Special new covers developed by Air Force Global Strike Command should save time and money by keeping B-52 bomber engines from icing up in Arctic environments.
With regular deployments to northern Europe and a wing stationed in North Dakota, B-52s are no strangers to chilly weather. Maintainers cover the aircraft’s eight engines to protect them from the cold, but the current system does not provide a full seal or sufficient insulation, Charles Hoffman, Global Strike Command’s chief of media operations, told Air & Space Forces Magazine.
That means ice, which can damage the engines, delay takeoffs, and force Airmen to spend time de-icing the engines, Master Sgt. Adam Vasas, a champion for the new cover project, said in a Nov. 20 press release.
“We found 10 engines were damaged across 2021-2023 due to ice debris, which resulted in $17 million in damages and 160-plus manhours lost,” he said.
Fixing the issue fell to STRIKEWERX, a kind of innovation incubator that helps research, test, and scale solutions to Global Strike Command problems. STRIKEWERX started looking into the engine icing problem in July 2022, and by that October it had a prototype modified from a previous design that would let maintainers heat the engine cowling of the B-52. That prototype did not pan out, but Vasas and other experts kept working on it.
The result is the Transhield Pod Cover, which wraps around the engines to seal all ducts, inlets, and exhausts. Also used to protect boats, commercial aircraft engines, and other military equipment, the Transhield ArmorDillo fabric is covered in polyurethane, which prevents water intrusion and corrosion, Hoffman said.
“Maintainers will now have the ability to operate more efficiently in Arctic weather environments, while people and equipment previously dedicated to keeping the engines warm can be utilized elsewhere or saved in reserve,” Vasas said in the release.
Unlike past covers, this one has a built-in adaptor that lets maintainers attach a ground heater hose to blow heated air into the engine inlets.
“The heating becomes necessary due to extreme low temperatures,” Hoffman said. “This is a standard maintenance practice and the covers allow the heating to be more efficient by containing the heat [and] by blocking the wind and insulation.”
The Air Force Operational Energy Savings Account gave Minot Air Force Base $1.2 million to buy engine covers for its entire B-52 fleet. Each cover costs about $12,800, but they should save about 7,500 manhours, according to the release.
The new covers are designed for the B-52H equipped with T-33 engines, Hoffman explained. They will remain functional until the arrival of the B-52J, an improved version with new engines, radar, communications, navigation, and other equipment to keep the bomber running through the 2050s. The J model will sport Rolls Royce F130-200 engines with new nacelles and pylons, which would require new engine covers.
That’s still a few years away though: a government watchdog report in June estimated that the B-52J won’t reach initial operational capability until 2033.