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Aviation Engineering 🛩️ | Impossible Engineering | Science Channel
Aviation Engineering 🛩️ | Impossible Engineering | Science Channel
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0:03
Three crew,
0:04
six engines,
0:07
two fuselares,
0:09
the largest wing ever built.
0:13
After 6 years of design, engineering,
0:16
and construction,
0:19
it all comes down to this moment.
0:31
The United States military,
0:34
home to the largest fleet of fighter
0:36
aircraft on the planet.
0:42
They're the essential tool of modern
0:45
warfare.
0:46
>> Carry strike group 10.
0:50
capable of defending airspace over land
0:52
and at sea anywhere on the face of the
0:56
earth.
0:58
But with the potential for conflict to
1:00
arise at any moment, staying one step
1:03
ahead of an unknown enemy with unknown
1:06
capabilities presents an enormous
1:08
challenge.
1:14
Today, engineers have pushed the
1:16
boundaries of aviation technology
1:18
further than ever before
1:21
and created a brand new revolutionary
1:25
fighter aircraft,
1:30
the F35
1:32
Lightning 2.
1:34
This multi-roll fighter is the most
1:37
technologically advanced aircraft in the
1:39
world.
1:44
This is the F-35C Lightning 2. It's the
1:47
US Navy and US Marine Corps carrier
1:49
capable version of the joint strike
1:51
fighter designed to launch from and
1:53
recover two Ford and Nimtts class
1:55
aircraft carriers.
1:59
Commander Mark Cochran is part of a
2:01
small group of pilots trusted to fly the
2:03
Navy's brand new over $100 million
2:07
weapon.
2:08
The F-35 Lightning 2 takes its name from
2:11
the P38 Lightning made by Loheed Martin
2:13
Corporation during World War II. Both
2:15
aircraft are cutting edge for their day.
2:17
Both aircraft are multi-roll and both
2:19
aircraft are to be used across all
2:21
theaters of conflict.
2:25
>> But despite their similarities, the F-35
2:28
has capabilities engineers in the 1930s
2:31
could have only dreamed of.
2:34
All right. So, from front to back, some
2:36
sensors that you'll find on the F-35 are
2:37
some mission systems. At the front,
2:39
you're going to have an active
2:40
electronically scanned array radar. They
2:42
can locate targets just by their
2:43
physical presence.
2:45
After that, you're going to have the
2:46
electrooptical targeting system. It's
2:48
going to allow us to target aircraft and
2:50
ground targets via their IR uh
2:52
signature. Above that, you'll have the
2:54
distributed aperture system or DAS,
2:56
which is primary function is missile
2:58
warning. So, to see uh missiles launched
3:00
by another aircraft. However, uh it also
3:03
provides the pilot the ability to see in
3:06
the dark. Moving out, we're going to
3:08
have the largest wing of the F-35
3:10
family, and that's designed for
3:11
increased maneuverability. Uh it
3:13
increases our range.
3:16
>> At the F-35 factory in Texas,
3:19
the task of turning raw materials into a
3:22
fullyfledged war machine is the
3:24
responsibility of senior fellow Don
3:27
Kard.
3:30
There's about 7 and 12 million square
3:31
feet total here in Fort Worth uh for
3:34
building the airplanes plus storage.
3:37
>> 1 and a2 kilometers long and covering an
3:40
area the size of over 130 football
3:42
pitches, the F-35 factory is one of the
3:45
most advanced in the world.
3:48
>> Well, first of all, we get lots of
3:49
parts. So, for the wings and forward
3:52
fuselages, we get composite parts, metal
3:55
parts, tubes and wires from all of our
3:57
suppliers.
4:00
Each station on the factory floor
4:02
carries out a specific role. At one end
4:05
of the mile, the forward fuselage nose
4:08
and cockpit section is assembled.
4:11
Whilst at the other, the wing sections
4:13
are formed and mounted together.
4:16
At final assembly, the control surfaces
4:18
are added and the F-35 gets its Prattton
4:21
Whitney engine
4:23
before leaving the factory for final
4:25
checks and flight testing.
4:29
This aircraft is about as advanced as it
4:31
gets in terms of technology.
4:37
>> At the F-35 factory in Texas, chief test
4:40
pilot Alan Norman is getting handson
4:43
with this upgraded thrust vectoring
4:45
system.
4:47
Every time I get in the airplane, it's I
4:49
know it might sound cliche, but I almost
4:51
have to pinch myself a little bit for
4:53
how much fun I'm I'm going to have.
