A quick look at the F-22 reveals an adherence to fundamental shaping principles of a stealthy design. The leading and trailing edges of the wing and tail have identical sweep angles (a design technique called planform alignment). The fuselage and canopy have sloping sides. The canopy seam, bay doors, and other surface interfaces are sawtoothed. The vertical tails are canted. The engine face is deeply hidden by a serpentine inlet duct and weapons are carried internally.
Advances in low-observable technologies provide significantly improved survivability and lethality against air-to-air and surface-to-air threats. The F-22's combination of reduced observability and supercruise accentuates the advantage of surprise in a tactical environment. The most publicized and most revolutionary technology for aircraft is stealth. Stealth makes an object become very difficult to detect by sensors such as radar, heat seekers (infrared), sound detectors and even the human eye. While not invisible, the F-22's radar cross section is comparable to the radar cross sections of birds and bees. Compared to other current fighters, the F-22 is much more difficult to detect.
To make a stealthy aircraft, designers had to consider five key ingredients: reducing the imprint on radar screens, muffling noise, turning down the heat of its infrared picture, stifling radio transmissions and making the plane less visible. The leading and trailing edges of the wing and tail have identical sweep angles (a design technique called planform alignment). The fuselage and canopy have sloping sides. The canopy seam, bay doors and other surface interfaces are saw-toothed. The vertical tails are canted. The engine face is deeply hidden by a serpentine inlet duct and weapons are carried internally.
The F-22 represents a significant design evolution beyond the highly successful F-117A Nighthawk stealth fighter, with performance not achievable by today's front-line fighters. Low observable, or stealth, technology has advanced to the point where conventional aerodynamic configurations can be made incorporating low observability without compromising aerodynamic performance or increasing costs significantly. Design development risk was greatly reduced by the performance demonstrated in the dem/val program where angle of attack attitudes up to 60 degrees were flown. The validity of the low observability features of the F-22's design were confirmed by full-scale pole model testing.
Low observability is achieved by a range of measures. The F-22 employs planform shaping and faceting with blended facet boundaries, the latter a necessary concession to high performance aerodynamics. This is apparent in the shape of the nose, the fuselage sides about the inlets and engines, and the upper forward fuselage. Lockheed/B/GD used serrated edges extensively, as with the F-117A, to control the returns from panel boundaries, this is very visible on the undercarriage and weapon bay doors. The planform results in a multiple lobe design, as the boundaries of the major surfaces are not parallel with respect to each other. Planform return lobe structure is defined by the radiation pattern lobes resulting from surface wave reflections which occur at the leading and trailing edges of the airframe's major surfaces. The objective of lobing is to concentrate this unavoidable radar return into specific directions so as to minimise frontal/aft/beam aspect return and maximise scintillation in the direction of the lobe. Scintillation is a measure of how rapidly the size of the return varies with angle, the greater this variation, the more difficult a target is to track. The lower the number of lobes and the narrower the lobes, the lower the probability of detecting any return.
Radar absorbant materials, or RAM is applied sparingly on the F-22 airframe as opposed to the entire airframe on the F-117. This is because designers have incorporated curves on crucial surfaces and edges, which lessens the need for RAM. For example, new ceramic-matrix RAM is utilized on the engine exhaust nozzles to reduce radar and IR signatures, and a greater amount of wide-band structural RAM is used on the wing edges. The interesting shape of the radome on the F-22 reflects radar signals at all frequencies except the precise wavelengths emitted from the F-22. This can be attributed to the radome's low bandpass type.
To apply the complex system of paints and coatings necessary to meet the F-22's stringent radar cross section (RCS) requirements takes not only state-of-the-art equipment and hands-on technicians, but also a wide-ranging support system. A new type of paint, or topcoat, increases the F-22 Raptor's stealthiness by reducing its vulnerability to infrared threats. To meet F-22 requirements, Boeing developed the topcoat to protect the aircraft against a broad range of wavelengths. The new paint replaces conventional topcoats, performing all the required environmentally protective functions while also reducing the aircraft's vulnerability to detection. The topcoat does not add to the F-22's weight, and provides performance enhancement at a very modest cost. It is applied in a two-tone camouflage design, patterned after the F-15 "Mod-Eagle" paint scheme. Development of the new topcoat began during the early stages of the F-22 program. Since that time, a small team at Boeing in Seattle has worked to refine the paint and improve its application characteristics in a production-level environment. Technicians at Lockheed Martin painted the first few aircraft by hand, however, robotic application is planned for future Raptors, including Raptor 04, which is scheduled to fly this summer. The topcoat application for each Raptor is expected to take one to two days.
