Defense Industry Daily

Arrow test concept
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In a dawning age of rogue states, ballistic missile defenses are steadily become a widely accepted necessity. Iran is widely believed to be developing nuclear capabilities, and Israeli concerns were heightened after Iranian President Mahmoud Ahmadinejad urged that Israel be “wiped off the map” (the fact that America was also placed in that category went largely uncovered).

Because missile defenses are so important, states like India and Israel have taken steps to ensure that they have the ability to build many of the key pieces. The Arrow project is a collaboration between Boeing and IAI to produce the missile interceptors that accompany the required radars, satellites, command and control systems.

NOTE: Article capped and coverage suspended in 2011.

The Arrow System

Arrow launch
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In general, the Israeli Arrow is a more advanced weapon than the Patriot and possesses far more range, undertaking high altitude interceptions and covering a wide area (est. 90km/ 54 mile range, maximum altitude 30 miles/ 50 km for Arrow 2) as a Theater Missile Defense (TMD) system. Unlike the USA’s THAAD, PAC-3, or SM-3 which all use “hit to kill” technology, Israel’s Arrow relies on a directed fragmentation warhead to destroy enemy missiles. It can work in conjunction with a number of systems, but its main Israeli partner is the Green Pine long-range, ground-based fire control radar. The system and its engagements are controlled by the mobile Citron Tree battle management center. Since the launchers are also mobile, and the radars are semi-mobile, the system is resistant to pre-emptive strikes if good discipline is maintained.

The exoatmospheric, 2-stage Arrow-3 will use pivoting optical sensors and its own upper-stage kick motor, instead of separate control rockets for final steering. The goal is a highly maneuverable missile that can reach more than double the height of existing Arrow-2 interceptors, using a lower-weight missile. This will also have the effect of extending the missile’s range.

In contrast, Israel’s Patriot PAC-2s are more of a local point defense system with a range of about 40km/ 24 miles. They were all Israel had during the 1991 Gulf War, but these days, Israel’s Patriot PAC-2 GEM+ missiles will only be launched if the Arrow missile fails, or the target is outside the Arrow’s protective umbrella. In that respect, the Arrow/Homa system will play a role similar to the longer-range naval SM-3 Standard missile that forms the high end of Japan’s planned ABM shield (and seems destined for Europe and other states in a land-based role), or the US Army’s THAAD.

Overall responsibility for Arrow lies with the U.S. Missile Defense Organization (MDA) in Washington, DC, and the Israel Ministry of Defense in Tel Aviv, Israel. The program is executed by the Israel Missile Defense Organization in Tel Aviv, and the US Army Program Executive Office for Air and Missile Defense’s Arrow Product Office in Huntsville, AL. Key contractors include:

• Israel Aircraft Industries (prime contractor, Arrow missile, Green Pine fire control radar)
  
• Tadiran Electronics in Holon, Israel (Citron Tree battle management center)
  
• Boeing (about 35% of the Arrow missile, manages many US subcontractors)
  
• Lockheed Martin Missiles & Fire Control in Orlando, FL (radar seeker)
  
• Raytheon in Santa Barbara, CA (Infrared seeker)
  
• Other American subcontractors include ATK in Iuka, MS and Clearfield, UT; Manes Machine, in Fort Collins, CO; Ceradyne Thermo-Materials, Inc., in Scottsdale, GA; and Sanmina SCI, in Huntsville, AL.
  
• Rafael Armament Development Authority, Haifa, Israel (Black Sparrow air-launched target; joint U.S./Israel effort).

EL/M-2080 “Green Pine”
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Israel deployed the first battery of Arrow-1 missiles on March 14/2000, and has continued to upgrade the system. The summer of 2005 marked delivery of the first co-produced Boeing/IAI missiles. Israeli and US troops engaged in pre-training for the biennial Juniper Cobra exercise in 2007, and part of that process includes working out interoperability issues between the Patriot PAC-3 system (ad PAC-2 GEM+ that Israel deploys) and Arrow.

On July 29/04 Israel and the USA carried out joint experiment in the USA, in which the Arrow was launched against a real Scud missile. The experiment was a success, as the Arrow destroyed the Scud with a direct hit. In December 2005 the system was successfully deployed in a test against a replicated Shahab-3 missile. This feat was repeated on February 11/07.

Despite some international interest in the Arrow, the USA has blocked export initiatives so far. Although India purchased an Arrow-capable “Green Pine” radar from Elta in 2001, and has expressed interest in deploying its own battery of Arrow interceptor missiles, U.S. concerns regarding compliance with the Missile Technology Control Regime (MTCR, an international agreement limiting the proliferation of ballistic missile technology) have effectively halted such plans for the time being. This did not stop India from using the Green Pine technology in its own November 2006 anti-missile test, using a modified Prithvi short-range ballistic missile with an exo-atmospheric kill vehicle and a hit to kill warhead.

Contracts & Key Events, 2004-Present

Arrow-3 development
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The section is still being updated.

September 6/18: Canister made in the USA Missile canisters for Israel Aerospace Industries’ Arrow-3 system are currently manufactured by Mississippi-based company Stark. Stark recently delivered the first canister to IAI. Israel’s Arrow differs from US systems like THAAD, PAC-3 and SM-3, because it relies on a directed fragmentation warhead instead of “hit to kill” technology. The exoatmospheric, 2-stage Arrow-3 is the latest version of the combat proven system. Arrow-3 is a highly maneuverable missile that can reach more than double the height of existing Arrow-2 interceptors, using a lower-weight missile increases the systems operational range. Stark is one of many US vendors that produce high-end components to Israel’s Arrow, David’s Sling and Iron Dome systems.

May 02/18: Arrow-3 Test Cancellation No. 3 Israel has postponed a planned live test of its Arrow-3 ballistic missile interceptor to improve the system’s readiness. The Arrow system is a more advanced weapon than the Patriot and possesses far more range, undertaking high altitude interceptions and covering a wide area as a Theater Missile Defense (TMD) system. Unlike the USA’s THAAD, PAC-3, or SM-3 which all use “hit to kill” technology, Israel’s Arrow relies on a directed fragmentation warhead to destroy enemy missiles. It can work in conjunction with a number of systems. The system passed its first full interception test over the Mediterranean Sea in 2015 and was deployed in Israel in 2017. The cancelled test in Alaska was scheduled for June 2018 and was supposed to test the missile’s interception distances. Arrow-3 is jointly manufactured by Israel Aircraft Industries and Boeing and is regarded as bulwark against Iran and Lebanon’s Hezbollah and serves as the top tier of an integrated Israeli shield built up to withstand various potential missile or rocket salvoes.

February 22/18: Arrow-3—Successful Test! After two test cancellations, the US Missile Defense Agency (MDA) and Israel Missile Defense Organization successfully completed a flight test of the Arrow 3 weapons system. The test launch of the anti-ballistic missile system took place at a test site in central Israel on Monday, February 19, and was led by Israel Aerospace Industries (IAI) in collaboration with the Israeli air force. The MDA, the system’s co-developer, also supported the test. Moshe Patel, the director of Israel’s Missile Defense Organization, said a more advanced test is scheduled to take place in Alaska later this year, and pictures of the launch were posted on Twitter by the Israeli Ministry of Defense.

