Refueling the SR-71during the Cold War

Charlie Vono, Colonel USAF, Retired

Links• This presentation on line at https://info.aiaa.org/Regions/Western/Utah

– Includes links to more info and photos– Including the SR-71 Flight Manual (

http://www.netwrx1.com/skunk-works/sr71flt.pdf)

• Examples here, more in notes pages of presentation– http://www.blackbirds.net– http://en.wikipedia.org– http://www.strategic-air-command.com– http://www.flybynightvideos.com– http://sonicbomb.com– http://www.area51zone.com– http://www.airliners.net/aviation-forums/military– http://uscockpits.com– http://airrefuelingarchive.wordpress.com– http://www.sr-71.org/blackbird/sr-71/

Overview

• Introduction– The Cold War Era -- 1947 to 1991– The SR-71 Era – 1957 to 1999

• Invincible Reconnaissance Speed KC-135Q Mission• The KC-135Q• The KC-135Q/SR-71 Refueling Mission

• Q&A

Charlie Vono, born 22 March 1952• The 50’s and early 60’s

– An age of aerospace miracles– Me and my grade school classmates grew up learning how to “duck and cover”– WWII was a recent event

• 70’s saw end of Viet Nam era, few military missions, mostly training– I was lucky to pull an assignment that included operational missions– KC-135 still required dozens of charts, water for take off, sextant, basically 1950’s technology

After the War (1944)Dorothy Roe, Associated Press

After the war . . .

We'll just a press a button for food or for drink,

For washing the dishes or cleaning the sink.

We'll ride in a rocket instead of a car.

And life will be streamlined . . .

After the war.

1960 Ford Starliner

1966

1977 - 1982

• First GPS satellite launched in 1978, feasibility demonstrated in 1985 after 11th launch, constellation completed in 1994

• 1st Space Shuttle flight was 1981, frequent radio black out regions• Long distance phone calls were very expensive• DARPANET existed for DoD and Universities• HF radio position updates (CB Radio)• Personal Computers arrived around 1981• You could still work on your own automobile

In the 1950’s, the US needed to overfly the USSR to see their missiles– Kelly Johnson’s U-2s were designed and built and did the job– But U-2s would be vulnerable to better and better defenses

“Highly modified” F-104

We needed a spy plane that could outrun the missiles

– High speed means lots of heat– Only titanium could withstand the temperatures– And there was no way to seal in the fuel– A high flash point fuel was needed

SR-71 Era• In 1957, before Francis Gary Powers was shot down in 1960, the A-12 was

already in work

• SR-71 was in service from 1964 to 1999– In SAC from 1966 to 1989 (1992)– First deactivated 1989 to 1993

• Beale AFB, US• Kadena AFB, Japan • AF Mildenhall, UK

A-12 with D-21 Drone

SR-71 was in service from 1964 to 1999In SAC from 1966 to 1989 (1992); first deactivated 1989 to 1993

In 1957, before Francis Gary Powers was shot down in 1960, the A-12 was already in work

Speed

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MPH

Since 1976, world record for the fastest air breathing manned aircraft– SR-91 Aurora, supposed super secret SR-71 successor (MACH 5 to MACH 8 at 100,000’)– X-43 unmanned rocket-boosted hypersonic (~MACH 10) vehicle – Space shuttle at engine cut off is 17,500 mph or about MACH 23– Apollo capsules could reach MACH 30 as they entered the atmosphere

SR-71 flew from LA to NY in 68 minutes

Speed means Heat, Lots of Heat!

• Forward cockpit canopy on inside ~ 250 deg F• Heat on pilot during ejection: 450 deg F• Aircraft Skin temp > 500 deg F• Cockpit canopy around 575 deg F after landing• Leading edge of wing 800 deg F• Wiring rated to 900 deg F• Engine nozzle > 1500 deg F

• ½ foot longer at speed

SR-71 Heat Management

JP-7• Design solution was JP-7 jet fuel

– High flash point (140 - 160 °F) – Also used as coolant and hydraulic fluid before being burned

• Flash point: ignitable mixture in air– JP4 flash point is 0 deg F– JP4 is 50/50 kerosene and gasoline– Most common jet fuel at the time

• Autoignition temperature (or kindling point)– Lowest temperature to spontaneously ignite without a source of ignition– JP7 > 1000 deg F?– JP4 = 450 deg F

