LONG BEACH, Calif., Oct. 09, 1996 -- The manufacturing of detail parts for a new, lower-cost engine nacelle and thrust reverser for the U.S. Air Force/McDonnell Douglas C-17 Globemaster III Airlifter began Oct. 4 at Northrop Grumman facilities in Dallas, Texas.
The nacelle redesign, a major affordability initiative undertaken by McDonnell Douglas, is expected to save more than $4 million in acquisition costs per aircraft. This will result in a net savings in excess of $300 million on an additional 80 aircraft ordered by the Air Force under a new multi-year procurement contract. Ultimately, this contract will provide 120 C-17s to the U.S. Air Force.
The new design was produced during the past 20 months at the McDonnell Douglas Military Transport Aircraft facility in Long Beach, Calif., using integrated product development processes through a multi-functional, multi-company integrated product team.
In addition to McDonnell Douglas employees, the team of 75 included representatives from Northrop Grumman, the nacelle manufacturer; Pratt & Whitney, the engine maker; the Air Force's C-17 System Program Office; and the U.S. Air Force's Air Mobility Command.
To facilitate the design and production, the new nacelle concept was designed entirely in three-dimensional (3-D) computer models. This allows direct transfer to Northrop Grumman tool designers for use of 3-D computer models in design of fabrication and assembly tools.
The major nacelle design change is the replacement of high cost titanium and composite parts with aluminum components, in particular the fan thrust reverser cascades. The cascades, large eggcrate-like devices, direct fan airflow upward and forward to slow the aircraft on landing and to allow the aircraft to back up. The reversers can also be used during flight for rapid descent.
In addition, the exterior surfaces of the inlet and the sleeve covering the cascades were also changed from composite to less-costly aluminum material. Other design changes included the core reverser and the translating fairings, which were changed from multi-piece assemblies to one-piece integral parts.
Assembly methods for the nacelle, produced by Northrop Grumman at its Commercial Aircraft division in Dallas, have been refined to improve quality and reduce costs.
The first deliveries are scheduled for the 4th quarter of 1997. The nacelle will then undergo ground tests at the Pratt & Whitney facility in West Palm Beach, Fla. Subsequent flight testing will be conducted at Edwards Air Force Base in California from December 1997 thru February 1998. The first aircraft with the new nacelles will be delivered to the U.S. Air Force in mid-1998.
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