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F-35 Program Information
Non-Export Controlled Information – Releasable to Foreign Persons
© 2009 Lockheed Martin Corporation
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.
2
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
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
3
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
Tri-Variant Joint Strike Fighter (JSF)
F-35C CV
Span . . . . . . . . . . . . . . . . . . . . . . . . 43 ft / 13.11 m
Length . . . . . . . . . . . . . . . . . . . . . 51.4 ft / 15.67 m
Wing area . . . . . . . . . . . . . . . . . . 668 ft2 / 62.06 m2
Combat radius (internal fuel) >600 n.mi / 1,111 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 ft2 / 42.7 m2
Combat radius (internal fuel) >450 n.mi / 833 km
Range (internal fuel) . . . . . . ~900 n.mi / 1,667 km
F-35A CTOL
Span . . . . . . . . . . . . . . . . . . . . . . . . 35 ft / 10.67 m
Length . . . . . . . . . . . . . . . . . . . . . 51.4 ft / 15.67 m
Wing area . . . . . . . . . . . . . . . . . . 460 ft2 / 42.7 m2
Combat radius (internal fuel) >590 n.mi / 1,093 km
Range (internal fuel) . . . . . ~1,200 n.mi / 2,222 km
Conventional
Take-
Off and
Landing
Short
Take-
Off and
Vertical
Landing
Carrier
Variant
4
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
F-35 Full Scale TestsLocations & Fixture Sharing
STOVL Static STOVL DurabilityCTOL Static
CTOL Durability
CV Durability
CV Static
CV Drop
Vought Aircraft Industries,
Grand Prairie TX, US
Lockheed Martin
Fort Worth, US
British Aerospace Systems
Brough, UK
5
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
Requirements Comparisonof AG-1 and BG-1
AG-1 (CTOL) BG-1 (STOVL)
159 Load Rams 164
3335Strain and Deflection
Channels3711
163 Test Runs 211
6
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
Full Airframe Test Conditions for AG-1 and BG-1
AG-1 (CTOL) BG-1 (STOVL)
No. Maneuver Description No. Maneuver Description
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
7
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
STOVL Local Static Tests
Refuel Probe Back-up
Structure and Mechanism
Outboard Weapons Bay Door (WBD)
Inboard WBD and Cradle
Fwd Main Landing Gear (MLG) Door
MLG Inboard Trunnion Support Structure
MLG Drag Brace Interface at FS450
MLG Outboard Trunnion Support Structure
Nose Landing Gear
(NLG) Doors
Fwd Fuse Side Skin
* Weapons Bay Sta 8 Hardpoints
Jacking
Hoist
Cockpit Pressure
Fuel Tank PressureEngine Thrust Mount
Engine Mount-Fwd Upper
Vane Box
Lift Fan Exhaust
Lift Fan Mounts
Boarding Ladder Door
Aux Air Inlet
Lift Fan Inlet
RCN Door Attach
Structure
Nose Landing
Gear (NLG)
Backup
Structure
* Wing-Pylon Sta 9
* Wing-Pylon Sta 10
* Wing-Pylon Sta 11
Completed Tests
102 Local Test Runs
50 Local-Global Test Runs
* Sta 6Performed airframe capability
testing at in support of future
weapon systems
*
8
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
CTOL Local Static Tests
Completed Tests
53 Local Test Runs
43 Local-Global Test Runs
Cockpit
Pressure
In-Flight Refuel
Receptacle
Backup StructureHoist
Engine
Thrust
Mount
Weapons Bay
Sta 8 Hardpoints
MLG
Backup
Structure
Wing – Pylon Sta 9
Wing – Pylon Sta 10
Wing – Pylon Sta 11
Jacking
Fuel Tank
Pressure
Inboard WBD, Sta 5,
and Backup Structure
Outboard WBD and
Backup Structure
Arresting
Gear Backup
Structure
MLG Uplock
Backup
Structure
Vertical
Tail
Hinge 3
Vertical Tail
Shear
Fitting
Engine
Mount, Fwd
Upper
Engine
Mount,
Fwd Side
Airframe capability testing
planned in support of future
weapon systems
Airframe capability testing
planned in support of future
weapon systems
9
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
AG-1’s Journey Across the Atlantic
Transport from FW to Houston, TX
Secured in hull of
shipping vessel
Transfer to barge for trip
down Humber River
Ocean
journey took
18 days
Reported UFO
sighting in Dallas, TX
10
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
AG-1 Arrival at BAES April 25, 2009
Arrival at Brough at 6:30 AM
Largest
crane in UK
used to lift
AG-1 from
barge.
