DESIGNING ADVANCED FIGHTER AIRCRAFT Burt Dicht Managing Director ASME Knowledge and Community Sector

TODAY’S AGENDA Fighter Aircraft Requirements The Evolution of Stealth Technology The Advanced Tactical Fighter The Design Process The Future of Aircraft Design Opportunities for ME’s in Aerospace ASME

MY BACKGROUND Currently Director, ASME Managing Director, Knowledge & Community Started out as an ASME student member - just like you. A member for 27 years. BS Temple University, Philadelphia MA, CSUN, Northridge, CA Staff of Congressman Jon Fox (PA/13) Northrop Grumman – Lead Engineer T-38 Talon • F-5E/F Tiger II • F-20 Tigershark • YF-23 Advanced Tactical Fighter, F/A-18E/F Super Hornet Rockwell Space Systems Division (Boeing) Space Shuttle Program NASA Kennedy Space Center Summer Intern - Space Shuttle Launch Facility Design

MODERN FIGHTER AIRCRAFT REQUIREMENTS Air Superiority – controlling the airspace within a limited area and within a limited length of time Stealth – seeing the enemy before they see you Maneuverability – not top speed, but climbing performance, acceleration and turning speed Aerodynamics – wing loading – aircraft weight divided by wing area – one of the most important Range – ability of the aircraft to reach the combat zone and cover it Engine – thrust to weight ratio, favorable fuel consumption, low infrared and smoke Avionics – Vehicle and systems management, reduced pilot workload, all weather capability Armament- kind and quantity of stores on board Reliability and Maintainability – systems have a high operational rate and are easy to repair

THE EVOLUTION OF STEALTH AIRCRAFT From the earliest days, deception and stealth have been used to gain the advantage over an enemy in combat. Early combat aircraft used camouflage to make visual detection difficult. The advent of RADAR in the late 1930’s and during WWII enabled the early detection of aircraft in flight. Romulan “Bird of Prey” Equipped with “Cloaking Device.” Made the craft invisible to Federation sensors.

THE EVOLUTION OF STEALTH NORTHROP YB-49 BOMBER Designed by Jack Northrop in the late 1940’s. Role was as a strategic bomber. Its unique wing shape produced a low radar cross section, although the goal was improved performance.

THE EVOLUTION OF STEALTH DESIGN IN THE 50’S AND 60’S Stealth in aircraft design does not mean invisible – it means “Low Observable,” reducing the radar cross section. Little effort in the 50’s and 60’s. Integrating low observable aspects meant compromising performance – so designers concentrated on speed, maneuverability, and weapons. A-12/SR-71 has rounded lines, wing/body blending, conical center bodies, fuselage chine and canted twin fins to reduce radar reflectivity. Lockheed SR-71 Blackbird

Typical RCS diagram B-26 Invader RADAR CROSS SECTION An object's Radar Cross Section depends on its size, reflectivity of its surface, and the directivity of the radar reflection caused by the object's geometric shape. RCS = Geometric cross section × Reflectivity × Directivity Typical RCS diagram B-26 Invader (From Wikipedia)

STEALTH CHARACTERISTICS Airframe shaped for Low Radar Cross Section Use of Radar Absorbent Material (RAM) Minimized engine noise Reduced infrared signature Reduced visual signature Use of electronic countermeasures

THE FIRST STEALTH AIRCRAFT F-117A Nighthawk USAF and DARPA studies initiated in 1973 – project Have Blue Air Force invites proposals to develop technology prototype Lockheed and Northrop were finalists and each built a prototype for a “fly-off” Lockheed wins production contract in 1976 Mission – covert reconnaissance and covert surgical strikes Subsonic – limited performance

STEALTH GROWS UP 1980 report concluded that B-1 bomber would be unable to penetrate Soviet air space beyond 1990 Positive results from Have Blue (F-117) justified launch of a full-scale low-observable bomber program (Advanced Technology Bomber – ATB) Lockheed/Rockwell team and a Northrop/Boeing team responded to requests for proposals Northrop relied on experience studying stealth technology and its extensive experience with flying wing designs and was awarded the contract

STEALTH GROWS UP NORTHROP – GRUMMAN B-2 SPIRIT Length – 69ft Height – 17ft Wingspan – 172 ft Max Speed – Mach .85 Range 6300 nm Armament – 40,000 lbs in internal weapons bays Powerplant – four GE F-118-GE-100 turbofans – 17,300 lbs

DEVELOPING A TRULY STEALTH FIGHTER WHY THE NEED? Late 1970’s – Soviets building far more fighters than US Massive Soviet surface to air missile threat USAF looking to technology to counter Soviet numerical advantage In 1981 USAF issued a Request for Information (RFI) for the Advanced Tactical Fighter (ATF) A RFI does not offer any money or production contracts, it defines mission, the threat, service entry date and new features that are desirable and feasible Supercruise (the ability to achieve supersonic flight without afterburner) and stealth were considered essential components, although stealth was still considered an exotic technology

