BAE Systems will progress the design and testing of revolutionary flow control technologies that could deliver “significant operational enhancements”.

According to a release from the firm:

“The U.S. Defense Advanced Research Projects Agency (DARPA) awarded the contract to BAE Systems to design a full scale demonstrator concept with Active Flow Control at its core. The aircraft’s ability to maneuver in flight without conventional flight control surfaces will enable improved performance, maintainability, and survivability.

The contract award forms part of DARPA’s Control of Revolutionary Aircraft with Novel Effectors (CRANE) project, which intends to inject Active Flow Control technology early into the aircraft design process to demonstrate significant efficiency benefits, as well as improvements to aircraft cost, weight, performance, and reliability.”

BAE Systems’ say that its role in Project CRANE builds on its innovation demonstrated through MAGMA in 2019, where a subscale aircraft was successfully maneuvered in flight using supersonically blown air and Active Flow Control technologies for the first time in aviation history.

Speech marksTom Fillingham, Senior Vice President – US Programs, BAE Systems Air said:

“BAE Systems has been at the forefront of digital design for more than 20 years. This award enables us to progress Active Flow Control and our digital engineering capabilities at full scale, in collaboration with DARPA and the University of Manchester in the UK. Since our groundbreaking MAGMA trials, our engineers across the UK, US, and Australia have continued to innovate to identify improvements in the aircraft digital design process to deliver military value and operational advantages to the warfighter.”

As military aircraft confront increasingly contested and sophisticated threat environments, BAE claim that Active Flow Control offers potential military benefits that “could deliver operational advantage in the battlespace”.

“Active Flow Control technologies can supplement or replace conventional moveable control surfaces to improve the performance of an aircraft at various points in the flight regime, as well as reduce mass and volume compared to aircraft with conventional controls to enable greater payloads and greater flexibility to the operator.”

The contract will see BAE Systems mature design, integration, and de-risking activities, including wind tunnel testing at its facilities in the North West of England in 2022.

George Allison
George has a degree in Cyber Security from Glasgow Caledonian University and has a keen interest in naval and cyber security matters and has appeared on national radio and television to discuss current events. George is on Twitter at @geoallison

50 COMMENTS

  1. I assume I’m missing something here as the aircraft are limited by pilot’s ability to withstand G. Are they looking at future use on drones then ???

    • Removing of control surfaces allows aircraft to potentially be even stealthier as you are removing flat surfaces that might reflect radar. Typhoon for example is pretty stealthy airframe overall but has canards which could be pointed in an unfortunate direction when in use, to mitigate this the aircraft has software that adjusts the trim to try and maintain minimum time at reflection angles.

      • As the control surface moves up/down, left/right it exposes a flat or concave piece of the wing thereby making a very good radar reflector.

        However, all aircraft require a gap between the control surface and the fixed part of the wing/fin. This is to compensate for expansion through heat and therefore stop the control from rubbing or binding on the fixed part of the wing/fin. However, you can only make this gap so small, before it becomes a problem. Depending on the width of the gap and the frequency of the illuminating radar, these gaps can become resonate cavities and not only reflect the radar, but also increase the return strength.

        By getting rid of the moving control surface by using a blown air control system, you eliminate a major radar reflector.

      • “Reflect radar” but if a “stealth” jet is turning or moving at all angles that make the radar beam hit a flat surface won’t stealth just be useless?

        • The goal is always to reduce signature, you can never eliminate it, most low observability aircraft are designed to minimise their frontal aspect return as your more likely to need it when heading towards your enemy than away. The Chinese and Russian aircraft in particular have quite poor side on concealment but their primary concern is flying as fast as they can directly towards an enemy fleet, launching then running away.

  2. Interested how manoeuvrable and aircraft an air vehicle can be by blowing jets of air over the surfaces as opposed to flaps, slats etc..

    • It depends on how much of the wings surface area is used for the air jets. The larger the surface area covered the more responsive the aircraft will be. You can take it to the extreme and have blowing over the leading edge, mid span and trailing edge. By doing this you can make the airflow more laminar at higher angles of attack and thereby maintain lift. Therefore, you wouldn’t need leading and trailing edge flaps. You could make the aircraft even more responsive, if you also included jets that blew perpendicular to the wing, i.e. 90 degrees to the airflow. This would force the wing to move away from the air jets. This would be especially advantageous at very high altitudes, where mechanical flight controls get more and more sluggish the higher you go.

