On Electromagnetic Aircraft Launch System:
Posted on InsideDefense.com: May 23, 2014
The Navy is preparing to begin ship-based testing of its new Electromagnetic Aircraft Launch System, designed to replace the service's aging steam-driven catapults, the program manager told Inside the Navy last week.
The Navy has just completed its second and final phase of land-based testing at its flight test facility in Lakehurst, NJ, Capt. Jim Donnelly, aircraft launch and recovery equipment program manager, said in an interview last week. The Navy has conducted 452 aircraft launches since the start of the program in December 2010, including tests of the F/A-18 Super Hornet; the EA-18G Growler electronic attack aircraft; the C-2A Greyhound; the E-2D Advanced Hawkeye; the T-45C training aircraft; and the F-35C.
The next time aircraft will be launched from EMALS will be off the launch system on the new aircraft carrier Gerald R. Ford (CVN-78), Donnelly said. The ship is scheduled to deliver in March 2016, and the first launch from EMALS will take place later in the spring of that year, he added.
In the meantime, the Navy will conduct dead-load launches from the system, Donnelly said, which simulate different aircraft types by weight. These tests will aid the team in system reliability growth, he said.
"At this point, we are really doing software revisions," Donnelly told ITN. "I'm talking about a normal test program where you find things as you test and you go in and you redesign and you make fixes."
In his annual report released earlier this year, J. Michael Gilmore, the Pentagon's director of operational test and evaluation, outlined testing and reliability issues associated with some of the key systems on the Ford carrier, including EMALS.
At the Lakehurst test site, over 1,967 launches have been conducted and 201 chargeable failures have occurred, Gilmore wrote. "Based on expected reliability growth, the failure rate is presently five times higher than should be expected," the report reads.
However, Donnelly dismissed Gilmore's concerns because he said his team was "injecting failures into the system intentionally" during the testing phase.
"I'm not as concerned because we were testing in the most aggressive test phase and we were trying to break the system essentially," Donnelly said. "We were injecting failures into the system intentionally, we were overloading the system intentionally to find things and also to ensure that we were meeting our critical launch reliability."
Donnelly added that he will not change his plan for the system in response to the DOT&E report.
"I am pressing on with my plan," he said. "I am pressing on with correcting components if I need to, and like I said at this point I'm talking more about software revisions."
EMALS works by using electrical power generating by the ship's naval reactors, Donnelly explained. This electricity is converted into an electromagnetic field that propels a 20-foot aluminum plate down the catapult track. The aircraft to be launched sits atop the aluminum plate, and when the plate comes to a stop at the end of the track, the aircraft continues to fly.
"They basically make an electromagnetic field, which kind of is a wave, kind of like Waikiki, and the aluminum plate is the surfboard that just rides the electromagnetic wave down the catapult," Donnelly said.
EMALS is more capable and more accurate than the steam catapult, Donnelly said, and has the capacity to launch heavier as well as lighter aircraft.
"From an operational perspective, the airwing has grown in size and the energy that is required to launch [aircraft]," he said. EMALS "is able to launch heavier aircraft or aircraft that require more energy. In the lower ends of the operational envelope, it also expands, so it's more aircraft-friendly in the lower weight."
Despite repeated delays in the program dating back several years, Donnelly is confident that EMALS will be ready for installation into CVN-78 by the ship's delivery date.
"The date that [CVN-78] was going to be introduced into the fleet never changed," Donnelly said. "We had less of a schedule margin, [but we are] still meeting the ship delivery date."