Another important feature of the F-22's stealth characteristics is the new low-RCS air data system. This system uses four ports distributed along the forward fuselage to reduce emission control (EMCON). In addition, the F-22 is the first fighter aircraft to include a completely frameless canopy. This eliminates RCS reflections from the windshield arc without compromising structural integrity.
Fundamentals of Stealth Design
In the late 1950s, radar absorbing materials were incorporated into the design of otherwise conventionally designed aircraft. These materials had two purposes: to reduce the aircraft cross section against specific threats, and to isolate multiple antennas on aircraft to prevent cross talk. The Lockheed U-2 reconnaissance airplane is an example in this category. By the 1960s, sufficient analytical knowledge had disseminated into the design community that the gross effects of different shapes and components could be assessed. It was quickly realized that a flat plate at right angles to an impinging radar wave has a very large radar signal, and a cavity, similarly located, also has a large return.
Thus, the inlet and exhaust systems of a jet aircraft would be expected to be dominant contributors to radar cross section in the nose on and tail on viewing directions, and the vertical tail dominates the side on signature.
Radar Cross Section Fundamentals
At normal incidence, the flat plate acts like a mirror, and its return is 30 decibels (dB) above (or 1,000 times) the return from the sphere. If we now rotate the plate about one edge so that the edge is always normal to the incoming wave, we find that the cross section drops by a factor of 1,000, equal to that of the sphere, when the look angle reaches 30 degrees off normal to the plate.
As the angle is increased, the locus of maxima falls by about another factor Of 50, for a total change of 50,000 from the normal look angle.
Now if you go back to the normal incidence case and rotate the plate about a diagonal relative to the incoming wave, there is a remarkable difference. In this case, the cross section drops by 30 dB when the plate is only eight degrees off normal, and drops another 40 dB by the time the plate is at a shallow angle to the incoming radar beam. This is a total change in radar cross section of 10,000,000!
From this, it would seem that it is fairly easy to decrease the radar cross section substantially by merely avoiding obviously high-return shapes and attitude angles.
However, multiple-reflection cases have not yet been looked at, which change the situation considerably. It is fairly obvious that energy aimed into a long, narrow, closed cavity, which is a perfect reflector internally, will bounce back in the general direction of its source. Furthermore, the shape of the cavity downstream of the entrance clearly does not influence this conclusion.
However, the energy reflected from a straight duct will be reflected in one or two bounces, while that from a curved duct will require four or five bounces. It can be imagined that with a little skill, the number of bounces can be increased significantly without sacrificing aerodynamic performance. For example, a cavity might be designed with a high-cross-sectional aspect ratio to maximize the length-to-height ratio. If we can attenuate the signal to some extent with each bounce, then clearly there is a significant advantage to a multi-bounce design. The SR-71 inlet follows these design practices.
When energy strikes a plate that is smooth compared to wavelength, it does not reflect totally in the optical approximation sense, i.e., the energy is not confined to a reflected wave at a complementary angle to the incoming wave. The radiated energy, in fact, takes a pattern like a typical reflected wave structure. The width of the main forward scattered spike is proportional to the ratio of the wavelength to the dimension of the reradiating surface, as are the magnitudes of the secondary and tertiary spikes. The classical optical approximation applies when this ratio approaches zero. Thus, the backscatter - the energy radiated directly back to the transmitter increases as the wavelength goes up, or the frequency decreases.
When designing a cavity for minimum return, it is important to balance the forward scatter associated with ray tracing with the backscatter from interactions with the first surfaces. Clearly, an accurate calculation of the total energy returned to the transmitter is very complicated, and generally has to be done on a supercomputer.
Coatings and Absorbers
High Temperature Coatings
Based on the discussion of simple flat plates, it is clear that it is generally unsatisfactory to have a door edge at right angles to the direction of flight. This would result in a noticeable signal in a nose on aspect. Thus, conventional rectangular doors and access panels are unacceptable. The solution is not only to sweep the panel edges, but to align those edges with other major edges on the aircraft.
