THE OFFICIAL MAGAZINE OF AEROSPACE TESTING, DESIGN & MANUFACTURING EXPO EUROPE WWW.AEROSPACETESTINGINTERNATIONAL.COM JUNE 2014

JUNE 2014

NASA’s Commercial Crew Program heats up with launch abort testing at SpaceX, while Space Boeing and Sierra The next step continue to make progress PUBLISHED BY UKIP MEDIA & EVENTS LTD & EVENTS MEDIA BY UKIP PUBLISHED

737 MAX REPORT A350 TEST UPDATE ALTERNATIVE FUELS Chief project engineer Michael Teal EXCLUSIVE: Details about the recent A joint research campaign could talks about the latest powerplant environmental testing of the A350 at have far-reaching implications for testing for the 737 Max the McKinley Climatic Laboratory the global community

C –130 UPGRADE • GLOBAL TEST SITES: SPACE • CFRP INSPECTION • INAUGURAL F1 AIR RACE www.AerospaceTestingInternational.com z Air Race F1

Winning formula With the first demonstration race having successfully taken place in Spain, Air Race F1 is now set to become a World Series in 2015. We talk to the pilots and the organizer

BY CHRISTOPHER HOUNSFIELD

ver the clear northern Catalan This latest air sport needs to be skies, 11 internationally taken seriously. The Reno annual air Orenowned pilots battled it race is huge, and hundreds of out at Europe’s first-ever international thousands attend, but it is a national Formula 1 class air series – Air sport within the USA. Air Race F1 STEVE Race F1 – in Lleida, near Barcelona, is global. The results of the first race TEMPLE Spain. Pilots from the USA, UK, France were ratified by three recognized and Sweden revved up to showcase international air associations from the some of the world’s best air racing, in USA, France and UK, respectively the which French pilot Christian Guilie International Formula 1 Air Racing won the overall title on June 1, 2014. Association, the Association des Pilotes It was not against a clock like in d’Avions de Formules and the Formula Red Bull Air Racing, or straightforward Air Racing Association. timed flights. The pilots flew a circuit against each other, vying for lead spot. THE AND THE PILOTS Imagine F1 car racing, but 3D, and a Jay D Jones is president of J J Air lot faster. Works, and happens to be one of the As the roar of the hugely powerful pilots. He came second out of the eight aircraft has died down, and the ‘Gold’ racers, showing an average champagne has been drunk, the event speed of 239mph. He is adamant that could mark a totally new era of air the race brings back the golden age of JAY racing, which could bring back a air sport: “This race in Spain is back to JONES golden age not seen for more than the real air racing that was started in 50 years. 1947 where eight competitors

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JUNE 2014 AEROSPACETESTINGINTERNATIONAL.COM | 11 z Air Race F1

BELOW: The air race involved teams from four different nations. Even the demonstration drew crowds above 6,000 right: Christian Guilie’s engineering crew start up the aircraft pre-race

