{"id":65442,"date":"2023-06-01T19:03:02","date_gmt":"2023-06-01T19:03:02","guid":{"rendered":"https:\/\/one.sightlinemg.com\/defensenews\/uncategorized\/2023\/06\/01\/auditors-future-f-35-cooling-needs-unknown-as-dod-eyes-engine-upgrade\/"},"modified":"2026-08-08T00:43:48","modified_gmt":"2026-08-08T00:43:48","slug":"auditors-future-f-35-cooling-needs-unknown-as-dod-eyes-engine-upgrade","status":"publish","type":"post","link":"https:\/\/one.sightlinemg.com\/defensenews\/air\/2023\/06\/01\/auditors-future-f-35-cooling-needs-unknown-as-dod-eyes-engine-upgrade\/","title":{"rendered":"Auditors: Future F-35 cooling needs unknown as DoD eyes engine upgrade"},"content":{"rendered":"\n

Update: This story was updated June 2 with additional information from the F-35 Joint Program Office.<\/i><\/p>\n\n\n\n

WASHINGTON \u2014 The F-35 program only knows how much cooling the Joint Strike Fighter\u2019s engine<\/a> will need through 2035, government auditors said in a new report.<\/p>\n\n\n\n

But that\u2019s a few years after the F-35 program<\/a> needs to finish upgrading its thermal management system to be able to support rapidly arriving new capabilities, the Government Accountability Office<\/a> said in a Tuesday report.<\/p>\n\n\n\n

And GAO said it\u2019s hard to predict how long the planned upgrades to the F-35\u2032s power and thermal management system, or PTMS, and engines will be effective, though the fifth-generation fighter is expected to fly for another 50 years. PTMS uses the \u201cbleed air\u201d from the engines to cool systems throughout the fighter including weapons and radars.<\/p>\n\n\n\n

The finding spotlights the uncertainty the program faces as it prepares for a major upgrade to the Pratt & Whitney-made F135 engines, dubbed the Engine Core Upgrade<\/a>. Just a few years after completing the effort, the F-35 program \u201cwill face a period of unknown requirements\u201d for its future capabilities \u2014 and may be in danger of future cost overruns and other mistakes, according to the new report<\/a>.<\/p>\n\n\n\n

\u201cWithout defined PTMS and engine modernization requirements, the F-35 program is at greater risk of repeating prior missteps,\u201d GAO said. \u201cBy proceeding with planning and development of future capabilities without considering the demands on the PTMS and engine, the program endorsed capabilities that neither could support. The program risks repeating a similar mismatch between PTMS and engine capability and future modernization needs if the military services select an option without first defining future requirements.\u201d<\/p>\n\n\n\n

GAO said the F-35 program can\u2019t fully predict how much power and cooling the fighter will need until the military services flying the aircraft define their own requirements.<\/p>\n\n\n\n

But already, new capabilities being added to the F-35 are stretching its cooling capabilities beyond their original design, causing the engines to wear out faster. An upgrade program known as Block 4<\/a> \u2014 a $16.5 billion project to add new sensors, more advanced weapons, and more powerful data fusion and advanced electronic warfare \u2014 will further tax the engines\u2019 cooling capabilities.<\/p>\n\n\n\n

Without an engine upgrade, GAO said, the added heat could drive up the cost of maintaining the existing engines by $38 billion.<\/p>\n\n\n\n

In a statement to Defense News, the F-35 Joint Program Office said it is confident the ECU engine upgrades can \u201cminimize\u201d the $38 billion in costs GAO highlighted.<\/p>\n\n\n\n

\u201cThe ECU will restore engine life, and the [power thermal management system improvements] will ensure that the air vehicle can support future capability growth,\u201d JPO spokesman Russ Goemaere said in an email.<\/p>\n\n\n\n

GAO recommended the Pentagon order the JPO, before moving forward with the engine modernization effort, to re-evaluate its analysis of how to upgrade the F-35\u2032s engines after the services spell out what power and cooling capabilities they will need.<\/p>\n\n\n\n

The Pentagon disagreed with that recommendation, saying the F-35 program will re-evaluate its analysis when necessary as the services\u2019 requirements are updated.<\/p>\n\n\n\n

In a Friday statement after this story\u2019s initial publication, the JPO said, \u201cWe have a firm handle on engine and power thermal management system options that are needed for future cooling needs, based on the service\u2019s requirements.\u201d The JPO also said the services will provide the cooling requirements they need to support the capabilities they want for their F-35s.<\/p>\n\n\n\n

Goemaere said in his original email the JPO is in the early design stages as it weighs several options for improving the fighters\u2019 thermal management systems, which will take place alongside the F135\u2032s core upgrades.<\/p>\n\n\n\n

