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FY98 Annual Report |
F/A-18 E/F SUPER HORNET
Navy ACAT IC Program: | Prime Contractor | |
Total Number of Systems: | 12 LRIP-1 20 LRIP-2 548 Production | Boeing |
Total Program Cost (TY$): | $46.1B | |
Average Unit Cost (TY$): | $54.4M | |
Full-rate production: | 3QFY00 | Service Certified Y2K Compliant |
SEP Production | 3QFY94 | No |
SYSTEM DESCRIPTION & CONTRIBUTION TO JOINT VISION 2010
The F/A-18E and F Super Hornet, single and dual seat respectively, will be advanced derivatives of the F/A-18 C/D now in operational service with the Navy, Marine Corps and several foreign countries. Designed to overcome existing deficiencies in F/A-18 C/D range, specifically endurance and carrier bring-back payload, the new design will feature a larger airframe with more fuel capacity and two additional store stations. It will also have a reduced radar signature, advanced engines, extensive use of composites, and improvements to some avionics and displays. The projected firepower from Super Hornets operating from aircraft carriers is a key contributor to the Joint Vision 2010 concepts of dominant maneuver and precision engagement.
BACKGROUND INFORMATION
In April 1992, the DAB approved a Milestone (MS) IV/II for the F/A-18 E/F program. As a result of the DAB MS, the Navy entered the EMD phase, which will conclude in FY99 with OPEVAL (OT-IIC). Two EOAs (OT-I and OT-IA) and two periods of IOT&E (OT-IIA and OT-IIB) have been conducted. OT-I and IA were completed in February and December 1996 respectively. In both cases, COMOPTEVFOR concluded that the F/A-18E/F was potentially operationally effective and potentially operationally suitable.
A single DAB-level decision was reached in March 1997, with a decision to enter Low Rate Initial Production (LRIP) and delegation to the Navy of the MS III full-rate production decision. First flight of the F/A-18E/F occurred in November 1996. A total of seven aircraft are included in the EMD program. These aircraft have been undergoing testing by an integrated test team of contractor and Navy pilots since early 1997 and have amassed over 3500 flight hours. Flight-testing during 1997 revealed the presence of a phenomenon described as "wing drop." The current status of these phenomena is discussed in the Test and Evaluation Assessment section.
Prior to full-rate production, three LRIP lots are planned. LRIP-1 (12 aircraft) and LRIP-2 (20 aircraft) are currently under contract. LRIP-1 includes the aircraft that will be tested during OPEVAL.
The F-18E/F Live Fire Test and Evaluation Program was granted a waiver to conduct less than full-up, system-level testing in May 1992. Concurrent with the waiver approval, the program was permitted to execute an Alternative Plan, which included comprehensive ballistic testing of components and major assemblies. Building on the vulnerability reduction program for the early F/A-18 aircraft and joint live fire testing of the F/A-18C, as well as actual combat damage incidents, the Navy continues to pursue an aggressive LFT&E program for the F/A-18E/F.
TEST & EVALUATION ACTIVITY
OT-IIA was completed in November 1997 with an assessment of potentially operational effective and potentially operationally suitable. Flight-testing focused on validation of the performance data base to assess the accuracy of range and performance predictions. All key performance parameters were met.
OT-IIB, conducted in two phases, was completed in November 1998. An expanded envelope afforded the pilots the opportunity to evaluate the aircraft in a wide variety of tactical roles such as Weapons Delivery Accuracy, Dissimilar Air Combat Maneuvering, Night Vision Device Suitability, Fighter Escort, Interdiction, and Close Air Support.
Other testing that pertains to F/A-18E/F survivability and is being monitored by DOT&E includes the ALE-50 Towed Decoy and the Integrated Defensive Electronic Countermeasures System (IDECM).
The LFT&E Alternative Plan includes ballistic tests on the F/A-18E/F airframe originally manufactured for drop and barricade testing. Prior to the airframe being designated as an LFT article, it suffered damage during barricade testing. Subsequently, the airframe was shipped to Boeing facilities in St. Louis, MO, where all repairs were completed. Following certification by the Navy, the airframe was designated as SV52, the LFT article. SV52 is the third production F/A-18E EMD aircraft. A fuel cell qualification test (non-ballistic) was conducted on the airframe during June 1998, which indicated that design goals would be met. Ballistic events against the SV52, scheduled for FY99, include testing of the horizontal stabilator and the wing leading edge, various engine vulnerability tests, and various fire suppression tests. Testing conducted during FY98 has focused on system components and subassemblies. An extensive effort was also conducted on the F414 engine.
