JSF Brief 20080808 - Propultion Overview

F135 Program Overview
for
for
2008
2008 ADF
ADF Propulsion
Propulsion Systems
Systems Symposium
Symposium
Victoria,
Victoria, Australia
Australia
Jim Higgins
Pratt & Whitney, Military Engines
Program Manager, F135 Weapon System Integration
08 August 2008
Higgins/08-08-08/jms Approved for public release; distribution is unlimited. Approval # JSF08-269 J4848_F135_Aus_Prop_Symp - 1
VISION
DELIVER AND SUSTAIN THE MOST ADVANCED,

AFFORDABLE STRIKE FIGHTER AIRCRAFT TO
PROTECT FUTURE GENERATIONS WORLDWIDE
Approved for public release; distribution is unlimited. Approval # JSF08-269

Agenda
• Program Overview
• Evolution of F135 From F119
• Single Engine Safety
• PHM / Life Management
• F135 Program Plan
• Summary
Joint Strike Fighter Air Systems
4 Pillars, 3 Aircraft, 2 Propulsion Systems
F-35 Conventional
Takeoff and Landing
(CTOL)
CV Engine
CTOL Engine
F-35 Carrier
Variant
(CV)
STOVL Propulsion System
F-35 Short Takeoff JSF

JSF Program
Program Pillars:
Pillars:
Vertical Landing Affordability
Affordability
(STOVL) Lethality
Lethality
Survivability
Survivability
Supportability
Supportability
Engine Interchangeability Objectives
Common Components Support Engine Interchangeability
Requirements
Identical specification –
Nozzle
thrust, weight
Conventional
Axi Duct
3-Bearing
Interchangeable Unique Swivel Duct
engines within and Turbomachinery/Augmentor
across aircraft
Airframe
variants
Inlets
Lift Fan
Identical airframe interfaces -

inlet, exhaust Roll Posts Unique
Common
Engine
Engine Brand
Brand Transparent
Transparent to
to Pilot
Pilot
F135 Built on Solid F119 Foundation
F135 Is Derivative Based With Flight Experience
10,000+ Hours
Flight Test Ongoing
F135
8 Flight Test Leveraging
Leveraging Experience
Experience
Engine Delivered •• Design
Design
•• Manufacturing
Manufacturing Processes
Processes
3,600+ Hours •• Sources / Suppliers
190 Flight Hours Sources / Suppliers
•• Materials
Materials
JSF119
Powered Both
Concept Demonstrators
70,000+ Hours
F119
Powers
Operational F-22
F135 Technical Performance & Validation
Technical Characteristics Proven Through Successful Flight Qualification
VALIDATED Release To Service Derivative (F119)
Engine
Engine (F135)
Technical
Information
Release To Flight Test

Maturity
e
tive Engin
a
Deriv
Proven
Qualified
Engine Core
ngine
- Lower Risk - New E PDR CDR FETT IFR ISR OCR
UNVALIDATED
Conceptual Preliminary Final Initial Flight Operational
Design Design Design Development Qualification Qualification
System
System &
& Development
Development Program
Program Maturity
Maturity
F135 Propulsion System Characteristics
40K Thrust Class
Split Cases and 6 Stage

Stators Compressor (HPC) Nozzle
3 Stage Fan
3rd Stage
Turbine Blade
1st Stage Hollow IBR Intermediate Case
F119
F119 Based
Based Advanced
Advanced Prognostics
Prognostics Health
Health
Manufacturing
Processes Management
Management Features
Features
F135 Propulsion System Characteristics
40K Thrust Class / Variable Cycle Engine
Modulated Exhaust Cooling
Fan Duct Blocker
2 Stage LPT
2 Stage Lift Fan Clutch Evolved F119 Core

Lift Fan & Driveshaft
3 Stage Fan
F119 Based
Controls & Externals
Variable Area 3 Bearing Swivel

Roll Control Ducts and
Vane Box Nozzle Module
Nozzles
F119
F119 Based
Based Advanced
Advanced Prognostics
Prognostics Health
Health
Manufacturing
Processes Management
Management Features
Features
Development and Validation Test
Completed Over 10,091 of 14,250 Planned Test Hours
CTOL / CV STOVL
– >4615 Test Hours Achieved – >5476 Test Hours Achieved