January 18/18: Arrow-3—Test Cancellation No. 2 A “communications malfunction” has been reported by Defense News as the reason why Israel called off a test of its Arrow-3 advanced missile defense system. The cancellation follows an earlier such test that was called off in December, however, the Defense Ministry insisted that the cancelled trial “has no impact” on already operational Arrow-2 and Arrow-3 missile defense systems. Moshe Patel, head of Israel’s missile defense arm, said that had an Iranian missile been launched at Israel, the Arrow-3 system—which has been operational since January 2017—would have still been used to intercept it.

December 6/17: Development Testing-Postponement A planned developmental test of the Arrow-3 interceptor system was postponed on Monday after its target missile started acting unsafely. The target—an upgraded version of Rafael’s Sparrow family of air-launched missiles—started to behave strangely shortly after launch in a way that was not conforming to safety parameters determined in advance, and resulted in testers calling a ‘no test’. Engineers are now evaluating the data from the missile target to see what went wrong. Speaking on the incident, Israel’s Defense Ministry noted that Monday morning’s planned test was part of a series of tests periodically conducted by Israel and the US to continuously validate the nation’s multitiered defense network, while Boaz Levy, executive vice president for lead contractor Israel Aerospace Industries (IAI), insisted that the planned intercept test was a developmental test aimed at validating new capabilities planned for future block versions of the Arrow-3, and thus had no bearing on the operational capability of the Arrow weapon system or its continuously upgraded Arrow-2 and Arrow-3 intercepting missiles deployed by the Israeli Air Force. Arrow-3 is Israel’s highest layer of a multitiered and intentionally overlapping network of active defenses against rockets and tactical ballistic missiles aimed at intercepting advanced, possibly nuclear-tipped threats hundreds of kilometers in space.

August 04/17:  Early concept work has begun on the Arrow-4 interceptor, Israel’s new air defense system designed to counter future ballistic missile threats from Iran. Involved in the work are Israel’s MAFAT Defense Research and Development Authority, state-owned Israel Aerospace Industries, as well as other firms, who are now evaluating the technologies needed to improve the ability to track, target and ultimately destroy such threats. While the work is in its infancy— IAI executive vice president Boaz Levy called said the effort is too early to call Arrow-4—the new interceptor will extend capabilities beyond Arrow-2, which intercepts Scud-type ballistic missiles high within Earth’s atmosphere, and Arrow-3, which is designed to destroy targets in space. The new system will specifically look into countering salvo strikes, sub-munition warheads and multiple reentry vehicles (MRV).

June 12/17: The Israel Missile Defense Organization will partner with the US Missile Defense Agency (MDA) to test the Arrow anti-ballistic missile system in Alaska. On announcing the upcoming test, director of the MDA Adm. James Syring stated that Tel Aviv experiences “significant range constraints within the Mediterranean” when it comes to missile testing capabilities, and bringing the Arrow test to the Kodiak Island facility would help to overcome that. The test is likely to take place next year with Alaska Aerospace Corp scheduled to help with the test.

March 20/17: Israel’s Arrow anti-ballistic missile system has been combat tested for the first time. The system came into operation in order to intercept a Syrian surface-to-air missile that was targeting Israeli warplanes returning from a raid on Syrian sites. Despite claims from Damascus that one Israeli plane had been downed, IDF officials stated that no aircraft had been lost.

January 20/17: The Israeli Air Force has received delivery of their first Arrow-3 missile defense battery. A joint-development effort by Boeing and Israel Aerospace Industries (IAI), the Arrow-3 interceptor will form the upper-tier layer of Israel’s multi-tiered Arrow Weapons System (AWS), and is designed to fly nearly twice as high at half the weight of the Arrow-2 interceptor, which covers the lower-tier segment of the network. Arrow-3 missiles will allow the IAF to shoot twice against a single ballistic target, assess for battle damage and, if needed, divert to other approaching threats, with the Arrow-2 operating as a back-up.

June 16/15: Joint US-Israel missile programs may benefit from additional funding under a Defense Appropriations Bill, following a vote in the House. The programs covered by the increase in funds include the Iron Dome, Arrow, Arrow 3 and David’s Sling systems. The last of these will receive the most significant boost, with an additional $286.5 million allocation.

Feb 22/11: An Arrow System successfully intercepts a ballistic target missile during a flight test conducted at Pt. Mugu Sea Range, CA. This test is part of the Arrow System Improvement Program (ASIP) and was conducted jointly by the Israel Missile Defense Organization and the U.S. Missile Defense Agency.

The test represented a realistic scenario, and all the elements (Arrow, Green Pine radar, Citron Tree BMC) performed in their operational configurations, using new Block 4 software designed to improve their ability to discriminate targets. US MDA release | video || Defense News.

July 27/10: The House Appropriations Subcommittee on Defense votes to fund Israel’s missile defense programs at $422.7 million for 2011, nearly $96 million above the original White House funding request. This represents a doubling of aid for missile defense from 2010, in the wake of an emerging consensus that the CIA’s 2007 estimate of Iran’s nuclear weapons program was wrong, and underestimated Iranian progress.

On the other hand, the structure of that funding is less good for the Arrow program. While the HASD added $58 million to the administration’s original FY 2011 Arrow-3 request, that provisional $108.8 million is actually less than FY 2010 funding of $157.4 million ($60M request + $97.4M Congress added). Likewise, the complementary medium range RAFAEL/Raytheon David’s Sling/Magic Wand dropped from $134.7 million in FY 2010 to $84.7 million requested in 2011. The net increase comes from a one-time, $205 million grant for the procurement of 10 RAFAEL Iron Dome batteries for defense against short-range missiles. HASD Chair statement [ PDF] | HASD Table [PDF] | AllGov | Jerusalem Post | Israel’s Globes business news.

July 26/10: Israel and the United States sign a deal to develop and field the Arrow 3 system. It will be capable of tracking and shooting down ballistic missiles at a higher altitudes, including fully exoatmospheric threats. US MDA | China’s Xinhua.

March 22/10: Defense News reports that U.S. and Israeli government and industrial partners will press ahead with Arrow 3 work through good faith understandings, until formalized government-to-government accords catch up. The goal is to deploy the new missile by 2014.

Production of the Arrow-2 is winding down, and final deliveries are planned by the end of 2010. Government and industrial partners have apparently been working together on Arrow-3 for nearly 2 years, moving the program through at least 4 of the US Missile Defense Agency’s required technology “knowledge points, and validate critical subsystems. A first fly-out is planned for 2011.

Manufacturing
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April 7/09: The Israeli Ministry of Defense and the U.S. Missile Defense Agency conduct a successful test of the Arrow ballistic missile defense system. The operationally realistic test was conducted in Israel, using an ASIP interceptor co-produced by Boeing and Israel Aerospace Industries (IAI). The event marked the co-produced Arrow II’s 2nd intercept in 2 attempts, as well as its 3rd successful flight test. Boeing.

Jan 4/09: Israel’s Arutz Sheva news service reports that the Arrow missile defense system has been deployed near Ashkelon, in part because IAI has worked with American firms and developed an updated radar system named MC4. The new radar can also deal with smaller missiles, such as the Hamas government’s Kassam or Grad rockets being launched from Gaza. Using GPS and camera sensors, the MC4 system tracks the flight path, and within a minute of launch, it can determine both the launch site and projected landing site of the missile.

