(A&C, aug.14)
Onera is working on the Superman project to define what tomorrow's fighter aircraft could be, with an aircraft that is both stealthy and manoeuvrable. A special feature of the project is the use of Levcon control surfaces, hitherto unheard of in France.
Superman and supermanoeuvrability
Superman. This is one of the research programmes unveiled to the public by Onera during the visit by the DGA and DGAC to Modane, where part of the large wind tunnels are located, on 17 March 2023. The aim of this research programme is to study the behaviour of a combat aircraft at the limits of its flight envelope, with a view to preparing tools for the design and evaluation of future combat aircraft. Superman "refers to supermanoeuvrability. The survivability of a combat aircraft is the result of a compromise between manoeuvrability, stealth and speed", explains Eric Garnier, Deputy Director of the Aerodynamics, Aeroelasticity and Acoustics Department at Onera. "The fighter jets developed in Europe in the 1980s were designed with limited consideration of stealth constraints. The next generation of aircraft will have to achieve a more balanced compromise between the three components of survivability. The choice of name for the project is perhaps a little ill-chosen in that it may suggest extreme manoeuvrability, when in fact it's more a question of manoeuvrability under stealth constraints".
Reconciling stealth and manoeuvrability
Until now, stealth aircraft have not been very manoeuvrable, or at least their manoeuvrability has been inferior to that of other aircraft. But contrary to what you might think, it is possible to reconcile the two areas to a certain extent. "A machine like the F-22 is both manoeuvrable and stealthy. But at the risk of grumbling, the aerodynamic formula that is close to ideal for manoeuvrability remains that of an aircraft that is not stealthy. I'm thinking in particular of the Sukhoi 27 family. The versions derived from the Su-35 and those equipped with canard planes from the same aircraft manufacturer, with three-axis thrust vectoring, are a good example. In comparison, the F-22 has only two-axis vectoring thrust, complicated by the fact that it had to be made stealthy in the rear. Generally speaking, there is an antinomy here, because the greater the surface area of the vertical stabiliser, the greater the manoeuvrability of the aircraft and the less stealthy it is. So it's all a question of compromise. Finally, we mustn't neglect the specification aspect either. With the NGAD, for example, the Americans seem to want to create what they call a "command plane", an aircraft that flies very high, intended to be very stealthy, and which will direct other aircraft, including remote carriers. We can therefore imagine this aircraft not needing to be very manoeuvrable", comments Eric Garnier.
A beautiful baby with a 60 cm wingspan weighing 7 kg
Superman, for its part, is an aircraft that has not sacrificed too much manoeuvrability on the altar of stealth. "However, at Onera we are not in the process of designing a combat aircraft, but rather a generic form that is sufficiently realistic to have the same problems as those encountered on a real aircraft. The aircraft we have chosen is similar to the Sukhoi Su-57, in that it is a manoeuvrable aircraft that incorporates stealth constraints. The shapes are therefore a compromise between aerodynamics and stealth," adds Eric Garnier. The generic Superman model is on a scale of 1:25, with a wingspan of 60 cm for an equivalent length, and weighs around 7 kg. It is made of an aluminium alloy and its control surfaces are operated by servomotors. The model was blown in a research wind tunnel at Onera's Lille centre, the L1 horizontal wind tunnel. Tests are currently under way in the SV4 vertical wind tunnel at the Lille centre.
Levcon or Leading Edge Vortex Controllers
The tilting planes located at the apex are Levcon (acronym for Leading Edge Vortex Controlers). "These devices are of particular interest to us because they are supposed to control the vortices emitted at the leading edge of the wing. They have appeared on both the Su-57 and the Indian Navy's Tejas, but remain little known. In fact, it's the only control surface that we don't know enough about," comments Eric Garnier. The model has no air intake and/or nozzles. For the moment, only the wing and its interaction with the Levcon are being studied.
100 degrees per second
"In this project, we are not interested in the possible positioning of air inlets. However, we can expect interactions between the air inlets and the Levcon for certain ranges of incidence. However, the example of the Su-57 shows that this situation is manageable. It should also be noted that the model is a technical masterpiece: the control surfaces move at 100 degrees per second and their positioning is guaranteed to within 0.1 degrees. This is a technological feat to the credit of Onera's wind tunnel, engineering and model department in Lille", explains Eric Garnier. For the moment, the model has only been blown at 'low' speeds. "With the mobile levcon, we won't be able to go to high speed because they haven't been dimensioned in terms of effort for this purpose. The fixed version is feasible. The possible extensions to the model would be around a motor integration, a more complete set of control surfaces, and the increase in speed, since for the moment we are limited to around 200 kph. However, we have to remember that very high manoeuvrability is not possible at Mach 2," comments Eric Garnier. While the mock-up bears no resemblance to the silhouette of the Su-57, there are some notable differences.
A similar wing shape
"Although it is not a real fighter aircraft, the shape is both generic and realistic, so that both the aerodynamic and fluid mechanics problems are very similar to those of a fighter aircraft. This aircraft is a creation, as we are working within a NATO group. The plan form had been decided by other members of the group, who had not worked at all on the profiles, which were, after several iterations, chosen by ONERA. The generic shape of the aircraft, which is representative, includes the usual profiles found on combat aircraft, on which we worked on the camber, twist and leading edge radius to achieve something sufficiently realistic. The shape of the wing, seen from above, is very similar to that of the Su-57. The arrows are 45° at the root at Levcon level, then 75° and 45° again", explains Eric Garnier. In particular, work has been carried out on the spin laws, to limit the incidence at the wingtips and avoid stalling the wingtips first. In addition, "We concentrated particularly on pitch balance. At its cruising angle of attack, the aircraft's pitching moment is zero. We have worked to ensure that the pitch is balanced at both low and high speeds, i.e. up to Mach 0.85", adds Eric Garnier.
Levcon and vortex flows
Levcon is just one aspect of the project, with the characterisation of vortex flows another of Superman's subjects of study. "Vortices are areas of low pressure that translate into suction on the wall, in other words free vortex lift. Although airliners don't use this lift, combat aircraft use it a lot. There are crucial fluid mechanics issues here, including understanding the movement of these vortices, their intensity and their positioning. These phenomena will determine the aerodynamic forces and consequently the trajectory of the aircraft. Superman's aim is to make the link between these vortices and the forces and then from the forces to the trajectories, all in the presence of Levcon. If the Russians have called it a "controller", it's not without reason, since it's a control surface that controls the leading edge vortices. You can see on the images that when the Levcon is turned, the vortices move drastically", explains Eric Garnier. Aerodynamically, the Levcon modifies the pitching moment, i.e. the aircraft's balance. "In addition to the elevators, which can be reduced in size as a result (see A&C no. 2823 "Reducing the surface area of the vertical stabilizer and increasing its efficiency"), they provide the ability to pitch down at a higher rate. Typically, during a very sudden manoeuvre, during which a lot of energy has been lost with an aircraft positioned with its nose very high, the Levcon will allow the aircraft to return to a nose-down attitude to regain speed. So the Levcon manipulates these vortex flows," explains Eric Garnier.
Lighting up the future
Will the Levcon be used on future air combat aircraft? The answer cannot be affirmative for the moment, because the choice of whether or not to use them will be up to the manufacturers, i.e. the aircraft manufacturers, depending on the choices they make. However, Onera has provided interested parties with extensive documentation. "Our role is to shed light on the future by proposing new measurement methods, new actuation technologies and new modelling strategies, among other things," concludes Eric Garnier. /deepl