Aerospace Testing International - June 2022

76 Pages·2022·19.1 MB·English

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Airships
rise again
The latest technology and digital tools are helping
dirigible developers relaunch lighter than air flight
WWW.AEROSPACETESTINGINTERNATIONAL.COM

contents
Global briefing
6 // World test update
The latest testing news from
around the globe
8 // Airship advances
The world’s largest airship is being
built in Ohio, USA
10 // lilium transition
eVTOL aircraft passes key test
12 // Virtual training Inside this issue
AR-enabled flight is a success
14 //
Flight testing
A scaled flight demonstrator aims to
recalibrate how aircraft are developed
22 22 //
50 Cover Story: Age of the Airship
Test engineers are taking the first steps on
the road to commericalizing airship travel
30 //
Digital dimensions
The T-7 Red Hawk’s fatigue and structural
testing is pushing boundaries
38 //
111444 Core compression
333000
The future development of aero-engines is in
reducing core size and increasing efficiency
44 //
Testing talk: Clint Church
Aurora’s chief engineer on the past and future
of the R&D-focused aerospace company
50 //
Biofuel bonanza
The rocket fuel of the future could be made
from waste plastics
111333/// aaccaaddeemmiicc iinnssiigghhtt 56 //
Concept crunch
Research into wings that can
change shape mid-flight Rapid development of eVTOL aircraft requires
similar growth in their Concept of Operations
666333 ////// ppprrroooddduuuccctttsss aaannnddd ssseeerrrvvviiiccceeesss
All the latest product
innovations, case studies,
company news and more
777444 ////// aafftt ccaabbiinn
Explore the Vickers Vimy’s
historical flight
44
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AEROSPACETESTINGINTERNATIONAL.COM // JUNE 2022
editor’s view
// The team
// A sustainable journey EDITOR Ben Sampson
([email protected])
Several times during the last few months I have been However, since Covid-19 was tamed in most of the ASSISTANT EDITOR Paige Smith
reminded of the ingenuity of engineers at different world another driver can be added to that list – the
EDITORIAL ASSISTANT Benedict Evans
business conferences and events. environment. Societal concern over climate change
SENIOR ART EDITOR Louise Green
I have seen eVTOL aircraft and flying cars at a and an acceptance of the importance of protecting
DESIGN CONTRIBUTORS Andy Bass,
business aviation conference, heard about automated our environment has been growing since the start Anna Davie, Julie Welby
drones at an engineering event and viewed the world’s of the 21st century. The pandemic then showed us
PRODUCTION
first vertiport during a press visit. that life can go on without air travel. Subsequently Sejal Patel
That’s just a modicum of the stunning amount of post-pandemic I have met several people at business CIRCULATION MANAGER
innovation happening in the aerospace sector. And events and conferences who chose not to travel by air Chris Jones
as I hope regular readers of this magazine will attest because of the carbon it would have emitted. Instead PUBLICATION DIRECTOR
to, the industry has seldom seen such high levels of they opted for rail or electric car. Tom Eames ([email protected])
PUBLICATION MANAGER
testing and development before. Large OEMs and It is gratifying to see that environmental Jag Kambo ([email protected])
small startups alike are working hard to reshape air considerations are at the core of most innovation
EDITORIAL DIRECTOR Tom Stone
travel. Engineers are moving concepts off of computer in aviation currently. While other transport modes
screens and into the sky at a rapid rate. similarly reconfigure themselves, that environmental PUBLISHER Simon Hughes
But, it is a valid exercise to pause and analyze what focus needs to be explicit and laser ([email protected])
the end goal of all this industrial progression is. The sharp. The alternative is a COO Jon Benson
changes to aviation are being driven by several factors. significantly smaller world CEO Ben Allen
CHAIRMAN Mark Allen
Technical advances in areas such as electrification, for most people, as was
new materials, computing and communications are experienced during the
playing a large role. Certainly, there is always a drive to pandemic’s lockdowns.
improve products within any industry to better meet
consumer requirements and improve sales. Ben Sampson,
Part of
Air transport is no exception to this. Developing editor
www.markallengroup.com
bigger, better, faster, safer and comfortable aircraft has ben.sampson@
been the goal in aviation for most of its existence. markallengroup.com Aerospace Testing International, ISSN 1478-2774 (print),
ISSN 2397-6411 (online), (USPS 020-657) is published
quarterly by MA Business Ltd,
Hawley Mill, Hawley Road, Dartford, Kent, DA2 7TJ,
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Paul Willis Paul Eden David Hughes Rob Coppinger This will explain how we process, use and safeguard your data.
