Electromagnetic railgun video from the Office of Naval Research

A test shot fires from the Office of Naval Research-funded Electromagnetic Railgun prototype launcher located at the Naval Surface Warfare Center Dahlgren Division. The test shots begin a month-long series of full-energy tests to evaluate the technology. This prototype, developed by BAE, is the first of two industry-built launchers that will bring the Department of the Navy a step closer to producing a new-generation, long-range, weapon for surface ships.

First F-35C launch from EMALS

Navy test pilot Lt. Chris Tabert takes off in F-35C test aircraft CF-3 Nov. 18, the first launch of the carrier variant of the Joint Strike Fighter from the Navy's new electromagnetic aircraft launch system, set to install on future USS Gerald R. Ford (CVN 78).

USN’s Electromagnetic Railgun Launches 1,000th Projectile

The United States Navy's Electromagnetic Railgun system has been fired for the 1,000th time, bringing the system one step closer to integration on USN warships deployed at sea.

Less than 12 months ago, the railgun established a new world record when it fired a projectile with 33 megajoules of force. Since then, the tests have been ongoing, culminating in the landmark 1,000th launch, which occurred on 31 October.

The 999 previous firings have examined various aspects related to the system's performance, including potential damage caused to it by the massive forces involved when it's in operation.

USN Electromagnetic Railgun

The USN's Electromagnetic Railgun's being put through its paces by scientists working at ONR - the Office of Naval Research.

"A railgun weapons system must be able to launch hundreds of projectiles and withstand extreme pressures, currents and temperatures", Captain Paul Stewart, the US Naval Research Laboratory Materials Testing Facility's Commanding Officer, explained.

"Today's firing of the 1,000th shot demonstrates Navy researchers are steadily progressing toward achieving that goal, developing a more effective and efficient future ship combat system."

US Navy Railgun: Projectile Launch

The US Navy railgun defies the convention set by earlier weapons designs, which typically launch their projectiles with an explosive force. It, by contrast, draws on electromagnetic power to charge a projectile forwards. This launched projectile travels on rails, before leaving the railgun at extreme velocities, up to a maximum of seven times the speed of sound (Mach 7).

"This test demonstrates continued advances in armature development, rail design, and barrel materials used in high power railgun launch", Doctor Robert Meger, who leads the Charged Particle Physics division of ONR, said in a statement. "Firing up to 15 shots per week on the laboratory's experimental railgun, researchers at NRL perform detailed testing and analysis of rails and armatures, providing S&T expertise to the Navy program that is directly applicable to tests at large-scale power levels", he added.

From here on in, the USN will continue to progress the Electromagnetic Railgun concept, despite the chance that its future might be endangered by budget costs.

Railgun image copyright US Navy

EMALS Lauch of an E-2D Advanced Hawkeye

 

LAKEHURST, N.J. (Sept. 27, 2011) A U.S. Navy E-2D Advanced Hawkeye aircraft launches using the Electromagnetic Aircraft Launch System (EMALS). EMALS uses stored kinetic energy and solid-state electrical power conversion. This technology permits a high degree of computer control, monitoring and automation. The system will also provide the capability for launching all current and future carrier air wing platforms - lightweight unmanned to heavy strike fighters. (U.S. Navy video/Released)

Navy Launches First Aircraft Using Electromagnetic System

From Naval Air Systems Command

PATUXENT RIVER, Md. (NNS) -- The Navy made history Dec. 18 when it launched the first aircraft from the Naval Air Systems Command (NAVAIR), Lakehurst, N.J., test site using the Electromagnetic Aircraft Launch System, or EMALS, technology.

The Navy has been using steam for more than 50 years to launch aircraft from carriers.

The Aircraft Launch and Recovery Equipment (ALRE) program launched an F/A-18E Super Hornet Dec. 18 using the EMALS technology that will replace steam catapults on future aircraft carriers.