competed with each other at the same time around the pylons. The best combination of pilot and will The man behind it all cross the finish line first.” Jeff Zaltman, CEO, Air Race F1 Aircraft are tested thoroughly and to the same criteria as motor racing: wing area no less than 66ft2, empty How did Air Race F1 of the knowledge that the Formula 1 air racing weight of no less than 500 lb, fuel come to fruition? support crews have, but at least I can capacity no less than 5 gallons, and the Air Race F1 came appreciate their expertise, dedication and engine must be a Continental 0-200 about following my importance; support is integral to the sport. with 100hp. Other criteria include JEFF years of development height, wheel size, vision requirement ZALTMAN of other forms of air How does Air Race F1 differ from Red and seat height. racing and Bull Air Race, the and the On top of this, there are strict events and media projects. I had long Rocket Racing League? technical guidelines on any engine identified Formula 1 air racing as a format that It is quite different from any other competition modification or detailing – just the could have high growth opportunities, and format out there. In the Red Bull Air Race, only same as for – such as finally I found the right moment to run with it. one aircraft competes at a time against a sweep volumes, compression ratios The sport has a lot of history, but has not clock; Formula 1 is eight aircraft competing and carburetor guidelines; and had the benefit of proper promotion and directly against each other in a real race. The individual parts weights such as development, so I decided about 18 months Rocket Racing League is a fascinating concept cranks, push rods, valves, pistons ago to use my 10 years of experience in this but never really took off, and the race would and connecting rods. area to focus solely on Formula 1 air racing take place thousands of feet away from Jones says, “F1 racers are built to and to take it into the mainstream of the audiences. It is a sound platform for gaming go fast, fly low and turn left. But F1 sporting world. So, Air Race F1 is the new but it doesn’t benefit from having any history aircraft are also built with love by international series dedicated to this sport, or existing fan base. The Reno Air Races are airplane enthusiasts and designers with a focus on media and commercialization the mecca of the sport and a grand event, but who think they can make a faster and and sustainability. it takes place only once a year and is a US a better design that can slip through National Championships – not an international the air better than their competitors. You used to be an aircraft technician. series like the Air Race F1. However, we do “I have spent years trying to remove Did that influence the creation of Air hope to have a good working collaboration any gram of drag on the aircraft – Race F1? with it in the near future. everything from the wheel parts, My time in the US Navy as an avionics intersection fairing, cowling shapes, technician on carrier-based attack aircraft How did you get into air racing? fuselage, engine cooling and engine certainly contributed to my early inspiration As a basic private pilot, I met other pilots who induction. Each part added to the to both fly and develop an aviation career. In do some amazing things, and I wondered, ‘Why airplane is tested over and over, and particular it helps me to grasp and contend don’t more people know about this stuff?!’ So each variation is test flown to remove with the technical side of Formula 1 air racing – I decided there might be an opportunity to any drag, and tested for flutter, which is at least as demanding as any introduce new audiences to air racing, and air vibration and performance.” maintenance support environment that I saw sports in general, as the last frontier of sport Steve Temple is another air in the military. I’m still not a very technically yet untapped. I chose air racing as the most race pilot who took part in the minded person, and I don’t have a tiny fraction audience-friendly format, and off I went! demonstration race in Spain, and

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LEFT AND BELOW: Engine and component checks on aircraft Catch 22 (Jane Jarvis)

was unlucky not to complete the last laps because of technical problems. He agrees that the aircraft have to follow stringent guidelines, but that they do vary: “There are some purpose-built racers such as the Boyd GR-7 Panther YOU HAVE COMPLETED THE FIRST environments. This meant that there was some and the French Arlety [moulded to the DEMONSTRATION RACE SERIES IN SPAIN. HOW discrepancy between rules, and even pilot’s body]. Most are sport flying DID IT GO ? perspectives. But everyone came together in a machines, meaning you can fly them at I couldn’t be happier with the outcome! There surprisingly seamless and collaborative the weekends from airport to airport were many hurdles and unforeseen obstacles, manner to make this happen because they all and also do some minor but they were quickly overcome by the wide recognized the benefits for the growth and with them. The most widely accepted support and motivation of all the people who development of the sport. racing design is a Cassutt.” contributed to the event, including pilots, Ultimately, all parties equally wanted a safe engineers, racing associations, enthusiasts event and a fair and fun competition that THE SETUP and even the authorities and governmental participants and audiences would enjoy. The The teams have many support crew organizations. The biggest mark of its success airport management team we worked with was and engineers on the ground. Temple is that everyone – from host city to competing also super-helpful and indeed a driving force in explains, “Typically there is one pilots – want to come back for more next year. the development of the event. It was their dedicated pilot and a crew chief who vision and effort that kept the event alive. The functions as the aircraft mechanic. In HOW DO THE AIRCRAFT PERFORM? ARE THEY aviation authorities were also admirably open order to facilitate safe starting, many ALL DIFFERENT? to analyze this and to study the event. of the teams have a dedicated starter Formula 1 airplanes need to meet a certain as many of the aircraft must be hand- defined set of criteria to qualify for the race. AS A COMPETITION, HOW DO YOU SEE started or propped. There is usually But pilots can take those criteria and ‘connect THE FUTURE? one team member dedicated to the dots’ however they wish. So although there This event will have a big impact on the aviation assisting the pilot in and out of the is a standardized starting point for design and industry, on an awareness level and also on a airplane. So typically pilot, crew chief, build, there is an impressive variation in design technical level. Formula 1 air racing is an starter, pilot assistant.” characteristics and use of technology. Each excellent platform for testing and researching Jones says that the responsibility plane is truly different, yet compatible in new technologies and products. Just like other of engine testing is entirely down to sporting fairness. events involve manufacturers, this him, but he has the kit: “I have full series could be the proving ground for many new telemetry recording equipment on HOW DID YOU ACHIEVE APPROVAL FROM THE technologies. To prove this, we signed an board, designed by MGL Avionics, VARIOUS FLYING ORGANIZATIONS? important and respected market-leading sponsor that monitors engine output, This Air Race F1 event was the first time that all for the event, Continental Motors, which makes performance, EGT, CHT, rpm, oil three official Formula 1 air racing associations aircraft engines. We see a big synergy with such pressure, oil temperature and had come together to organize one a fine company and product range and I am manifold pressure; and all flight international event. This was, if I may say so, confident that many new enhancements to their characteristics such as speed, altitude, historic. The associations had all evolved in engines and other products will be a result of g-load, and GPS tracking.” different ways over the years, mainly because future testing and research during our racing Temple goes into more detail, but of operating in different regulatory events. Watch this space… agrees that tests are the responsibility of the pilot in order to keep safe, and