DEVELOPING A TRULY STEALTH FIGHTER THE ADVANCED TACTICAL FIGHTER (ATF) PROGRAM Air Force opts to build a truly air-to-air fighter to follow the F-15 Eagle air superiority fighter - designed to enter service in mid 90’s In 1983 USAF issues Request for Proposals (RFP) for ATF and the Joint Advanced Fighter Engine (JAFE) General Electric and Pratt & Whitney vie for engine contract Lockheed, Rockwell, Grumman, McDonnell Douglas, General Dynamics, Boeing and Northrop vie for aircraft contract McDonnell Douglas and General Dynamics were thought to have the inside track because of F-15 and F-16 But stealth proved to be the deciding factor. Both Northrop and Lockheed fell back on their stealth experience and proposed stealthy fighters that could perform as well as non-stealthy fighters

DEVELOPING A TRULY STEALTH FIGHTER THE ADVANCED TACTICAL FIGHTER (ATF) PROGRAM In October 1986 the USAF awards the contracts to build prototype aircraft to Northrop and Lockheed Northrop teamed with McDonnell Douglas to build the YF-23A Lockheed - Boeing - General Dynamics comprised the other team to build the YF-22A. Aircraft first flights in the Fall of 1990. Lockheed Martin awarded contract in April 1991. The F-22 is now in production.

YF-23A BLACK WIDOW II Two Prototypes were built Wing Span 43.6 ft Length 67.4 ft Height 13.9 ft Wing area 900 sq. ft. Top Speed Mach 2+ Range 800 Nm Altitude 65,000 ft Air Superiority Low Observable Super-cruise - mach 1+ without afterburner Two Prototypes were built PAV 1 - two Pratt & Whitney YF119 engines PAV 2 - two GE YF120 engines

NORTHROP GRUMMAN AN AIRFRAME MANUFACTURER Responsible for the design, manufacture and integration of aircraft and aircraft sub-assemblies F/A-18 Carrier Takeoff Boeing (McDonnell Douglas/Northrop) F/A-18F Super Hornet

AIRCRAFT DESIGN PROCESS Customer Requirements Conceptual Design Phase General size and configuration of the aircraft • aerodynamics studies • thrust loading • wing loading • wing sweep • general body, wing and tail configurations Preliminary Design Phase Best conceptual design is chosen for testing • inlet/engine/airframe integration • major loads and stresses • weight • stability and control • internal arrangement Detailed Design Phase Configuration frozen • Detailed structural design • Detailed system design and installation • Production drawings Development Phase Manufacturing and assembly

AIRCRAFT ENGINEERING GROUPS Aerodynamics Advanced Design Avionics (airborne electronics) Crew Station (cockpit) ECS (environmental control system) Electrical Flight Test Fuel Systems Hydraulic Systems Propulsion Integration (engines) Reliability and Maintainability Safety Structures Vehicle Management (flight control)

CONFIGURATION/ SYSTEMS INTEGRATION Responsible for overall internal and external systems arrangement Work with every design group and coordinate and integrate their designs into a single aircraft design Final Product: Inboard Profile Drawing • Aperture Arrangement • Three Views • Zone Drawings F-20A Tigershark

F-23A Advanced Tactical Fighter INBOARD PROFILE F-23A Advanced Tactical Fighter Profile View

YF-23A Prototype Air Vehicle – Plan View APERTURE ARRANGEMENT YF-23A Prototype Air Vehicle – Plan View

AIRCRAFT DESIGN IS A COMPROMISE It is the task of the aircraft design engineer to balance the customer requirements with the physical constraints, cost and time-scale, in order to produce the most effective aircraft possible. Aircraft Design Requires Teamwork No “one” design group is more important than the others. Note: All Engineering involves Compromises!

LOOK WHAT HAPPENS WHEN DESIGN GROUPS HAVE THEIR WAY

ENGINEERING JOB DESCRIPTIONS Design - From Concept to Production Good understanding of engineering principles See things in 3-D (Geometry, Graphics, Kinematics) Like to solve problems, come up with better ways of doing things Analysis - Verify engineering designs (Stress, Thermal, Aerodynamics, Dynamics) Engineering Theory and Mathematics Problem solving Test - Verify functionality of design Basic understanding of engineering theory and design principles Lab work and strict guidelines and procedures Operations- Maintaining and operating final product Basic understanding of engineering design and systems Understand how and why things work

YF-23A BLACK WIDOW II

LOCKHEED MARTIN F-22A RAPTOR Wing Span 44.5 ft Length 62 ft 1 in Wing area 830 sq. ft. Top Speed Mach 2+ Range 800 Nm Altitude 65,000 ft Air Superiority Low Observable Two Pratt & Whitney F119-PW-100 Turbofans @ 35,000 lbs

LOCKHEED MARTIN X-35 (F-35) JOINT STRIKE FIGHTER

Bureau of Labor Statistics - Aerospace Outlook Employment Change 2004 - 2014 Aerospace engineers held about 76,000 jobs in 2004. Aerospace engineers are expected to have slower-than-average growth in employment over the projection period. Although increases in the number and scope of military aerospace projects likely will generate new jobs, increased efficiency will limit the number of new jobs in the design and production of commercial aircraft. Even with slow growth, the employment outlook for aerospace engineers through 2014 appears favorable: the number of degrees granted in aerospace engineering declined for many years because of a perceived lack of opportunities in this field, and, although this trend is reversing, new graduates continue to be needed to replace aerospace engineers who retire or leave the occupation for other reasons. Mechanical engineers held about 226,000 jobs in 2004. Employment of mechanical engineers is projected to grow at an average rate for all occupations though 2014. .