The pilot's head, complete with helmet, is a major source of radar return. It is augmented by the bounce path returns associated with internal bulkheads and frame members. The solution is to design the cockpit so that its external shape conforms to good low radar cross section design rules, and then plate the glass with a film similar to that used for temperature control in commercial buildings. Here, the requirements are more stringent: it should pass at least 85% of the visible energy and reflect essentially all of the radar energy. At the same time, a pilot would prefer not to have noticeable instrument-panel reflection during night flying.
On an unstable, fly by wire aircraft, it is extremely important to have redundant sources of aerodynamic data. These must be very accurate with respect to flow direction, and they must operate ice free at all times. Static and total pressure probes have been used, but they clearly represent compromises with stealth requirements. Several quite different techniques are in various stages of development.
On board antennas and radar systems are a major potential source of high radar visibility for two reasons. One is that it is obviously difficult to hide something that is designed to transmit with very high efficiency, so the so called in band radar cross section is liable to be significant. The other is that even if this problem is solved satisfactorily, the energy emitted by these systems can normally be readily detected. The work being done to reduce these signatures cannot be described here.
While a low emissivity surface will reduce the emitted energy, it will also enhance reflected energy that may be coming from a hotter internal region. Thus, a careful optimization must be made to determine the preferred emissivity pattern inside a jet engine exhaust pipe. This pattern must be played against the frequency range available to detectors, which typically covers a band from one to 12 microns.
The short wavelengths are particularly effective at high temperatures, while the long wavelengths are most effective at typical ambient atmospheric temperatures. The required emissivity pattern as a function of both frequency and spatial dispersion having been determined, the next issue is how to make materials that fit the bill.
The big push at present is in moving from metal layers in the films to metal oxides for radar cross section compatibility. Getting the required performance as a function of frequency is not easy, and it is a significant feat to get down to an emissivity of 0.1, particularly over a sustained frequency range. Thus, the biggest practical ratio of emissivities is liable to be one order of magnitude.
Everyone can recognize that all of this discussion is meaningless if engines continue to deposit carbon (one of the highest emissivity materials known) on duct walls. For the infrared coating to be effective, it is not sufficient to have a very low particulate ratio in the engine exhaust, but to have one that is essentially zero.
Carbon buildup on hot engine parts is a cumulative situation, and there are very few bright, shiny parts inside exhaust nozzles after a number of hours of operation. For this reason alone, it is likely that emissivity control will predominantly be employed on surfaces other than those exposed to engine exhaust gases, i.e., inlets and aircraft external parts.
The other available variable is temperature. This, in principle, gives a great deal more opportunity for radiation reduction than emissivity, because of the large exponential dependence. The general equation for emitted radiation is that it varies with the product of emissivity and temperature to the fourth power. However, this is a great simplification, because it does not account for the frequency shift of radiation with temperature. In the frequency range at which most simple detectors work (one to five microns), and at typical hot-metal temperatures, the exponential dependency will be typically near eight rather than four, and so at a particular frequency corresponding to a specific detector, the radiation will be proportional to the product of the emissivity and temperature to the eighth power. It is fairly clear that a small reduction in temperature can have a much greater effect than any reasonably anticipated reduction in emissivity.
The third approach is masking. This is clearly much easier to do when the majority of the power is taken off by the turbine, as in a propjet or helicopter application, than when the jet provides the basic propulsive force.
In summary, infrared radiation should be tackled by a combination of temperature reduction and masking, although there is no point in doing these past the point where the hot parts are no longer the dominant terms in the radiation equation.
The main body of the airplane has its own radiation, heavily dependent on speed and altitude, and the jet plume can be a most significant factor, particularly in afterburning operation. Strong cooperation between engine and airframe manufacturers in the early stages of design is extremely important. The choice of engine bypass ratio, for example, should not be made solely on the basis of performance, but on a combination of that and survivability for maximum system effectiveness.
The jet-wake radiation follows the same laws as the engine hot parts, a very strong dependency on temperature and a multiplicative factor of emissivity. Air has a very low emissivity, carbon particles have a high broadband emissivity, and water vapor emits in very specific bands. Infrared seekers have mixed feelings about water vapor wavelengths, because, while they help in locating jet plumes, they hinder in terms of the general attenuation due to moisture content in the atmosphere. There is no reason, however, why smart seekers shouldn't be able to make an instant decision about whether conditions are favorable for using water-vapor bands for detection.
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