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Old 3rd Dec 2007, 20:34
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ORAC
Ecce Homo! Loquitur...
 
Join Date: Jul 2000
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JSF Hit By Serious Design Problems

The AD software module issue seems a mirror image of the Typhoon A-G issues that so many have been slagging off for so long. So maybe it won't be that much better than the GR9 in the AD role for a while. Standby for further slippages and price escalations....

DID: F-35 JSF Hit by Serious Design Problems

On May 3, 2007, during the 19th test flight of the prototype of the F-35A Joint Strike Fighter (JSF), a serious electrical malfunction occurred in the control of the plane. After an emergency landing the malfunction could be identified as a crucial problem, and it became clear that redesign of critical electronic components was necessary. Producer Lockheed Martin and program officials first announced there was a minor problem, and later on they avoided any further publicity about the problems.

The delay has become serious, however, and rising costs for the JSF program seem to be certain......

On May 3, 2007 with the second test pilot Jeff Knowles at the stick, a serious malfunction hits the JSF. At 38,000 feet (12 km) level flight and at a speed of some 800 km/hour, the plane executed a planned, 360-degree roll but experienced power loss in the electrical system about halfway through the manoeuvre.

In an emergency procedure, power is restored and Jeff Knowles regains control of the plane. The pilot cuts short this 19th test flight and makes an emergency landing in Fort Worth, TX. Due to control problems with right wing flaperons, the JSF has to make that landing at an exceptional high speed of 220 knots (350 km/hr). The plane's undercarriage, brakes and tires are damaged. The plane is stopped, surrounded by emergency vehicles, and towed away, but several eyewitnesses take pictures of the emergency landing.

Lockheed Martin technicians identify a component in the 270-power supply as the culprit in the near-accident. The JSF's new technology includes new electro-hydrostatic actuators (EHAs) for the flight control system, replacing more conventional hydraulic systems......After several weeks of evaluations, the engineers learn that there are serious design problems in this new electrical system. Expensive redesign will be necessary.....

Another fact was discovered via a military employee of one of the European air forces, who works within the JSF project team, and is a liaison person for several air forces. He says that flying in 2012 with the JSF may be safe and the JSF can be used as a plane to fly around. But, the several software modules for weapons system integration will not be ready. Ground attack capability is the priority, so early-build F-35s will primarily be "bomb trucks" until the additional software modules can be tested and loaded. Air superiority capabilities will be restricted, and completed only after 2015. This means that full multi-role capability is possible by 2016 at the earliest, if and only if no major problems occur in development and testing of the weapon systems software.......

Nor are these the only challenging problems facing the F-35 program. The F-35C naval variant's Hamilton Sundstrand power generator was mistakenly designed to only 65% of the required electric output. To accommodate the required increase, it will also be necessary to redesign the gearbox for the standard Pratt & Whitney F135 engine, which will be fitted into the conventional F-35A version as well as the naval F-35C. The contract announced by the US Department of Defense in August 2007 says that this engine update won't be ready for use until the end of 2009, which is almost the beginning of low-rate initial production.

Lockheed Martin can issue a subcontract to Hamilton Sundstrand to fix the F135's power generator without any publicity, and they have done so. As of December 1, 2007, neither Lockheed Martin's nor Hamilton Sundstrand's 2007 news archives show any trace of this award. Pratt & Whitney has a separate government contract for the F135 engine, however, and the award's size forces the Pentagon to announce the award under its rules for publicizing contracts.

Although it seemed probable that last October the JSF would fly again, a new problem arose. During a test run of the F135 engine, part of the engine was blown up by overheating. On November 14, 2007, an eyewitness took pictures of the transportation of a new F135 engine. The date for test flight number 20 (of the scheduled 5,000 test flights) is still unknown.........
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