C-130 Structural Changes Through Its Life

Positive Changes to a Classic Design:
Structural Changes Through the Life of the C-130

Aircraft Airworthiness & Sustainment 2011 April 21, 2011
Frank McElwain
Dept Mgr, C-130 Structural Analysis
2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED
Outline
C-130 History, Variants, Missions Changes, Prior to the C-130J Call for the C-130J, C-130J Changes C-130J Features and Benefits The ESL Wing Closing Remarks
Initial Aircraft Requirement

The Year: 1951
The Current Platform: Fairchild C-119 Flying Boxcar

The Problem: As The US Entered The Korean War, The USAF Realized It Lacked A True Military Transport Capable Of Airlifting Combat Troops Over Medium Distances And Delivering Them To Short, Austere Airports.
Initial Aircraft Requirement

The Solution: A New Medium Cargo Transport
USAF Requirements: Carry Ninety-two Infantrymen Or Sixty-four Paratroopers On A Mission With A Combat Radius Of 1,100 Nautical Miles, Or, Alternatively, A Thirty-Thousand Pound Cargo Over 960 Miles, Operate From Short Unprepared Airstrips Of Clay, Sand Or Humus Soil, Slow Down To 125 Knots For Paradrops And Even Slower For Assault Landings, Have Both A Rear Ramp Operable In Flight For HeavyEquipment And Side Doors For Paratroop Drops, Handle Bulky And Heavy Equipment Including Bulldozers, Artillery Pieces And Trucks, And Fly With One Engine Out.
4
The Model 82
Design Team Lead: Willis Hawkins, Chief Of Preliminary Design Aesthetics Werent The #1 Priority
Kelly Johnsons Purported Assessment: "It's a pretty good design, but you won't sell more than a hundred of them."
Contract Awarded To Lockheed

The Competitors: Boeing Douglas Lockheed Fairchild The Winner: Lockheeds Model 82 On July 2, 1951 Lockheed Awarded Contract To Produce Two Prototype YC-130 Aircraft
Key Design Characteristics

The Model 82 Was The First Tactical Airlifter And Featured:

Large, Unobstructed, Fully-Pressurized Cargo Hold High-Wing Design To Place Cargo Floor At Truck-bed Height Integral Roll On/Roll Off Rear Loading Ramp Ability To Be Quickly Reconfigured For Carriage Of Troops, Stretchers, Passenger Box, Or Support Or Airdrops Of Troops And/Or Equipment Into Forward Battle Zones. Tremendous Lift Capacity, Range, 365 Mph Cruising Speed, And Flight Handling Characteristics Low Landing Speeds, Short-Field Capability, And Previously Unavailable Austere Landing Field Capabilities
First Flight August 23, 1954
Shes a real flying machine. I could land it crossways on the runway if I had to.
Stan Beltz, Test Pilot
YC-130 Flight Test Performance

Maximum Payload Of 40,000 Pounds
Weight Control Measures Kept Airframe Weight At 108,000 Pounds: 5,000 Less Than Estimated
Exceeded All Air Force Specifications

Cruised Faster, Climbed Higher, And Landed In 20% - 40% Less Distance Than Required
Shortly After The Successful First Flight, The Air Force Increased Its Order From Seven C-130As To Seventy-Five
Lockheed In Georgia
Air Force GOCO Plant 6 The Bomber Plant
1942: Ground Broken in March 1943: Bell Begins B-29 Production in April 1945: 28,000 Bell Aircraft Company Employees Turning Out 50+ B-29s/Month When WWII Ends And Plant Closes
Lockheed Moves To GA , Re-Opens Air Force Plant 6

1950: USAF Invites Lockheed To Re-Open AF Plant 6 And Refurbish B-29s For Korean Conflict 1951: 275 Key Lockheed Engineers And Managers Move To Georgia from California 1952: Lockheed Wins B-47 Co-Production Contract & Decision Made To Move C-130 Production To Georgia
10
Initial Production
Building B-1, Position #1 Final Check-Out
C-130A Production Begins in 1953 At Air Force Plant 6, In Marietta, GA
The First Lady (a/c 3001) First Flight April 7, 1955

First C-130A delivered to 463rd Troop Carrier Wing at Ardmore AFB, Oklahoma in December 1956
The First Lady Now Resides At Eglin AFB Armament Museum
11
Longest Running Military A/C Production Line