4:58
One of the easiest things about the
5:00
airplane is honestly one of the hardest
5:02
things about other airplanes, which is
5:04
to get this airplane in the
5:06
configuration to hover and the ability
5:08
of this airplane to hover. For the
5:11
pilot, all it is for us is a few button
5:14
switches. The centerpiece of the F-35B's
5:17
thrust vectoring capability is its
5:19
Rolls-Royce lift fan. As the pilot
5:22
engages hover mode, it reveals itself
5:25
and begins rotating, reaching 29,000
5:28
horsepower, drawing in enough air to
5:31
empty a squash court in just over 1
5:33
second.
5:35
Connected to the main engine via a drive
5:38
shaft, it produces a downwardflowing
5:40
column of air at the front of the plane.
5:43
At the rear, the exhaust nozzle twists,
5:46
aiming its thrust toward the ground.
5:49
For directional control, bypass thrust
5:52
from the main engine is directed to
5:54
outlets located under the wings,
5:57
allowing the F-35B to gently touch down.
6:04
For the team behind this incredible
6:06
airplane, the sense of achievement is
6:09
untold.
6:10
When I think about all the engineering
6:12
and all the technology that's gone into
6:14
the F-35, I I'm still amazed to this
6:16
day.
6:18
everything that we've done, everything
6:20
we've put into it, and honestly, what
6:22
will carry on way past the F-35's day
6:26
that changed how we fly, what we do.
6:32
When I see an F-35 flying, and I don't
6:34
care what variant it is, I feel
6:35
absolutely proud. I've worked on this
6:38
program in many different aspects over
6:40
the years, and it just knocks my socks
6:43
off every time.
6:50
A remote outpost in western Germany,
6:54
home to NATO's main operating base.
6:58
This specialist crew from around the
7:00
world are constantly on alert.
7:04
Their job to spot hostile intrusion as
7:07
they protect state borders that span the
7:10
northern hemisphere.
7:12
The military are permanently on the
7:14
lookout for different types of threats
7:16
from all around the world.
7:22
This is Awax,
7:27
one of the planet's most sophisticated
7:30
surveillance aircraft,
7:32
able to seek out, locate, and defend
7:35
against threats, no matter how fast
7:38
moving or well hidden.
7:40
This is a massive and highly
7:42
sophisticated machine. It's carrying 4.7
7:46
tons of ingenious technology on its
7:48
back. 7.6 tons of equipment in the body
7:52
of the plane. That's a staggering 12.3
7:55
tons of specialist equipment. And it's
7:57
airborne.
7:59
The technology behind this amazing
8:01
aircraft is kind of magic.
8:04
It's just a tremendous piece of
8:07
engineering.
8:12
This aircraft is like no other. Able to
8:16
see threats not only in the air but also
8:18
at sea.
8:21
Operated by a specialist crew of
8:23
engineers and technicians, surveillance
8:26
experts and weapons controllers.
8:30
Beneath the crew lies state-of-the-art
8:32
signal amplifiers, the nerve center of
8:35
this aircraft's most unique feature.
8:38
An enormous 9 m rotating rad dome
8:42
housing a 1 million watt radar system
8:45
with a scanning range of 300,000
8:49
km an area larger than Arizona
8:56
number two target.
9:01
The Awax technical supremacy also
9:03
enables it to function as a flying
9:05
command post for large and complex
9:08
missions. This incredible machine can be
9:11
used to coordinate up to 150 aircraft at
9:14
one time, and that's what makes it so
9:16
extraordinary.
9:18
There has never been an aircraft with
9:19
this capability in military history.
9:22
It's an impressively fast and accurate
9:24
way of keeping the airspace safe. When
9:27
the Awax is in the air, nothing and
9:29
nobody can hide.
9:37
Today, the crew have been scrambled to
9:39
investigate suspicious activity due
9:41
south. They'll be airborne for 12 hours.
9:45
>> Traffic bra 330.
9:49
>> Awax is an incredibly complex piece of
9:52
aviation equipment. The machine itself
9:54
is awesome. The number of pieces that
9:56
interplay is almost beyond
9:58
comprehension.
10:00
>> And all the groundbreaking technology
10:02
that's been added enables Awax to carry
10:05
out the most complicated of missions.
10:08
But creating a machine like this poses
10:11
massive challenges.
10:12
>> So how do you mount this huge radar
10:15
system on the back of an airplane?
10:20
So we are going close forward.
10:24
>> Engineer Roger Snider services the radar
10:27
assembly.
10:30
>> Okay.
10:34
>> The Rayome's interior is the heart of
10:37
Awax
10:43
only seen by the qualified few. Up front
10:46
you see a motor who turns the antenna.
10:50
It's a hydraulic motor. This make it
10:52
possible that the antenna is spinning at
10:54
six rotations per minute.
10:57
Up here you have three receiver
10:59
protectors and just below low noise
11:02
amplifiers.
