Training for First Flight 12 Nov 09

1. Air Force Flight Test Center War-Winning Capabilities … On Time, On Cost Training for First Flight 12 Nov 09 Scientia est Virtus Mr David Vanhoy Mr Karl Major USAF Test Pilot School (661) 277-3000 Approved for public release; distribution is unlimited.AFFTC-PA No.: 09462 I n t e g r i t y - S e r v i c e - E x c e l l e n c e

2. Roadmap • USAF TPS Course Overview • 1st Flt Course Objectives • PA HQ • Model Validation • ASE • 1st Flight Checkride • Purpose / Scenario • Planning Elements • Key Questions • Summary

3. J F M A M J J A S O N D TEST MGMT 600 TEST MGMT 900 FLYING QUALITIES 600 PERF 600 AN 500/CF 500 FLYING QUALITIES 700 GRADUATION SYSTEMS 600 FIELD TRIP PERF 700 SY STEM S 700 FLYING QUALITIES 800 SYSTEMS 800 PERF 800 FLYING QUALITIES 900 QUAL EVAL 900 TPS Course Layout

4. Motivation!!!!

5. Who wants to be this guy????

6. Or this guy???? Video courtesy of Gary Aldrich

7. Objectives • List the 3 kinds of FQ testing that should be conducted during the First Flight of an airplane • Describe the types of powered approach Handling Qualities testing that should be conducted on a First Flight • Describe the flight conditions at which First Flight powered approach HQ testing should be conducted • Name the 3 test methods that can be used to evaluate the Aero-Servo-Elastic stability of the landing configuration • State the fundamental principle of test point selection for First Flight Aero-Servo-Elastic testing

8. Risks & Risk Reduction GVT SCT Load Proof & Cal FMET • Ground Testing • Verified and Validated FCS • Nearly Validated Structure • Uncertainty in Predicted Aero • Unavoidable • Design for Robustness • Uncertainty in Predicted Handling Qualities • Simulator: Lack of Fidelity • Incomplete Evaluations • Biased Evaluations Design Principles Piloted Sim

9. Block Diagram of Simple Pitch Axis Control System Structural Coupling HIL Gnd Test UNKNOWN GVT Structural Coupling Design &Sim Sensitivity Studies HIL Gnd Test

10. Primary Objective: LAND SAFELY!! Secondary Obj: Don’t hit chase plane and get cool pics

11. Primary Objective: LAND SAFELY!! Secondary Obj: GET AWAY FROM THE GROUND and Sample PA HQ

12. 3 Kinds of FQ Testing for 1st Flights Handling Qualities Primarily in PA Config 2. Aero Model Validation 3. ASE OBJ 1 Predict – Test – Validate and use the Build-up Approach

13. Handling Qualities • Powered Approach Photo from vets-helping-vets.com

14. 1st Flt Handling Qualities Tests • Open Loop and Semi-Closed Loop FTTs • Closed Loop Elevated Gain FTTs • Closed Loop Ops Representative OBJ 2 Photo from skyscrapercity.com

15. 1st Flt Handling Qualities Tests Open Loop and Semi-closed Loop FTTs • Static Stability Trim Shot • Time Delay and ASE Raps • Dynamic Stability 3 Axis Doublets • Initial Response and Steady State Resp Small Steps • Directional Stability and dR Control Power Sideslips • Lateral Stability & da Control Power Stabilized Turns & Bank-to-bank Rolls • “Elevated” g Stabilized Turns • Predictability Attitude Captures • Higher Gain PA HQ & Throttle Response Simulated App & Go-Arounds LIMIT AMPLITUDE of PILOT INPUTS OBJ 2

16. 1st Flt Handling Qualities Tests Closed Loop Elevated Gain FTTS • Workload Build-up • Increase aggressiveness to something greater than anticipated for landing • Tracking a Target (real or simulated) • Longitudinal and Lateral/Directional Axis • Tracking pitch attitude or flight path angle or AOA OBJ 2

17. 1st Flt Handling Qualities Tests Closed Loop Ops Representative Tasks • There generally aren’t any • Exceptions could be for modified a/c versus actual 1st flights of new a/c Do NOT make 1st landing a Closed Loop Ops Representative task!!!!!!

18. 2. Aero Model Validation

19. Types of Tests Open Loop FTTs • Trim Shot • Raps • 3-axis Doublets • Small Steps • Sideslips • Bank-to-bank Rolls PTI for Individual Surfaces if required

20. Types of Tests Open Loop FTTs • Trim Shot • Raps • 3-axis Doublets • Small Steps • Sideslips • Bank-to-bank Rolls These are the same maneuvers previously shown for open loop HQ PTI for Individual Surfaces if required

21. 3. ASE Servo Rigid Body Limit Cycle Structural Coupling Aero Elasticity Flutter

22. Identify the points where the stability margins are the smallest If there is a chance you may reach one of these points during approach, you need to test this at altitude first If you will not get anywhere near your lowest stability margin points on first flight, then STAY AWAY from them Use Raps as appropriate to verify ASE stability Test Pt Selection for ASE Testing OBJ 5