2,370 Aircraft Produced In Five Major Versions Since 1953 And Delivered to 61 Different Nations:
C-130A Entered Service Dec 1956
231 Delivered; ~17 Still in Service 230 Delivered; 100+ Still in Service 488 Delivered; 300+ Still in Service 1,205 Delivered; 950+ Still in Service 217 Delivered; Current Production Model
12
C-130B Entered Service Nov 1958
C-130E Entered Service Jun 1961
C-130H Entered Service Mar 1965
C-130J Entered Service Jun 1998
Variants, 70 and Climbing

One Of The Most Versatile Airframes In The World:
Aerial Delivery Aerial Fire Fighting Aerial Photography And Mapping Aerial Refueling Airborne Drone Launch And Control Airborne Hospital Airlift Commercial Airline Passenger Service Electronic Surveillance/ Communication/ Battlefield Control Gunship / Close Air Support Hurricane Hunter Maritime Patrol Missile Tracking And Satellite Recovery NASA Research Oil Spill Control / Dispersal Personnel Transport Rapid Ground Refueling Tanker Search And Rescue Ski Bird Special Ops Special Accommodations / VIP Module Weather Observation And Research
13
Missions
Since Its First Flight Over 50 Years Ago, C-130s Have:
Landed And Taken Off From The Icy North And South Poles Participated In All Major US Military Operation Since Korea Responded To Major Disasters Around The World Air Dropped Everything From Leaflets To 15,000 Pound Bombs Supported Special Forces As Gunships And For Search And Rescue, Deep Insertion, Surveillance, And Electronic Combat Missions Tracked Icebergs In The North Atlantic And Drug Traffickers In The Caribbean Flown Into Hurricanes, Forest Fires, And Mapped The Earth Air Dropped Insecticides, Fire Retardants, And Oil Dispersing Agents Hauled Killer Whales, Camels, Cows, Chickens, And Horses Been Flying Hospitals, Commercial Airliners, And VIP Quarters Performed Solo And Formation Aerial Demonstrations Carried As Many As 452 Passengers, Despite Being Designed To Carry Only 90 Landed And Launched Off Of A US Navy Aircraft Carrier
14
Outline
15
Major Structural Components
16
Assy Techniques and Material

Material Technology Evolution
1950s
C-130A/B
C-130 Materials
1990s 2011
C-130H3/J
1960s
C-130E* (1)
1970s
C-130H1(3)
1980s
C-130H2 (2)
Low Durability Minimal Corrosion Protection High Corrosion Susceptibility
High Durability Enhanced Corrosion Protection Low Corrosion Susceptibility
(1) Includes: C-130E (61-72), MC-130E, MC-130P, HC-30P, HC-130N (69), AC-130H (2) Includes: C-130H2 (78-91), MC-130H, HC-130N (88-92), AC-130U (3) Includes: C-130H1(73-74) and EC-130H
Original C-130A/B/E Used Best Materials Available in 1950s/1960s Durability not a Requirement in C-130A/B/E Design. Major Design Changes Incorporated Improved Materials in Late 1960s Through 1990s and Increased Durability: - Center Wing Redesign (FY 68, SOF) - Outer Wing Redesign (FY 73, FY 84)
Assembly Techniques
A/B Surface Treatment & Paint Fay Surface Sealing Wet Installed Fasteners Interference Fit Fasteners Automatic Hole Drilling Limited Limited Limited Limited Limited E More Yes Yes Limited Limited H1 H2 Improved Improved Improved Yes Yes H3/J
C-130 Assembly Techniques

Corrosion Prevention Designed into C-130H/J:
- Increased Use of Anodizing and Paint System Upgrades

- Increase Use of Corrosion Inhibiting Sealant in Joints and Fastener Installation Interference Fit Fasteners Improve Durability Automatic Hole Drilling Improves Fastener Hole Quality and Enhances Durability
17
C-130H1 Durability Improvements

STRUCTURAL MEMBERS
Cargo compartment floor beam end ftg at FS 577
PRE 1973 PRODUCTION

7075-T6
IMPROVEMENT
4340 steel assembly
LMAS S/N
3884
Engine mount drag angles, O/W

Nose landing gear
7075-T6 forging
4340 steel
7075-T73 forging
300M forging, re-profiled
4542
4638
Windshield doublers
Flap track ribs, rear beam stiffener Center wing upper skin panels Center wing lower skin panels
7075-T6 clad
7075-T6 7178-T6 or 7075-T73 * 7075-T6 or 7075-T73 *
2024-T42 clad, increase t

