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Garrett ATF3

The Garrett ATF3 is a three-spool, low-bypass turbofan engine developed by the Garrett AiResearch division in California during the late 1960s, featuring a unique reverse-flow core design with advanced component technology for efficiency in small business jets and military applications.^[1]^[2] It employs a single-stage low-pressure fan, a five-stage intermediate-pressure axial compressor, a single-stage high-pressure centrifugal compressor, a single-stage high-pressure turbine, a single-stage intermediate-pressure turbine, and a six-stage low-pressure turbine, achieving an overall pressure ratio of approximately 21 and a bypass ratio of 2.8 to 3.9.^[3]^[4] First run in 1968, the ATF3 underwent extensive ground and flight testing, including NASA evaluations at the Propulsion Systems Laboratory for performance up to simulated 60,000 feet altitude and endurance exceeding 24 hours, with certification achieved in the mid-1970s.^[2] Its innovative features, such as eight exhaust ejectors to diffuse hot gases, reduced infrared signature and noise levels, making it suitable for stealthy operations and compliance with early federal noise regulations.^[2]^[1] The engine's military designation is F104, and it powered experimental programs like the Teledyne Ryan YQM-98A Compass Cope Tern unmanned reconnaissance drone.^[2] Primarily applied in civil aviation, the ATF3-6 variant delivered up to 5,450 lbf (24.2 kN) of thrust at takeoff, equipping the Dassault Falcon 100 and Falcon 200 business jets from their introductions in the 1970s and 1980s, respectively, as well as the U.S. Coast Guard's HU-25A Guardian maritime patrol aircraft, a militarized Falcon 200 variant.^[4]^[2] With a dry weight of 1,125 lb (510 kg), length of 102 in (2,591 mm), and diameter of 33.6 in (853 mm), it represented a compact, high-performance solution for transonic flight in its class, though production ended in the 1990s following Garrett AiResearch's merger into AlliedSignal in 1985 (later Honeywell Aerospace). As of 2020, only about a dozen engines remain operational, with Honeywell using additive manufacturing for replacement parts.^[4]^[3]^[5]

Development History

Origins and Initial Design

The development of the Garrett ATF3 turbofan engine was initiated in the mid-1960s by the California division of Garrett AiResearch, with studies beginning in 1965, aiming to produce a compact and efficient propulsion system suitable for business jets and light military aircraft.^[6]^[7] This effort responded to the growing demand for engines that could enable executive aircraft to achieve coast-to-coast range capabilities while prioritizing fuel efficiency and reduced noise, particularly as emerging regulations like FAR Part 36 began addressing aircraft noise pollution in the late 1960s.^[6] The design emphasized a low-bypass ratio configuration to balance thrust for short-haul operations with overall performance improvements, drawing on advancements in small turbofan technology to meet the needs of both civilian and potential military applications.^[8] Key initial design goals centered on a three-spool architecture to allow independent optimization of the low-, intermediate-, and high-pressure spools, enhancing operational flexibility and efficiency. A distinctive reversed core flow path was incorporated, where air enters the core, reverses direction through the compressor and combustor, and mixes with bypass air before exhaust, promoting compactness by shortening the engine length and incidentally lowering the infrared signature through shielded hot sections and mixed exhaust plumes.^[6] This innovative mixed-flow turbofan concept, the first of its kind globally, was intended to deliver thermodynamic performance rivaling larger engines while minimizing emissions and simplifying maintenance.^[8] The prototype achieved its first ground run in May 1968, marking a significant milestone in validating the core design principles.^[7] Early prototypes underwent rigorous ground testing and wind tunnel evaluations to refine aerodynamics and structural integrity, with a focus on the transonic flow characteristics of the compressor stages. Titanium alloys were selected for high-temperature components, such as the forged inserted blades in the low-pressure compressor, to withstand operational stresses while keeping weight low and enabling the engine's compact form factor.^[6] These foundational efforts established the ATF3 as a pioneering small turbofan, setting the stage for its subsequent applications in diverse aircraft platforms.

Testing, Certification, and Challenges

Ground testing of the Garrett ATF3 began in the late 1960s at AiResearch facilities, encompassing altitude simulations to verify performance under operational conditions exceeding business jet requirements, as well as static thrust demonstrations achieving 5,000 pounds.^[9] Endurance evaluations and noise assessments were also conducted during this phase, with ground static tests confirming compliance with Federal Aviation Regulation Part 36 noise standards.^[9] Flight testing progressed with integration into the Dassault Falcon 20G, a modified business jet testbed, culminating in the variant's maiden flight on November 28, 1977.^[10] The engine received FAA type certification on July 17, 1981, for its ATF3-6 variant, enabling civilian applications shortly thereafter.^[11] Development faced challenges from the engine's unique three-spool, reverse-flow architecture, which introduced complexities such as elevated bearing thrust loads and intricate crossover ducting that increased weight and manufacturing costs.^[9] Vibration concerns, including up to 13 critical speeds across the spools, were mitigated through hydraulic flexmounts that utilized pressurized oil to dampen synchronous and nonsynchronous whirl modes.^[9] For military evaluation, the ATF3 was adapted with low-observable enhancements, notably in the Northrop Tacit Blue demonstrator, where deeply buried dorsal inlets and engine placement reduced infrared signatures to support stealth surveillance roles during 1980s testing.^[12]