– Completed 45 Flights – >2014 Hours Powered Lift
– >3814 Clutch Engagements
– Completed 9 Flights
F135 Powering AA-1 and BF-1 Flight Test
F135
F135 –– Only
Only Propulsion
Propulsion System
System Powering
Powering F-35
F-35 “Lightning
“Lightning II”
II” Flights
Flights
F-35 Flight Test Program Status
F135 is Performing Flawlessly in Flight Test
CTOL STOVL
9 45 Flights Completed 9 9 Flights Completed
9 53.7 Total Flight Hours 9 7.1 Total Flight Hours
¾FTEs
¾FTEs Demonstrating
Demonstrating Excellent
Excellent Reliability,
Reliability, Performance,
Performance, and
and Thrust
Thrust Response
Response
¾Mil
¾Mil and
and Max
Max Power
Power Takeoffs
Takeoffs
¾Flight
¾Flight Envelope
Envelope Expansion
Expansion Continues
Continues
F135 Single Engine Safety
Focused on Single Engine Safety from Day One
F135
F135 Single
Single Engine
Engine Safety
Safety Pillars:
Pillars:
P&W
P&W Single
Single Engine
Engine Legacy
Legacy
F119
F119 Design
Design Platform
Platform
CDA
CDA Test
Test Experience
Experience
F135
F135 SDD
SDD Program
Program
Rigorous
Rigorous Fleet
Fleet Management
Management
F135 Single Engine Safety
F119 Flight Hours Lead the F135 Fleet - Building Confidence
with Every Flight Hour
600,000
F119/F135 Engine Flight Hours
500,000
(CY based)
400,000
F119
300,000
F135
200,000
100,000
0
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
F135
F135 LRIP I F135 STOVL F135
IOC CTOL IOC
500,000+
500,000+ F119
F119 Flight
Flight Hours
Hours at
at F135
F135 Operational
Operational Introduction
Introduction
F135 Engine Maintainability Features
Reduces Potential for Induced Maintenance Error by Incorporating
Many New Design Features to Facilitate Maintenance
Installation
• Time to R&R • No installation rigging
– CTOL - 40 minutes • No aircraft leveling for servicing
– STOVL engine - 90 minutes • No engine trim (leak check only)
– Lift Fan - 75 minutes
Engine
• Integrated diagnostics
• Multiple borescope points
• No safety wire on externals
• Adequate tool access
• Connecting devices prevent
improper installation
• Plumbing connects at flanges
• “O” level fan trim balance
Components
• No rigging for positive securing fasteners
LRCs • Minimize drainage / spillage
• One deep on bottom • Prevent improper installation
• No plumbing removal for access • Interchangeable sensor replacement
• Captive Fasteners
Nothing
Nothing Drops
Drops to
to the
the Deck
Deck During
During Flight
Flight Line
Line Maintenance
Maintenance
CTOL/CV PHM System Configuration
Distributed Sensors Provide Data for Prognostics / Diagnostics
Engine Pressures
Engine Temperatures
Debris Monitoring
Engine Rotor Speeds
Fuel System
Control Effectors
Thermal Management
Vibration
Lube System
Sensor
Sensor Suite
Suite Coupled
Coupled with
with PHM
PHM Algorithms
Algorithms Allows
Allows Increased
Increased
Time
Time on
on Wing
Wing and
and Comprehensive
Comprehensive Component
Component Life
Life Management
Management
STOVL PHM System Configuration
STOVL Propulsion System Sensor Measurements Support
Advanced Prognostics & Health Management
LS/ME Control Effectors
LS/ME Fuel/Hydraulic Systems
Communications
LS/ME Pressures LS/ME Temperatures
LS/ME Rotor Speeds
Debris Monitoring
LF Shaft
LS/ME Lube Systems Thermal Management
LS/ME Vibration
STOVL
STOVL PHM
PHM Allows
Allows On
On Condition
Condition Maintenance
Maintenance and
and Life
Life Management
Management
for
for Lift
Lift System
System Components
Components Subjected
Subjected to
to Harsh
Harsh STOVL
STOVL Operational
Operational Conditions
Conditions
STOVL PHM System Configuration
PHM System’s Data Fusion Starts with Sensor Data and Ends
with Information Being Sent to Air Vehicle
Operationally significant failures
are communicated to pilot
Sensor processing
provides valid data & Failure Accommodation Cautions/Warnings
features for monitoring
Valid Op Detection
Data
Control
Control Mode
Sensor
Sensor
based on
Processing modeled As info available, it’s
Sens Processing Model-
Data
Model-
Based limits transmitted to air
Valid Based
w/
w/Failure
Failure Limits
Failure vehicle storage prior
Control
Data Models Failure