7075-T73 7075-T73 7075-T73
3667
35014541 4303 4325
Outer wing skin panels

Center wing beam caps
7075-T6
7075-T6
7075-T73
7075-T73
4542
4359
Outer wing beam caps

Wing corner fittings
7075-T6
7075-T6
7075-T73
7075-T73
4542
4331-4515
Fuselage lower (sloping) longeron

end fittings at FS 737 & FS 1041.5
7075-T6
7049-T73
4587
* Used on production aircraft LASC 4301 and LASC 4303 (1968) and up.
USAF C-130E S/S 3651 4527 1964 - 1972
USAF C-130H1 S/S 4544 4735 1973 1974

18
Airframe Changes, Overview

New Center Wing Design (1968):
Increased Front & Rear Beam Web Thickness Upgraded Wing Panels, Beam Caps, & Corner Fittings Reduced-Stress Access Doors & Openings To Operating Stress Levels In Critical Areas Reduced 20% Upgraded Fatigue Life & Fail Safe Characteristics Increased Corrosion Resistance
New Outer Wing Design (1973):

Upgraded Wing Panel & Beam Caps Materials Increased Upper & Lower Rainbow Fitting Thickness Upgraded Rainbow Fitting Material Reduced-Stress Access Doors & Openings Operating Stress Levels In Critical Areas Reduced 18% Upgraded Fatigue Life & Fail Safe Characteristics Increased Corrosion Resistance
Upgraded Center Wing Design (1990):

Hi-Tigue Pins Used In Majority of Wing Structure
Upgraded Outer Wing Design (1984): New Nose Gear Design (1975 & 80):
Redesigned NLG Cylinder & Cylinder Fulcrum to Fulcrum Shaft Joint New Steering System Components Improved Corrosion Resistance Stronger Outer Wing Box Rib Caps and Rib Braces Skin Min-Thickness Doubled
More Structural Capability Improved Lightning Protection
New Main Gear Design (1988):

One Piece Forged Main Landing Gear Piston Incorporated
Hi-Tigue Pins Used In Majority of Wing Structure
19
Center Wing Design Improvements

Re-design of Lower Forward Beam Cap
New design extended previous tapered thickness run-out at WS 174 further outboard. Front beam web splice moved from WS174 to WS168.
Re-design of WS 178 Bulkhead

Sheet metal web with fastened stiffeners to monolithic machined web made from plate material.
Re-design of Front and Rear Beam Webs

Increased material thickness and fewer splices. The new front beam thickness = 25% greater in critical locations. The new rear beam web also increased in thickness and replaced 3 webs and 2 splices with one web.
Re-design of Wing to Fuselage Attach Angle at WS 61.625

Vertical and horizontal leg thicknesses increases.
Re-design of Upper Forward and Aft Beam Caps:

Change from 1 row to 2 rows of fasteners at the cap to panel splice outboard from WS140 to the corner fitting. New upper corner fittings with wider flanges to accommodate the increased beam width were also required for this change.
20
Outer Wing Design Improvements

Major Redesign of Outer Wing occurred in
1973 at the first USAF C-130H (SN 4542) incorporated the following improvements:
Thicker Surface Panels for reduced Operating Stresses (Increased Durability) Improved Materials to reduce Corrosion and Stress Corrosion Cracking Eliminated riser weep holes which were prone to fatigue cracking
21
Outer Wing Design Improvements

Current Production Outer Wing Box based on
the 1984 Improved Outer Wing

Incorporated Externally Mounted Fuel Probes for Improved Maintenance Access Thickened the Outer Wing Surface Panels for Improved Lightning Protection Improved Fastening System for Increased Durability
22
Fuselage Design Improvements

Many Design Improvements incorporated during C-130E and C-130H production Design Improvements addressed both Fatigue and Corrosion Problems encountered in Service by: Improved Detailed Design Thickness/Area Increases Material Changes to Improve Fatigue and Corrosion Resistance
23
Empennage Design Improvements

Designed for Torsional and Bending Stiffness, Operating Stress Levels are very low Very few reported service problems, relatively minor design changes since C-130B:
SN 4426 Horizontal Stabilizer Tip Attachment, added Steel Straps and Angles SN 4471 Added Bearing Retainers for the Rudder Hinges SN 4515 Increased Thickness of H-Stab Leading Edge Formers SN 4653 Eliminated Spot-welds and cut-outs from Rudder and Elevator Control Access Doors SN 4809 FS 946 V-Stab Attach Fittings changed to 7075-T73 SN 4992:
Added provision for Aft-Body Ventral Strakes to H-Stab Changed V-Stab to Dorsal Fin Leading Edge Assy to Kevlar/Epoxy and Foam Core construction (for flush mount HF Antenna)
24
Outline
25
The C-130J Super Hercules