TEST & EVALUATION ASSESSMENT
The DOT&E assessment agrees with COMOPTEVFOR's conclusion that the FA-18E/F is potentially operational effective and potentially operationally suitable. The aircraft is mature for this stage of development and performed impressively in several areas. However, current roadmap systems such as the Joint Helmet Mounted Queuing System, AIM-9X, Integrated Defensive Electronic Countermeasures and other programs are key to E/F viability against future threats. Fighter escort and Combat Air Patrol were two areas that the aircraft's increased weapons loadout and increased fuel capacity overcame several deficiencies. These included high altitude climb performance, buffet, tactical ceiling, Vmax and acceleration. Air Combat Maneuvering noted several positive features including increased departure resistance, improved cockpit field of view, and the ability to positively point the nose. Air to Ground Weapons delivery accuracy was lauded as superior garnering 2 mil accuracy.
The OT&E and LFT&E programs underway and planned for the remainder of the EMD phase are judged adequate to resolve all critical operational issues by MS III in 2000. DOT&E is closely involved in ongoing DT and OT, is monitoring the program's LFT&E activities, and will provide an independent assessment of the final results via a B-LRIP report at MS III. In that report, DOT&E plans to assess the survivability of the F/A-18E/F both in the "as tested" OPEVAL-configuration and in the intended fleet configuration incorporating the IDECM suite currently under development as a separate EMD program.
The following paragraphs highlight key testing issues:
Towed Decoy
- The ALE-50 towed decoy is expected to be critical to meeting the survivability criteria for the F/A-18E/F since it will be the only Electronic Protection available for the airplane during OPEVAL. The current ALE-50 towed decoy cable burns off in flight with afterburner selected under certain conditions. Flight-testing has also demonstrated that the heat from engine exhaust in basic engine (no afterburner) can cause the dielectric material in the cable to soften, thus causing arcing that inhibits electrical power to the decoy. The useable flight envelope continues to be explored in flight test.
- Efforts to correct this problem have included a "goal post" attachment on the aft bottom of the airplane designed to hold the cable further from the jet exhaust. Although testing to determine the useable flight envelope is not complete, initial results show this attachment helps keep the cable from burning. Total endurance time for the cable with maneuvering is currently unknown.
- IDECM will use a fiber-optic tow cable that will have different properties from the current ALE-50 tow cable. The current IDECM design has the fiber optics wrapped around the outside of the cable's structural core. Flight characteristics and reaction to exhaust heat of the fiber optic cable are not fully known; however, similar problems with engine exhaust burning the cable are likely. Another unknown factor is the effect of the IDECM fiber-optic cable rubbing or chaffing against the goal post fixture rather than free floating in the air stream. Flight tests of a mass model representing the IDECM decoy have been conducted. Further flight tests of the IDECM design are planned for early FY99, using a modified F/A-18D.
Lateral Activity and Buffet
- "Wing Drop" describes an uncommanded rapid wing drop, or change in roll angle, that occurs in the heart of the maneuvering flight envelope. During Integrated Test Team flight testing, wing drop was found to occur between 7-12 degrees angle of attack and .7-.95 mach. It was repeatable because it could be expected to occur when flying within this regime; however, it was not "predictable" because of the conditions that caused onset of wing drop and the resulting direction and severity of roll varied. Sometimes the pilot could easily correct the roll with a small bank-angle change; other times, full lateral stick was not enough to "lift" the wing. When this occurred the pilot had to release the stick to allow the aircraft to recover nose low and build airspeed before flying again. Other times the wing drop did not occur.
- In support of program office efforts, a Blue Ribbon Panel including both NASA-Ames and NASA-Langley members conducted an independent review in September 1997. As more flight-testing revealed no easy solutions, in December 1997, a second Blue Ribbon Panel was formed, consisting of many industry and government members. The panels made numerous recommendations. To better understand the flow mechanisms of wing drop, the panel recommended a flight test approach with supporting wind tunnel and Computational Fluid Dynamics solutions. Specifically for the F/A-18 E/F program they advised to "continue the systematic approach of flight-testing to optimize their design so as to minimize buffet and other impacts." The program complied with this recommendation, analyzing and flight testing a variety of potential solutions. Another panel recommendation was that the DoD "initiate a national effort to thoroughly and systematically study the wing drop phenomena" so that future programs could benefit. DOT&E championed this national effort to study wing drop. Accordingly, AIR 4.0, the Assistant Commander for Research and has taken the lead in coordinating efforts both within the services and industry. The F/A-18E/F program office is cooperating fully with the effort.
- A porous wing fold fairing was determined to be the most promising fix for wing drop, and multiple versions were tested to determine the optimum design. A Developmental Test phase included a limited number of test flights with operational test pilot on a chosen configuration to access the acceptability of the solution. Wing drop was found to be greatly reduced but two forms of buffet were manifested. The first was experienced in 1G transonic flight and is analogous to driving on a gravel road. The other occurred at a variety of altitudes and configurations and was associated with varying angle of attack in a turn. Neither was qualitatively assessed to interfere with task accomplishment. Testing of various engineering configurations to alleviate buffet continues to include flight test of a thickened trailing edge flap and improved flight control software.