      It does come at a cost though. You need to use at least 1/3 of the available engine thrust if you use the whole wing for the jets. The Buccaneer used blown jets just behind the leading edge and over the trailing edge flaps. The initial S1 aircraft powered by the Gyron Junior turbojets were a bit feeble power wise, and the blown flaps meant they had to red line the engines to make sure there was enough power going to the boundary layer control. This wasn’t properly solved until the S2 version came along with the more powerful Spey engines. Buccaneers did have incidents where the amount of air blown over the port and starboard wing weren’t the same, this led to one wing developing more lift and thereby causing it to roll. The pilots had to train for such a failure which would have been extremely hazardous if it happened when trying to land on a carrier.

        • It is not new. Russians have anti stealth radars. Data fusion of low frequency radars – so less precise – can be enough for tracking. Or going millimetre wave and imagery radar for final interception.

        • Both Russia and China have claimed that their HF/VHF/UHF radars can detect stealth aircraft. But you have to take their statement with a pinch of salt, as what was the target aircraft they were using and thereby what was its radar cross section?

          Aircraft like the F22 and F35 will be susceptible to resonant affects due to the following phenonium: “There is a ‘step change’ in an aircraft’s signature once the wavelength exceeds a certain threshold and causes a resonant effect. Typically, such resonance occurs when any feature on the aircraft is less than eight times the size of a particular wavelength, as happens with the tail-fin of a fighter.”

          However, radars using wavelength of 1m or greater can generate these resonant effects. Higher frequency radars with shorter wavelengths can also generate resonant effects, but it helps if the aircraft has a 90 degree angled cavity, such a the joint between a flying control and the wing.

          But this effect by longer wavelength radars also relies on the aircraft having straight edge that meets the criteria. A curve may resonate under some conditions, but the signals direction will be dispersed over a greater width of angles and thereby reduce what is reflected back to the receiver. Low frequency radars operating with 1m or longer wavelengths are much more susceptible to picking up background noise that can be misinterpreted as a legitimate target. Furthermore, older style radar absorbent materials (RAM) such as the ferrite coatings, had little if any effect on these wavelengths. But today RAM has moved on and incorporates both signal capturing as well as attenuation. Yes, there is a physical threshold, whereby the radars signal strength will overcome the ability of the RAM to counter it. But the manufacturer will know this limitation and it will be passed on to aircrew. Who will use radar warning receivers to detect the radar’s signal strength and thereby be able to plot a no-go radius from the radar.

          This is where I have my doubts on their statement of being able to detect a stealth aircraft, as its based on what evidence? It certainly won’t be based on actual live radar scanning of a B2, F22 or F35, so it will be based on a theoretical model, which does not take into account the actual performance of the RAM.

          To have a guaranteed chance of detecting a stealthy aircraft you need to use multiple active or bi-static radars that build up a picture of the target through additive triangulation. So far all the Chinese have stated is that they have designed a HF radar that operates much in the same way as an AESA radar, where individual elements are tied together in an array and when used form a coalesced picture of an object. Hmm, nothing new there, synthetic aperture radar has been doing it for decades! A single array operating on its own will struggle to detect a stealthy aircraft, however, using a number of them networked together, you may get a hit, tracking it may be a problem though, as it will depend up the relative return angle from the aircraft, which wont be flying straight and level on a mission.

          Radars that transmit using wavelengths greater than 1m, have real target resolution issues, as the article describes. But its also due to the larger beam width. A lot of the beam will miss the target, as there will be less energy hitting the target, there will be less returned to the receiver, which is further compounded by the background noise it receives. You can improve the situation by multiplexing a lot of individual signals/transmissions together. But that means you also have to have a similar number of receivers to detect the individual transmissions. By interleaving the signals you can then work out the approximate range, velocity of target, the relative bearing and to some degree the height. Even by using this method, you will not get a pinpoint fix on the target again due to the beam widths used. However, if you then network together lots of these radars, you can reduce the error quite significantly through signal processing.

          The B2 was the first production stealth aircraft to use a form of embedded RAM. The F22 used the same techniques, but the F35 took this to a new level. The B21 Raider builds on the F35’s technique. Due to its size and wingtip chord lengths, it will be less susceptible if at all to the resonant affects attributed to HF radar. It will probably generate resonance at longer wavelength which match the criteria for the wing tip chord length. But as the wavelength gets longer so does the beam width and therefore the error will be compounded. Which means even ,more signal processing. So good luck trying to detect that!