Paul has been a Editor of the Official David Hughes is an Rob is an engineer Printed in the UK by Pensord, Pontllanfraith, Blackwood, NP12 2YA
journalist for the past 10 Royal Air Force Annual aviation writer with turned journalist, who
years, writing for some Review magazine 20 years at Aviation has been writing about MOVING ON?
of the UK’s largest and Salute historical Week magazine and 10 aerospace technology If you change jobs or your company moves to a new location,
newspapers and journal, Paul is a in the FAA. He served for approaching 20 please contact [email protected] to continue receiving
your free copy of Aerospace Testing International
leading magazines. dedicated aerospace as a USAF Reserve years. He has recently
writer, editor and C-5 pilot. relocated to Brittany, Average net circulation per issue
blogger. France. for the period January 1, 2021 to
December 31, 2021 was 10,078
COVER IMAGE: Airlander
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JUNE 2022 \\ AEROSPACETESTINGINTERNATIONAL.COM
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NEWS
WORLD
test update
//
EVTOL PARTNERSHIP
BEGINS IN BRAZIL
Brazilian aircraft
manufacturer Embraer
is partnering with
READ MORE
several companies to online // VOLTAERO CASSIO HYBRID
// help it develop
FINNISH RESEARCHERS SURPASSES 10,000KM
autonomous systems
USE DRONES TO FIGHT FIRE
for use in its future VoltAero’s Cassio 1 hybrid
Researchers in Finland are to run products, including its Eve electric aircraft surpassed
flight trials of swarms of drones eVTOL aircraft. 10,000km flown this April.
to detect and prevent forest fires. The agreements, which are The milestone was achieved
“We are developing a new part of Project EASy (Embraer as the aircraft flew to Germany’s
AI-based drone technology to Autonomous System), include AERO Friedrichshafen general
quickly detect forest fires and R&D work with USA-based aviation show.
provide situational awareness company Near Earth Autonomy, Cassio 1 is equipped with the
when extinguishing the fires,” camera-based detect and avoid 600 kilowatt parallel hybrid
said Professor Eija Honkavaara, system developer Iris electric propulsion system that
the FireMan project leader Automation, simulation software VoltAero plans to use in its family
from the National Land Survey company Ansys, as well as of 4-12 seat Cassio aircraft.
of Finland. Swiss-AI developer Daedalean VoltAero plans to begin
More researchers will test the and Brazil’s Motora.ai. delivering hybrid-electric Cassio
drones, AI and communications Maurilio Albanese Novaes // aircraft to customers by the end
SKYPORTS TRIALS
systems during prescribed Junior, head of research and of 2023.
DRONES IN SINGAPORE
burning by state-owned forestry technology at Eve said, “We have The Cassio 1 testbed aircraft
organisation Metsähallitus and been working intensely to Vertiport and drone achieved 10,000km (6,200 miles)
the Finnish Forest Centre. co-create the aviation of the infrastructure developer during the 1,650km (1,025 mile)
More than 400,000 hectares of future in a broader collaboration Skyports is to trial ship-to-shore flight between VoltAero’s
forest burned down in 2019 and with key technological partners. cargo drone operations at Royan-Médis headquarters on
half a million hectares was lost This joint work will allow Jurong Port in Singapore. France’s Atlantic Coast to AERO
last year in Europe. Forest fires Embraer to develop innovative Over the next year, Friedrichshafen, where it is
are expected to increase due to new products in line with the Skyports and Jurong being exhibited on Stand A7-101.
global warming. company’s continuous search Port will commence MORE detail The demonstrator aircraft is
Controlling forest fires is of for an efficient and sustainable joint studies to ONLINE a modified Cessna 337
particular interest in Finland future, such as the eVTOL by determine the Skymaster, which was chosen
where 75% of the land area Eve, Embraer’s Urban Air feasibility and for the airframe’s adaptability
is forest. Mobility company.” development of plans for to Cassio’s “push-pull”
Vantaa, Finland Sao Paulo, Brazil cargo drone delivery operations propulsion concept.
and related infrastructure at the Medis, France
port. The trials are part of an
agreement to explore the
development of ship-to-shore
infrastructure and large-scale
drone delivery operations in
Singapore.