At the same time, pressure is building to add Northrop Grumman’s SkyGuard laser system to Israel’s defenses, a system whose technology is based on joint US-Israeli research:

“Supporters claim that the Skyguard laser based system is more suited to Israel’s needs than the rocket-based Rafael solution. Firstly, the laser can intercept short range missiles such as the Kassam rocket which hit their targets in less than 10 seconds. The rocket-based Rafael system can only hit medium-range rockets which reach their targets in more than 20 seconds. In addition, each laser round fired costs approximately $3,000. In contrast, defensive rockets for the Iron Dome system are estimated to cost over $100,000. Supporters also claim that the Skyguard system could be deployed in a short amount of time, whereas the completion of the Iron Dome rocket system is not foreseen in the near future.”

Sept 29/08: The USA has deployed an unspecified X-band radar system in Israel, manned by around 120 American personnel. Reports hint that the system may be similar to the radars deployed to Japan, or the AN/TPY-2 used as part of the THAAD system. The Guardian:

“One key feature of the system is that information from early-warning satellites – which greatly increases the radar’s ability to pinpoint launches – would remain in US hands. The satellite ground station would be in Europe and transmit data to Israel.

…The high-powered X-Band system, manufactured by Raytheon Company, would allow Israel’s Arrow II ballistic shield to engage an Iranian Shehab-3 missile about halfway through its 11-minute flight to Israel, six times sooner than Israel’s existing Green Pine radar can. The X-Band can track an object the size of a baseball from 2,900 miles away.”

Feb 14/08: IAI announces that The Israel Ministry of Defense (IMOD) / Missile Defense Organization (IMDO) has awarded a follow-on production contract to Israel Aerospace Industries (IAI)’s MLM Division for an undisclosed number of additional Arrow 2 Anti-Tactical Ballistic Missile (ATBM) system interceptors. The interceptors will be assembled in Israel at IAI’s MLM Division, the Arrow prime contractor, with major portions coming from Boeing IDS, the U.S. prime contractor in Huntsville, AL., ATK in Luka, MS., and various other subcontractors across the U.S.

Aug 23/07: The Jerusalem Post publishes “IDF modifying Arrow deployment in the North.” Key quote:

“Following this past summer’s war and the recognition that the next war will involve Syrian and Iranian missile barrages, the Air Defense Forces decided to adopt a “wide deployment” for its Arrow missile batteries.”

Aug 6/07: Jane’s Defence Weekly: “Israel is leaning towards upgrading its own anti-ballistic missile Arrow Weapon System (AWS) rather than acquiring the US Theatre High Altitude Area Defence (THAAD) system. While no formal decision has yet been taken, Jane’s has learned that officials from the Israel Ballistic Missile Defence Organisation (BMDO) have informed the US Missile Defense Agency (MDA) about potential complications with integrating THAAD into the country’s missile-defence alignment.”

March 26/07: An improved Arrow II missile, with modifications to its hardware and electronics under the Arrow System Improvement Program, is successfully test-fired this afternoon at Palmahim Air Force Base. The interceptor performed successfully according to design specifications, meeting all expectations and objectives. This is the 1st successful test of the improved configuration, and the 2nd test overall of a co-produced interceptor. Testing is managed by the Israeli Missile Defense Organization, in close cooperation with the U.S. Missile Defense Agency.

Test objectives were to collect flight engineering data for future test events, and to test the capabilities of the improved Arrow interceptor. This test marks the U.S./Israeli Arrow II program’s 14th success in 16 attempts. US MDA [PDF].

Feb 12/07: A successful ballistic missile intercept test by the Arrow missile defense system, conducted at night over the Mediterranean Sea. It’s the 1st test of a co-produced Arrow intercept missile fired from an improved launcher, using 2 Arrow batteries separated from each other. The target, called “Black Sparrow,” was launched from an F-15 fighter aircraft at which point the Fire Control Radar acquired the target and notified the Battle Management Center. A defense plan was issued and a mission command was sent to the Launch Control Center to fire the interceptor missile. This test marks the U.S./Israeli Arrow II program’s 13th success in 15 attempts. US MDA [PDF].

Spring 2005: The 1st co-produced Arrow 2 interceptor is delivered by IAI to the MoD. Source [PDF].

Feb 2/05: Israel Defense Forces carry out a successful test of the IAI/Boeing Arrow anti-missile system at a secret location in the center of the country. The Jerusalem Post reports that “an F-15 fighter jet flying over the Mediterranean dropped a Black Sparrow test missile specially designed to simulate an incoming Iranian Shihab 3 missile headed toward the Israeli shore.” The successful interception occurred at a higher altitude than previous efforts, and tested recent improvements made to the Arrow 2 system.

Israeli Air Force Patriot missile batteries also participated passively in the test, following the incoming missile with their radars. The Times of India notes that this was the 14th test of the system, which has included joint tests in the USA and advanced tests simulating advanced separating warheads. As evidenced by the Patriot batteries’ participation in this latest test, Israel is working to integrate all of its key assets and connections to US data into one national system, rather than relying on fragmented local control. Jerusalem Post | copy at United Jerusalem.

Pt. Mugu launch
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Aug 26/04: US Missile Defense Agency [PDF]:

“The Arrow anti-ballistic missile system was used today in a joint Israel/United States test exercise as part of the ongoing Arrow System Improvement Program (ASIP). The test was the second in a series conducted at the Point Mugu Sea Range in California. It was the thirteenth Arrow intercept test and the eighth test of the complete weapon system. The Arrow interceptor was launched toward the target but no intercept was achieved. Many of the test objectives were successfully completed, and the test data is being analyzed by test engineers to determine why an intercept did not occur.”

July 29/04: A modified Arrow System Improvement Program anti-ballistic missile successfully intercepts and destroys a ballistic missile target today, west of San Nicolas Island on the Pt. Mugu Sea Range in California. Point Mugu was used, in order to offer a realistic scenario that could not have been tested in Israel due to test-field safety restrictions.

The objective of the test was to demonstrate the Arrow system’s improved performance against a target that represents a threat to Israel. This was the 12th Arrow intercept test, and the 7th test of the complete Arrow system. US MDA [PDF]

April 1/04: Boeing announces a $78 million contract from Israel Aircraft Industries (IAI) to produce Arrow II interceptor components. The contract, effective immediately, runs through 2006 with options for additional production until Q2 2008. The total contract value could exceed $225 million if all options are exercised.

Boeing and IAI signed a teaming agreement in 2002 to co-produce the interceptor for the Arrow weapon system. The firm is responsible for production of the electronics section, the radome, motorcases for the booster and sustainer, and the canister that holds the interceptor in the missile launcher. Boeing production and program management will be conducted in Huntsville, AL. IAI, the prime contractor of the Arrow system, is responsible for system integration and final interceptor assembly in Israel.

Boeing will manage several major subcontracts to support the Arrow interceptor production including Alliant-Techsystems in Iuka, MS and Clearfield, UT; Manes Machine, in Fort Collins, CO; Ceradyne Thermo-Materials, Inc., in Scottsdale, GA; and Sanmina SCI, in Huntsville, AL.