Maneuvering around BAES site Delivered at BAES
test facility
11
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
Achieved Unprecedented Test Rates
0
50
100
150
200
250
0 100 200 300 400 500 600 700 800 900 1000 1100 1200
Days from Test Start
Test Runs
Legacy ALegacy CLegacy E - Less unit loads Legacy F - Less calibrationsLegacy TF-35 BG-1 Orig PlanF-35 BG-1 Current PlanF-35 BG-1 Execution
Calendar Days from Test Start
12
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
Still Improving……
• 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
• 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
0
25
50
75
100
125
150
175
200
225
Jan-08
Feb-08
Mar-08
Apr-08
May-08
Jun-08
Jul-08
Aug-08
Sep-08
Oct-08
Nov-08
Dec-08
Jan-09
Feb-09
Mar-09
Apr-09
May-09
Jun-09
Jul-09
Aug-09
Sep-09
Oct-09
Nov-09
Dec-09
Jan-10
Feb-10
Mar-10
Apr-10
May-10
Test Runs
Actual
Baseline Plan
Flight Clearance Dates
Expanded Testing
STOVL Doors
? Planned Delivery 01/11/08
? Actual Delivery 05/28/08
�Test Completion 11/12/09
First Flight
80%/64%
100%/80% Need
Date 5/26/2011
Phase 0
Phase 1
Phases 2 & 3
Phase 4
Phase 5
Phases
6, 7 & 8
NLG Door
STOVL Static Test (BG-1)
CTOL Static Test (AG-1)
Projected Test
Completion
0
25
50
75
100
125
150
175
200
225
Nov-08
Dec-08
Dec-08
Jan-09
Mar-09
Mar-09
Apr-09
May-09
Jun-09
Jul-09
Aug-09
Sep-09
Oct-09
Nov-09
Dec-09
Jan-10
Feb-10
Mar-10
Apr-10
May-10
Jun-10
Jul-10
Aug-10
Sep-10
Oct-10
Nov-10
Dec-10
Jan-11
Feb-11
Test Runs
AG-1 ActualAG-1 Baseline PlanAG-1 Revised Plan (BG-1 Rate Incorp)AG-1 Extended TestsFlight Clearance DatesAG-1 Extended Testing
80%/64%
100%/80%
Need date
01/26/201
1
Phase 0
Jan-09
Feb-09
Apr-09
May-09
Jun-09
Jul-09
Aug-09
Sep-09
Oct-09
Nov-09
Dec-09
Jan-10
Feb-10
Mar-10
Apr-10
May-10
Jun-10
Jul-10
Aug-10
Sep-10
Oct-10
Nov-10
Dec-10
Jan-11
Feb-11
Mar-11
Phase 1
Phase 2
Phase 3
Phase 4
First Flight
Transport
13
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
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
Test Data Agrees Very Well With Predictions – Full Correlation in Work
TCN 29966, Test Values vs. Strain Predictions at 150% DLL
-12500
-7500
-2500
2500
7500
12500
-12500 -7500 -2500 2500 7500 12500
Strain Prediction (micro strain)
Test Value (micro strain) .
Above Prediction
Above Prediction
Below Prediction
Below Prediction
Reversal
Reversal
Linear FEM Prediction
RHS Wingbox Rib - Vesette
Measured strain
@ 150% DLL
Non-Linear
FEM Prediction
14
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
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)
Cracks at Fwd Chevron Root on LHS and
RHS Lift Fan Exhaust Doors
Cracks occurred above 115% DLL; DUL
test completed without failure
Interference Between Inboard Weapon Bay
Door and Fuselage at 50% DLL
Required door and fuselage trim
Aft Downlock Mechanism on LHS Auxiliary
Air Intake (AAI) Door failed at 129% DLL of
applied test loads
Mechanism Redesigned - added door
lock stops; replaced LHS AAI Door and
Aft Downlock Mechanism; successfully
completed DUL test without rupture
TEF and Rudder Blade Seal damage during
Control Proof of Operations Test
Presented on following charts
CTOL (AG-1)Rudder Blade Seal damage during Control
Proof of Operations Test
Presented on following charts
15
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
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
LHS Aft Door Hinge
RHS Vertical Tail and Rudder View Lkg Inbd & Fwd
Bullnose Seal Cut-out
for Rudder Hinge Bullnose
Seal
Blade
Seal
16
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
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
AftLower
Blade Seal
View Looking Inboard and
Down at RHS VT
Middle
Blade Seal
Chafing of upper edge on
outboard lower blade seal
Down
Aft
IML of Outboard Middle Blade Seal
at Bullnose cut-out for RH VT Hinge 3
Surface delamination on
IML of middle blade seal
17
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
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
View of Upper Surface
Inbd
Aft
• 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
HT installed in fixture with upper
surface facing downward.
18
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
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 TestInbd
Aft
View
Looking Up
Horizontal Tail Hinge Spar
Lower Cap
Exposed Bearing
Outer Race
Fixture
Inboard
Lug
19
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
BG-1 Testing Supports Flight Test Envelope Expansion
BG-1 Phase 0 – 1st Flt & Out-of-fixture Conditions
• NLG Door Open & VAVBN Vane Loads
• Cockpit & Fuel Tank Pressure Tests to DUL
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
BG-1 Phase 7 – Local & Global/Local Tests
• MLG Backup, Taxi & Tow, Wing Hardpoints* & Ladder Door
•Weapons Bay Hardpoints* & Sta 5/7 ASRAAM Hangfire
BG-1 Phase 8 – Final Tests
• Engine & Lift Fan Mounts, Jacking, Hoist & Tie-down, Sta 6*
Jun ‘08
Oct ‘09
Nov ‘09
Test Completion
NLG Test Supports BF-1
Initial Flight Clearance
CTOL Flight w/ open
STOVL Doors
Hover Pit Entry
Limited STOVL Mode
Clearance
Air Refuel
80/64% Allowable
Load Envelope Flight
Clearance Support
Weapons
Separation
Ship Suitability &
Final Certification
Clearance Event
100% Allowable Load
Envelope Pursuit for
Loads Aircraft
May ‘09
Jun ‘09
Oct ‘09
Dec ‘09
Feb ‘09
BF-1 1st Flight
Sep ‘08
* Includes Extended Capability Tests
20
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
AG-1 Test Phases & Flight Test Support
Test Completion Clearance Event
AG-1 Phase 0 – 1st 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
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
Feb ‘09
Aug ‘09
Oct ‘09
Oct ‘09
Dec ‘09
100/80% ALE Flight
Clearance
Weapons Separation
Arresting Gear 100%
Max Take-Off Gross
Weight
May ‘10
• 46% of Testing Completed to Date
AF-1 1st Flight
21
Non-Technical Information
Use or disclosure of the information contained herein is subject to the restrictions on the Cover Page© 2009 Lockheed Martin Corporation
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