11:04
>> But powering this million watt system
11:06
provides engineers with a further
11:08
problem.
11:09
>> One challenge in transmitting at that
11:11
high power of course is the heat that's
11:13
generated by the transmitter.
11:18
Therefore, we are cooling and
11:20
stabilizing the temperature with
11:22
fluoride carbon and therefore having a
11:25
very stable temperature. What is
11:27
important for the antenna to work as
11:30
designed.
11:31
>> High temperatures inside could also
11:34
cause the rayome structure to distort,
11:36
obstructing the radio waves. So the
11:39
honeycombs impregnated with a resin mix
11:42
that helps maintain the rad stability
11:44
during temperature changes. It's the
11:46
perfect environment for radar
11:48
transmission.
11:49
>> We are able to work and pick up targets
11:53
with less noise. Therefore achieving a
11:57
higher range.
12:00
>> Octane 58 magic loud and clear. Such a
12:03
highly sophisticated cooling system is
12:06
the only reason Awax is able to achieve
12:08
its mission.
12:09
>> 33,000 passing from west.
12:11
>> It's an extraordinary and seemingly
12:14
impossible feat of engineering.
12:22
Awex is engineered to be the most
12:24
EMPresistant plane possible.
12:28
An aircraft structure designed and built
12:30
to withstand and redistribute electrical
12:32
charges.
12:36
Door seals fitted with EMP conducting
12:38
gaskets.
12:40
But the EMP proofing doesn't stop there.
12:45
>> All the cabinets inside the aircraft are
12:47
also smaller cages here protecting all
12:51
the electronics inside even further.
12:54
>> And the sensitive radar equipment is
12:56
shielded too. There are also filters in
12:59
the lines from the antennas filtering
13:01
out whatever spikes of electromagnetic
13:03
energy is coming through there.
13:06
>> But there's still one more challenge.
13:08
The plane's windows.
13:10
Glass doesn't stop EMP. So the windows
13:14
are laced with a fine wire mesh. The
13:17
holes are smaller than the
13:18
electromagnetic waves so they won't pass
13:21
through it and the crew can see out.
13:28
left. You can do 180 left. Easy inbound
13:30
CP. Okay.
13:31
>> 100.
13:33
Yep.
13:34
>> 50 40 30.
13:38
>> The mission today has analyzed a huge
13:40
amount of data to build a clear picture
13:43
of activity across the Mediterranean in
13:45
and out of North Africa.
13:48
The classified information has been
13:50
relayed directly to Allied NATO forces.
13:53
>> Excellent.
13:55
No wonder Awax has been declared the
13:57
most significant single tactical
13:59
improvement since the advent of radar.
14:03
>> It's uh incredible how people manage to
14:06
overcome all these challenges. Putting
14:07
radars in here, electronic systems here,
14:11
inertia navigation systems.
14:14
This aircraft is just a tremendous piece
14:17
of engineering and I'm actually very
14:18
glad that I'm allowed to help
14:21
maintaining it.
14:30
The Mojave Air and Spaceport, Southern
14:33
California.
14:35
At this secretive facility, an
14:38
aeronautical revolution is occurring.
14:41
Engineers are preparing to create
14:43
history by flying a new aircraft for the
14:46
very first time. designed to lift a 220
14:50
ton payload to altitudes of over 9,000
14:54
m. If Zack Crever and his team can get
14:57
off the ground, they will set a new
14:59
aviation record. To achieve this goal,
15:02
they've had to redefine aeronautical
15:05
engineering and create an airplane
15:07
unlike any other.
15:12
Strata Launch.
15:16
The Strat Launch is in a league of its
15:18
own in terms of airplanes.
15:23
When it comes to just sheer size,
15:26
wingspan engines fuselages
15:30
nothing can compare to Strat Launch.
15:34
It is the world's largest wingspan
15:36
airplane. 385 ft wingspan. That is
15:40
roughly the size if you took a Saturn 5
15:42
rocket from the Apollo days and laid it
15:44
on its side. That's roughly the length
15:47
of our wing. It's also longer than the
15:50
first three flights that the Wright
15:52
brothers did combined.
16:00
Standing over four stories high and with
16:03
a wingspan wider than a Boeing 747,
16:07
Strata Launch is the largest aircraft
16:09
ever constructed.
16:11
Powered by six gigantic engines, each
16:14
producing over 50,000 lb of thrust.
16:19
Its mission to carry rockets and
16:21
prototype aircraft to altitudes of over
16:24
9,000 m.
16:27
before releasing them into the
16:29
atmosphere or beyond.
16:35
Lifting this much weight means that
16:36
every part of Strata Launch's airframe
16:39
needs to be superersized,
16:41
including its elevator control surfaces,
16:44
the devices that enable the airplane to
16:46
ascend and descend.