"This is a tremendous achievement not just for the ALRE team, but for the entire Navy," said Capt. James Donnelly, ALRE program manager. "Saturday's EMALS launch demonstrates an evolution in carrier flight deck operations using advanced computer control, system monitoring and automation for tomorrow's carrier air wings."

EMALS is a complete carrier-based launch system designed for Gerald R. Ford (CVN 78) and future Ford- class carriers.

"I thought the launch went great," said Lt. Daniel Radocaj, the test pilot from Air Test and Evaluation Squadron 23 (VX 23) who made the first EMALS manned launch. "I got excited once I was on the catapult, but I went through the same procedures as on a steam catapult. The catapult stroke felt similar to a steam catapult and EMALS met all of the expectations I had."

The current aircraft launch system for Navy aircraft carriers is the steam catapult. Newer, heavier and faster aircraft will result in launch energy requirements approaching the limits of the steam catapult system.

The mission and function of EMALS remains the same as the steam catapult; however, EMALS employs entirely different technologies. EMALS will deliver the necessary higher launch energy capacity as well as substantial improvements in system weight, maintenance, increased efficiency and more accurate end-speed control.

"I felt honored to be chosen as the shooter to help launch the first live aircraft tested on the new EMALS track at Lakehurst," said Chief Petty Officer Brandon Barr, Naval Air Warfare Center Aircraft Division Test Department, Lakehurst. "It was very exciting to knowingly be a part of naval aviation history. Petty Officers 1st Class Hunsaker and Robinson, Petty Officers 2nd Class Williams, Wong and Simmons, were the Sailors on my team who worked together to help make this test a success. We all look forward to seeing this cutting edge technology deployed on the Gerald R. Ford."

"I'm excited about the improvement EMALS will bring to the fleet from a capability and reliability perspective," said Cmdr. Russ McCormack, ALRE, PMA-251, deputy program manager for future systems. "EMALS was designed for just that purpose, and the team is delivering that requirement."

The system's technology allows for a smooth acceleration at both high and low speeds, increasing the carrier's ability to launch aircraft in support of the warfighter.

The system will provide the capability for launching all current and future carrier air wing platforms – lightweight unmanned to heavy strike fighters.
Engineers will continue system functional demonstration testing at NAVAIR Lakehurst. The team will expand aircraft launches with the addition of T-45 and C-2 aircraft in 2011.

Test of Futuristic Railgun A Success: U.S. Navy

WASHINGTON - The U.S. Navy announced a successful test Dec. 10 of an electromagnetic cannon capable of firing a projectile 110 nautical miles at five times the speed of sound.

"This demonstration moves us one day closer to getting this advanced capability to sea," said Rear Adm. Nevin Carr, chief of naval research.

Tested at the Navy's Dahlgren Surface Warfare Center, Va., the futuristic weapon uses powerful jolts of electric current to propel a non-explosive slug along rails before launching it at supersonic velocities.

The latest test involved a 33-megajoule shot, the most powerful ever attempted and three times that of the previous test in January 2008.

A megajoule is equivalent to the energy released when a one-ton vehicle slams into a wall at 100 miles per hour.

"Today's railgun test demonstrates the tactical relevance of this technology, which could one day complement traditional surface ship combat systems," Carr said.

"The 33-megajoule shot means the Navy can fire projectiles at least 110 nautical miles, placing sailors and Marines at a safe standoff distance and out of harm's way."

He added that "the high velocities achievable are tactically relevant for air and missile defense."

The test model bears little resemblance to a gun. Instead, thick black cables plug into the rear of what looks like a long rectangular grill.

That armature holds the rails together as a powerful electric current surges through them, pushing the slug forward.

Related Article

EMALS hopes for first shot before Christmas

The first launch of an aircraft by the U.S. Navy’s new Electro-Magnetic Aircraft Launch System could take place by mid-December, an event that would mark a major step ahead for a program with its full share of critics and doubters.

“The shot should take place within a couple of weeks,” said Rob Koon, a spokesman for Naval Air Systems Command (NAVAIR). Asked if the engineers were trying to make the launch before Christmas, Koon replied, “that’s what they’re hoping for.”

