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Flight Test Risk Reduction 

and Lessons Learned from 
the “Scorpion” Aircraft 
Development Program

Dave Sitz
Flight Test Engineer/Pilot
Textron Aviation

SETP Flight Test Safety Workshop
May 2015

Company Confidential and Competition Sensitive


1
Overview

 What is the Scorpion Program?

 Aircraft Description

 Risk Reduction/Lessons Learned from 3 Scenarios:
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• Preparation for First Flight Company 
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- Spin Chute Taxi Test
• Initial Landing Gear Operations

 Conclusion
• Condense our experiences into one unified safety approach or theme

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The Scorpion Program

$$$$$$ 5th Gen

$$$$ 4th Gen

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Price

Confidential and Competition Sensitive 3 Scorpion is
$20M designed to fill a
gap in the tactical
aircraft spectrum
$
Vast Majority of ISR/Strike
Missions

Capability
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Aircraft Description

DIMENSIONS AIRFRAME Standard Empty Weight 11,800 lbs


Wingspan: 47.3 Feet Composite Structure and Skin
Length: 43.5 Feet
Max Takeoff Weight 21,250 lbs

ELECTRONIC SYSTEMS EXTERNAL STORES


Modular Architecture Scalable, Precision Munitions
Max Internal Fuel Load 6,000 lbs

RADAR Max Internal Payload 3,000 lbs


Weather, Growth Space
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Max External
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ENGINES Thrust >8,000 lbs


2 x Turbofans

SENSOR Maximum Speed 450 KTAS


EO/IR Ball, Laser Designator

PAYLOAD BAY Service Ceiling 45,000 ft


Sensors and Comms

Ferry Range 2,400 NM

* Design Targets

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Aircraft Description

Insert EXTRA
LARGE Flight Test
Instrumentation
Package HERE

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Communications SAT, Network, UHF, VHF, HF Hotspot, Air‐Ground, Air‐Air, Air‐First Responders


Sensors EO/IR Ball Passive
Fuel 3,000 lbs Auxiliary

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Aircraft Description

 Aircraft Design
• Maximum Use of Existing Systems
- Engines
- Avionics
- Ejection Seats
- Sub‐Systems: Hydraulics, Electrical, Fuel,                                                           
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OBOGS, ECS, Flight Controls Company 
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• New Composite Airframe
- New Main Landing Gear Struts
- Engine Inlet

Airframe structure, and the main landing gear struts,


are the only completely original parts

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Aircraft Description

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Upper Drag Brace


Lower Drag Brace

MLG Axle
MLG Trunnion
Piston
Metering Pin
Stand Pipe

Torque Links

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Risk Reduction/Lessons Learned

 Preparation for First Flight – At a “Macro” Level
• “Where Do You Even Start?”

• Cessna Engineering Flight Test                                                                
Processes and Procedures
- Quality/Configuration Control
- Test Planning 6/16/2015 9:47 AM Company 
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- Independent Safety Reviews
- Flight Readiness Reviews
- Special Inspection (Pre‐First Flight)

• SETP Pilots Handbook

Resources, processes, and procedures existed to


guide macro-level planning

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Risk Reduction/Lessons Learned

 Preparation for First Flight – At a “Micro” Level
• Aircrew involved in design process for over 1½ years before first flight
• Where are the “booby traps” due to unique configurations/interactions?
• The 4 Forces of Flight (what’s really important?):

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Flight Test had the time to identify and mitigate


- THRUST: Propulsion/Fuel Systems
potential aircraft-unique “booby traps”
- LIFT: Aerodynamics/Flight Controls

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Event 1 ‐ Preparation for First Flight

 First Engine Run – September 2013

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Event 1 ‐ Preparation for First Flight

 Inlet: Aerodynamics and Airframe Location (behind Gear Doors)

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Event 1 ‐ Preparation for First Flight

 Engine Inlet
• Natural Flow Visualization of Vortices

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Event 1 ‐ Preparation for First Flight

 Inlet Risk Reduction
• “What Can You Do to Reduce Risk?”
• Pre‐Flight Taxi: Test “Worst‐Case” Gear Door  Configuration

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Event 1 ‐ Preparation for First Flight

 Landing Gear Availability
• “What Can You Do to Reduce Risk?”

“The first flight plan should


never6/16/2015 9:47 AM
be more ambitious Company 
than the ground test program
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that supported it…”


SETP Handbook

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Event 1 ‐ Preparation for First Flight

“The primary purpose of a First Flight


is to make a successful landing…”
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SETP Handbook

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Event 1 ‐ Preparation for First Flight

 December 12, 2013

“One flight test condition is worth


a thousand expert opinions…”
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Wernher von Braun

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Event 1 ‐ Preparation for First Flight

 Acknowledging the Team’s Efforts

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“Share the pilot’s exhilaration of a First
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Flight with the ground team. It is


probably the only good thing that has
happened to them in the last 6
months…” SETP Handbook
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Event 2 ‐ Spin Chute Taxi Test

 Pre‐Flight Taxi Testing
• Brakes/Steering
• Low/Moderate Speed Taxi Testing
• Elevator Control Power Evaluation (Aerodynamics: Rotation and Flare)
• Spin Chute Operational Test (Deploy/Jettison)
• Last‐Minute Aircraft Squawk
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• “Were We Ready?”Confidential and Competition Sensitive 18

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Event 2 ‐ Spin Chute Taxi Test

 Spin Chute Controls
• Two Chutes, Fwd and Aft Panels
• Fwd: “Drive”, Aft: “Execute Test”

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Event 2 ‐ Spin Chute Taxi Test

 Crew Resource Management in Action

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Event 2 ‐ Spin Chute Taxi Test

 Was my “experience” working against me?