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RIGHT: A win from French pilot Christian Guilie, beating the best of the USA, UK, France and Sweden

FAR RIGHT: Pre-race cockpit checks for the US team

things are really fairly simple: “The They must also conduct an engine-out aircraft are tested using standard landing and a simulated aborted take- RACE PLAN home-built stress tests that typically off. Typically, a volumetric test is have a load placed on the wing with conducted using a liquid measuring Air Race F1 is motorsport at its sandbags to demonstrate the wing- device – typically a buret. Load it with fastest. It is a test of pilot skill loading capability. Marvel Mystery Oil and test for volume based upon the long- “There is also the requirement of at top dead center of the piston stroke historic Formula 1 aircraft class. the airplane to demonstrate a 6g pull to make sure the engine displacement All airplanes race against each with a mobile g-meter attached in the is standard and there has been no other at speeds of over 450km/h cockpit. During the check ride, the stroking or boring of the cylinder. together on a circuit just 2km end pilots must do a full left and right roll, There is also a cam test conducted to end. The first aircraft to cross and a half left and right roll, using a dial indicator to measure valve the finish line wins. demonstrating the upset recovery rise and fall. These measurements are capability of the airplane and pilot. then loaded into a program to make KEY FACTS: sure that the camshaft meets lobe › 8 aircraft racing together measurement formula criteria.” simultaneously › Each race is 10 laps of 5 FLYING THE COURSE kilometers each lap “AS PILOTS, WE MUST Inspections by the pilots, race › Takes place on a circuit organizers and ground experts are entirely visible in front of crowds KEEP BOTH OUR BODIES regular and thorough, but how do the AND MINDS IN SHAPE” pilots prepare? “You prepare for a race › Two days of racing (plus by trying to get as much formation several practice days used flight time as you can. We say this is in advance) an uncooperative formation. There are different ways to fly the course. The high line keeps you out of the are practiced and tested. “As athletes, AIR RACE HISTORY turbulent air that is created by the we train by running, cycling and other airplanes. However, most pilots exercising. As pilots, we must keep The sport of air racing has over 100 years of rich do not fly a high line – they prefer to both our bodies and minds in shape.” heritage and has captured the public imagination get as low as possible to best judge the Jones sums up: “I am very and inspired many millions of people. Air racing exact distance from the pylon. A optimistic that this joint national event began in , France in 1909 and soon became constant altitude is the best way to fly will rekindle the aviation spirit and a global phenomenon, reaching its Golden Age in the course as no energy is spent either bring the golden age of flying back to the 1920s and 1930s. Throughout the past century, or . However, since the the public.” Air Race F1 will hold its air racing was regularly used as a platform to develop entire course is flown by line-of-sight, first full annual World Series in 2015. technology and improve engineering, as well as for this is what the pilot finds most Dates are being planned and venues recreation and enjoyment of the public. difficult and that is where the skill set arranged, with announcements to come Racing took many forms from pylon racing (like is – flying at a constant level.” later in the year. Anyone who has been the Reno Races and Aero GP) to single-plane time Jones concurs, “Practice, practice to a Formula car race, will see and feel trials (like the Red Bull Air Race) to the long-distance and practice; flying in all racing cars shoot past every few seconds, but air races (like the , the Powder Puff conditions, from flat flying to sharp did not really have a clue what is going Derby, the and many others). turns, from quick climbs to controlled on. I have a feeling this will be very descents. Acrobatic safety maneuvers different – and more thrilling. z

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