JP-7

• Very slippery, difficult to light

• Contains • Fluorocarbons to increase its lubricity• Oxidizing agent to enable it to burn in the engines• Cesium compound, A-50, to disguise the exhaust's radar signature

• For engine start, triethylborane (TEB) injected into the engines – Ignites on contact with air – Characteristic greenish flame as engines were ignited or afterburners used– 20 fluid ounce of TEB on board for each engine, enough for 16 uses

SR-71 Fuel TanksHoneycomb structure

No sealant could withstand the temperaturesLeaks everywhere

Just After Take Off

http://bobshermanspage.com/USAFPlanes.html

SR-71 in AfterburnerNote standing waves

Thus, special tactics and special tankers are needed to – Carry the high flash point fuel– Find the SR-71 and refuel it while maintaining secrecy

Tanker 101• Because of Tankers

– Fighters and bombers fly deeper in enemy territory with more ordnance– Intel and recon aircraft loiter longer– More cargo is delivered faster

• In flight refueling demands that aircraft fly 35 feet apart – Altitudes: 14,000’ to 30,000’ (SR-71 normally refuels at 26,000’)– Speeds: 190 to 320 knots (for SR-71, KC-135Q operates at top speed)

• Safety demands strict procedures and discipline– Aerodynamics dictate that aircraft in close vertical proximity tend to collide– Military Accepts Responsibility for Separation of Aircraft (MARSA)– SR-71 factors: Weather, radio silent, poor visibility, formation with other tankers

Rendezvous

http://www.aroundthepattern.com/military-flying/aviation-history-air-refueling-the-c-5-part-1/

Air Refueling Tracks• Tanker flies in a holding pattern• Receiver enters at the air refueling initial point (ARIP) • Tanker alters the orbit and flies toward the receiver aircraft in order to arrive

at the air refueling control point (ARCP) at a specific time• While the two aircraft are approaching each other at more than 800 mph,

they are separated by 1,000 feet of altitude• At a predetermined range, the tanker executes a 180-degree turn to roll out

one mile ahead of the receiver aircraft• Once the tanker is identified by the receiver, the receiver is cleared to

increase speed and climb to join up with the tanker

• With the SR-71, further complications include matching speeds, radio-silent, formation flying with 2 or 3-ship of tankers, high-priority of mission accomplishment, poor visibility of SR-71 cockpit, & ground alert

Angle of Attack

Angle of Attack

Angle of Attack

Unusual Events

• Breakaway• Failed Air Refueling (Mission Planning)• Refueling in the flight pattern• Thunderstorms• St. Elmo’s Fire• Trying to refuel behind an airliner• “Fighter drags” “across the pond”

Boom Limits

KC-135A

http://en.wikipedia.org/wiki/File:Boeing_B-52D-70-BO_(SN_56-0582)_is_refueled_by_Boeing_KC-135A-BN_(SN_55-3127)_061127-F-1234S-009.jpg

KC-135A / KC-135Q“Water Wagon”

KC-135A

http://www.strategic-air-command.com/

• KC-135 Stratotanker assigned to Strategic Air Command (SAC) from 1957 through 1992 – 1954: SAC ordered the first 29 of its future fleet of 732– August 1956: First aircraft flew – June 1957: Initial production Stratotanker delivered to Castle AFB– 1965: Last KC-135 was delivered to the Air Force– Air National Guard and Air Force Reserve units from 1975 through 1992

• Derived from the original Boeing jet transport "proof of concept" demonstrator, the Boeing 367-80 (commonly called the "Dash-80")– Narrower fuselage shorter than Boeing 707 jetliner, denoted the Model 717– “Water wagon”, sextant, HF radio, 50,000’ ceiling,– P&W J-57-P-59W turbojet 10,000 lbf of thrust dry, 13,000 lbf of thrust wet

KC-135Q• Modified to carry JP-7 fuel necessary for the SR-71 Blackbird• Segregates JP-7 from the KC-135's own fuel supply

– Body tanks carrying JP-7, and the wing tanks carrying JP-4 – Two ground refueling ports, located in each rear wheel well so ground crews

can fuel both the body tanks and wing tanks separately• Strobe Lights, Special Comm, & Boom Interphone for radio silent missions• Crew Training