The Electro-magnetic Aircraft Launch System (EMALS) is a critical piece of technology that will be installed in the new Gerald R. Ford-class aircraft carriers, the first of which is now under construction. If the system isn’t ready in time, the Navy would have to revert to older steam catapults to launch aircraft from the ships, a move that would mean costly delays and redesigns.

An F/A-18E Super Hornet strike fighter is now being instrumented for the launch, Koon said. Test data is being analyzed for safety issues to obtain the necessary flight clearances.

The launch will take place at NAVAIR’s facility at the Naval Air Engineering Station Lakehurst, N.J., where the service and prime contractor General Atomics have built a full-scale test site replicating a shipboard installation, including major software and hardware components.

The development team began shooting test “dead-loads” from the system in the spring, Koon said. Since then, 722 dead-load launches have been made at speeds of up to 180 knots, the highest end-speed requirement for the system. The launch tests are part of the program’s system functional demonstration phase.

If the Super Hornet launch is successful, other types of carrier aircraft will be tested next year, including C-2 carrier-on-board-delivery planes and T-45 Goshawk jet trainers.

Koon said the EMALS program remains on track to deliver its first components to the new aircraft carrier in 2011.

The EMALS system would be the first new launch system since the Navy replaced hydraulic catapults with steam-powered systems in the 1950s. An electro-magnetic system has numerous advantages over steam. EMALS, which involves energizing a series of electro-magnets, is less stressful on aircraft and can launch a wider range of aircraft. The new system also would, theoretically, need less maintenance and cost less to operate.

The efficacy of the EMALS technology and particularly its test program has long been a question for the Navy, Congress and industry. The program — like nearly all technology development programs — has had its share of setbacks, but the service and General Atomics continue to insist the new system will be ready in time for installation on the Gerald R. Ford.

General Atomics made something of a statement of confidence on July 13, when it agreed to a $676.2 million fixed-price contract to produce the EMALS system and a new advanced arresting gear installation for the carrier.

But nothing will quiet critics like the launch of a front-line jet fighter.

The Electromagnetic Aircraft Launch System at Naval Air Systems Command, Lakehurst, N.J.

EMALS motor, HCT-1

From Steam to Magnets: EMALS vs. Current Approach.

Current steam catapults use about 615 kg/ 1,350 pounds of steam for each aircraft launch, which is usually delivered by piping it from the nuclear reactor. Now add the required hydraulics and oils, the water required to brake the catapult, and associated pumps, motors, and control systems. The result is a large, heavy, maintenance-intensive system that operates without feedback control; and its sudden shocks shorten airframe lifespans for carrier-based aircraft.

To date, it has been the only option available. Hence its use on all full-size carriers.

EMALS (Electro-Magnetic Aircraft Launch System) uses an approach analogous to an electro-magnetic rail gun, in order to accelerate the shuttle that holds the aircraft. That approach provides a smoother launch, while offering up to 30% more launch energy potential to cope with heavier fighters. It also has far lower space and maintenance requirements, because it dispenses with most of the steam catapult’s piping, pumps, motors, control systems, etc. Ancillary benefits include the ability to embed diagnostic systems, for ease of maintenance with fewer personnel on board.

EMALS’ problem is that it has become a potential bottleneck to the USA’s new carrier class. It opportunity is that it may become the savior of Britain’s new carrier class.

The challenge is scaling a relatively new technology to handle the required weights and power. EMALS motor generator weighs over 80,000 pounds, and is 13.5 feet long, almost 11 feet wide and almost 7 feet tall. It’s designed to deliver up to 60 megajoules of electricity, and 60 megawatts at its peak. In the 3 seconds it takes to launch a Navy aircraft, that amount of power could handle 12,000 homes. This motor generator is part of a suite of equipment called the Energy Storage Subsystem, which includes the motor generator, the generator control tower and the stored energy exciter power supply. The new Gerald R. Ford Class carriers will require 12 of each.

