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Approximately 400 aircraft launches are being conducted using EA-18G, F/A-18E, F/A-18C, E-2D, T-45, and C-2 aircraft. The Navy has also conducted an additional 1,200 dead-load launches (non-aircraft, weight equivalent, simulated launches). Approximately 55 percent of the EMALS government furnished equipment (GFE) has been delivered to the shipyard.

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July 20/10: UK. Jane’s reports that the UK Ministry of Defence (MoD) is funding development of an electromagnetic catapult system for the Royal Navy’s Queen Elizabeth-class aircraft carriers, in case the F-35B STOVL is abandoned. Rather than go through the involved process of joining America’s EMALS program, however, they appear to have contracted with Converteam, who was already developing an electro-magnetc launch systems for UAVs under an April 2006 EMKIT(Electro Magnetic Kinetic Integrated Technology) contract.

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Dec 21/11: UK. General Atomics in San Diego, CA receives $17/4 million cost-plus-fixed-fee contract modification to provide engineering support for the development of EMALS and Advanced Arresting Gear configurations for Britain’s Queen Elizabeth Class Aircraft Carrier Program. One of Britain’s 2 new carriers is slated to receive the combination, and operate F-35C fighters.

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American Heritage Magazine, via WayBack (Spring 2006) – Shot Into the Air. A very good look at the use of naval catapults from their earliest days to the forthcoming EMALS. Includes a fine conceptual schematic of the modern steam catapult.

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Russ McCormack of PMA-251 is deputy program manager for future systems. US NAVAIR | USN Photo release | Gannett’s Navy Times.

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January 26/17: Developments on the new Advanced Arresting Gear (AAG) have been given the thumbs up from the US Navy and will be installed on board the next USS John F. Kennedy. Designed to stop carrier-borne aircraft, the decision was made following a thorough review by an AAG Resource Requirements Review Board (R3B) last November. The 350th trap of an F/A-18E Super Hornet fighter was completed in December and the AAG team continues multisite test operations with the next type/model/series and the E-2/C-2 platform.

Nov 15/11: The US DSCA announces [PDF] Britain’s official request for Electromagnetic Aircraft Launch System/Advanced Arresting Gear (EMALS/AAG) long lead sub-assemblies. EMALS long-lead items include the Energy Storage System, Power Conditioning System, and Launch Control System. AAG long-lead items include Power Conditioning, Energy Absorption Subsystems, Shock Absorbers, and Drive Fairleads.

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NAVAIR PMA-251, The Aircraft Launch and Recovery Equipment (ALRE) Program Office gets a new program manager, as Rear Adm. Randy Mahr leaves PMA-251 to become NAWCAD(Naval Air Warfare Center Aircraft Division) Commander. He is replaced by his deputy, Capt. Jim Donnelly, who became the deputy program manager for future systems – EMALS and the Advanced Arresting Gear (AAG) in April 2008.

By 2021, however, the Royal Navy had discovered that adding catapults to its new carrier design was much more difficult and expensive than BAE had led them to believe. In an embarrassing climb-down, the government retreated back to the F-35B STOVL (short Take-Off, Vertical Landing) fighter, and ended efforts to add catapults to its carriers.

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The Navy is reportedly starting detailed, fixed-price contract negotiations with General Atomics. If that becomes the basis for a renegotiated contract, it would shift the risk of delays or additional work onto the contractor.

EMALS reaches the 10,000 High Cycle Testing, phase 1 (HCT-1) milestone at the General Atomics test facility in Tupelo, MS. HCT-1 was conducted in order to verify the performance capabilities of EMALS’ electrical and thermal power equipment, and the shipboard cycling rate of the energy storage subsystem. Those tests reduce the risk of structural failure, strengthen confidence in EMALS’ reliability, and help to validate both system life predictions and electromagnetic interference predictions.