– Formation – Radio Silent / Take Command

Cockpit

Pre-FD-109

Pilot Station

Engines

Fuel Panel

EWO Mission

Navigator’s Station

The KC-135 Sextant

http://dandickey.com/air_force.htm

Today’s KC-135R

Today’s KC-135R• KC-135As modified with CFM-56 engines are KC-135Rs• Power Plant: CFM International CFM-56 turbofan engines

– Thrust: 21,634 pounds each engine • SIZE

– Wingspan: 130 feet, 10 inches – Length: 136 feet, 3 inches – Height: 41 feet, 8 inches

• PERFORMANCE– Speed: 530 miles per hour at 30,000 feet – Ceiling: 50,000 feet – Range: up to 11,015 miles – Maximum Takeoff Weight: 322,500 pounds – Maximum Transfer Fuel Load: 200,000 pounds – Maximum Cargo Capability: 83,000 pounds, 37 passengers

• Unit Cost: $39.6 million (fiscal 98 constant dollars)http://www.af.mil/information/factsheets/factsheet.asp?id=110

Q & A

Other Fun Stuff

SR-71 Cockpits

T-38 Cockpit

http://en.wikipedia.org/wiki/SR-71_Blackbird

SR-71 Cockpit

SR-71 Cockpit

SR-71 RSO Cockpit

SR-71 Ejection Seat Tests

KC-135Q Other Missions

• SR-71 recovery from abort location• U-2/TR-1 Cargo & Ground Crew Support• Area 51 Missions• Various conventional refuelings, e.g.– C-130 – C-5– “Fighter Drags”

Upgrades• KC-135 generally upgraded for increased capability and reliability

– 1975 to 1988 all KC-135s had lower wing surfaces replaced with an improved aluminum alloy skin (1500 sq ft) and replacement of the engine strut fittings

– 1999-2002: Compass, Radar And GPS (CRAG) eliminated Navigator– Last upgrade: Navigation Surveillance & Air Traffic Management

Variants & Upgrades• VC-137 (AF1) was a Boeing 707 variant, not a C-135 variant• EC-135 Looking Glass Post Attack Command & Control Systems

– USAF EC-135 Looking Glass replaced Navy E-6 Mercury aircraft– Based on both the Boeing 707 and KC-135

• KC-135Es retired in 2009 (first re-engine program)• NKC-135A's are flown in test programs• RC-135 Rivet Joint (Special Reconnaissance)• KC-135R(RT) are receiver-capable tankers – 8 exist

– Force extension and Special Operations missions– Upgrades for communications, navigation, auto-pilot, and surveillance

• OC-135 ACC observation platform for Open Skies Treaty• KC-135Qs with CFM-56 engines are KC-135Ts

http://www.af.mil/information/factsheets/factsheet.asp?id=110http://www.boeing.com/defense-space/military/kc135-strat/index.html

The Boomer• Air refueling boom is controlled by a highly trained boom operator

– Controls operate two small ruddervators on the boom– A smaller pipe is extended to make contact with the aircraft taking on fuel

Just After Refueling

VIDEO

• http://www.sonicbomb.com/iv1.php?vid=sr71_1&id=746&w=448&h=320&ttitle=SR-71+Blackbird&sms_ss=facebook

Re-engining• In the 1980s the first modification program re-engined 157 Air Force Reserve (AFRES) and Air National

Guard (ANG) tankers with the Pratt & Whitney TF-33-PW-102 engines from 707 airliners retired in the late 1970s and early 1980s. The re-engined tanker, designated the KC-135E, was 14% more fuel efficient than the KC-135A and could offload 20% more fuel on long duration flights. (The difference is that the A-model weighed only 104,000 lb empty, while the E-model weighed 115,000 lb empty. But the maximum takeoff weight was not increased for the E-model. Therefore, the A-model could takeoff with 200,000 lb of fuel, while the E-model could only takeoff with 190,000 lb of fuel.) Only the KC-135E aircraft were equipped with thrust-reversers for takeoff aborts and shorter landing roll-outs. The KC-135E fleet has since either been re-engined into the R-model configuration or placed into long term storage ("XJ"), as Congress has prevented the Air Force from formally retiring them. The final KC-135E, tail number 56-3630, was delivered by the 101st Air Refueling Wing of the Maine ANG to the 309th Aerospace Maintenance and Regeneration Group (AMARG) at Davis-Monthan AFB in September 2009.[5]