Sept 14/2000: The Israel Ministry of Defense, in cooperation with the U.S. Ballistic Missile Defense Organization and the U.S. Army, conduct the 2nd successful intercept of a target ballistic missile by the Arrow Weapon System (AWS) in Israel. This was the 8th overall Arrow-2 flight test, but the 1st intercept for the against a new air-launched, in-bound target called the Black Sparrow.

The Arrow interceptor took off and flew in a nominal trajectory, acquired the Black Sparrow target, then locked on and homed on the designated threat. The warhead was fused at the proper range and the Arrow interceptor destroyed the target. The Green Pine fire control radar and Citron Tree battle management center participated fully in the test, performing battle planning, launch operations, and up link/down link message applications, as well as post intercept verifications. Both assets worked according to plan and fulfilled all test objectives. Analysis of all data is underway to evaluate and confirm results. US MDA [PDF]

Additional Readings & Sources

• Israeli MoD – Arrow Weapon System site.

• US MDA – Arrow gallery. Covers joint tests to 2004.

• Boeing – Arrow Interceptor

• Israeli-Weapons.com – Arrow. Profiles the entire Homa system, including Green Pine and Lemon Tree.

• Claremont Institute MissileThreat.com – Arrow Missile

• Claremont Institute MissileThreat.com – Shabab-3

• Wikipedia – Arrow Missile

• yNet News – Iran: We will build 20 new nuclear plants. also discusses the Arrow system test, and the larger efforts underway on the international front.

• BBC News (Feb 11/07) – Israeli missile test ‘successful’

• Jerusalem Post (Dec 2/05) – ‘Arrow’ Scud buster test a success

• India Times (Dec 2/04) – Israel successfully tests Arrow missile system

• Claremont Institute MissileThreat.com (Nov 17/04) – Aegis Test Successful: Marks First Attempt Against More Advanced Separating Target. This had been a key concern re: the system.

• Globes Online (Nov 7/05) – Jane’s: First IAI-Boeing “Arrow 2” missile delivered to IAF

• US Army News Service (Nov 2/05) – Air defenders train with Israeli counterparts

• A Daily Briefing on Iran (Oct 29/04) – Why Haven’t We Seen This? Sometimes a picture really is worth 1,000 words, and it’s worth looking at this one from Ahmadinejad’s infamous speech… but the thousand words in documents like Hassan Abbassi’s “War Preparation Plan” can be at least as chilling.

• MEMRI Translation Special Dispatch Series (Oct 28/05) – Translated excerpts from Iranian President Mahmoud Ahmadinejad’s speech

• UPI (Aug 27/04) – Arrow anti-ballistic missile test fails. It was tested against a separating warhead. The articles gives details re: what happened – but the most fascinating part to me was the difference between American and Israeli weapons testing philosophies.

• JINSA (Aug 4/04) – First U.S. Test of Arrow Missile Defense System Goes ‘Beautifully’. Adds useful background re: the overall US-Israeli program.

• Israeli IDF (Aug 2/04) – The ‘Arrow’ System Test- A Strategic Accomplishment

Americas

The US Missile Defense Agency’s Low Power Laser Demonstrator program is moving into the design review stage. Lockheed Martin, General Atomics and Boeing are each being awarded with contract modifications, amounting to a total of $69.2 million. Under these modifications, the contractors will each complete a comprehensive design review of their respective laser systems. The MDA is seeking a new high altitude long endurance (HALE) unmanned aerial vehicle with the unique capacity to carry a high energy laser system that can stop enemy missiles when they have barely left the launch pad. Destroying enemy ballistic missiles in boost phase is particularly beneficial because with one shot it could destroy multiple independently targeted missile warheads, as well as decoys designed to foil missile defenses. The LPLD project is to demonstrate the feasibility of firing a laser from a UAV before it gets on to developing a high energy laser system. Lockheed Martin, received $25.5 million and will perform all work at its facility in Sunnyvale, California. General Atomics, received $23.4 million, with work being performed in San Diego, California. Boeing received $20.4 million and will review the design at its facilities in Huntsville, Alabama; Huntington Beach, California; and Albuquerque, New Mexico. The contracts are scheduled to end by July 31, 2019.

Lockheed Martin will perform a variety of engineering services in support of the Navy’s AN/SPY-1 radar. The cost-plus-fixed-fee job order is valued at $12.9 million and is expected to be completed by August 2023. The AN/SPY-1 is at the heart of the Aegis ballistic missile defense system. The 3D air/surface search and tracking radar is able to perform search, track and missile guidance functions simultaneously, and has the ability to track over 100 targets to over 100 miles. Terminal guidance depends on mounted illuminators, since current SM-2 missiles are limited to semi-active radar homing. The effort provides for radar readiness enhancements and improvements. Work will be performed at Lockheed’s facility in Moorestown, New Jersey.

The US Army needs new items for its WIN-T network. General Dynamics will procure a number of configuration items for the warfighter information network-tactical program. The contract has a value of $81.8 million and provides for network and pre-priced hardware items. The WIN-T program is the Army’s high-speed, high-capacity tactical communications network to distribute classified and unclassified information through all echelons of Army command by means of voice, data, and real-time video. The program has seen its up and downs over the years, the current WIN-T Increment 2 started fielding in 2012 but hasn’t reached the whole force yet. Army experts are currently looking for alternative systems over fears that WIN-T are not resilient and secure enough to be used in combat against technological advanced adversaries. Work will be performed at GD’s facility in Taunton, Massachusetts, and is expected to be completed by August 2020.

Middle East & Africa

Turkish President Tayyip Erdogan is determined to move ahead with the acquisition of Russian-made S-400 surface-to-air missile batteries as soon as possible. The S-400 nicknamed Triumf, also known as SA-21 Growler is a long range surface-to-air missile system produced by Almaz-Antey. The system can engage all types of aerial targets including aircraft, unmanned aerial vehicles (UAV), and ballistic and cruise missiles within the range of 400km, at an altitude of up to 30km. The system can simultaneously engage 36 targets. A regular S-400 battalion reportedly consists of at least eight launchers with 32 missiles and a mobile command post. Erdogan’s reaffirmation will likely put a further dent into the already fragile US-Turkish relations and threaten the purchase of several F-35s. Speaking at a graduation ceremony for military officers, Erdogan said Turkey also needs F-35 fighter jets and will continue to pay its installments to procure them from the United States, but would procure jets elsewhere if the United States halts the delivery of the F-35 fighter jets.

Europe

Defense News reports that German shipbuilding advocates call for the government to protect the German military ship sector from international competition as means to boost the domestic industry. Germany currently plans to buy four new MKS-180 multi-role frigates at a cost of $4 billion. If the tender goes to an international competitor thousands of jobs in northern Germany would be threatened. Industry representatives want the defense sector to be exempted from European acquisition requirements. The two contenders for the program are Dutch Damen Shipyards and German Naval Yards Kiel. Government officials said protectionism would play no role whatsoever in an eventual award, shortly after it turned down a solo bid for the new frigate by ThyssenKrupp Marine Systems.