The upgrades to the engines\u2019 core and thermal management system are expected to be fielded in the early 2030s, he said, though the exact schedule will depend on what design is ultimately approved.<\/p>\n\n\n\n

However, that means the engine upgrades necessary to handle the added heat may come a few years later than the F-35 will receive its Block 4 upgrades, now projected to be finished in 2029.<\/p>\n\n\n\n

More engine cooling \u2014 but will it be enough?<\/h1>\n\n\n\n

In a briefing with reporters Wednesday, Jen Latka, Pratt & Whitney\u2019s vice president of F135 programs, said the current engines would be able to handle the Block 4 upgrades, albeit at an increased maintenance cost. An upgrade to the engine\u2019s core alone would let the F135 more fully enable Block 4, she said. And an upgrade to the power thermal management systems would allow the F-35 to handle future upgrades beyond Block 4, Latka said.<\/p>\n\n\n\n

She said the engine core and thermal system upgrades together \u201cprovides a tremendous amount of cooling margin\u201d \u2014 more than enough to comfortably allow future F-35 capability upgrades beyond 2035, without further improvements to the engine.<\/p>\n\n\n\n

\u201cIf we\u2019re back here talking about a potential engine upgrade in another 15 years, my guess is it\u2019s for a different reason,\u201d Latka said. \u201cThe amount of cooling that will be feasible with the ECU and the upgraded [thermal] system \u2026 there\u2019s a tremendous amount of design margin there.\u201d<\/p>\n\n\n\n

The Defense Department considered two main options for upgrading the F-35\u2032s engines \u2014 Pratt & Whitney\u2019s upgrade to the current engines, and a General Electric Aerospace-made engine it dubbed the XA100 that uses an adaptive design. The so-called adaptive engine uses three streams of air, instead of two, to cool the engine and the aircraft, and can adjust to the configuration that would give the plane the most thrust and efficiency in the moment.<\/p>\n\n\n\n

But during the 2024 budget rollout in March, the Pentagon said it decided to upgrade Pratt\u2019s engines<\/a> instead of going with a new design under the Adaptive Engine Transition Program, or AETP<\/a>.<\/p>\n\n\n\n

Air Force Secretary Frank Kendall<\/a> said at the time that while GE\u2019s adaptive engine would provide more thrust and cooling capability, it was only certain to fit in his service\u2019s F-35A variants. This meant the other services were not interested in an AETP engine, and the cost was too high for the Air Force<\/a> to bear on its own, Kendall said.<\/p>\n\n\n\n

GAO said in the report the Navy\u2019s carrier-based F-35Cs would also be able to use an AETP engine.<\/p>\n\n\n\n

But GAO said AETP engines would not fit in the Marine Corps\u2019 F-35B, which has a unique vertical take-off capability, without a major redesign that would drive up costs and sacrifice commonality across all three variants.<\/p>\n\n\n\n

In the roundtable with reporters, Latka said the GAO report supported the company\u2019s position that an F135 upgrade was the best option for upgrading all three fighter variants\u2019 propulsion systems at the best cost.<\/p>\n\n\n\n

But in an email, GE spokesman Adam Kostecki said the report shows how important it is for the Pentagon to anticipate what the F-35 will need in the future and start investing in technology to meet those requirements. The XA100 would be able to provide considerably greater range, acceleration and cooling capacity, he said, and GE urged Congress to support its engine \u2014 effectively overruling the Pentagon\u2019s decision \u2014 as lawmakers continue to craft the 2024 budget.<\/p>\n","protected":false},"excerpt":{"rendered":"

\u201cWithout defined [cooling and engine] requirements, the F-35 program is at greater risk of repeating prior missteps,\u201d GAO said.<\/p>\n","protected":false},"author":7,"featured_media":117933,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_yoast_wpseo_meta-robots-noindex":"","_yoast_wpseo_meta-robots-nofollow":"","_yoast_wpseo_canonical":"","_acf":"","_yoast_wpseo_primary_category":7,"_jetpack_feature_clip_id":0,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","_smg_distribution_targets":[]},"categories":[7,160,36],"tags":[],"coauthors":[3412],"class_list":["post-65442","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-air","category-daily-news-roundup","category-newsletters"],"acf":{"subheadline":"","legacy_arc_id":"BLIYC4N7WFHJXLUX7OCIKZ2VUU","arc_canonical_url":"\/air\/2023\/06\/01\/auditors-future-f-35-cooling-needs-unknown-as-dod-eyes-engine-upgrade\/","remove_feature_photo":false,"is_sponsored":false,"subtype":"","redirect_url":"","disable_inline_ads":false,"native_logo_pretext":"Presented 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