The Year: 1988 The Current Platform: C-130A-H Models The Problem: C-130A-H Fleet Reaching The End Of Its Product Life. US And International Operators Facing Early Replacement Decisions And Looking For New Systems With Digital Technology, Lower Cost Of Ownership, Improved Readiness, And That Need Fewer Personnel To Maintain.
I Need A Digital Cockpit For My Digital Kids. . .Call It A C-130J

Gen. Duane Cassidy, CINCMAC, 1988
The Solution = The C-130J

26
C-130 Main Instrument Panel
C-130J
27
C-130J Super Hercules Key Features And Enhancements
Worlds Most Advanced Airlifter

The C-130J Is Nearly A Complete Reinvention Of The Hercules
28
C-130J Super Hercules Propulsion System And Performance

Prop: Dowty R391
All Composite Six-Bladed Propeller 50% Fewer Parts 15% Weight Reduction (1,032 lbs)
Engine: Allison AE 2100D3

Flat Rated At 4591 SHP Twin Spool Design Full Authority Digital Electronic Control (FADEC) 29% More Static Thrust 15% More Fuel Efficiency Automatic Thrust Control System Engine Monitoring System
Early Component Fault Detection Reduces MMH/FH And MTTR
Performance:
38,000 lb Payload
C-130J 1300 nm C-130H 260 nm
Range Comparison
Sea Level 45C

29
C-130J Airframe Changes

New Wing Components (1996):
Composite Flaps & Trailing Edges
Other Improvements (1996): New Nacelle (1996):

Enlarged Oil Cooler Redesigned To New FAA Cert. Standards Longeron & Bulkhead Beef-Ups Eliminated Magnesium Extensive Use of White Polyurethane In Trapped Areas
New Forward Fuselage Design (1996):

Integral IFR Probe Prov. Modular Avionics Racks & Wire Harnesses New Bird Strike Option
30
C-130J Airframe Changes, Fuselage: C-130H to C-130J
31
Outline
32
Comparison of C-130H & C-130J-30
Sorties Required
Flight Hours
Crew Hours
33
Troop Deployment, High and Hot
34
C-130J Program, Flying Hours Experience
35
Superior Performance
36
Outline
37
Enhanced Service Life (ESL) Center Wing

ESL Center Wing Developed as Special Operations Forces (SOF) Center Wing, Severe Missions, early 1990s as a retrofit kit for SOF C-130E derivative aircraft Provides 2 to 3 Times The Life of Standard CW
ESL CW Increases Aircraft Weight by 725 lbs

Minimal Performance Penalty For 725 lbs Weight Increase Range Impact Less Than 1% for C-130H Payload Impact Less Than 3% for C-130H The First C-130J Production Aircraft to Receive an ESL Center Wing is LM Ship Serial # 5619 Delivered in 2009.
38
First C-130J Enhanced Service Life Center Wing
39
ESL CW, Surface Changes

Upper and Lower Surfaces Changed from the C-130H Upper Stringer Extrusions Changed From 7075-T6 to 7075-T73511 Most Taper-Loks Changed to Hi-Tigues (Some Blinds Still Used) Stringer Area Increase (20% Upper Surface, 30% Lower Surface)
Area Increase
Area Increase
Upper Surface
Lower Surface
40
ESL CW, Box Changes

Upper Cap Horizontal Flange Width Increased for Added Row of Fasteners
Front Beam - WS 142 to WS 206 Rear Beam - WS 151 to WS 215
BL 0.0
Web-to-Cap Lockbolts Changed to Hi-Tigues Front Beam Webs

Added Web Splice at WS 84.3 WS 174 Web Splice Relocated to WS 168.3 WS 61.6 to WS 84.3, 0.112 in 7075-T6 Changed to 0.1 in Ti-6Al-4V WS 84.3 to WS 168.3, 7075-T6 Increased from 0.112 in to 0.140 in WS 168.3 to WS 219.8, 301-H Increased from 0.063 in to 0.071 in
Rear Beam Webs

WS 61.5 WS 206, 7075-T6 Increased from 0.112 in to 0.125 in
41
ESL CW, Joint Changes Rainbow Fittings