Jurong Port, Singapore
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NEWS
//
BOEING STARLINER
COMPLETES TEST FLIGHT
// Boeing’s CST-100 Starliner
SECOND FLIGHT TEST FOR
spacecraft successfully launched,
US HYPERSONIC MISSILE
performed a planned orbital
DARPA and the US Air Force insertion burn to send it to the
completed a flight test of the // International Space Station and
GERMAN HYDROGEN
Lockheed Martin version of the returned to Earth during its
AIRCRAFT ALTITUDE RECORD
Hypersonic Air-breathing second test flight.
Weapon Concept vehicle in April. HY4, the hydrogen powered Starliner’s first test flight in
The Defense Advanced four-seater aircraft being 2019 did not achieve all of its
Research Projects Agency’s developed by Stuttgart, Germany objectives, leading to a second
(DARPA) Hypersonic Air- based H2FLY, has achieved what being scheduled but eventually
breathing Weapon Concept it claims is a world record abandoned last year.
(HAWC) program is developing altitude of 7,230ft. President and CEO of Boeing
and demonstrating technologies Having first flown in Defense, Space and Security Ted
READ more
for air-launched hypersonic 2016, the demonstrator Colbert said, “Starliner is
cruise missiles. The program is aircraft has conducted online designed, built, tested and flown
looking at different designs, more than 90 test by a team of people who are
hydrocarbon scramjet-powered flights and is being used committed to their mission of
propulsion, different ways to deal as a development platform for safely and reliably transporting
with the heat effects experienced a planned 40-seat hydrogen astronauts. They will remain
at hypersonic speeds and electric Dornier 328, which is laser-focused on the spacecraft
different manufacturing planned to enter service in 2025. and its performance throughout
approaches. During the recent Alongside claiming the this flight test.”
test flight the Lockheed Martin altitude record, HY4 also carried The spacecraft carried an
HAWC vehicle was released from out a 77 mile (124km) journey “anthropomorphic test device”
a carrier aircraft, whereupon its between Stuttgart and named Rosie the Rocketeer
scramjet engine was fired and it Friedrichshafen, the first time during the mission.
reached speeds of more than such a flight has been made Low Earth Orbit
Mach 5 and altitudes greater between two major airports,
than 65,000ft. according to H2FLY.
Maryland, USA “This is a remarkable
achievement for H2FLY, as no
other hydrogen-powered
passenger aircraft has flown
between two commercial
airports to date,” said Josef Kallo,
For regular news updates:
co-founder and CEO of H2FLY.
AerospaceTestingInternational.com
Stuttgart, Germany
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AEROSPACETESTINGINTERNATIONAL.COM // JUNE 2022
news
Airship firm
scaling up for
first flight
// An LTA
employee installs
a piece of flight
hardware on
the airship
W ork to build the largest airship in the and to deliver humanitarian aid during “Testing is a critical
world is ramping up in advance of the disaster response and relief efforts.
first flight of its design, which could Manufacturing of Pathfinder 3 is yet to part of building the
happen before the end of this year. start at the Akron Airdock, although the
Founded in 2015 and backed by Google company has assembled prototype framing
next generation
co-founder Sergey Brin, LTA (Lighter Than Air) there. Akron’s Airdock was used almost 100
Research is building a 120m (400ft) long years ago to build Goodyear blimps and US
of airships”
airship called Pathfinder 1 in Mountain View Navy Airships the USS Akron and Macon. The
California, and its 180m (600ft) successor, facility at Moffett Field in California was a
Pathfinder 3 at Akron, Ohio. blimp hangar and is one of the world’s largest
When completed, Pathfinder 1 will be the freestanding structures, covering eight acres.
largest airship in the world. LTA Research’s airships will use
According to media reports, LTA Research non-flammable helium as a lifting gas and a
plans to fly Pathfinder 1 for the first time frame made up of 3D printed girders.
before the end of this year. The airship will be “Our team has reimagined every
able to lift 28 tons, cruise at 70mph (110km/h) component that is part of a lighter than air
and have a range of more than vehicle, from the engineering and materials to
2,800 miles (4,500km). assembly and pilot training. One example is
Denny Carter, chief engineer at LTA the materials used to construct the frame of
Research said, “You can expect some exciting Pathfinder 1, which is being built using
things to happen with our first full-size airship carbon fiber reinforced polymer tubes and
later this year. titanium joints,” said Carter.
