TECHNOLOGY AREAS: Air Platform, Ground/Sea Vehicles, Materials/Processes

ACQUISITION PROGRAM: F-35, Joint Strike Fighter Program

OBJECTIVE: Develop innovative materials capable of operational effectiveness in a high temperature fuel system and engine oil lubrication system

DESCRIPTION: Multiple notional Thermal Management Systems (TMS) studies have shown that increasing both the fuel system and the engine lubrication system allowable temperatures by +25 degrees Fahrenheit would reduce the return-to-tank heat by about 50% (relative to a realistic, representative baseline return-to-tank system). It is necessary to improve both fuel and oil sides of the system due to the strong coupling at the Fuel-Oil Cooler (FOC), where heat exchange from the oil to the fuel requires that allowable temperatures on both side increase in a similar way. As the fuel temperature increases, the amount of excess fuel circulating through the system is reduced and less heat is returned to the tank. Current materials are limited due to thermal creep issues associated with castable aluminum gearboxes as well as fuel pump and valve housing materials (about 300 F) and temperature limitations of elastomeric seals (about 400 F).

Increasing the temperature capability of the entire system would enable the Joint Strike Fighter (JSF) to take advantage of JP8+100 and high thermal stability oils, resulting in a significant TMS improvement. The innovative material developed should be suitable to be used for one or more of the following: elastomeric seals, bearings/ bearing coatings, and rotating seals and coatings. The operational effectiveness of these new materials includes maintaining surface integrity and materials properties during long term exposure (80 days) to fuel temperatures of a maximum of 350 degrees Fahrenheit and engine oil temperature limited to a scavenge temperature of 425 degrees Fahrenheit.

PHASE I: Define the design concept and the materials selection test and validation plan for the high temperature components.

PHASE II: Develop, construct and validate prototype hardware based on the technical requirements and validation plan developed in Phase I.

PHASE III: Transition validated hardware for transition to applicable platforms. It is anticipated that the small company would need to partner with an Original Equipment Manufacturer.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: High temperature, durable, fuel system materials/components are in demand in the private sector for use in various aircraft. Materials that operate at higher temperatures and are more durable than current materials will result in lower maintenance costs and overall life cycle cost reductions.

REFERENCES:
1. Bevilaqua, P. M.,(2005, September-October). Joint Strike Fighter Dual-Cycle Propulsion System. Journal of Propulsion and Power, 21( 5,)778. (http://pdf.aiaa.org/jaPreview/JPP/2005/PVJA15228.pdf)

2. Rajagopalan, R., Schryver, M., & Wood, B. (2003, July). Evolution of Propulsion Controls and Health Monitoring at Pratt and Whitney. AIAA/ICAS International Air and Space Symposium and Exposition: The Next 100 Years. Dayton, Ohio. AIAA 2003-2645.

3. Busam, S. (2000, April) Discussion of `Internal Bearing Chamber Wall Heat Transfer as a Function of Operating Conditions and Chamber Geometry'. Journal of Engineering for Gas Turbines and Power. 122(2) 314, 320, 364

KEYWORDS: F135; F35; Thermal; Managment; Fuel; Lubrication

** TOPIC AUTHOR (TPOC) **

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