          Until these countries produce documented evidence of not only the specifications of the radar used but also the target, I will only see the statement as Nationalistic spin. I have no doubt that you can detect a stealth aircraft through a combined radar network. But for it to have the ability to generate a missile tracking solution, I have my doubts, especially as the missile will have to be command guided to the target., whereby the target has a large enough IR signature or the missile’s radar can get a decent hit.

          • A Johns Hopkins report no less, that’s more like it!

            The synthetic inverse aperture radar (SIAR) is an interesting subject. In many ways it operates similarly to a TACAN beacon. By modulating the transmission through 360 degrees you create a defined code that represents a bearing, that a tacan receiver can then interpret to find the bearing to the beacon.

            It seems this is what they are doing with SIAR. Using the 25 transmitters that look like half a dipole element, you would expect a lot of mutual interference, as the transmitted beam will have a circular beam profile around the pole. However, you can counter this by modulating (codifying each element) so that with signal processing the interference can be mitigated and negated. The shape of the beam could also be using positive and negative phase interference as per a electronic scanned array to shape the beam further.

            They have also said that the radar uses inverse synthetic aperture radar (ISAR) techniques, to track an object through doppler shift. That is true, ISAR is predominantly used to build up an image of the ground over time. However, to reveal ground details you need a radar with a high resolution and therefore a much smaller wavelength, i.e. greater than S-band (the smaller the better). However, a meter long wavelength will have a terrible resolution even after significant signal processing. So for ground mapping it would be useless. But you could use it to track an object over time, as each successive image captured will show an object moving in relation to its previous captured image.

            I can agree that this system will give range and bearing and to some degree velocity. But I am not sure how they can get verifiable elevation? Normally you’d rely on the antenna mechanically tilting or using phase interference to steer the beam. But with system, you will need multiple dipoles placed on top of each other to achieve this with the SIAR using beam steering. Perhaps this is achieved through the use of the receiver dipoles being of differing heights. Bujt again you would really want them stacked on top of each other, to use receiver differentiation to work out a rough height.

            The SRC AN/TPQ-49/50 is a lightweight incoming fire detection radar and is sometimes called a lightweight counter mortar radar (LCMR). It uses a similar method of detection but at a much higher frequency (L-band). It uses 24 blade antenna arranged in a circle. Each blade has I think 5 antenna horns, which are then used to phase steer the beam 360 degrees around and in elevation.

            https://www.globalsecurity.org/military/systems/ground/images/an-tpq-50-image02.jpg

            https://www.popsci.com/uploads/2019/03/18/UWFHEL6N4D3CZC2PVXB3DG745U.jpg?width=785

            As the report states, they cannot conclude that the radar will detect a stealthy aircraft like an F35 or a B2, as there is not enough evidential data to work with.

          • They work fine in a lab, but not outside in the real world. The reason for this is due to the quantum entanglement. You have to use a pair of identical twins in this case photons, which are generally generated by a laser. One half of the photons is then converted into a microwave and transmitted as per a normal radar, where it interacts with the target and returns to the receiver. It is then converted back into a photon and measured against the captured twin for comparison. From this, you can work out the time it took to get to the target and back as per a normal radar. But if the photon showed a shift change in phase you can determine a number of factors such as, has the photon been delayed by the target etc, i.e. delayed by a stealthy aircraft’s RAM.

            This all sounds great in principle and has been shown to work in a laboratory. However, there is a major hurdle to overcome. This is the method that is used to capture the “idler” twin, i.e. the photon you use to measure the other against. At present they use a fibre optic, where the photon can pass down and not lose too much energy. But here’s the problem, if the transmitted “photon” travelled say 10km to the target and then returned, therefore a total distance of 20km. The captured photon would also have to travel the same distance, so if there’s a discrepancy it can be measured against. Therefore, if the transmitted photon travelled 100km, you would need at least 200km of fibre optic. Admittedly this can be shortened by using mirrors to bounce the photon between. But these have to be above 99% reflective, so the photon doesn’t lose too much energy. But you are still going to need lots of fibre optic and a large clean room space for the photon to bounce between.

            This is why there has been a push into trying to model quantum memory, which can then be produced. The problem is clearly that the idler photon still wants to travel, so you need a medium that can convert it but still maintain the entanglement. As far as I know, we are not there yet! Until China publish actual data on their quantum radar claim, it remains unviable and unproven.

          • As ever a very informative response, I do need to read up more on the subject. But I do confess quantum mechanics can be a bit baffling.

  3. I’m interested that

    including wind tunnel testing at its facilities in the North West of England in 2022″

    As the work is done in the UK it would fall under UK regulations which means US has access to it but so does HMG. Presumably this was because MAGMA was MOD IP?