Technical Design

Core Architecture and Innovations

The Garrett ATF3 turbofan engine features a pioneering three-spool architecture, distinguishing it from conventional two-spool designs by incorporating independent low-pressure, intermediate-pressure, and high-pressure spools. The low-pressure spool drives a single-stage fan, the intermediate-pressure spool powers a multi-stage axial compressor, and the high-pressure spool operates the centrifugal compressor paired with its turbine. This separation allows each spool to rotate at its individually optimized speed, minimizing mechanical losses from interconnected shafts and enabling superior thermodynamic matching across diverse operating conditions, such as takeoff, cruise, and part-throttle scenarios. By avoiding the constraints of concentric shafts, the design achieves efficiencies comparable to larger engines while maintaining compactness suitable for business jets.^[6] A hallmark innovation is the reversed core flow path, where airflow enters the core rearward after the fan and intermediate compressor, passes through a reverse-flow annular combustor and high-pressure turbine at the engine's aft end, then reverses direction forward through an annular low-pressure turbine before mixing with the bypass stream. This layout, the first of its kind in a mixed-flow turbofan, facilitates a highly compact overall structure and enhances exhaust mixing by integrating the hot core gases with cooler fan bypass air prior to nozzle exit. The resulting cooler exhaust plume reduces the engine's infrared signature, a feature particularly advantageous for low-observability applications, while the intermediate-pressure compressor consists of five stages optimized for this flow reversal.^[6] Complementing the spool independence, the ATF3 employs a low bypass ratio of approximately 2.7:1 under cruise conditions (Mach 0.8 at 40,000 feet), emphasizing core efficiency over high-bypass propulsion. Innovations such as variable inlet guide vanes in the intermediate-pressure compressor adjust airflow incidence to maintain stall margins and boost performance at off-design points, including part-throttle operations common in business aviation. These elements collectively reduce mechanical inefficiencies, with the design targeting a 30-40% improvement in cruise specific fuel consumption relative to existing small turbofans of the era through precise component optimization and minimized parasitic losses.^[6]

Compressor and Turbine Systems

The compressor system of the Garrett ATF3 turbofan engine comprises a single-stage low-pressure fan featuring titanium blades measuring 33.6 inches in diameter, which accelerates the majority of incoming air for bypass flow. This is followed by a five-stage axial intermediate-pressure compressor achieving a pressure ratio of 5.8:1 and constructed with forged titanium blades for lightweight strength and efficiency. The high-pressure compressor is a single-stage centrifugal design, optimizing compression in the core flow path while maintaining compact dimensions. The turbine configuration includes a two-stage high-pressure turbine with air-cooled blades to manage extreme temperatures, a single-stage intermediate-pressure turbine, and a six-stage low-pressure turbine, all fabricated from directionally solidified superalloys to enhance creep resistance and thermal durability under operational stresses. Cooling air is extracted from compressor bleed ports and directed through internal passages in the high-pressure turbine blades, utilizing approximately 1-1.5% of core airflow depending on thrust setting, thereby extending component life.^[13] Inter-spool independence is maintained via specialized ball and roller bearings equipped with hydraulic flexmounts for vibration damping, complemented by carbon-face seals reinforced with labyrinth configurations to prevent cross-flow leakage between the low-, intermediate-, and high-pressure spools. This modular arrangement allows each spool to operate at its optimal rotational speed, improving overall efficiency and reliability. A distinctive feature is the geared fan drive system, which reduces fan rotational speed relative to the low-pressure turbine, minimizing tip speeds to suppress aerodynamic noise and structural vibration—key factors in achieving the engine's compliant takeoff noise profile of 85 dB.

