IMPROVING THE EFFICIENCY OF ENGINES FOR LARGE NONFIGHTER AIRCRAFT
THE NATIONAL ACADEMIES PRESS
Washington, D.C.
www.nap.edu
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NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The members of the committee responsible for the report were chosen for their special competencies and with regard for appropriate balance.
This study was supported by Grant F49620-01-1-0269 between the U.S. Air Force and the National Academy of Sciences. Any opinions, findings, conclusions, or recommendations expressed in this publication are those of the author(s) and do not necessarily reflect the view of the organizations or agencies that provided support for the project.
International Standard Book Number-13: 978-0-309-10399-2
International Standard Book Number-10: 0-309-10399-1
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THE NATIONAL ACADEMIES
Advisers to the Nation on Science, Engineering, and Medicine
The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished scholars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. Upon the authority of the charter granted to it by the Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and technical matters. Dr. Ralph J. Cicerone is president of the National Academy of Sciences.
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COMMITTEE ON ANALYSIS OF AIR FORCE ENGINE EFFICIENCY IMPROVEMENT OPTIONS FOR LARGE NON-FIGHTER AIRCRAFT
KENNETH E. EICKMANN, Chair,
U.S. Air Force (retired)
NATALIE W. CRAWFORD, Vice Chair,
The RAND Corporation
DILIP R. BALLAL,
University of Dayton, Ohio
MEYER J. BENZAKEIN,
Ohio State University
JOHN-PAUL B. CLARKE,
Georgia Institute of Technology
DAVID E. (ED) CROW,
University of Connecticut
ALAN H. EPSTEIN,
Massachusetts Institute of Technology
FRANK C. GILLETTE, JR., Independent Consultant
WILFRED GOODSON,
STR, L.L.C.
JEFFREY W. HAMSTRA,
Lockheed Martin Aeronautics Company
S. MICHAEL HUDSON, Independent Consultant
CLYDE KIZER,
Airbus Service Company, Inc.
NEIL E. PATON,
Liquidmetal Technologies
JONATHAN PROTZ,
Duke University
RENE G. RENDON,
Naval Postgraduate School
ELI RESHOTKO,
Case Western Reserve University (emeritus)
RAYMOND VALEIKA, Independent Consultant
ALAN VAN WEELE,
Northrop Grumman
FRANCIS VELDMAN,
The Boeing Company
OBAID YOUNOSSI,
The RAND Corporation
Staff
JAMES C. GARCIA, Study Director
DANIEL E.J. TALMAGE, JR., Program Officer
CARTER W. FORD, Associate Program Officer
MARTA VORNBROCK, Associate Program Officer
LaNITA R. JONES, Program Associate
LINDSAY D. MILLARD, Research Associate
DIONNA ALI,
Anderson Commonweal Intern
AIR FORCE STUDIES BOARD
LAWRENCE J. DELANEY, Chair,
Titan Corporation (retired)
TAYLOR W. LAWRENCE, Vice Chair,
Raytheon Company
FRANK J. CAPPUCCIO,
Lockheed Martin Corporation
THOMAS DARCY,
EADS North America Defense Company
STEVEN D. DORFMAN,
Hughes Electronics (retired)
PAMELA A. DREW,
Boeing Integrated Defense Systems
KENNETH E. EICKMANN,
U.S. Air Force (retired)
JOHN V. FARR,
Stevens Institute of Technology
RAND H. FISHER,
Titan Corporation
JACQUELINE GISH,
Northrop Grumman
KENNETH C. HALL,
Duke University
WESLEY L. HARRIS,
Massachusetts Institute of Technology
LESLIE KENNE,
LK Associates
DONALD J. KUTYNA,
U.S. Air Force (retired)
GREGORY S. MARTIN,
GS Martin Consulting
DEBASIS MITRA,
Bell Laboratories
CHANDRA N. KUMAR PATEL,
University of California
ROBERT F. RAGGIO,
Dayton Aerospace, Inc.
GENE W. RAY,
GMT Ventures
LOURDES SALAMANCA-RIBA,
University of Maryland
MARVIN R. SAMBUR,
Headquarters, U.S. Air Force (retired)
LYLE H. SCHWARTZ,
Air Force Office of Scientific Research (retired)
EUGENE L. TATTINI,
Jet Propulsion Laboratory
Staff
MICHAEL A. CLARKE, Director
JAMES C. GARCIA, Senior Program Officer
DANIEL E.J. TALMAGE, JR., Program Officer
CARTER W. FORD, Associate Program Officer
MARTA VORNBROCK, Associate Program Officer
DETRA BODRICK-SHORTER, Administrative Coordinator
CHRIS JONES, Financial Associate
LaNITA R. JONES, Program Associate
LaSHAWN N. SIDBURY, Program Associate
WILLIAM E. CAMPBELL, Senior Program Associate
Preface and Acknowledgments
This study was requested by the Secretary of the Air Force and the Commander of the Air Force Materiel Command to identify opportunities to address the impact of rapidly increasing aircraft fuel costs. The committee sincerely hopes that this report—the culmination of an extremely focused effort on a short schedule—will enable the Air Force to make informed decisions on improving fuel efficiency for the large nonfighter aircraft inventory. We applaud the committee members for their commitment and diligence, which enabled us to complete the task successfully.