• The second modification program re-engined 500 aircraft with new CFM International CFM56 (military designation: F108) engines produced by General Electric and Snecma. The CFM-56 turbofans are capable of producing approximately 22,500 lbf of thrust, nearly a 100% increase in power compared to the original J-57 engines. The re-engined tanker, designated either the KC-135R or KC-135T, can offload up to 50% more fuel (on a long duration sortie), is 25% more fuel efficient, costs 25% less to operate and is 96% quieter than the KC-135A (sideline noise levels at takeoff were reduced from 126 to 99 decibels).[6]

Air Speed RecordsYEAR PILOT MPH KPH LOCATION1903 Wilbur Wright 6.82 10.98 Wright Flyer Kitty Hawk, NC, USA1905 Wilbur Wright 37.85 60.91 Wright Flyer III1908 Henry Farman 40.26 64.79 Voisin biplane1909 Louis Blériot 47.82 76.96 Blériot XII1910 Alfred Leblanc 68.2 109.8 Blériot XI1911 Edouard Nieuport 82.73 133.1 Nieuport Nie-2 N1912 Jules Vedrines 108.2 174.1 Deperdussin Monocoque1913 Maurice Prevost 126.7 203.8 Deperdussin Monocoque1914 Norman Spratt 134.5 216.5 RAF SE.41918 Roland Rohlfs 163.1 262.4 Curtiss Wasp1919 Joseph Sadi-Lecointe 191.1 307.5 Nieuport-Delage 29v1920 Joseph Sadi-Lecointe 194.5 313 Nieuport-Delage 29v1921 Joseph Sadi-Lecointe 205.2 330.3 Nieuport-Delage1922 Billy Mitchell 224.3 360.9 Curtiss R-61923 Alford J. Williams 267.2 430 Curtiss R2C-11924 Florentin Bonnet 278.5 448.2 Bernard Ferbois V21927 Mario de Bernardi 297.8 479.3 Macchi M.521928 Mario de Bernardi 318.6 512.7 Macchi M.52bis1929 Giuseppe Motta 362 582.6 Macchi M.671931 George H. Stainforth 259.16 417.06 Supermarine S.6B seaplane Lee-on-the-Solent, UK1933 Francesco Agello 424 682 Macchi M.C.72 seaplane1934 Francesco Agello 440.6 709 Macchi M.C.72 seaplane1935 Howard Hughes 352 566 Hughes H-1 Racer landplane1939 Fritz Wendel 469.22 755.13 Me 209 V1 Augsburg

http://en.wikipedia.org/wiki/Flight_airspeed_record

Air Speed Records• 1941 Heini Dittmar 623 1003 Rocket powered - Not an Official FAI record but over the 3 km FAI

distance• 1944 Heinz Herlitzius 624 1004 Not an Official FAI record Messerschmitt Me 262 S2

Leipheim [4]• 1944 Heini Dittmar 702 1130 Rocket powered - Not an Official FAI record Messerschmitt Me

163B V18 Lagerlechfeld [5]• 1945 H. J. Wilson 606 975 Gloster Meteor F Mk4 Herne Bay, UK• 1946 Edward Donaldson 615 990 Gloster Meteor F Mk4 Littlehampton, UK• 1947 Col. Albert Boyd 623 1003 Lockheed P-80R Shooting Star Muroc, California,

USA[6]• 1947 Cmdr. Caldwell 640 1031 Douglas Skystreak Muroc, California,• 1947 Chuck Yeager 670 1078 Bell X-1- Rocket powered - not an official FAI C-1 record

Muroc, California,• 1948 Maj. Johnson, USAF 670 1079 North American F-86A-3 Sabre Cleveland, USA[7]• 1952 J. Slade Nash 698 1,124 North American F-86D Sabre Salton Sea, USA• 1953 William Barnes 715 1,151 North American F-86D Sabre Salton Sea, USA• 1953 Neville Duke 727 1,171 Hawker Hunter F Mk3 Littlehampton, UK• 1953 Mike Lithgow 735 1,184 Supermarine Swift F4 Castel Idris, Tripoli, Libya• 1953 James Verdin, USN 753 1,213 Douglas F4D Skyray Salton Sea, USA• 1953 Frank Everest USAF 755 1,215 North American F-100 Super Sabre Salton Sea, USA• 1955 Horace A. Hanes 822 1,323 North American F-100C Super Sabre Palmdale, USA• 1956 Peter Twiss 1,132 1,822 Fairey Delta 2 Chichester, UK• 1957 USAF 1,207 1,942 McDonnell F-101A Voodoo Edwards Air Force