“Climate change is an increasing threat LTA Research currently employs more than
and natural disasters occur with greater 65 engineers in a range of disciplines and is
frequency and intensity. Airships can offer an recruiting for several engineering positions,
innovative approach to delivering including test engineers.
humanitarian aid and reduce the carbon Carter said, “Testing is a critical part of
emissions normally associated with aircraft.” building the next generation of airships,
LTA Research’s airship design was first allowing us to ensure reliability, mitigate risk
revealed in 2020 after the company filed a and increase the safety of our airships. We
patent application. The massive dirigibles are welcome individuals who are excited to
intended to carry both cargo and passengers change the future of aviation to apply.” \\
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news
Turn to page 22
to read our cover
feature on modern
airship development
h
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ar
e
s
e
R
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s:
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P
// LTA crew members
maneuver Pathfinder 1 For regular news updates:
inside the hangar at AerospaceTestingInternational.com
Moffett Field
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AEROSPACETESTINGINTERNATIONAL.COM // JUNE 2022
news
Lilium Jet
7 seater
Capacity: 6 passengers
Cruise speed: 280km/h (175 mph)
Maximum range: 250km (155 miles)
including reserves
Cruise altitude: 10,000 ft
Propulsion: 36 ducted fans, each driven
by a battery-powered electric motor
Fuselage: Carbon fiber composite
Wingspan: 13.9m (45.6ft)
Length: 8.5m (27.9ft)
// Lilium’s Phoenix 2 unmanned test
aircraft is remotely piloted
eVTOL jet aircraft
achieves first transition
e
VTOL jet aircraft developer Lilium’s Phoenix 2 achieving transition of the aircraft’s forward canards “We plan to start building our first handful of
test aircraft has successfully transitioned from and high-speed flights. conforming aircraft – the only type of aircraft that
vertical to horizontal flight for the first time. Transition means that the airflow going over the can be used for certification – next year. Upon
Phoenix 2’s “main wing transition” as it is flaps attaches and becomes smooth, allowing lift to completion of the conforming aircraft build process
described by Lilium, is the first time a be generated by the wing as in conventional fixed we will then spend the following 15-18 months
full-size electric jet aircraft has moved from wing aircraft, rather than by the engines, which is running our final test campaign with the aim of
hovering to wing-borne flight. The transition flight the case during the hovering phase. receiving our initial Type Certification in 2025, with
was conducted at the ATLAS (Air Traffic Laboratory Phoenix 2 achieved this across the entire main scale production of our aircraft set to begin
for Advanced Systems) flight test center in Spain wing while remaining stable and behaving as immediately upon certification.”
during May. predicted by a flight dynamics model. The wing transition ends a busy first half of the
Phoenix 2 is an unmanned technology The transition is a key milestone for the Munich, year for Lilium. This month the company appointed
demonstrator fitted out with test instrumentation Germany-based eVTOL aircraft company. Lilium has 30-year Airbus veteran and former head of A320
that first flew in 2019. The aircraft is being used to faced heavy criticism from aerospace industry Klaus Roewe as its CEO. When Roewe joins Lilium in
prove the design’s architecture and gain confidence commentators for its alternative and ambitious August, current CEO Daniel Wiegand will become
in the flight behavior and capabilities. design and development timeline, which targets the company’s chief engineer for innovation and
Lilium has one other test aircraft, Phoenix 3 in 2025 for certification and production. future programs and continue as a board director.
development which is expected to be delivered to In February 2020 Lilium’s first test aircraft In May the company announced a R&D
the Spanish flight test center this summer. Phoenix 1 was damaged beyond repair after it partnership with lithium battery company Livent,
The current flight test campaign will continue caught fire at the company’s base at a major supplier of automotive batteries. It also
until September to further expand Phoenix 2’s flight Oberpfaffenhofen Airport, causing speculation that announced a partnership with motor supplier Denso
envelope. The testing program will include flight testing and certification would be delayed. to develop and manufacture the motors for its
Matthias Meiner, Phoenix chief engineer and aircraft and is already partnered with Honeywell,
Lilium co-founder said, “This is a landmark moment which is supplying the avionics.
for Lilium and for electric aviation as a whole. We Lilium was founded in 2015 and employs around
For regular news updates:
are still gathering learnings from the testing. 750 people. \\
AerospaceTestingInternational.com
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