AEROSPACE & ME SALARIES Average starting salary for Bachelor’s degree candidates in aerospace engineering is $53,471 a year. (2006) Average starting salary for Bachelor’s degree candidates in mechanical engineering is $52,165 a year. (2006)

THE FUTURE BOEING 787 DREAMLINER

THE FUTURE AIRBUS A380

THE FUTURE Northrop Grumman X-47B Pegasus Unmanned Combat Air System Demonstrator (UCAS-D).

BOEING 797 FLYING WING PASSENGER JET THE FUTURE BOEING 797 FLYING WING PASSENGER JET

(Building Spaceship Two for Virgin Galactic) THE FUTURE SCALED COMPOSITES SPACESHIP ONE (Building Spaceship Two for Virgin Galactic) http://www.scaled.com/index.html

SPACE EXPLORATION TECHNOLOGIES THE FUTURE SPACE EXPLORATION TECHNOLOGIES FALCON 1LAUNCH VEHICLE http://www.spacex.com

ORION CREW EXPLORATION VEHICLE THE FUTURE ORION CREW EXPLORATION VEHICLE

THE FUTURE ARES V Launch Vehicle (two - 5 segment shuttle SRBs and a 33 ft diameter liquid fueled booster with 5 RS-68 engines for the 1st stage and an Earth Departure Stage with a single J2X engine) ARES I Launch Vehicle (5 segment shuttle SRB for the 1st stage and a liquid fueled J2X engine for the second stage)

LUNAR SURFACE ACCESS MODULE THE FUTURE LUNAR SURFACE ACCESS MODULE

THE FUTURE ORION AND LSAM

AEROSPACE WEB SITES Bureau of Labor Statistics http://www.bls.gov/ About Aerospace/Aviation - Links to many aerospace employers http://aerospace.about.com/industry/aerospace/cs/aviationjobs/index.htm SpaceJobs.com - Aviation and Aerospace business news and job search http://www.spacejobs.com/index.shtml Aircraft Design Sites http://www.aircraftdesign.com/other.html Aerospace Industries Association – sign up for AIA Update http://www.aia-aerospace.org/

AEROSPACE WEB SITES AOL Hometown - Aerospace Job Search http://hometown.aol.com/aerojobs/Welcome.html Nation Job - Job database and search engine http://www.nationjob.com/aviation/ NASA - Job and internship information http://www.nasajobs.nasa.gov/ http://www.nasajobs.nasa.gov/stud_opps/ Aerospace Mall - A directory of many aerospace/aviation related companies (From airframe to suppliers, from military to general aviation) http://www.aerospacemall.com/ Internships http://www.Tech-Interns.com

DOING YOUR HOMEWORK NASA to lose 8,600 jobs with shuttle retirement. The New York Times (4/2, A24, Leary) reports, "Retiring the space shuttle in 2010 could result in the loss of 8,000 jobs among NASA contractors and 600 Civil Service workers at the agency, NASA said Tuesday." Associate administrator for space operations William Gerstenmaier said that "the job losses might appear worse than they would end up," because "a potentially large number of employees could transfer to new openings developing, building and operating Constellation spacecraft and rockets." Private companies and retirees are other areas that might lessen the impact of the job losses. The two facilities hardest hit would be the Kennedy Space Center (KSC) and the Michoud Assembly facility, losing 6,400 of 8,000 and 1,300 of 1,900 employees respectively.        

MORE ABOUT THE AEROSPACE INDUSTRY ASME’s Professional Practice Curriculum – Industry Series http://professionalpractice.asme.org/ The Aerospace Module: Industry Scope Industry Sectors Industry Operations Job Functions Industry Outlook Mapping Your Career Industry Resources

ASME STUDENT MEMBERSHIP Founded in 1880 as the American Society of Mechanical Engineers, today ASME International is a nonprofit educational and technical organization serving a worldwide membership of 100,000 members and 20,000 student members. ASME offers students a wide range of technical and non technical benefits that will enable them to grow professionally, learn about the engineering profession, and gain valuable skills needed in today;s highly competitive work environment. Any student enrolled in any curriculum leading to a degree in engineering at a regionally accredited school is eligible to join. You don’t have to be a Mechanical Engineering Student. Dues, $25 per year (10/1 thru 9/30) Freshmen can join for free. http://www.asme.org/students or call 800-843-2763

FOR MORE INFORMATION Burt Dicht, Managing Director Knowledge and Community Sector dichtb@asme.org ASME Headquarters Three Park Avenue, M/S 23S1 New York, NY 10016 212-591-7074