Asia-Pacific

The Bangladesh Air Force is now capable of conducting independent maintenance and overhaul work on its fleet of F-7 fighter jets. The Asian-country is currently in the process of implementing its Vision 2041 strategy, a part of which includes the reduction of maintenance and supply costs. Prime Minister Sheikh Hasina told press representatives during a ceremony “we can reduce costs by 30 to 40 per cent when overhauling aircraft on our own without any foreign technical support. It also saves out time as well”. The J-7 is a single-engine, lightweight fighter aircraft that has 28 domestic variants and 26 export variants. According to Airforce Technology the Bangladesh Air Force purchased 16 F-7MB, 16 F-7BG and eight FT-7B aircraft. These F-7MB aircraft were replaced with 100 beyond visual range-capable F-7BGs through to 2010.

South Korea will soon integrate a new advanced infrared missile countermeasure system onto its helicopters. The directional infrared countermeasure (DIRCM) is being jointly developed by the Defense Acquisition Programs Administration and defense contractor Hanwha Systems. DIRCMs rely on two distinct systems to defend against missile attacks. The first system includes ultraviolet sensors that detect an incoming missile. The second includes the transmitter that directs a beam of infrared energy at the missile’s seeker. Both systems are enclosed within a single compact pod, which mounts to the underside of a jet’s fuselage. When an enemy missile is launched at the aircraft the DIRCM gives an automatic alarm and shoots a high intensity quantum cascade laser at the incoming weapon’s guidance sensor, causing it to loose its lock. The system has been tested in several live firing tests and will now be gradually introduced to a variety of aircraft types.

Today’s Video

Watch: Rising Thunder 2018

WIN-T concept
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As the Army’s tactical portion of the USA’s Global Information Grid (GIG) network, Warfighter Information Network-Tactical (WIN-T) is designed to help deployed forces tap into that global network and its databases, collectors, and connections to national agencies. At present, this requires multiple private networks, or outright forward deployment of representatives from the agencies in question. If it can be done at all.

WIN-T has absorbed the program formerly known as the Joint Network Node, and another 3 fielding increments will gradually add key capabilities to the system. Increment 1/ JNN is widely fielded, Increment 2 is being fielded, and R&D contracts are beginning fleshing out Increment 3.

The WIN-T Program

WIN-T has changed a lot since it began in 2002. The timeline below captures key shifts and events, as well as future plans:

The biggest program change involved its split into different increments. So, what’s involved?

The New Structure: Incremental Change

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WIN-T Increment 1 provides soldiers access to the GIG while stationary, and used to be known as the Joint Node Network. It lets small platoons on the ground communicate with the rest of the world, something they couldn’t do in the past.

The JNN-N node was originally intended as an interim bridge before WIN-T arrived. It consists of vehicles and shipping containers (the Joint Network Node, the Battalion Command Post Node, the Ku SATCOM trailer and the Hub Node) equipped with systems that provide voice over IP, dynamic IP, videoconferencing and access to the military’s classified and unclassified networks. The US Army likes the idea of using commercially available Ku-band satellites via an integrated suite of state-of-the-art baseband, switching and termination equipment. Commercial Ku-band SATCOM offers performance and availability advantages that include higher throughput rates, as well as the ability to upgrade many of the fielded Ku-band terminals to Ka-band used by the military’s own Wideband Global SATCOM (WGS).

JNN was so successful that it became WIN-T Increment 1 in 2004. By 2006, the Army had fielded JNN to every infantry battalion operating in Iraq, and was started to push the gear down to the company level. The June 2007 WIN-T program restructuring added WGS broadband military Ka-band satellite connectivity as Increment 1a, to lower bandwidth costs and offer more networking options. WIN-T Increment 1b added Net-Centric Waveform software to optimize bandwidth, and a “colorless” core security architecture.

General Dynamics is developing Increment 2 and Increment 3 under a 2007 contract. General Dynamics C4 Systems leads a WIN-T team that includes Lockheed Martin, BAE Systems, Harris Corporation, L-3 communications, and networking rivals Juniper Networks and Cisco Systems.

WIN-T Increment 2 is designed to provide connectivity on the move. Integrating SATCOM, line-of-sight and terrestrial signal types, the “self healing” WIN-T increment 2 is designed to provide high-bandwidth connectivity that can automatically switch as between ground-based and satellite connections. For example, if a commander is moving into a city, which begins blocking line-of-sight signals, the system automatically connects to SATCOM.

This increment begins embedding WIN-T communications gear in select vehicles, bringing them Secure Internet Protocol Router (SIPR) connectivity. It also has to be backward-compatible with WIN-T Increment 1/1a/1b, because the reality of purchases and rollouts mean that different Army units will be equipped with different WIN-T Increments at any given time.

WIN-T Increment 3 will introduce an airborne network node to act as a relay, creating a 3-tier failover of land line-of-sight, then airborne relays, and then satellite as a last resort. The intended result is fully mobile networking, with better reliability and capacity. Inc 3 also aims to field smaller, more tightly integrated communications and networking gear.

Increment 3 was supposed to be part of the Army’s Future Combat Systems vehicles, but they were canceled in June 2009.

WIN-T Increment 4, the last of the WIN-T developmental program elements, is pending definition and contract award. It’s still supposed to cover on-the-move protected satellite communications, though that’s going to mean using the AEHF constellation rather than the envisioned T-SAT program.

WIN-T: Program Dashboards

Contracts and Key Events FY 2018

 

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September 5/18: New items The US Army needs new items for its WIN-T network. General Dynamics will procure a number of configuration items for the warfighter information network-tactical program. The contract has a value of $81.8 million and provides for network and pre-priced hardware items. The WIN-T program is the Army’s high-speed, high-capacity tactical communications network to distribute classified and unclassified information through all echelons of Army command by means of voice, data, and real-time video. The program has seen its up and downs over the years, the current WIN-T Increment 2 started fielding in 2012 but hasn’t reached the whole force yet. Army experts are currently looking for alternative systems over fears that WIN-T are not resilient and secure enough to be used in combat against technological advanced adversaries. Work will be performed at GD’s facility in Taunton, Massachusetts, and is expected to be completed by August 2020.

FY 2015

November 5/15: In an attempt to downsize the Warfighter Information Network – Tactical (WIN-T) system, the Army is working to reconfigure the system – currently reserved for larger vehicles – to fit onto Humvees. The smaller nodes will allow rapidly-deploying forces to better communicate and tap into the digital battlefield on the move, with testing scheduled to take place in May 2017 and low-rate initial production of the smaller systems slated to see deliveries early next year.

June 10/15: The go-ahead has been given to General Dynamics for full rate production of the Warfighter Information Network – Tactical (WIN-T) Increment II, following Defense Acquisition Board approval to the Army in May. This means that the system – which is designed to act as a mobile command post, providing mobile command, control and communications – may be bought for remaining units due to receive the WIN-T system up to 2028. This increment also begins embedding WIN-T communications gear in select vehicles, such as MRAPs, bringing them Secure Internet Protocol Router (SIPR) connectivity as well as SATCOM capability.

April 21/15: General Dynamics was awarded a $36.4 million contract to produce and repair components for the WIN-T, with the firm beating two other bids to take the contract.

FY 2014

 

These funds are on top of the $921 million R&D contract to develop both Increment 2 & Increment 3 (q.v. Sept 18/07), and see also the May 23/13 SAR report for cost escalation background. GDC4S was already responsible for Increment 3, and just 1 offer was solicited and 1 bid received by US Army Contracting Command at Aberdeen Proving Ground, MD (W15P7T-14-D-0002).