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In parallel the Navy is working on demonstrating “an automation control environment for carrier shipboard equipment,” in order to reduce manpower requirements and ongoing costs. They won’t elaborate, but EMALS System Development and Demonstration (SDD) continues to be scheduled for completion by Q2 2021. To get there, the Navy intends to conduct full system and risk mitigation testing at the System Functional Demonstration (SFD) site by completing repeated cycles with deadload testing and gap variation tests. They aim to reach 4,000 deadload launches to assess reliability. Sources: US Navy PE 0603512 [PDF].

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GA Electromagnetic Systems Group will manufacture EMALS and AAG components at its state-of-the-art 367,000 square foot manufacturing facility in Tupelo, MS. Work will also be performed in San Diego, CA (47%); Mankato, MN (35%); Spring Grove, IL (16%), and Detroit, MI (2%), and is expected to be complete in January 2021. This contract was not competitively procured pursuant to FAR 6/302-1, by US NAVAIR in Patuxent River, MD, (N00019-14-C-0037). See also: GA, “General Atomics Awarded Initial Contract for Launch & Recovery Systems for Future John F. Kennedy Aircraft Carrier”.

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The 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 (https://yamamotonight-m.ru/hack/?patch=831) Class will require 12 of each, and 5 of each are currently being manufactured under General Atomics’ Systems Development & Demonstration contract. One is slated for component level testing, and 4 will be installed and used for system level testing at the Lakehurst, NJ, EMALS catapult site.

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DID FOCUS Article – Design & Preparations Continue for Britain’s New CVF Future Carrier (updated). At one point, EMALS was slated for use in this class as well.

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Work will be performed in San Diego, CA (35%); Mt. Pleasant, PA (28%); Tupelo, MS (15%); Waltham, MA (12%); and Aston, PA (10%), and is expected to be complete in September 2021. The Naval Air Warfare Center Aircraft Division in Lakehurst, NJ manages the contract (N68335-09-C-0573).

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The US would be willing to sell aircraft carrier-related technologies to India, DoD procurement chief Frank Kendall said Friday, including the EMALS catapult system. India’s aircraft carrier – the INS Vikramaditya – is not equipped with an aircraft catapult system. A joint working group has now been established to move things forward.

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A DSTL report has explained some of the capabilities Britain would lose by abandoning the F-35C, but the government justifies their decision by saying that the F-35C’s improved capabilities and compatibility with American and French carriers would come at too steep a cost. Staying with the F-35C, they say, would delay Britain’s return to carrier capability from 2021 – 2021 or later, cost nearly GBP 2 billion to modify 1 of their 2 carriers, and leave the Royal Navy with no carrier capability if their converted ship needs maintenance. In contrast, the F-35B will be compatible with the US Marines and with Italy, and gives Britain the option of taking its 2nd CVF carrier out of strategic reserve when the primary carrier is out of service for long refits or maintenance dockings.

Jan 28/14: DOT&E Testing Report. The Pentagon releases the FY 2021 Annual Report from its Office of the Director, Operational Test & Evaluation (DOT&E). EMALS is included, as part of the CVN-78 assessment, and EMALS/AAG remain 2 of the 4 key risks for the carrier.

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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.

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Or is it just a complex technology with more issues than expected, each of which is being dealt with but at a rate that creates some schedule concerns? What, if anything, does a realistic Plan B look like? Delay construction until EMALS is ready, given its promised operations costs savings? Extensively redesign CVN 78 for steam catapults? Buy another CVN 77 design ship instead, and store the pieces that have already been made?

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EMALS performs 18 launches of a VX-20 Sqn. C-2A Greyhound cargo delivery aircraft, over a wide range of aircraft weights. The C-2 is also the E-2 Hawkeye AWACS plane’s base airframe.

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EMALS/ AAG: Electro-Magnetic Launch & Recovery for Carriers

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Risk: Beyond redesign risks, the Navy needs to confront larger ship delivery risks. At present, EMALS isn’t scheduled for TRL 7 level maturity until FY 2021, with AAG to follow in FY 2021. The ship is due for delivery in FY 2021. Systems are already maturing so late that comprehensive testing must wait until the ship is at sea, so further schedule delays have nowhere else to go. Launch delays would mean delays to post-launch test programs, which are closely synced with ship delivery.