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Event 2 ‐ Spin Chute Taxi Test

What I expected:
“Deploy Confirmed” –or-
“No Chute, No Chute”

Mortar Fire Noise

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Kinesthetic (Seat of Pants)
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Visual

Control Panel

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Event 2 ‐ Spin Chute Taxi Test

What I expected: What happened:
“Deploy Confirmed” –or-
Nothing (Com blocked)
“No Chute, No Chute”

Mortar Fire Noise Nothing (Com blocked)

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Kinesthetic (Seat of Pants) Nothing
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Visual Nothing

Control Panel No Change

My Conclusion: Failed Chute Deployment

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Event 2 ‐ Spin Chute Taxi Test

What I expected: What happened (Pilot):
“Deploy Confirmed” –or-
Nothing (Com blocked)
“No Chute, No Chute”

Mortar Fire Noise Heard Mortar Fire

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Visual Nothing

Control Panel No Change

Pilot Conclusion: Jettison Chute

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Event 2 ‐ Spin Chute Taxi Test

 Inadequate/misleading feedback led to delayed chute jettison
• Aircrew CRM saved the day
• Fortunately, the only consequence was a few extra thousand feet of FOD 
walk for ground crew…

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Event 3 ‐ Initial Landing Gear Operations

 Initial Gear Ops – Gear Up Attempt

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Event 3 ‐ Initial Landing Gear Operations

 Under airloads, NLG doors overlapped
• MLG retract sequence did not complete
- Notice where MLG doors are…

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Event 3 ‐ Initial Landing Gear Operations

 Initial Gear Ops – Gear Down Attempt (the one that counts…)

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Event 3 ‐ Initial Landing Gear Operations

 Gear Down
• “What Would You Report?”

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Event 3 ‐ Initial Landing Gear Operations

 Gear Down – Cockpit Indications

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Event 3 ‐ Initial Landing Gear Operations

 Chase reported “apparent down and locked”
• No MLG “greens” due to incomplete sequence?
 We did NOT declare an in‐flight emergency
• We were doing gear testing, after all
• Experimental License dictates initial takeoffs/landings from home field
 Emergency Gear Extension?
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• Booby Trap: Continuous 3000 psi hydraulics vs. one‐shot pneumatics
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 Airloads on MLG Drag Brace higher than anticipated
• Did not quite reach over‐center
• Gear locked over‐center during landing rollout

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Event 3 ‐ Initial Landing Gear Operations

 Gear Down – After Landing

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Event 3 ‐ Initial Landing Gear Operations

 ∑ MLG Forces

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Event 3 ‐ Initial Landing Gear Operations

 Troubleshooting and Changes
• For Gear Up: Adjust NLG Doors
• For Gear Down: Alleviate MLG Drag Loads
- Positive G and engine RPM (to assist “mechanical advantage”)
- Adjust airspeed (to reduce airload on MLG drag brace)
- Sideslip (to change airload direction from aft gear doors; “air dam” 
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- Pulse braking on rollout to ensure load assists over‐center locking
• Additional Instrumentation

 Next Attempt
• NLG closed but mains still didn’t completely lock over‐center
• This time we DID declare an emergency with McConnell Tower…

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Event 3 ‐ Initial Landing Gear Operations

 Declaring an Emergency…
• We were “called to the principal’s office…”

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Event 3 ‐ Initial Landing Gear Operations

 Declaring an Emergency…
• We were “called to the principal’s office…”

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“When you come to a fork in the
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road, take it…” Yogi Berra

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Event 3 ‐ Initial Landing Gear Operations

 More Troubleshooting and Changes
• Engineering “Tiger Team”
• More NLG Door adjustments, and new actuator 
• Aerodynamic Fairing to reduce MLG Drag Loads
• New MLG actuator

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 Final Success Confidential and Competition Sensitive 37
• Aircraft‐unique changes worked
• Procedural Lessons Learned 
• Follow‐on improvements made

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Event 3 ‐ Initial Landing Gear Operations

 Drag Brace Aerodynamic Fairing

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Event 3 ‐ Initial Landing Gear Operations

 Final Gear Ops – Gear Up (watch for “special” signal…)

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Event 3 ‐ Initial Landing Gear Operations

 Final Gear Ops – Gear Down

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Event 3 ‐ Initial Landing Gear Operations

 Final Drag Brace Downlock Spring

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Conclusion

 “The (Flight Test Safety) Theory of Everything”
• Theory of Relativity and Quantum Physics
There isn’t one (yet…)

 MACRO: Proven Processes and Procedures
• Use of Cessna’s Established Methods
• SETP Guidance
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• Practice Good CRMConfidential and Competition Sensitive 42
• Ground Test before Flight Test

 MICRO: Integration with Design; aircraft‐unique “Booby Traps”
• Inlet Risk Reduction
• Elevator Control Power Evaluation
• Initial Landing Gear Operations

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Questions?

 Picture Placeholder

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Dave Sitz
Flight Test Pilot
Textron Aviation
(316) 831‐4252
dsitz@txtav.com
www.ScorpionJet.com
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Photo Gallery

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Photo Gallery

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Photo Gallery

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Photo Gallery

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Questions?

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6/16/2015 9:47 AM Company 
Confidential and Competition Sensitive 56

Dave Sitz
Flight Test Pilot
Textron Aviation
(316) 831‐4252
dsitz@txtav.com
www.ScorpionJet.com
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