The F-35 Lightning II: From Concept to Cockpit

In the years since the F-35 Joint Strike Fighter development program was awarded to Lockheed Martin, countless articles have appeared in the popular media discussing the merits and challenges of the program. F-35 information has also occasionally appeared in the scientific literature through AIAA or other technical venues. However, an integrated story of the F-35's technical de...

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In the years since the F-35 Joint Strike Fighter development program was awarded to Lockheed Martin, countless articles have appeared in the popular media discussing the merits and challenges of the program. F-35 information has also occasionally appeared in the scientific literature through AIAA or other technical venues. However, an integrated story of the F-35's technical development has heretofore never been presented in a single work.

The purpose of The F-35 Lightning II: From Concept to Cockpit is to tell that story -- a full-spectrum history of the design, development and verification of the F-35 Lightning II as described by the engineers, scientists and managers who were intimately involved throughout the development program. The journey to achieve the F-35's extraordinary capability was long with untold challenges encountered on the path. The reader will find many of the key technical challenges, and the innovative solutions that resulted, discussed herein.

The reader should realize this work is not intended as an overall assessment of the F-35 or the Joint Strike Fighter program. Rather, it is an engineering development story from the perspective of insiders, many of whom dedicated the best part of their career to F-35 and are justifiably very proud of their work.

The book is based on eighteen technical papers presented in a two-day F-35 track at the 2018 AIAA Aviation Forum. The From Concept to Cockpit subtitle appropriately summarizes the contents, with the chapters grouped into three major sections:

· F-35 Program Overview, which begins with an overall history of the program and further presents discussion of aircraft configuration design, weapons integration, key technologies brought into the program, and overviews of aircraft manufacturing and the flight test program.

· F-35 Air Vehicle Design, which presents discussion of key aircraft systems, including airframe structure, flight controls, propulsion, subsystems and mission systems.

· F-35 Test and Verification, which presents discussion of the flight and ground test programs undertaken to verify the F-35's airworthiness, flight performance and mission capability.

The chapters are in a logical progression but are not interdependent, and so one may read the contents in any order without confusion.