23. Course Evaluation C-12 First Flight

24. Purpose Develop and Execute a 1st Flt Profile with Emphasis on FQ

25. Scenario C-90 King Air Make suitable for Special Ops mission

26. Scenario C-12 Special Ops Prototype The Answer?

27. Assumptions • Ground Tests and Taxi Tests • Successfully completed • Same engines as C-90 King Air • Same system components, but application new • fuel lines different, tanks different, pump locations different, etc • Performance model: Flight manual • Initial starting envelope given

28. Goal • Effectively determine ability to land safely • Via long, low gain straight-in approach & landing

29. Planning Elements • How best to get away from ground? • Basic instruments confidence • How to expand the envelope? • Test point selection • Flying / Handling Qualities • Aero Model Validation • Aeroelastic considerations • Test point prioritization • System operations

30. Mission Variables • Potential System Failures • Mock aircraft write-ups • Airspeed, pressurization, flaps, DAS, etc. • MIL-STD 1797, Flying Qualities of Piloted Vehicles • Team Unique Compliance Checks • Program office special interest item

31. Key Questions • First flight objectives and priorities? • Test point purpose? • Best envelope expansion approach? • How slow, what increment? • How much sideslip, roll rate? • Minimum maneuvers to attempt landing? • What if something goes wrong? • How do mitigate first landing risks? • Configuration changes • How much should you elevate the pilot’s gains? • Cooper-Harper ratings

32. Do Your Homework Simulation Thorough Ground Test Team Practice Predict, Test, Validate Method + Build-up Approach PA Handling Qualities, Aero Model Validation, ASE Reduce Unknowns: Start test at Ideal Conditions Contingency Plans for Undesirable HQ or Failures First Flight Summary Get Away from the Gnd Eval PA HQ & Land Safely

33. First Flight Testing

34. BACKUPS

35. It’s Just a Minor Mod…… V∞

36. Starting Envelope Heart of the Envelope, then where? • 140-160 KCAS • 15,000 ft PA • ½ Maximum Aileron Input • 0.8G to 1.5G Load Factor • 5° Sideslip • Flight Manual Limits for A/C Systems • Takeoff designed for 40% flaps OBJ 3

37. Objectives Priorities A/C Status / Mods / SI Go / No-Go Safe Envelope Envelope Expansion Plan Predictions Time / Fuel Line Wx Area Considerations Safety Brief Limits Terminology Com Plan Duties Contingency Plans Brief Items

38. Test Limits • 60° Max Bank Angle • 0.5G to 2.0G Load Factor • Recover from stall at first indication of BUFFET • All minimum speed maneuvers (VMCA) will be terminated not later than first indication of stall (horn or buffet, whichever occurs first) • Maximum pressure altitude of 17,000 ft PA • No High Gain Aggressive tracking in wingtip formation • Flight Manual Limits • Engine Parameters, pressurization, yaw damper, etc It’s the crew’s responsibility to keep the aircraft within the test limits

39. Questions You Should Ask • What can go wrong? • engines, fuel, configuration, etc. • How are you going to minimize risk? • What are the contingency plans? • Include those plans (or the philosophy) in the brief & be able to apply to your cards • How far do you go looking for PIO?? • How do you accomplish higher gain PA tasks?

40. Questions You Should Ask • How Slow should you go? • Vapp??? • Stall Warning?? • Stall?? • How much Sideslip should you generate? • How far should you expand roll rate? • How do you expand roll rate? • Do you Evaluate Engine Out? • Power settings / Airspeeds / Maneuvers?

41. Questions You Should Ask • Do you raise the gear?? – ALL Config Changes should be dedicated events • What tasks are best to simulate landing? • What axis is the most critical? • What do you track? • What are the desired and adequate criteria? • How important are Cooper-Harper Ratings? – Don’t make the landing a C-H Task!!!

42. It was Built to Specs……

43. Flying Qualities Phase

44. Risks & Risk Reduction • Prepare the Aircraft • Prepare the Pilot • Plan the Envelope Expansion Profile • Plan for Emergencies

45. First Flight: Short and Cautious • Riskiest parts • Take-off • Close to Ground • No Build-up • Landing • Risk Reduction • Low Bandwidth Take-off and Landing • Good Weather • Long, Smooth Runway • Controlled Airspace • Crash and Rescue

46. Test Conditions Heart of the Envelope, Approach Speeds OBJ 3 2 1 3 4

47. Generic Profile GET AWAY FROM THE GROUND Heart-of-the-envelope Trim Shot Air Data Checks ASE if required Open Loop PA HQ - compare to predictions Closed Loop PA HQ - compare to predictions Engine Checks System Checks Expand envelope to meet primary objective: LAND SAFELY Long Straight-in approach /low gain landing

48. 1st Flt Handling Qualities Tests Open Loop and Semi-closed Loop FTTs • Trim Shot (Accel into to eval Static Stability) • Raps (Time Delay and ASE) • 3-axis Doublets (Dynamic Stability) • Small Steps (Initial Response and Steady State Resp) • Sideslips (Directional Stability and dR Control Power) • Bank-to-bank Rolls (Roll mode time constant & da Control Power) • Stabilized Turns (Spiral Stability and “elevated” g) • Attitude Captures (Predictability) • Simulated App & Go-Arounds (Higher Gain PA HQ & Throttle Response) LIMIT AMPLITUDE of PILOT INPUTS OBJ 2

49. CASE STUDIES Adam Aircraft Industries Photo CASE STUDY: ADAM AIRCRAFT M309