WIN-T-3 development add-on

Oct 31/13: WIN-T-3. General Dynamics C4 Systems Inc. in Taunton, MA receives another $475 million cost-plus-incentive-fee contract to complete WIN-T Increment 3’s research and development. Work location and funding will be determined by each order.

Oct 3/13: WIN-T-2. The US Army announces that they’ve been approved to proceed with a $111 million WIN-T Increment 2 delivery order, as part of continued but contingent limited production. GDC4S will produce the next lot of WIN-T Inc 2 network nodes for additional brigade combat teams and division headquarters units.

WIN-T Inc 2 will be extended within 10th Mountain Division as part of wider CS 13 communications deployments, adding their 3rd Brigade Combat Team alongside 4 BCT. In addition, 2 more 101st Airborne Division BCTs will be conducting fielding and training with CS 13 and WIN-T Inc 2. The Army adds an important caveat when they note that:

“At the same time that it fields [WIN-T Inc 2] to CS 14 units, the Army will continue to coordinate with the Office of the Secretary of Defense and the test community to address remaining issues and simplify the system.”

See our March 28/13 and Jan 17/13 entries for more on that subject. Sources: US Army | GD, Oct 3/13 release.

FY 2012 – 2013

 

WIN-T-2 on M-ATV
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June 27/13: Testing. DefenseTech quotes Army officials who explain how new equipment, including WIN-T, are driving tactics in exercises – and how the results change equipment design in return. With respect to WIN-T:

“There is a lot of complexity and challenge to mission command on the move,” he said. “A commander’s got a lot going on. He’s got to know where his elements are and at the same time know what the enemy is doing. You have to manage the data elements in real time. One solution was to have another soldier take on the monitoring of the data and manage the data so that the commander is not stuck to the screen.”

After installing the second version of the system on wheeled vehicles, the Army plans to configure numerous tracked vehicles with the technology, Smith said.”

June 8/13: WIN-T. General Dynamics touts the Army National Guard’s use of WIN-T Increment 1 after Hurricane Sandy hit New Jersey in October 2012. The system reportedly became a hub for law enforcement, other first responders, and the military after power was lost and cellular and mobile communications were down. Sources: GDC4S, June 18/13 release.

May 23/13: SAR. The Pentagon’s Selected Acquisitions Report ending Dec 31/12 includes shifts in WIN-T: 690 nodes subtracted from Increment 2, and 429 added to Increment 3. The result is a net subtraction of 261 nodes, coupled with a $2.1 billion overall cost increase…

WIN-T Increment 2 – Program costs decreased $1,323.9 million (-20.5%) from $6,461.3 million to $5,137.4 million, due primarily to a quantity decrease of 690 nodes from 2,790 to 2,100 nodes to align with the capability sets (-$1,115.8 million) and associated schedule and estimating allocations (+$38.8 million). Other decreases were due to the removal of the Armored Brigade Combat Team recurring A-Kit costs (-$150.8 million), a decrease in initial spares resulting from the decrease of 690 nodes (-$107.6 million), and decreases in fielding, new equipment training, and software maintenance resulting from 690 fewer nodes (-$83.5 million). These decreases were partially offset by an increase due to revised escalation indices (+$82.7 million) and increases resulting from additional costs for follow-on operational test and evaluation; platform certification testing; initial operational testing; and joint command, control, communications, computers, intelligence, surveillance, and reconnaissance radio production qualification testing (+$70.4 million).

WIN-T Increment 3 – Program costs increased $3,434.6 million (+23.8%) from $14,455.5 million to $17,890.1 million, due primarily to a procurement quantity increase of 404 nodes from 3,045 to 3,449 nodes (+$1,232.4 million) and associated schedule, engineering, and estimating allocations (-$497.7 million), and a development quantity increase of 25 nodes from 39 to 64 nodes (+$158.2 million) for limited user testing. Additional increases related to the increase of 404 procurement nodes include: fielding, new equipment training and hardware end of life (technology refresh) (+$1,556.1 million), software licenses (+$230.9 million), initial spares requirements (+$99.5 million), and engineering change orders for hardware procurement (+$79.1 million). There were other increases attributable to updates to the systems engineering and program management cost estimate (+$322.7 million) and the application of revised escalation indices (+$302.4 million). These increases were partially offset by decreases resulting from descoping of the Point of Presence-Command and Modular Communication Node-Global Information Grid Interface (-$42.8 million) and a reduction in development engineering due to leveraging of the WIN-T Increment 2 design (-$42.5 million).

SAR – WIN-T-2 shrinks, WIN-T-3 grows

May 6-23/13: Testing. WIN-T Increment 2 completes a Follow-on Operational Test and Evaluation (FOT&E) during the US Army’s Network Integration Exercise (NIE) 13.2, using the JTRS-compliant AN/PRC-154 Rifleman and AN/PRC-155 2-channel Manpack networking radios as key interfaces.

During the evaluation, more than 3,800 soldiers from the 2nd Brigade Combat Team, 1st Armored Division conducted a wide range of on-the-move military and peacekeeping operations, both day and night, at White Sands Missile Range, NM. Sources: GDC4S, June 19/13 release.

April 18/13: Training. General Dynamics announces that WIN-T Increment 2 is now in the hands of the U.S. Army’s 10th Mountain Division, whose 4 BCT is training for their upcoming deployment to Afghanistan with the system. Their point of interface is their JTRS-compatible Thales AN/PRC-154 radios.

Late last year, GD says that the Army ordered 136 additional WIN-T Increment 2 network nodes, bringing total orders to 532 and extending its reach to the company level. Sources: GDC4S, April 18/13 release.

March 28/13: GAO Report. The US GAO tables its “Assessments of Selected Weapon Programs“. Which is actually a review for 2012, plus time to compile and publish. With respect to WIN-T-2, the technologies and manufacturing are deemed to be mature, but:

“Based on the results of the May 2012 operational test, the Director, Operational Test and Evaluation, concluded that only some of the program’s configuration items and technologies were operationally effective and that the program is not operationally suitable as six of the eight configuration items did not meet their reliability targets. The Director recommended that the Army dedicate resources to fix the program’s reliability and ability to support a 72-hour mission, and demonstrate improvements through a future operational test event. The Director also recommended that the Army consider appointing an independent review panel to determine if the program is capable of meeting its original reliability targets or recommend redesign changes. The Army is to perform a life-cycle cost analysis to determine the additional costs for maintenance support due to the program’s inability to meet its original reliability targets.”

With respect to WIN-T-3:

“WIN-T Increment 3 will not demonstrate the maturity of all 18 of its critical technologies in a realistic environment until its planned April 2015 production decision…. The program office stated that it has dropped two critical technologies from the original set of 20; the Joint Command, Control, Communications, Computers, Intelligence, Surveillance, and Reconnaissance Transmission Management Subsystem, and the Distributed Network Agent were removed due to their similarities with several of the program’s other critical technologies…. The program plans to begin employing alternative methods to assess design stability once it has completed its design review, now scheduled for June 2013, and has a stable baseline design, but has not made any final decisions about those methods. The program intends to conduct system-level developmental testing on a fully configured, production representative prototype in July 2014.”