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Both EMALS and the F-35C are currently in test and evaluation, but the F-35C is especially important to the new catapult. The heavy fighter will be EMALS most significant technology companion over their life cycle together, and its 70,000 pound/ 31,800 kg maximum takeoff weight places it very close to the F-14D Tomcat. EMALS and the F-35C need to demonstrate that they can help each other with maintenance costs, or the real price of EMALS will escalate significantly.

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US Navy PMA-251, the Aircraft Launch and Recovery Equipment Program Office, completes shared generator testing for EMALS at Joint Base McGuire-Dix-Lakehurst, NJ. Launches to date have involved just 1 aircraft, but the real system will have to drive up to 4 launchers. The motor generator stores the system’s energy in the inertia of its rotor, and releases that energy for aircraft launch. Hence “shared generator” testing for multiple catapults, which was completed ahead of schedule. That should make OT&E happy.

July 28/17: The US Navy has validated a software fix to the service’s Electromagnetic Aircraft Launch System (EMALS) after it was found during testing that the next-generation catapult generates excessive vibration to the aircraft when external fuel tanks are attached. However, final testing involving launches with an instrumented aircraft have been postponed for an additional year, with the service citing competing testing priorities as the reason for the delay. EMALS is one of many new technologies planned for the Navy’s Ford (check over here)-class aircraft carrier fleet and is already installed on the Gerald R. Ford (CVN-78). The Ford is expected to receive the software update in 2021, following the ship’s Post Shakedown Availability.

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As a result of the [2009 EMALS] tests, the program identified design changes that are necessary to improve the performance of EMALS, but add cost and schedule risk to the program. The Navy plans to test EMALS with actual aircraft in summer 2021. The Navy awarded a not-to-exceed fixed-price production contract to General Atomics for EMALS and the advanced arresting gear in 2009. At the time of award, the contract price had not been finalized.

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NAVAIR successfully launched an EA-18G Growler for the 1st time. This starts the 2nd phase of their manned aircraft launch tests, as they intend to proceed with more than 300 launches this year to test all aircraft currently launched from carrier catapults, save for E-2C Hawkeyes. They have already launched each of the Navy’s newest planes at least once. This ramp-up comes at about the same time railguns are also seeing more tests.

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Once CVN 78 is built, EMALS and AAG’s reliability will continue to hamper operations. As of March 2021, both systems are far below where they’re supposed to be, with critical failures every 2-3 cycles. Since Initial Operational Test & Evaluation requires certain reliability levels between critical failures (MTBCF), continued problems could endanger the ship’s entry into service. GAO points out that the Navy’s “Duane” model for reliability growth doesn’t match their long-standing data, and even under optimistic planned growth levels, AAG isn’t supposed to hit the ~100 cycle MTBCF minimums before 2021. EMALS will take even longer, to 2032.

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This second phase of High Cycle Testing (HCT-2) will involve full power train testing, and will give a specific prediction of EMALS operations. HCT-2 will also perform environmental qualification testing, which is used to confirm the adequacy of the equipment design and safety under normal, abnormal, design basis event, post design basis event and in-service test conditions.

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

EMALS was also set to play a pivotal role in the British CVF Queen Elizabeth Class, until the window of opportunity shut in 2021. The F-35B’s ability to take off and land with full air-to-air armament was already a matter of some concern in Britain before the 2021 strategic defense review, which moved the heavier F-35C from “Plan B” for British naval aviation, to the Royal Navy’s preferred choice.

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Ford-Class Carriers: Lead Ship Testing and Reliability Shortfalls Will Limit Initial Fleet Capabilities

Officials at the Lakehurst Naval Base hold a ribbon-cutting ceremony to acknowledge the completion of the base’s new Electromagnetic Aircraft Launch System (EMALS) facility. General Atomics will have the system’s equipment installed at the Lakehurst base in the beginning of March 2008, with the strong intent of beginning testing in February 2009.