Because it’s such a big change, it’s a critical technology if the US Navy wishes to deliver its new carrier class on-time and on-budget, and fulfill the CVN-21 program’s cost-saving promises. If EMALS cannot deliver on time, or perform as advertised, the extensive redesign and additional costs involved in adding steam catapult equipment throughout the ship could easily rise to hundreds of millions of dollars.

The related Advanced Arresting Gear (AAG) sub-program will replace the current Mk 7 hydraulic system used to provide the carriers’ built-in system of arresting wires for carrier landings with the requisite combination of plane-slowing firmness and necessary flexibility. The winning AAG design replaces the mechanical hydraulic ram with rotary engines using proven energy-absorbing water turbines coupled to a large induction motor, providing fine control of the arresting forces. AAG is intended to allow successful landings with heavier aircraft, reduce manning and maintenance, and add capabilities like self-diagnosis and maintenance alerts. It will eventually be fitted to all existing Nimitz class aircraft carriers, as well as the new Gerald R. Ford class.

CVF concept
(click to view full)

EMALS may even prove critical to the future of the British CVF Queen Elizabeth Class, if the F-35B fighter proves unable to take off and land with full air-to-air armament. That’s a matter of some concern in Britain, which is looking into alternative landing approaches and sees the F-35C as its primary “Plan B” for naval aviation.

An F-35C would require catapults, however, and their new carrier’s CODAG (COmbined Diesel And Gas) propulsion doesn’t produce steam as a byproduct the way nuclear-powered carriers do. That threatens a significant redesign, and an accompanying rise in cost that could sink the program entirely. EMALS, on the other hand, would leverage the Queen Elizabeth Class’ design decision to become an all-electric ship, and require far less rework to install.

HMS Queen Elizabeth’s expected delivery date is now 2014-2015, and so the question is the same for Britain as it is for the USA: could a working, tested EMALS system be delivered in time?

Railgun moves closer to real use

Navy shooting for new world record with test of railgun prototype.

For now, the power of what may prove to be the Navy's most formidable weapon is confined to a research and development lab at the Dahlgren base in King George County.

On Friday, the Naval Surface Warfare Center Dahlgren Division and BAE Systems will take another step in an ongoing quest to put electromagnetic railguns on ships in the fleet.

About 1 p.m., Navy brass, civilian engineers, contractors and reporters will watch a video feed of a projectile--traveling five times the speed of sound--smashing into a steel box filled with sand.

Until recently, a railgun has been a fantasy weapon for video gamers, the stuff of science fiction.

But the technology has been slowly moving toward reality.

The railgun works by a pulse of electricity traveling along two parallel rails to propel a projectile at tremendous speed.

Friday's shot, expected to use 32 megajoules of electromagnetic energy, is by far the most powerful to date. It will take only a fraction of a second, as long as the blink of an eye. It is expected to establish a new world record in the annals of electromagnetic acceleration.

The goal is to show the tactical relevance of the technology, the Navy said in a press release.

"The importance of the 32-megajoule demonstration is the feasibility of the system at an energy level that has military significance," said Roger Ellis, electromagnetic railgun program manager for the Office of Naval Research.

A megajoule is a measurement of energy associated with an object traveling at a certain speed. For example, a vehicle weighing a ton, moving at 100 mph, equals a megajoule of energy.

The Navy would like to have a fully functional 64-megajoule system aboard a ship by 2025.

A shot of that power could reach a target 100 nautical miles away in a matter of minutes. The projectile would travel so fast that no warhead is needed; kinetic energy is sufficient to destroy its target.

Another advantage is that it is safer for sailors because it uses no explosives.

There are formidable technological challenges. The gun requires huge amounts of electrical power and must be scaled down to fit on ships.

The first test shot was in 2006. Then, in January 2008, a prototype at Dahlgren achieved a shot of 10.6 megajoules, a record.

BAE Systems, a national defense contractor with an office in Stafford County, was awarded a $21 million contract last year to develop the railgun prototype.

NSWC Dahlgren Division is the largest tenant command of the Naval Support Facility Dahlgren.