Jan 17/13: DOT&E Testing Report. The Pentagon releases the FY 2012 Annual Report from its Office of the Director, Operational Test & Evaluation (DOT&E). WIN-T is included:

“WIN-T Increment 2 is not suitable due to poor reliability and maintainability and not survivable due to deficiencies noted in the classified annex to the DOT&E BLRIP report…. In February 2012, the Army approved a revised requirement that lowered WIN-T Increment 2’s reliability requirement by 30 – 60 percent based upon an updated operational mission summary/mission profile…. As a result of IOT&E, DOT&E assessed WIN-T Increment 2 as not survivable due to significant Information Assurance vulnerabilities that would degrade a unit’s ability to succeed in combat. These vulnerabilities are discussed in a classified annex to the DOT&E BLRIP report.

On September 26, 2012, the DAE signed an ADM… Authorized the Army to procure an additional 538 WIN-T Increment 2 communication nodes as a second Low-Rate Initial Production [while requiring further testing and corrective plans].”

Oct 4/12: WIN-T-2. The U.S. Department of Defense has authorized the Army to continue WIN-T Increment 2 as part of the Army’s Capability Set 13 deployment, after its Initial Operational Test and Evaluation (IOT&E) was deemed to be successful during the Army’s Network Integration Evaluation 12.2 exercise.

Accordingly, General Dynamics C4 Systems receives a $346 million delivery order to buy more sets for Brigade Combat Teams and Division Headquarters units. Most production for the WIN-T Increment 2 system takes place at General Dynamics C4 Systems’ facility in Taunton, MA, with components from a variety of suppliers that include veteran-owned and small businesses in 28 states. GDC4S.

Oct 1/12: WIN-T-2. Initial fielding of the WIN-T Increment 2 network as a key component of Capability Set 13 begins at Ft. Drum, NY, and Ft. Polk, LA. Two brigades of the 10th Mountain Division begin their training using previously procured equipment. Source.

March 30/12: SAR The Pentagon’s Selected Acquisitions Report ending Dec 31/11 includes…

“WIN-T Increment 3 – Program costs decreased $1,600.4 million (-10.0%) from $16,055.9 million to $14,455.5 million, due primarily to a decrease in hardware costs reflecting fewer quantities of high cost Configuration Items being procured and a change in the mix of Configuration Items being procured (-$1,809.1 million) and a decrease of 123 nodes from 3,168 to 3,045 due to the removal of the requirement to replace Increment 2 hardware with Increment 3 hardware (-$291.4 million). There were additional decreases resulting from the descoping of the 4-channel Joint Command, Control, Communications, Computers, Intelligence, Surveillance, and Reconnaissance (JC4ISR) radio and antenna (-$287.2 million) and a decrease in systems engineering, program management, and spares costs due to compression of the procurement schedule by two years from FY 2026 to FY 2024 (-$262.4 million). These decreases were partially offset by a net increase in other support costs due to increased annual software license costs and the retrofit of the JC4ISR radios and antennas (+$383.8 million), an increase in hardware estimates for the Satellite Tactical Terminal-High Powered and Highband Radio Frequency Unit-Multiband Terrestrial antenna (+$352.6 million), and the application of revised escalation indices (+$325.6 million).”

SAR – WIN-T-3 reductions

Jan 17/12: DOT&E testing. The Pentagon releases the FY 2011 Annual Report from its Office of the Director, Operational Test & Evaluation (DOT&E). WIN-T is included, but only tangentially:

“The Army conducted a combined WIN-T Increment 2 and Increment 1b Limited User Test at Fort Stewart, Georgia; Fort Lewis, Washington; and Fort Gordon, Georgia, in March 2009. DOT&E assessed the WIN-T Increment 2 as supportive of voice, video, and data communications. However, the network needs improvement in the following areas:

• Reliability
  
• Ability to support on the move communications
  
• Training provided to Soldiers due to complexity of the system
  
• Speed of communication due to network routing
  
• Network Operations Management
  
• Information Assurance

Nov 18/11: The US Army is evaluating its latest build of field networking equipment, after the 3-week NIE 12.1 event. The spring 2012 event will test NIE 13, which will include the new WIN-T Increment 2 gear.

FY 2010 – 2011

 

Datapath equipment
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May 10/11: WIN-T-2. Lockheed Martin announces a $105 million contract from General Dynamics C4 Systems, for more WIN-T Increment 2 components. Lockheed Martin will deliver transmission subsystem radios, modems, antennas, and mast systems, which will be integrated into a variety of combat vehicle platforms.

Integrating SATCOM, line-of-sight and terrestrial signal types, the “self healing” WIN-T increment 2 is designed to provide high-bandwidth, on-the-move connectivity which can dynamically switch between terrestrial and satellite sources, depending on the terrain.

April 15/11: SAR. The Pentagon’s Selected Acquisitions Report ending Dec 30/10 includes “significant” program cost change for WIN-T Increments 1 & 2:

“WIN-T Increment 1 – Program costs increased $468.1 million (+12.2%) from $3,835.0 million to $4,303.1 million, due primarily to a quantity increase of 83 communications nodes from 1,777 to 1,860 communications nodes (+$119.5 million) and an increase in other support costs for modification work (+$477.4 million), partially offset by a decrease in the estimating costs for a volume discount due to the quantity increase (-$129.8 million).

WIN-T Increment 2 – Program costs increased $1,354.8 million (+27.1%) from $4,997.8 million to $6,352.6 million, due primarily to a quantity increase of 630 communications nodes from 2,216 to 2,846 communications nodes (+$983.4 million) and a resulting increase in other support costs due to an additional year of procurement and the refinement of the fielding schedule (+$476.6 million). There are additional increases in the cost of government furnished software due to the transfer in procurement responsibility from the contractor to the government (+$89.5 million) and in non-recurring production costs due to additional platforms requiring integration (e.g., the Mine Resistant Ambush Protected Vehicle) (+$62.3 million). These increases are partially offset by reductions in contract costs due to definitized prices, quantity lot discounts, and a decrease in actual contract hardware costs (-$272.8 million).”

SAR – WIN-T-2 grows

March 16/11: WIN-T-2 General Dynamics C4 systems announces $295.8 million in WIN-T Increment 2 delivery orders, to equip 5 additional brigade combat teams (BCTs).

The US Army has now ordered Increment 2 systems for a total of 8 BCTs under a 3-year contract that was awarded in March 2010 (vid. April 5/10 entry).

Aug 2/10: Sub-contractors. General Dynamics awards Lockheed Martin a contract worth up to $400 million to provide communications hardware and equipment for the WIN-T Increment 2 transmission subsystem, which will enable the network to transfer data over dispersed areas. Equipment produced will include transmission subsystem radios, modems, antennas and mast systems. The initial award is valued at $71 million.

July 21/10: Testing. General Dynamics C4 Systems touts a recent 4-day U.S. Army Brigade Combat Team Integration exercise at White Sands Missile Range, NM. Its 7 realistic mission scenarios included WIN-T and JTRS radio systems, allowing widely dispersed Army units to exchange command-and-control messages, location information, voice, electronic chat and imagery while on the move.

May 13/10: WIN-T-3. General Dynamics C4 Systems announces a $12.4 million contract modification to develop a line-of-sight communications payload for the MQ-1C Extended Range/Multi-purpose (ER/MP) UAV to serve as a communication relay on the WIN-T Increment 3 network.