Control && PHM
Detection/
Detection/ Models
Accommodate
Accommodate
Detection
Detection to transfer to ALIS
Symptom
Valid Data/Features Events Health
Status
PHM Sensors
PHM
Sensors
Life PHM
LifeUsage
Usage Accumulated
Data
Models Life Data
Models Manager
Manager
High Trend
Sens HighRate
Rate Trend
Health
Data Processing Data
Data Trend Data
Processing Report
Collector
Collector
On Board Processors
Air System Interface
F135 Fully Integrated in The F-35 Autonomic Logistics System
Fault Data Transferred to

1 On-board Fault Detection / Isolation 2 Ground Systems
Web-based Training
5 Refreshes Maintainer
as needed
6
Autonomic Logistics Information
System Manages Mx Process and
Resources
Off-board PHM Directs Joint Services Technical Data

3 Fault Isolation
4 Provide Mx Instructions
Evolution of the F-35 / F135
2005 and Beyond…
2005 2006 2007 2008 2009 2010 2011 2012 2013

STOVL CV
First First
CTOL Flight Flight Flight
Test STOVL Flight Initial Initial
Engine CTOL Test Service Service
Deliveries First Engine Release Release
Flight Deliveries (CTOL/CV) (STOVL) OCR
4 5 6-8
System Development & Demonstration (SDD)
LRIP 1 Contract 9/26/07 Deliveries 6/09, 7/09 (2)

2 CTOL – 4 Engines
LRIP 2 Long Lead Contract 9/2008 Deliveries 10/09-

10/09-8/10
6 CTOL / 6 STOVL – 16 Engine Contract 8/27/2007
Long Lead Contract 3/2009 - FF Deliveries 9/10-

9/10-9/11
LRIP 3
10 CTOL / 10 STOVL – 27 Engines 1st Partner Delivery
Delivering
Delivering Propulsion
Propulsion Systems,
Systems, Powering
Powering Flight
Flight Test,
Test, Building
Building Production
Production
F135 Program Milestones & Road Ahead
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
F-35 AA-1 Flight Test
STOVL Roll-Out – Dec 07
STOVL Flight Clearance Review – Mar 08
STOVL Up & Away Flight Clearance – May 08
STOVL First Flight – Jun 08
STOVL Full Flight Release – Jan 09
CV/CTOL Initial Service Release – May 09
CV CF-1 First Flight – Oct 09
STOVL Initial Service Release – Mar 10
F-35 BF-1 Flight Test
F135 Propulsion for the JSF
Summary
• F135 Powering Lighting II CTOL and STOVL Flight Test Program
• Building on Strong F119 Legacy Performance
• Program Remains Focused on delivering Single Engine Safety
• PHM and Life Management Systems Will Support Extended Time

on Wing
• Program Plan in Place to Support F135 Operational Introduction
DISTRIBUTION
Approved for
STATEMENT
public release;
A. Approved
distribution
for public
is unlimited.
release; distribution
Approval is # JSF08-269
unlimited.
Approved for public release; distribution is unlimited. Approval # JSF08-269

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F135 Program Overview

DELIVER AND SUSTAIN THE MOST ADVANCED,

Approved for public release; distribution is unlimited. Approval # JSF08-269

• Evolution of F135 From F119

• Single Engine Safety

• PHM / Life Management

• F135 Program Plan

F-35 Short Takeoff JSF

Identical airframe interfaces -

Release To Flight Test

Split Cases and 6 Stage

1st Stage Hollow IBR Intermediate Case

2 Stage Lift Fan Clutch Evolved F119 Core

Variable Area 3 Bearing Swivel

– >4615 Test Hours Achieved – >5476 Test Hours Achieved

LS/ME Pressures LS/ME Temperatures

LS/ME Rotor Speeds

Data Models Failure

Fault Data Transferred to

Off-board PHM Directs Joint Services Technical Data

2005 2006 2007 2008 2009 2010 2011 2012 2013

System Development & Demonstration (SDD)

LRIP 1 Contract 9/26/07 Deliveries 6/09, 7/09 (2)

LRIP 2 Long Lead Contract 9/2008 Deliveries 10/09-

6 CTOL / 6 STOVL – 16 Engine Contract 8/27/2007

Long Lead Contract 3/2009 - FF Deliveries 9/10-

• F135 Powering Lighting II CTOL and STOVL Flight Test Program

• Building on Strong F119 Legacy Performance

• Program Remains Focused on delivering Single Engine Safety

• PHM and Life Management Systems Will Support Extended Time

• Program Plan in Place to Support F135 Operational Introduction

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