Variants and Production

Engine Variants

The Garrett ATF3 engine family encompasses a series of variants derived from its core three-spool turbofan architecture, each optimized for specific thrust levels and operational environments while maintaining the engine's signature low infrared signature through inverted-flow exhaust mixing.^[14] The baseline civilian variant, the ATF3-6, serves as the foundational model for business jet applications, delivering 5,440 lbf (24.2 kN) of takeoff thrust with standard infrared suppression integrated into its reverse-flow turbine design to minimize detectability.^[15] This configuration emphasizes reliability and efficiency for executive transport, featuring a bypass ratio of approximately 3.9 for balanced performance.^[3] The ATF3-6A variant, used for maritime patrol duties such as the U.S. Coast Guard's HU-25A Guardian, provides 5,440 lbf (24.2 kN) thrust. Initial installations of the ATF3-6A-2C experienced corrosion issues in saltwater environments, leading to upgrades like the -4C model with improved protective coatings and materials on critical components for enhanced durability without altering the core thermodynamic cycle.^[16] The military designation is F104, with the ATF3-6 powering experimental and stealth-oriented platforms such as the Northrop Tacit Blue demonstrator, which used two ATF3-6 engines at 5,440 lbf thrust each. A derated YF104-GA-100 variant, rated at 4,050 lbf (18 kN), was developed for the Teledyne Ryan YQM-98A Compass Cope Tern unmanned reconnaissance drone.^[17] The ATF3 family includes the main certified variants ATF3-6 and ATF3-6A series (with sub-variants such as -6-2C for the Falcon 20G and -6A-4C), along with the military F104 designation.^[18]

Manufacturing and Production History

Production of the Garrett ATF3 turbofan engine commenced in the mid-1970s at facilities operated by Garrett AiResearch, including the AiResearch Manufacturing division in Torrance, California, where development work was centered, and the Garrett Turbine Engine Company in Phoenix, Arizona, which handled turbine production aspects.^[19] The ATF3-6A achieved FAA certification in 1981, enabling entry into service on aircraft such as the Dassault Falcon 20G and the U.S. Coast Guard's HU-25 Guardian.^[20] By the early 1980s, production rates had ramped up to support these low-volume applications, though specific peak outputs remain documented primarily in internal company records. New production of the ATF3 series tapered off in the late 1980s and ceased entirely by the 1990s, with estimates indicating over 200 units built in total across variants for civilian and military uses (including approximately 152 for the 35 Falcon 200s and 41 HU-25 Guardians, plus prototypes and experimental units).^[2] Corporate mergers reshaped ongoing support: Garrett AiResearch was acquired by Allied Corporation in 1985 to form AlliedSignal, which consolidated engine operations.^[21] In 1999, AlliedSignal acquired Honeywell Inc. in a $14 billion stock transaction and adopted the Honeywell name, relocating primary aerospace headquarters to Phoenix, Arizona, where ATF3 sustainment activities were centralized.^[22] Post-production emphasis shifted to spare parts manufacturing and overhaul services, reflecting the engine's niche role in legacy fleets. As of November 2025, Honeywell continues maintenance and lifecycle support for the ATF3 through programs like EMC², which covers scheduled and unscheduled repairs, parts, labor, and engine transportation to minimize operator costs.^[23] A key advancement came in 2020 with FAA certification of the first 3D-printed flight-critical component—a #4/5 bearing housing—for the ATF3-6 variant, enabling faster production of hard-to-source parts and extending service life for in-service engines on platforms like the Falcon 20.^[5] This additive manufacturing milestone, approved under Honeywell's delegated authority, supports the remaining global fleet without new engine builds. Initial unit costs were approximately $1.5 million, with modern economics centered on overhaul intervals rather than full replacements due to the low production volume.

Operational Applications

Civilian and Business Jet Use

The Garrett ATF3 turbofan engine saw its principal civilian application in the Dassault Falcon 200 business jet, which entered service in 1984 and featured two ATF3-6A-4C engines each rated at 5,200 pounds of thrust.^[24] This configuration enabled the aircraft to achieve a maximum range of approximately 2,500 nautical miles with four passengers, supporting transcontinental executive flights while accommodating up to nine passengers in a pressurized cabin.^[25] A total of 35 Falcon 200s were produced between 1984 and 1991, marking the engine's limited but targeted role in the mid-size business aviation segment.^[26] In operation, the ATF3 contributed to the Falcon 200's reputation for reliable performance in private and corporate aviation, with the engine's three-spool design providing efficient cruise specific fuel consumption suitable for medium-haul missions.^[27] Its low noise signature and enhanced short-field capabilities—allowing takeoff distances under 4,000 feet—made it particularly appealing for operations at smaller executive airports, enhancing accessibility for business travelers.^[28] The Falcon 200's integration of the ATF3 also introduced advanced features like a redesigned wing for improved lift, positioning the aircraft as a versatile option for 1980s corporate fleets. By the 2010s, most Falcon 200s had been phased out in favor of newer, more fuel-efficient business jets, though a handful remained in service as of 2025, benefiting from ongoing Honeywell support including part manufacturing via additive processes and overhaul programs.^[29] Economically, the engine-powered Falcon 200 facilitated growth in the mid-size business jet market during the 1980s by delivering competitive acquisition costs—around $7.85 million new in 1987—alongside performance that rivaled larger rivals like the Falcon 50.^[27]