Foreword ............................................. xv
Preface .............................................. xvii
Chapter 1 F-35 Program History: From JAST to IOC . . ........... 1
Arthur E. Sheridan, Lockheed Martin Aeronautics Company, Fort Worth, TX;
Robert Burnes, F-35 Lightning II Joint Program Office, Arlington, VA
I. Background . . . .......................................... 1
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Foreword ............................................. xv
Preface .............................................. xvii
Chapter 1 F-35 Program History: From JAST to IOC . . ........... 1
Arthur E. Sheridan, Lockheed Martin Aeronautics Company, Fort Worth, TX;
Robert Burnes, F-35 Lightning II Joint Program Office, Arlington, VA
I. Background . . . .......................................... 1
II. Joint Advanced Strike Technology ........................... 3
III. Concept Demonstration Phase: Joint Strike Fighter . ............. 7
IV. System Development and Demonstration .................... 15
V. International Participation . . ............................... 53
VI. Transition to Production . . . ............................... 59
VII. Operations: Road to Initial Operational Capabilities . ............ 65
VIII. Upcoming Plans: Future Developments . ..................... 70
IX. Summary and Conclusions . ............................... 70
Appendix: Acronym List . . . .................................... 71
Acknowledgments . . ......................................... 74
References . . . .............................................. 74
Chapter 2 F-35 Air Vehicle Configuration Development ......... 77
Mark A. Counts, Brian A. Kiger, John E. Hoffschwelle and Adam M. Houtman, Lockheed
Martin Aeronautics Company, Fort Worth, TX; Greg Henderson, Lockheed Martin
Aeronautics Company (retired), Beulah, WY
I. Introduction . . ......................................... 77
II. Initial Development: Technologies for Tactical Aircraft ........... 78
III. Concept Demonstration Phase . . . .......................... 83
IV. Concept Demonstration Aircraft . . .......................... 87
V. Preferred Weapon System Concept ......................... 93
VI. System Development and Demonstration .................... 97
VII. STOVL Weight Attack Team .............................. 103
VIII. Weight Management ................................... 111
IX. Test and Evaluation . ................................... 114
vii
X. Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Acknowledgments . . ........................................ 118
References . . . ............................................. 118
Chapter 3 F-35 Air Vehicle Technology Overview ............. 121
Chris Wiegand, Bruce A. Bullick, Jeffrey A. Catt, Jeffrey W. Hamstra,
Greg P. Walker and Steve Wurth, Lockheed Martin Aeronautics Company,
Fort Worth, TX
I. Introduction . . ........................................ 121
II. Integrated Air Vehicle Subsystems ......................... 124
III. Propulsion Technologies . . . .............................. 139
IV. Conclusion . . . ........................................ 157
Acknowledgments . . ........................................ 158
References . . . ............................................. 158
Chapter 4 F-35 Digital Thread and Advanced Manufacturing .... 161
Don A. Kinard, Lockheed Martin Aeronautics Company, Fort Worth, TX
I. Introduction . . ........................................ 161
II. F-35 Lean Manufacturing . . .............................. 164
III. F-35 Materials and Structures: Supportable Low Observables . . . . 166
IV. The Digital Thread . . ................................... 168
V. The Future of Advanced Manufacturing . .................... 176
VI. Conclusion . . . ........................................ 181
References . . . ............................................. 181
Chapter 5 F-35 Weapons Design Integration ................ 183
Douglas M. Hayward and Andrew K. Duff, Lockheed Martin Aeronautics
Company, Fort Worth, TX; Charles Wagner, F-35 Joint Program Office,
Arlington, VA
I. Introduction . . ........................................ 183
II. F-35 Weapons Suite and General Arrangement ............... 184
III. Internal Weapon Bay Design .............................. 187
IV. External Weapon Carriage Design ......................... 195
V. Suspension and Release Equipment Design . . . ............... 198
VI. Gun System Design . ................................... 203
VII. Stores Management System Design ........................ 206
VIII. Future Weapons Growth . . . .............................. 209
IX. Conclusion . . . ........................................ 211
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Acknowledgments . . ........................................ 212
References . . . ............................................. 212
Chapter 6 F-35 System Development and Demonstration
Flight Testing at Edwards Air Force Base and Naval Air Station
Patuxent River ........................................ 213
Mary L. Hudson and Michael L. Glass Lockheed Martin Aeronautics
Company, Edwards Air Force Base, CA; Lt Col Tucker “Cinco” Hamilton,
United States Air Force, Edwards Air Force Base, CA; C. Eric Somers
and Robert C. Caldwell, Lockheed Martin Aeronautics Company,
Naval Air Station Patuxent River, MD
I. Introduction . . ........................................ 213
II. Edwards Air Force Base .................................. 217