    There is clearly some very interesting stuff going on in UK basic R&D both in control (surfaces), electronics (radar) & platforms.

    Isn’t the real benefit of this the RCS reductions as there are less joins on the plane?

    • RCS reductions are obviously a significant boon, but simplifying maintenance and logistics is one of those strategic benefits that win wars – or more specifically, that keep militaries in a condition to win wars.

      The easiest example is WWII German tanks that would win a game of Top Trumps but were usually in no condition to actually fight.

      • Now this is true but things were changing as the war ended it could be argued. The Comet was a very competent medium tank and compared well with the Panther though the Battle of the Bulge slowed its take up as the 11th AD had to take out their Shermans as they were working up on them. The 17pdr was a great gun and in original unmodified form was deemed by many the best anti tank gun of the war and many of these tanks were still in service around the World towards the end of the last Century and in UK service up till the late 50s. Meanwhile early (if pre production version) Centurians was actually moving into Belgium as the War ended so perhaps just misses that otherwise Top Trump status but would have won it had the war in Europe lasted a few months longer. Meanwhile the Pershing was better than all but arguably the Tiger 2 main battle tank. So yes German tanks do have rightfully a top trump ranking in the War between say late 41 to the the final months but I think its important to say that the allies (including the Russians of course) were very much catching up and likely would have eclipsed their designs very soon after as they were getting bogged down in their ideas while the allies were progressing as in many other aspects (radar, jet engines) rather faster.

    • I would guess that a lot of that will depend upon how this technology develops I suspect they will keep it in mind even as they go the traditional route as things stand. Loyal wingman which is part of the programme I think will exploit it earlier I would suspect. Others will possibly know more about how much the overall design would have to be dictated by whether you exploit this or traditional means. I fear there will be, for an uncompromised design anyway, quite a significant series of decisions to make in this regard and until its proven technology you can’t really wait to make such a vital program dictating decision surely. And we already see with Ajax how ongoing modifications to fundamental design choices/decisions can end up even with (or maybe because of) pre existing designs. Those with greater engineering and aerodynamics knowledge/experience Im sure can hypothesise far better than I but would be interesting to be a fly on the wall inside Bae design offices.

    • I think it may have a very good chance of being included. However, this will be dependent on the engines that Tempest gets. Boundary layer control (BLC) can use up to 33% of the engine’s available power. Unlike flight control surfaces that require a modicum of either hydraulic or electrical power to move, BLC will always be demanding engine power. Therefore the engines that Tempest gets will have to have a massive surplus of power.

      The F22 Raptor has been said to be capable of flying 10,000ft higher than a F15. It uses the 2D thrust vectoring to assist its manoeuvring, when the moving control surfaces no longer provide adequate airflow deflection at altitude. The F22 has near parity of 1:1 thrust to weight ratio in dry military power, but near 1.25:1 when using the after burner. Whereas Typhoon is about 0.82:1 dry and 1.22 in reheat. Due to the demands that BLC makes on the engine, it will need a power to weight ratio better than unity when in dry, if it is to have any advantage in maintaining energy (thrust vs velocity) when manoeuvring.

      If Team Tempest are serious about reducing the aircraft’s RCS, so that it is better than a F35, then BLC will help massively, especially if it means getting rid of the conventional moving flight controls.

      • Problem is a lot of that extra power will be used for DEWs. I have heard the approach may be more hybrid, you use BLC when in full stealth mode to so you ‘set’ the control surfaces in the most stealthy position and use BLC manoeuvre. I assume there’s trade off as control surfaces create drag and the most stealthy position for control surfaces is probably the lowest drag configuration, the power saved due to this lower drag is then used for BLC. One question does BLC offer the same levels of manoeuvrability?

        • If you keep conventional moving flying controls, you will still need a gap, where the edges meet the wing/fin/fuselage to allow for material expansion through either high g manoeuvres or heat. These gaps will allow certain radar frequencies to either directly reflect or resonate. So that will have to be taken into account during the design.

          BLC will take a lot of energy from the engine. But it is highly dependent on how much BLC is used. If it used just to clean up the boundary airflow over the wing to reduce drag, then this will be fairly minimal. If it used instead of flaps, then this will take up a large portion of the energy available, as you will want the BLC to be used for the entirety of the flap deployment, i.e. during take-off and landings, but also high alpha angles manoeuvring. If you require it to replace an aileron, elevator or rudder. Then this gets a bit more complicated.