Machined from 7075-T73511 Extrusion (was 7075-T6511 Ext.)
Area Increased
Upper Fitting Approx. 20% Lower Fitting Approx. 30%
Area Increase Inner Tang Increase
Tangs Increased in Length and Width to Accommodate Additional Fasteners Node Counterbore Eliminated
Nodes Thickened Radius Washer Added
Outer Tang Increase

Fitting Node (Typ)
42
ESL CW, Joint Changes Rainbow Fittings

Fitting-to-Stringer Splice Straps
Reconfigured Material Changed from 7075-T7351 Plate to 7075-T73 Forging
Splice Angle Cross-Sectional Area Increased Most Taper-Loks Replaced with Hi-Tigues (Some Blinds Still Used)
Stringer
Splice Strap
Splice Angle
WS 220
Rainbow Fitting
Splice Strap Profile Increase
43
ESL CW Changes, Ribs

WS 61.6 Rib
Lower Cap Cross Sectional Area Increased by Approx. 20% Skin Flange of Lower Cap Increased in Width to Accommodate New Wing Attach (Drag) Angle Fastener Pattern Thickness of Forward Web Increased From 0.063 in to 0.071 in Thickness of Aft Web Increased From 0.190 in to 0.236 in BL 0.0 Door Assembly in Aft Web Removed Web-to-Cap Lockbolts Replaced With Hi-Tigues
Door Assy (Removed)
WS 178.8 Rib
Upper Cap Cross Sectional Area Increased by Approx. 20%
44
ESL CW Changes, Engine Support Structure

Truss Forging Upper, Lower, Vertical, and Diagonal Member Cross Sectional Areas Increased by Approx. 25% Truss Flanges Common to Front Beam Increased in Thickness by Approx. 25% Diagonal Brace Attach Lug Increased From 0.36 in to 0.60 in thick Diagonal Brace Tube Attach Bolts Increased in Diameter From 0.375 in to 0.500 in Hi-Loks and Lockbolts Replaced With Hi-Tigues
Upper Member
Front Beam Attach Upper Tang Vertical Member Front Beam Attach Lower Tang Lower Member
45
Diagonal Brace Tube
Diagonal Member
Closing Remarks
The C-130 was unique at inception. With a long and distinguished past, the C-130 continues to be a unique part of aviation history. Program pride has never been greater. The future has never been brighter. Program leadership has not allowed the design to become stagnant. Structural changes, both small and large, have played a pivotal role in keeping the aircraft current, effective, and affordable - while increasing its capabilities.
46

C-130 Structural Changes Through Its Life

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C-130 Structural Changes Through Its Life

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Positive Changes to a Classic Design:

Structural Changes Through the Life of the C-130

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

Initial Aircraft Requirement

The Current Platform: Fairchild C-119 Flying Boxcar

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

Initial Aircraft Requirement

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

Contract Awarded To Lockheed

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

Key Design Characteristics

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

First Flight August 23, 1954

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

YC-130 Flight Test Performance

Exceeded All Air Force Specifications

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

Lockheed Moves To GA , Re-Opens Air Force Plant 6

The First Lady (a/c 3001) First Flight April 7, 1955

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

Longest Running Military A/C Production Line

C-130B Entered Service Nov 1958

C-130E Entered Service Jun 1961

C-130H Entered Service Mar 1965

C-130J Entered Service Jun 1998

Variants, 70 and Climbing

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

Major Structural Components

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

Assy Techniques and Material

Low Durability Minimal Corrosion Protection High Corrosion Susceptibility

High Durability Enhanced Corrosion Protection Low Corrosion Susceptibility

C-130 Assembly Techniques

- Increased Use of Anodizing and Paint System Upgrades

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

C-130H1 Durability Improvements

PRE 1973 PRODUCTION

Engine mount drag angles, O/W

2024-T42 clad, increase t

Outer wing skin panels

Outer wing beam caps

Fuselage lower (sloping) longeron

USAF C-130E S/S 3651 4527 1964 - 1972

USAF C-130H1 S/S 4544 4735 1973 1974

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

Airframe Changes, Overview

New Outer Wing Design (1973):

Upgraded Center Wing Design (1990):

New Main Gear Design (1988):

Hi-Tigue Pins Used In Majority of Wing Structure

Center Wing Design Improvements

Re-design of WS 178 Bulkhead

Re-design of Front and Rear Beam Webs

Re-design of Wing to Fuselage Attach Angle at WS 61.625

Re-design of Upper Forward and Aft Beam Caps:

Outer Wing Design Improvements

Outer Wing Design Improvements

the 1984 Improved Outer Wing

2011. LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

Fuselage Design Improvements