Base, USA• 1958 Cap. Irwin, USAF 1,404 2,259 Lockheed F-104C Starfighter Edwards Air Force Base, USA• 1959 Col. Mosolov 1,484 2,388 Ye-66 (proto Mikoyan-Gurevich MiG-21) USSR• 1959 Maj. Rogers, USAF 1,525 2,455 Convair F-106 Delta Dart Edwards Air Force Base, USA• 1961 Robinson, US Navy 1606 2585 Modified McDonnell-Douglas F-4 Phantom II

Edwards Air Force Base, USA• 1962 Col. Georgii Mosolov 1665 2680 Mikoyan Gurevich Ye-166 -• 1965 Stephens /Andre 2,070 3,332 Lockheed YF-12A Edwards AFB, USA• 1976 Joersz /Morgan 2,194 3,530 Lockheed SR-71 Blackbird Beale AFB, USA

Speed of Soundin Earth’s Atmosphere

http://www.aerospaceweb.org/question/atmosphere/q0112.shtml

Air Speed Records

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SR-71 flew from LA to NY in 68 minutes

SR-71 Mission

• Focused reconnaissance– Cuba– Russia– China

• Battle Damage Assessment

KC-135A• SAC deactivated in 1992

• All AFRC and most KC-135s assigned to Air Mobility Command– Includes most Air National Guard – Alaska and Hawaii Air National Guard KC-135s operationally-gained by PACAF

• Some KC-135s assigned to– United States Air Forces in Europe – Pacific Air Forces – Air Education and Training Command

• As of 2009, Active duty, 180; Air National Guard, 171; Air Force Reserve, 64

http://www.strategic-air-command.com/

Point Parallel Refueling• The pre-contact position is about a mile behind the tanker and 50 below it. (If visual contact is not made ′

by the pre-contact position, the refueling mission is aborted and the receiver will divert to an alternate airport.)

• When the receiver has stabilized in this position, the next step is to make sure the aircraft is ready to accept the fuel.

• Once the receiver has stabilized in the pre-contact position, the receiver pilot makes a radio call to the boom operator acknowledging the “Ready” status. The boom operator replies that the tanker is also “Ready” and clears the receiver to the contact position.

• Air refueling initiation point (ARIP) is where the receiver enters the air refueling track. It serves as the first of the two points that defines the tanker orbit pattern. The receiver must be established 1,000 feet below the tanker prior to crossing the ARIP. If 1,000 feet of separation is not confirmed prior to crossing the ARIP, the receiver will hold at the ARIP.

• The air refueling control point (ARCP) is the primary reference for the rendezvous. It serves as the second point that defines the tanker orbit pattern.

• The air refueling track terminates at the exit point• The ARCT is the receiver’s planned arrival time at the ARCP. This time is determined for the mission and

discussed as part of the mission brief. • Air Refueling Altitude. Three consecutive altitudes will be requested for rendezvous and air refueling.

Normally, the tanker will be at the middle altitude and the receiver at the bottom altitude

The Refueling Mission

http://www.aroundthepattern.com/military-flying/aviation-history-air-refueling-the-c-5-part-1/

http://robrobinette.com/C-141/dash2_ar.htm

References• http://www.blackbirds.net/tankers/kc135q.html• http://en.wikipedia.org/wiki/KC-135_Stratotanker• http://www.strategic-air-command.com/• http://www.flybynightvideos.com/• http://www.flybynightvideos.com/blackbirds.html• http://en.wikipedia.org/wiki/SR-71_Blackbird

• http://sonicbomb.com/xv1.php?vid=sr71&id=470&h=420&w=560&s=35&ttitle=SR-71%20Blackbird

• http://phil.philwells.net/Photographs/MarchAirBase/marchfieldindex.html

• http://sonicbomb.com/modules.php?name=Downloads&d_op=search&query=

• http://en.wikipedia.org/wiki/Flight_airspeed_record

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