III. Naval Air Station Patuxent River . . ......................... 237
IV. Conclusion . . . ........................................ 249
Acknowledgments . . ........................................ 250
References . . . ............................................. 251
Chapter 7 F-35 Structural Design, Development,
and Verification ....................................... 253
Robert M. Ellis, Philip C. Gross, Joseph B. Yates and John R. Casement,
Lockheed Martin Aeronautics Company, Fort Worth, TX; R.H.L. (Tad) Chichester,
Lockheed Martin Aeronautics Company (retired), Fort Worth, TX; Kathryn
Nesmith, F-35 Joint Program Office, Arlington, VA
I. Introduction . . ........................................ 253
II. TASK I: Design Information . .............................. 256
III. TASK II: Design Analysis and Development Testing . ........... 262
IV. TASK III: Full-Scale Testing . . .............................. 267
V. TASK IV: Certification and Force Management Development ..... 282
VI. TASK V: Force Management Execution . . .................... 284
VII. Conclusion . . . ........................................ 285
References . . . ............................................. 285
Chapter 8 F-35 Flight Control Law Design, Development,
and Verification ....................................... 287
Jeffrey J. Harris and James Richard Stanford, Lockheed Martin Aeronautics
Company, Fort Worth, TX
I. Nomenclature . ........................................ 288
II. Introduction . . ........................................ 288
III. Control Law Design Methodology ......................... 290
TABLE OF CONTENTS ix
IV. Verification . . . ........................................ 309
V. Conclusion . . . ........................................ 310
Acknowledgments . . ........................................ 310
References . . . ............................................. 311
Chapter 9 F-35 Propulsion System Integration, Development,
and Verification ....................................... 313
Steven P. Wurth and Mark S. Smith, Lockheed Martin Aeronautics
Company, Fort Worth, TX
I. Introduction . . ........................................ 313
II. F-35 Propulsion System Overview ......................... 314
III. Conceptual Design, Test, and Verification for Concept
Feasibility: ASTOVL/LSPM . . .............................. 316
IV. Preliminary Design, Test, and Verification of Functional
Feasibility: CDP/X-35 ................................... 319
V. Detailed Design, Test, and Verification for Operational
Deployment: SDD/F-35 .................................. 339
VI. Conclusion . . . ........................................ 361
Acknowledgments . . ........................................ 363
References . . . ............................................. 363
Chapter 10 F-35 Subsystems Design, Development, and
Verification ........................................... 365
Drew Robbins, John Bobalik, David De Stena, Ken Plag, Keith Rail and Ken Wall,
Lockheed Martin Aeronautics Company, Fort Worth, TX
I. Introduction . . ........................................ 365
II. Systems Overview . . . ................................... 367
III. Requirements Derivation . . .............................. 375
IV. Key Technology Development . . . ......................... 378
V. Integration Qualification Effort/Challenges................... 385
VI. Conclusion . . . ........................................ 398
Acknowledgments . . ........................................ 398
References . . . ............................................. 398
Chapter 11 F-35 Mission Systems Design, Development, and
Verification ........................................... 399
Greg Lemons, Karen Carrington, Thomas Frey and John Ledyard,
Lockheed Martin Aeronautics Company, Fort Worth, TX
I. Introduction . . ........................................ 399
II. The Vision ............................................ 400
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III. F-35 Sensor Suite . . . ................................... 403
IV. Fusing the Data into Information . ......................... 413
V. Next-Generation Cockpit . . . .............................. 415
VI. Verification . . . ........................................ 418
VII. Conclusion . . . ........................................ 419
References . . . ............................................. 420
Chapter 12 F-35 Information Fusion ....................... 421
Thomas L. Frey, J. Chris Aguilar, Kent R. Engebretson, David K. Faulk and
Layne G. Lenning, Lockheed Martin Aeronautics Company, Fort Worth, TX
I. Nomenclature . ........................................ 421
II. Introduction . . ........................................ 422
III. Fusion Architecture . . ................................... 425
IV. The F-35 Information Fusion Approach . .................... 427
V. Information Tiers ....................................... 428
VI. Evidence-Based Combat Identification . . .................... 430
VII. Autonomous Sensor Management ......................... 433
VIII. Cooperative Sensing . ................................... 435
IX. Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
References . . . ............................................. 437
Chapter 13 F-35 Carrier Suitability Testing .................. 441
Tony Wilson, Lockheed Martin Aeronautics Company, Fort Worth, TX
I. Nomenclature . ........................................ 441
II. Introduction . . ........................................ 442