          If an aircraft has relaxed stability. The flight control computer during flight will be constantly making aileron, elevator and rudder adjustments just to maintain the aircraft in a straight and level condition. Now, for example you want to roll the aircraft to the right. Traditionally you’d increase the lift on the left wing, whilst decreasing it on the right wing. So left aileron down and right aileron up. The airspeed over the wings, along with aileron area, deflection angle and distance from the CoG will dictate how fast the aircraft rolls. For a controlled turn you will also use a bit of rudder and elevator to make sure you don’t slip or loose height during the turn.

          If we are using BLC to control the roll. We have the advantage of using the whole of the wing tip area for the BLC jets. This will have a larger leverage. It can also be made more responsive in that you can use the jets to force the wing down, if they are blown perpendicular to the wing or used to disrupt the airflow and therefore lift. Correspondingly, on the opposite wing you could have the jets blowing perpendicularly below the wing to force it up. However, if it was practical, you would include the jets over the majority of the wings surface. As this would allow a better proportional control of the airflow over the wing and how lift is controlled.

          For a controlled turn you will also need to include the moments generated by the elevator and rudder to add the pitch and yaw to the turn. This would need something along the lines of the Harrier’s/F35’s reaction jets placed at the extremities of the aircraft’s fuselage. So by using them behind the CoG they cause a lever action to point the aircraft in the desired direction.

          The proposed delta and canard aircraft shape that has been shown above, does not have any fin/fins, so no rudders! The Magma drone used a pair of canted out fins which moved for yaw control. The majority of tailless aircraft either use pop-up slats or wing tip split elevators for primary yaw control (B2 also uses differential thrust). Will it therefore be using blown reaction jets for yaw control? It’s certainly possible and would get rid of a major radar reflector and drag generator. You could even use wingtip perpendicular air jets to disrupt the airflow above and below the wing that kills lift generating lots of drag as airbrakes. But I don’t believe the Magma program has investigated that, yet!

          For this to happen, it would be desirable for the engine, if its a turbofan to have a higher bypass ratio, where some of the bypass air can then be used for the blc. You could also run a number of dedicated air pumps along with air pressure accumulators for the blc, so that the engine thrust is not affected.

          • That’s interesting. I know RR are proposing the engine core incorporates a generator so additional pumps could be a possibility. Power management and storage will be key though, Variable bypass is another possibility but blc only airframe appears to dictate high bypass which is either a large fan or a gtf design. Larger fans come with their own stealth challenges, not least the bulk of the airframe.

            I know Boeing and NASA have looked at morphing wings which would resolve the issue with gaps, but morphing wings are the oldest control method for powered flight and to my knowledge has not made it past demonstrators in modern times.

  4. If this is the ‘way forward’ insofar as Drone aircraft outperforming manned aircraft, why bother with the tempest in its current form?

    Why not redesign the tempest as a smaller super duper fighter drone thing?

    • Yeah, I’m a bit confused by what Tempest should be. Even the whole ‘Loyal Wingman’ thing makes me think it should be a largish 2 seater job with a pilot and a drone controller, especially if he’s supposed to be controlling 2 (or even more) drones, that’s proper ‘sticking the tongue out the side of the mouth’ levels of concentration !

      You would think any interceptions will be done by the Loyal Wingman’s as their role would be to preserve the controlling aircraft and they would be the more nimble part of the setup that requires the high G stuff. Your controlling aircraft could be the size of an F111 with a hefty fuel and weapon load in that case. Its all speculation at this stage I suppose.

      • Nah the Drones should 100% be autonomous, making the best moves possible, faster than the human brain, giving advantages we can only dream of today…I hope I’m still alive to see that shit, duno though life’s hard.

  5. A genuine concern to me is, the government or whoever, ‘chucking about’ loads of money to all these unmanned, drone or whatever enterprises, where maybe they should be combining some of these projects. (or is that too simple?)

    • Yep, far too simple..,yank drones, Israeli drones, American F35s, european Typhoon… Is anything even British in the RAF anymore?

      • Reaper, that’s my concern, where are the UK armed forces going to? My honest opinion is that our military no longer has much in the way of UK designed and built weaponry. I’ve said it before that parts of BAE should be sold off, ROF, ALVIS, GKN and the like, Independently I am sure could have designed Ajax and Boxer type vehicles, let alone revamped the Chally2 and Warrior.

    • Doooh my original post didn’t get submitted…
      Basically we’ve been developing this for a while and the technology is being used on tempest.

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