On 14th July Mick Mansell
visited Kingston from 'oop North' to tell
us about some of the things he was involved with as BAES HQ Future
Systems & Technology Director. Most us remember him from the late
'60s to the late '80s as an avionic systems engineer at Kingston and
Dunsfold, Head of Avionics, Chief Designer Harrier I and Executive
Director Design. He was promoted out of Kingston to be HQ Director of
Projects, Director of Advanced Technology at Warton, Joint Strike
Fighter Director & Chief Engineer at McAir, St Louis, then back at
Warton as Business Development Director, HQ FS&T Director and
finally Future Air Systems Director, retiring at the end of 2002.
In his introduction Mick explained that new
generations of systems
design was now concerned with exploitation of the electromagnetic
spectrum using digital networks, high power microwaves and lasers,
software and new media. The next steps would involve bioengineering and
nanotechnology.
Experiences With New Technologies
In the military field we now had network-centric warfare. Coming up was
the exploitation of space, quantum computing, fully autonomous systems,
full electromagnetic spectrum dominance and global strike. In the
digital battlefield everyone talks together. Target information is fed
to central control where target tracks are determined from sensors,
analysed and prioritised, then advised to the operators.
Moving on Mick stated that stealth was now
paramount. Ways of achieving stealth were then covered. Give-away radar
emissions could be minimised by utilising memorised one-pulse bursts
which might well go unnoticed or be misinterpreted by the enemy. This
is known as Low Probability of Intercept Radar technology. Vehicle
radar returns had to be minimised so appropriate shaping and absorbing
treatments (known as RAM-Radar Absorbent Material) was fundamental and
accurate manufacture and high quality finish with no discontinuities
was essential, hence the structure is fitted inside the finished skin.
Various radar-absorbent treatments could then be applied externally or
built into the aircraft skins or structure. Stealth was very expensive
to achieve and maintain so usually survivability, performance, weight
and cost were traded to achieve an affordable requirement. However, the
B-2 is said to have had no cap on stealth cost with the outcome that
each bomber had a radar cross section (RCS) reported to be slightly
less than a golf ball…but cost $800 million.
Radar detection range is proportional to the fourth
root of the RCS; reduce the RCS to reduce the detection range. For
every 10 db reduction in aircraft RCS, detection range is halved so a
100 mile detection range becomes 12.5 miles for a 30 db reduction
resulting in improved survivability rates.
To be avoided are: slots and cavities which enhance the radar return
through internal reflection, points which scatter the radar signal
resulting in some returns, circular protuberances round which the radar
waves creep back to the sender, joint gaps, discontinuities and joints
between different materials which all cause scatter.
Aircraft configuration contributors to the RCS are:
radome, radar antenna, cockpit and air intake cavities which all
reflect, visible engine fans, external stores, wing leading edge direct
reflection and trailing edge scatter, fins and tailplanes which need to
be angled to avoid reflections, and engine nozzles. The objective is to
ensure that the azimuth spikes in the radar reflection polar diagram
are limited in number. Four is the minimum achievable on a bomber (B2)
compared to a non stealth aircraft's plethora of spikes allowing
detection from any angle. The stealthy fighter design will have a
larger number of spikes due to retention of tailplanes and fins
dictated by manoeuvre requirements. Each reflecting section is then
carefully designed to minimize and control the direction of the spike.
This spike direction control is achieved by careful
shaping such as the forward fuselage section with flat planes and
chines and by using radar absorbent material (RAM). On wings and tails
all sweeps are aligned to give one spike, and fins are deleted or
angled. (The B-2 has no fins using split ailerons for yaw control, but
in the target area these are locked and differential thrust is used.)
All panel edges and hinge lines are similarly aligned. Radomes are
designed as filters allowing transmission of only the user's
frequencies and the bulkheads are treated with RAM. Engines are buried
and fed by long, smoothly curved, RAM-lined, 'S' shaped ducts which
hide the fan and attenuate radar waves entering and reflecting within
the intake. Boundary layer ducts and ramps are replaced by aerodynamic
shaping of the fuselage sides ahead of the intake. Canopies are coated
with gold or tungsten carbide to deflect the radar and prevent it
entering and being reflected back by the cockpit cavity. Wing leading
edges are made from Kevlar and act like radomes so the radar enters the
edge cavities to be absorbed by RAM. Joints are filled with "butter"-
plastic putty containing ferrous materials (eg iron filings). Pitot
sensors are flush and all antennas are buried in the skins (surface
mounted).
Radar signature measurement cannot be scaled so all
ground rig testing must be done using full size aircraft or components
on a special range such as that at Warton. In hostile areas
manoeuvring, especially in roll, is to be avoided because this would
negate the carefully contrived azimuth spikes and display spikes from
the upper of lower aircraft surfaces; approach to and exit from the
target is straight and level, a test of pilot nerve. Interestingly
there have so far been three generations of stealthy aircraft
approximately a decade apart: F-117A of 1983, B-2 of 1993 and the F-22
of 2003.
Thermal control is also necessary to prevent
infra-red (IR) sensing. Outlets on the front fuselage are avoided, all
hot exhausts being collected and dumped in the engine efflux which is
itself mixed with cool air and possibly released, hidden from ground
observers, over the top of the wing. Airframes can be treated to
minimise IR emissivity, in fact, G-HAWK was used for such trials. The
effects of kinetic heating and exhaust plumes cannot be accurately
predicted so it's a case of build and test. However, the use of reheat
in the target area is to be avoided.
This had been a concentrated, clear and
completely absorbing lecture, especially enjoyed by the retired
engineers amongst us who felt that they had been brought up to date in
one easy lesson. The vote of thanks was given by Mick's old boss at
Kingston, Ralph Hooper.