III. Background . . . ........................................ 445
IV. Shore-Based Testing . ................................... 468
V. Ship-Based Testing . . ................................... 485
VI. Conclusion . . . ........................................ 500
References . . . ............................................. 502
Chapter 14 F-35 Aerodynamic Performance Verification ........ 503
David G. Parsons, Austin G. Eckstein and Jeff J. Azevedo, Lockheed Martin
Aeronautics Company, Fort Worth, TX
I. Nomenclature . ........................................ 503
II. Introduction . . ........................................ 504
III. Background . . . ........................................ 504
IV. Performance Management . .............................. 508
TABLE OF CONTENTS xi
V. Flight Test Approach . ................................... 511
VI. Flight Test Analysis Results . .............................. 516
VII. Conclusion . . . ........................................ 523
Acknowledgments . . ........................................ 523
References . . . ............................................. 523
Chapter 15 F-35 High Angle of Attack Flight Control
Development and Flight Test Results ....................... 525
Daniel G. Canin, Jeffrey K. McConnell and Paul W. James, Lockheed
Martin Aeronautics Company, Fort Worth, TX
I. Nomenclature . ........................................ 526
II. Introduction . . ........................................ 526
III. Aircraft Description . . ................................... 527
IV. Control Law Design . ................................... 534
V. Flight Test Program . ................................... 545
VI. Flight Test Results . . . ................................... 553
VII. Summary ............................................. 570
VIII. Conclusion . . . ........................................ 572
Acronyms ................................................. 572
References . . . ............................................. 573
Chapter 16 F-35 Weapons Separation Test
and Verification ....................................... 575
Christopher F. Hetreed, Matthew D. Carroll and Joe E. Collard, Lockheed Martin
Aeronautics Company, Fort Worth, TX; Richard C. Snyder,
Naval Air Warfare Center, Naval Air Station Patuxent River, MD
I. Nomenclature . ........................................ 575
II. Introduction . . ........................................ 576
III. F-35 Lightning II and Various SDD Weapons . . ............... 579
IV. Modeling ............................................. 584
V. Ground Tests: Validation of the Dynamic System Model . . ...... 599
VI. Typical Store Separation Flight Test Instrumentation ........... 602
VII. F-35 Store Separation Flight Testing: Validating Store
Aerodynamics Models................................... 606
VIII. F-35 Store Separation Flight Test Vignettes . . . ............... 627
IX. Conclusion . . . ........................................ 637
Acknowledgments . . ........................................ 638
References . . . ............................................. 639
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Chapter 17 F-35 STOVL Performance Requirements
Verification ........................................... 641
David G. Parsons and Daniel E. Levin, Lockheed Martin Aeronautics Company,
Fort Worth, TX; David J. Panteny and Peter N. Wilson, BAE Systems,
Warton, United Kingdom; Michael R. Rask, Cummings Aerospace, Niceville,
FL; Brad L. Morris, Naval Air Systems Command, Naval Air Station
Patuxent River, MD
I. Introduction . . ........................................ 642
II. Background . . . ........................................ 643
III. F-35 STOVL Performance Requirements Verification . ........... 645
IV. Short Takeoff Performance Verification . .................... 646
V. Vertical Landing Bring-Back Performance Verification .......... 659
VI. Conclusion . . . ........................................ 679
References . . . ............................................. 680
Chapter 18 F-35 Climatic Chamber Testing and
System Verification ..................................... 681
Victorio J. Rodriguez and Billie Flynn, Lockheed Martin Aeronautics Company,
Fort Worth, TX; Marc G. Thompson, BAE Systems, Warton,
United Kingdom; Steven Brelage, Naval Air Warfare Center Aircraft
Division, Naval Air Station Patuxent River, MD
I. Introduction . . ........................................ 681
II. F-35 vs Previous Aircraft Climatic Testing .................... 682
III. Mckinley Climatic Laboratory Test Facility ................... 684
IV. Challenges and Decisions in Defining and Scheduling
Climatic Test Activities .................................. 684
V. Aircraft Modification, Facility, and Test Plan Preparation . . ...... 687
VI. Entry into Test Facility and Test Execution ................... 694
VII. F-35 Icing Cloud Testing . . . .............................. 696
VIII. Thermal Management System Testing . . .................... 704
IX. F-35 Climatic Testing Results Summary and Lessons Learned . . . . 705
X. Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 708
Acknowledgments . . ........................................ 709
About the Authors ..................................... 711
Index .............................................. 721
Supporting Materials .................................. 743
TABLE OF CONTENTS xiii
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