This report has been reviewed in draft form by individuals chosen for their diverse perspectives and technical expertise, in accordance with procedures approved by the National Research Council’s (NRC’s) Report Review Committee. The purpose of this independent review is to provide candid and critical comments that will assist the institution in making its published report as sound as possible and to ensure that the report meets institutional standards for objectivity, evidence, and responsiveness to the study charge. The review comments and draft manuscript remain confidential to protect the integrity of the deliberative process. We wish to thank the following individuals for their review of this report:
James L. Bettner, Propulsion Consultant
Pierre Chao, Center for Strategic and International Studies
Lawrence J. Delaney, Private Consultant
Jack L. Kerrebrock, Massachusetts Institute of Technology
James O’Connor, Pratt & Whitney (retired)
Frank Pickering, GE Aircraft Engines (retired)
Charles F. Tiffany, The Boeing Company (retired)
Robert C. Turnbull, T.K. Engineering Associates, Inc.
Although the reviewers listed above provided many constructive comments and suggestions, they were not asked to endorse the conclusions or recommendations, nor did they see the final draft of the report before its release. The review of this report was overseen by William G. Agnew, General Motors (retired), NAE. Appointed by the NRC, he was responsible for making certain that an independent
examination of this report was carried out in accordance with institutional procedures and that all review comments were carefully considered. Responsibility for the final content of this report rests entirely with the authoring committee and the institution.
The committee acknowledges and appreciates the contribution of the members of the Air Force Studies Board (AFSB) of the NRC for developing the study statement of task in concert with the Air Force sponsor. The AFSB was established in 1996 by the National Academies at the request of the United States Air Force. The AFSB brings to bear broad military, industrial, and academic scientific, engineering, and management expertise on Air Force technical challenges and other issues of importance to senior Air Force leaders. The board discusses potential studies of interest, develops and frames study tasks, ensures proper project planning, suggests potential committee members and reviewers for reports produced by fully independent ad hoc study committees, and convenes meetings to examine strategic issues. The board members listed on page vi were not asked to endorse the committee’s conclusions or recommendations, nor did they review the final draft of this report before its release, although board members with appropriate expertise may be nominated to serve as formal members of study committees or as report reviewers.
The committee is very grateful to the Air Force for its dedicated support throughout the study and for the efforts of National Research Council staff members Michael Clarke, Jim Garcia, Daniel Talmage, Carter Ford, Marta Vornbrock, Detra Bodrick-Shorter, LaNita Jones, LaShawn Sidbury, Bill Campbell, Lindsay Millard, and Dionna Ali.
Kenneth E. Eickmann, Chair
Natalie W. Crawford, Vice Chair
Committee on Analysis of Air Force Engine Efficiency Improvement Options for Large Non-fighter Aircraft
Acronyms
AAFRF assured aerospace fuels research facility
AD airworthiness directive
ADANS Airlift Deployment Analysis System
AFRL Air Force Research Laboratory
AFSAB Air Force Scientific Advisory Board
AFTOC Air Force Total Ownership Cost
ALBEN augmented load-balanced exhaust nozzle
AMC Air Mobility Command
APU auxiliary power unit
ATOW average time on wing
AWACS Advanced Warning and Control System
BMW/RR Bavarian Motor Works/Rolls-Royce
CAIG Cost Analysis Improvement Group
CALCM Conventional Air Launched Cruise Missile
CAMPS Consolidated Air Mobility Planning System
CCI capability-to-cost index
CER cost-estimating relationship
CIP component improvement program
CO2 carbon dioxide
CRAF Civil Reserve Air Fleet
CTL coal to liquid
DER Designated Engineering Repair
DESC Defense Energy Support Center
DLR depot-level reparable
DoD Department of Defense
DOE Department of Energy
DSB Defense Science Board
ECM electronic countermeasure
EGT exhaust gas temperature
EMDP Engine Model Derivative Program
EOC engine overhaul costs
EPA Environmental Protection Agency
ESPC Energy Savings Performance Contract
FAA Federal Aviation Administration
FAR Federal Acquisition Regulation
FCF functional check flight
FOB free on board
FOFSD follow-on full-scale development
FSD full-scale development
FSPC Fuel Savings Performance Contract
FT Fischer-Tropsch (process)
GSA General Services Administration
HPT high-pressure turbine
ICAO International Civil Aviation Organization
IHPTET Integrated High Performance Turbine Engine Technology
IPT integrated product team
JSTARS Joint Surveillance and Target Attack Radar System
L/D lift/drag
LCC life-cycle cost
LPT low-pressure turbine
LRS long-range strike
ManTech Manufacturing Technology (DoD program)
MDS mission design series (designator)
MQT military qualification test
NASA National Aeronautics and Space Administration
NATO North Atlantic Treaty Organization
NECPA National Energy Conservation Policy Act
NOx nitrogen oxide
NPV net present value
NRC National Research Council
NRE nonrecurring engineering
O&S operating and support
OEM original equipment manufacturer
OEW operating empty weight
ORNL Oak Ridge National Laboratory
OSD Office of the Secretary of Defense
P&W Pratt & Whitney
PAH polycyclic aromatic hydrocarbon
PMA Production Manufacturing Authority
R&D research and development
RFI request for information
ROI return on investment
RR Rolls-Royce
S&T science and technology
SAF/US Secretary of the Air Force/United States
SFC specific fuel consumption
SiS Share in Savings
SLEP service life extension program
SPR Strategic Petroleum Reserve
STOL short takeoff and landing
T/W thrust to weight ratio
TACC Tanker Airlift Control Center
TER total engine removal
TOW takeoff weight
TRL Technology Readiness Level
TSFC thrust-specific fuel consumption
UAS unmanned aircraft system
UEET ultraefficient engine technology
USAF United States Air Force
VAATE Versatile Affordable Advanced Turbine Engine
WE weight empty