16:48
By tilting the elevator up, the pilot
16:51
changes the air flow over the wing and
16:52
tail, causing the plane to climb and
16:55
vice versa.
16:56
>> In order to make the airplane pitch to
16:59
climb or dive, we need enough control
17:02
surface that that will change the
17:05
aerodynamics over the the tail and move
17:09
the tail, which then moves the rest of
17:11
the airplane.
17:14
Measuring 8.7 by 1.7 m, the four
17:17
elevators are the largest control
17:19
surfaces on Strata Launch.
17:22
>> Our elevators are larger than you will
17:25
find on most conventional aircraft
17:28
simply because of the weight and and the
17:30
size of the airplane that we need to
17:32
move.
17:34
>> But having surfaces this large causes a
17:36
problem. When in flight, the force of
17:39
the air passing over them would make
17:41
them impossible for Evan to move with
17:43
muscle power alone.
17:45
>> There would be no way a a person could
17:48
move that physically. The the forces
17:50
would be far too high. The Strat Launch
17:53
has control surfaces that are
17:55
hydraulically powered, but they're
17:56
mechanically signaled, which means we
17:58
have cables running from the yolk up in
18:02
the front cockpit all the way to all the
18:04
different control surfaces. We said,
18:07
"Well, rather than have a bunch of
18:08
computers that would control the
18:11
hydraulic system and display that
18:13
information to the pilots like it's done
18:15
on a modern airliner, we go back to the
18:18
old 747 or Hercules H4 days.
18:24
Despite the difference in design, some
18:27
things remain the same even 70 years
18:29
later.
18:31
To get an airplane this sized into the
18:33
sky still primarily requires two things.
18:36
lift and thrust.
18:38
>> It's the world's largest wingspan. Even
18:41
the biggest 747 or Airbus, their wing
18:44
stretches from our outer engine to the
18:48
other outer engine. And we've got
18:50
another 60 or 70 ft of wing on either
18:53
end of that. Uh so truly in terms of
18:56
wingspan, this is something that no one
19:00
else matches.
19:03
But now the time has come for the team
19:05
to attempt to get this gigantic aircraft
19:08
into the sky for the very first time.
19:11
>> 10 1.1.
19:14
>> If they are successful, they will pass
19:16
into the realms of aviation legend.
19:25
Three crew,
19:27
six engines,
19:29
two fuselares,
19:32
the largest wing ever built.
19:35
After 6 years of design, engineering,
19:38
and construction,
19:42
it all comes down to this moment.
19:56
Oh my gosh, dude. Get out of here.
20:01
>> We put the power up and pull back on the
20:03
column. It's like an elevator ride going
20:06
up.
20:07
>> Going up on 150.
20:11
>> The size of the aircraft does change the
20:14
way we fly. We do things slow to get
20:17
there faster. Do gentle turns. Uh no, no
20:21
high bank maneuvers, no high G
20:23
maneuvers. It is all slow and steady
20:25
wins the race.
20:29
Flying this airplane is not like
20:31
piloting a racing yacht. It's more like
20:33
a super tanker. It's going the direction
20:36
it is going. And in order to change that
20:39
direction, you have to think ahead.
20:44
That touch slow. He's going to pitch
20:45
down just a little. Engines look good.
20:50
After 149 minutes in the air, Evan and
20:53
the crew line Strata Launch up for the
20:55
most nerve-wracking moment of the
20:57
flight.
21:03
>> Super runway 3
21:06
at six.
21:10
>> Coming back
21:15
at 500 ft. Looking good. We're stable.
21:18
We're on our line. 200 ft. Still stable.
21:21
Still on our line.
21:27
Contact.
21:28
>> Touchdown. We straighten the plane out
21:31
on the runway. Break to a stop.
21:40
>> It's a feat of engineering few thought
21:43
possible. I've been working on Strata
21:45
Launch for 7 years now and it's uh a bit
21:48
like my baby and uh designing it, seeing
21:52
it come to fruition and seeing it fly
21:58
by looking to great pioneers of the past
22:01
for inspiration,
22:05
adapting their ideas,
22:08
refining their designs,
22:10
and overcoming monumental challenges. I
22:13
never thought that I would work on an
22:15
airplane this size or of this complexity
22:18
or this groundbreaking. Working on this
22:21
airplane was kind of like winning the
22:23
aerospace job lottery.
22:29
Engineers have built an agedefining
22:31
airplane
22:34
and succeeded in making the impossible
22:38
possible.
22:41
I think that in 40 to 50 years when we
22:44
look at aviation milestones, this will
22:47
stand out as one of those milestones.
