengers, including 100 U.S. citizens, on board the flight, which originated at Bagram Airfield, they said. All of the passengers were still believed to be on board, the officials said.

The problem appears to have begun when the flight's departure from Bagram was delayed three hours. As a result, Iranian authorities considered the flight plan "expired" by the time the charter plane crossed into Iran's airspace, officials said.

The plane was allowed to leave after Fly Dubai filed a new flight plan and arranged for more fuel, the officials said.

WPEC-TV CBS12 News :: News - Top Stories - Flight carrying 100 Americans forced to land in Iran, kept for hours

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