- A dynamic operational test of the aircraft, OT II B, was conducted in two phases. In the first phase, eighteen sorties were flown emphasizing weapons delivery accuracy and limited low-level flights. During this test phase, the single aircraft was equipped with a developmental version of the porous wing fairing. These flights, as well as concurrent developmental test events, suggested that wing drop was controlled to the point that it was called "residual lateral activity." Residual lateral activity involves small, uncommanded changes in wing bank angle that are moderate, correctable and assessed to have little mission impact and no task abandonment.
- Phase 2 of OT-IIB comprised 41 flights conducted with two aircraft and focused on tactics employment in the conduct of representative mission profiles. These missions included Dissimilar Air Combat Maneuvering, Fighter Escort, Interdiction, and Close Air Support. Both aircraft flew with the production-design of the porous wing farings and with the most recent flight control software. An expanded envelope afforded the pilots the opportunity to evaluate the aircraft in a wider arena than previously experienced. Preliminary results over a wide, aerodynamic spectrum representative of the tactical environment point to a further decrease in residual lateral activity. Some activity remains but has been termed as more analogous to a wing tremble. Buffet was still present and remains identical to what was experienced in the developmental test phase flights. Again, it did not interfere with task accomplishment but, in some long duration missions, could easily become tiring and distracting. The Integrated Test Team continues to test and has not yet flown all of the recommended fixes and combinations to further reducing buffet.
- Along with continued data collection in the air and wind tunnel, solution options will be assessed using a systems engineering approach to determine their impact on key performance parameters such as range, acceleration, and radar cross section. The goal is to maximize the improvements in flying qualities while minimizing the impact on other performance parameters. Any solution will involve tradeoffs.
Acceleration and Climb Performance
- Acceleration of the F/A-18E/F is comparable to the F/A-18C aircraft with either the basic F404 or the Enhanced Performance Engine F404 in subsonic and negative-G regimes. However, the F/A-18E/F is slower to accelerate to supersonic speeds in one G flight compared to the F/A-18C. Closely tied to this is the aircraft climb performance. Above 30000 ft, this performance is substandard. A tiger team is still investigating ways to improve aerodynamic performance. The tactical implications will be assessed during OPEVAL.
Reliability
- Reliability of the F/A-18E/F has been excellent and has received high praise from the test crews. In addition, controls and displays as well as night lighting have received favorable comment.
The F/A-18E/F TEMP, approved by DOT&E in April 1996, is current and being executed. Additionally, the program office completed a Live Fire Alternative Plan that was submitted to Congress by DOT&E.
The F/A-18E/F Live Fire Test program, based on vulnerability analysis, threat analysis, and ballistic testing of components and major subassemblies, is thorough and aggressive. Live Fire testing of the F414 engine indicated that if a blade became separated from a turbine wheel, the blade could penetrate the engine casing and cause damage to other components of the aircraft. The engine casing was redesigned and subsequent tests indicate separated blades will be contained. Fuel ingestion and ballistic tolerance testing have also been conducted on the F-414 with encouraging results in comparison to similar tests of the F-404. Redesign and testing are continuing for the dry bay and engine fire suppression systems. Included among the recommended design improvements: redundant paths in the gas generator ignition circuitry, intervention techniques to protect the gas generator ignition controller from electrical overloads, and revised casing components.
The FA18E/F program is Y2K compliant with the exception of two areas. The first area is the Tactical Mission Planning System (TAMPS). This system supports various phases of mission planning and employment of the Super Hornet as well as other aircraft. It is currently not Y2K compliant but an updated version is planned for release in December 1998. The second area of Y2K noncompliance is the Enhanced Comprehensive Asset Management System (ECAMS) used to track maintenance on the aircraft. It is planned to be replaced by Automated Maintenance Environment (AME) which will be Y2K compliant and in concert with the NALCOMIS Optimized System. AME will be fielded in early CY99.
LESSONS LEARNED
adequacy of supporting modeling and simulation has been mixed. A challenge to the OT program will be to design a test and evaluation strategy that will be able to determine if the F/A-18E/F is more survivable than the F/A-18C/D-a key requirement of the program. Due to the similarity between the two aircraft, any digital model that attempts to predict comparative survivability in a missile fly-out scenario must be a high-fidelity model that can account for the very dynamic environment (maneuver, IDECM, towed decoy, RCS reduction, etc.). Efforts to improve these predictive models using JMASS architecture will likely not be mature in time to support this program.
T&E Program Management has been superb. The Integrated Test Team conducting the EMD flight program at NAS Patuxent River, MD, consists of test pilots from the prime contractor, Navy system command and Navy OT communities. Maintenance and test support is also provided by a combination of government and contractor personnel. This unique management arrangement provides a very rapid, cooperative systems-approach to problem solving, using all available assets and knowledge while providing great insight with early OT involvement in developmental testing.
NEWSLETTER
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