Military and Experimental Use

The Garrett ATF3 engine found its primary military application in the United States Coast Guard's HU-25 Guardian maritime patrol aircraft, a variant of the Dassault Falcon 20G equipped with two ATF3-6 turbofans each producing 5,440 lbf of thrust.^[30]^[15] A total of 41 HU-25s were produced and entered service in 1982, providing medium-range surveillance, search and rescue, and overwater operations with a range of approximately 2,000 nautical miles and a service ceiling of 42,000 feet.^[10]^[16] The fleet accumulated over 500,000 flight hours before retirement in 2014, primarily due to aircraft age and the need for more advanced sensor platforms.^[31]^[32] In experimental roles, the ATF3 powered the Northrop Tacit Blue demonstrator, a single prototype built in 1982 to test low-observable technologies for battlefield surveillance.^[33] The aircraft utilized two ATF3-6 engines buried in its aft fuselage, emphasizing infrared signature reduction through the engine's reversed-flow design to support stealth validation during 135 test flights until 1985.^[33]^[34] Similarly, early ATF3 variants (designated YF104-GA-100) propelled two Teledyne Ryan YQM-98 Compass Cope R prototypes in the 1970s, enabling high-altitude, long-endurance reconnaissance missions at up to 55,000 feet and Mach 0.6 for over 24 hours.^[17]^[3] Additional military evaluations involved Falcon 20G testbeds fitted with ATF3 engines for U.S. Air Force assessments of propulsion technologies, though the engine saw no widespread adoption due to competition from more established Pratt & Whitney turbofans.^[35] The ATF3's infrared suppression features, demonstrated in platforms like Tacit Blue, contributed technical data to subsequent stealth programs, including the B-2 Spirit bomber and F-117 Nighthawk, by informing exhaust management for reduced detectability.^[34]^[36]

Specifications and Performance

General Characteristics

The Garrett ATF3 is a three-spool, axial-centrifugal flow, low-bypass turbofan engine with a reversed core configuration and a bypass ratio of 3.0:1 at takeoff (reducing to 2.7:1 in cruise), enabling compact packaging and efficient airflow management across independent spools. Its baseline physical dimensions comprise a length of 102.0 in (2,591 mm), a diameter of 33.6 in (853 mm), and a dry weight of 1,125 lb (510 kg).^[3] The engine incorporates a single-stage fan, a five-stage intermediate-pressure axial compressor, and a single-stage high-pressure centrifugal compressor in the compression section; the turbine section features a single-stage high-pressure turbine, a three-stage intermediate-pressure turbine, and a two-stage low-pressure turbine. Air mass flow is 162 lb/s (73.5 kg/s). It utilizes Jet A or Jet A-1 fuel as standard for operation.

Operational Performance

The Garrett ATF3 turbofan engine provides takeoff thrust ratings of up to 5,440 lbf (24.2 kN) for its baseline commercial variant, enabling efficient propulsion for business jets at sea-level static conditions on a standard day.^[4] Cruise performance is optimized for Mach 0.8 at 40,000 ft, where the three-spool architecture maintains effective thrust delivery while prioritizing fuel economy.^[1] Efficiency metrics highlight the engine's advanced cycle design, with an overall pressure ratio of 23:1 that supports a cruise specific fuel consumption reduced by 30-40% relative to contemporary small turbofans of similar thrust class.^[1] The bypass ratio varies from 3.0:1 at takeoff to 2.7:1 in cruise, contributing to balanced specific fuel consumption across part-load conditions, as demonstrated in component performance evaluations.^[1] This pressure ratio aligns with the intermediate-pressure compressor's contribution, achieving high thermodynamic efficiency without excessive complexity.^[1] Environmental performance emphasizes low observable characteristics and regulatory compliance, with the engine meeting FAR Part 36 noise standards through integrated diffuser boxes that act as effective silencers for core and fan noise.^[1] Its reversed core flow path and exhaust mixing with bypass air result in a significantly reduced infrared signature compared to conventional turbofans, rendering hot sections internally shielded and emissions largely invisible externally.^[37] The design also achieves low visible smoke and controlled levels of hydrocarbons, NOx, and CO emissions, supporting cleaner operation in civilian applications.^[1] Operational endurance is enhanced by the modular three-spool layout, which simplifies maintenance and allows for extended intervals between major inspections, though specific cycle-based overhaul times are determined by turbine life limits tied to inlet temperatures.^[38] The engine supports maximum operating altitudes exceeding typical business jet requirements, with certification up to 45,000 ft.^[1]

References

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