The payload will use the Highband Networking Waveform (HNW) to serve as a line-of-sight radio repeater while the UAS is in flight, which is especially useful to troops in urban environments, or other rugged terrain that block level line of sight.

April 5/10: General Dynamics C4 Systems in Taunton, MA receives a $164 million firm-fixed-price contract for WIN-T Increment 2 low-rate production, urgent 1st order, for the procurement of equipment for 3 brigade combat teams, 1 division headquarters, 4 regional hub nodes, and one base equipment complement to support the initial operational test and evaluation for WIN-T Increment 2.

Work is to be performed in Taunton, MA with an estimated completion date of June 30/10. The equipment then will undergo formal testing during 2011, culminating in an Initial Operational Test and Evaluation (IOT&E) in November 2011. One sole-source bid was solicited by the CECOM Acquisition Center in Fort Monmouth, NJ (W15PT-10-D-C007).

This 3-year contract has a total potential value of $2.8 billion, if all options are exercised. See also GDC4S release.

Increment 2 begins

FY 2002 – 2009

 

JNN-N

June 5/09: WIN-T. General Dynamics SATCOM Technologies receives a $119 million modification to an existing delivery order (W15P7T-06-D-L219) to provide satellite communications earth terminals and support services for Increment One of the US Army’s WIN-T program.

Under the contract, General Dynamics SATCOM Technologies will provide 293 satellite transportable terminals (STT), 6 unit hub SATCOM trucks (UHST) and 534 Ka-band upgrade kits and spares.

General Dynamics SATCOM Technologies’ work is being performed under an existing World Wide Satellite Systems delivery order, managed by the WIN-T program manager’s Commercial Satellite Terminal Program in Ft. Monmouth, NJ. This modification to the existing delivery order brings the contract’s total value to $378 million for 956 STTs and 17 UHSTs, which represent approximately half of the hardware quantities available on the 4-year program.

May 1/09: Boeing in Saint Louis, MO receives a $10 million cost-plus fixed-fee contract for WIN-T Point of Presence and the FCS Integrated Computer System (FCS ICS). They’re the Future Combat Systems lead integrator, and their task will be to integrate WIN-T functions (HAIPE & RFNM) and the Network Management System (NMS) with the FCS ICS on the program’s vehicles etc.

Work is to be performed in Bloomington, MN (93.02%), and St. Louis, MO (06.98%) with an estimated completion date of Dec 31/14. One bid was solicited with one bid received by TACOM Warren’s AMSXCC-TAC-AB in Warren, MI (W56HZV-05-C-0724).

April 6/09: WIN-T-2. General Dynamics announces that the US Army’s 4th Brigade – 2nd Infantry Division in Fort Lewis, WA, and 3rd Infantry Division in Fort Stewart, GA completed a limited user test of WIN-T Increment 2. A General Dynamics-led team supported the testing, during which soldiers from the 2 units planned and executed multiple missions, sharing command and control information from the command post down to the company level using WIN-T.

March 4/09: WIN-T-2. A General Dynamics-led team completes a developmental testing of the WIN-T Increment 2 on-the-move broadband networking capability. The test included building and operating a network comprising more than 35 network nodes. In a tactical environment, a network this size would support an Army division and associated brigade, battalion and company elements.

Feb 2/09: WIN-T. General Dynamics C4 Systems Inc. in Taunton, MA receives a $9 million cost-plus-award-fee contract, as part of WIN-T System Development & Demonstration. They’ll define, model, simulate, and demonstrate WIN-T System’s architecture in a field environment.

Work is being performed at Taunton, MA, and Gaithersburg, MD, with an estimated completion date of Sept 30/10. One bid was solicited by sole source and 1 bid received by the CECOM Acquisition Center in Fort Monmouth, NJ (DAAB07-02-C-F404).

Nov 3/08: General Dynamics C4 Systems announces delivery of the first WIN-T Increment 1 equipment to the US Army. Increment 1 builds on the former Joint Network Node-Network (JNN) and provides soldiers with a high-capacity communications network when they are stopped.

On schedule deliveries of WIN-T Increment 1 to the 5th Brigade, 2nd Infantry Division Stryker Brigade Combat Team (SBCT) at Ft. Lewis, WA, includes networking hubs, network management suites and network nodes. The equipment serves battalion, brigade and division/corps command posts and Expeditionary Signal Battalions.

1st WIN-T delivery

Sept 24/07: WIN-T. General Dynamics announces a $24 million contract from the U.S. Army Communications-Electronics Command in Fort Monmouth, NJ, to provide specialized JNN-N/ WIN-T Inc 1 satellite communications earth terminals and support services. Sources: GDC4S release.

Sept 18/07: WIN-T 2/3 development. A $921 million contract to the General Dynamics-Lockheed Martin WIN-T will develop WIN-T Increments 2 & 3. Sources: GD C4 Systems, Sept 27/07 release.

Win-T Increment 2 & 3 development

Aug 22/07: General Dynamics, Taunton, MA receives an $8.2 million increment as part of a $1,179,461,286 cost-plus-award-fee contract for the development of WIN-T.

Work will be performed in Taunton, MA (77%), and Gaithersburg, MD (23%), and is expected to be completed by June 30/10. Contract funds will not expire at the end of the current fiscal year. This was a sole source contract initiated on July 12, 2007. The U.S. Army Communications-Electronics Command, Fort Monmouth, NJ, is the contracting activity (DAAB07-02-C-F404).

July 10/07: General Dynamics, Taunton, MA receives a $22.5 million increment as part of a $1,069,909,287 cost-plus-award-fee contract for system development and demonstration for the architecture of the WIN-T system.

Work will be performed in Taunton, MA (40%), and Gaithersburg, MD (60%), and is expected to be completed by Sept. 30, 2011. Contract funds will not expire at the end of the current fiscal year. This was a sole source contract initiated on March 19, 2007. The U.S. Army Communications-Electronics Command, Fort Monmouth, NJ, is the contracting activity (DAAB07-02-C-F404).

June 2007: Restructured. The US Army restructures the WIN-T program into 4 major increments, after a formal cost breach under the terms of the USA’s Nunn-McCurdy legislation.

The former Joint Network Node (JNN) remains WIN-T Increment 1 from 2004, but it will add WGS satellite compatibility (1a) and some bandwidth management and security improvements (1b).

WIN-T Increment 2 development is valued at $126 million, to deliver initial on-the-move broadband networking using radio links that fail-over to SATCOM. Fielding is scheduled to begin in 2009.

WIN-T Increment 3 development is valued at $795 million. It will complete Increment 2’s goals and add better network capacity management, security and full on-the-move capabilities. Limited user testing is scheduled to begin in 2011. Increment Three also addresses the size, weight, power and cooling requirements for systems to be hosted in Future Combat Systems vehicles.

WIN-T Increment 4 is envisioned as an upgrades stage, based on new technology that includes enhanced satellite communications protection and compatibility with the ultra high-bandwidth T-SAT network. Sources: GD C4 Systems, Sept 27/07 release.

WIN-T Restructured

Feb 13/07: General Dynamics C4 Systems, Taunton, MA, was awarded on Feb. 8, 2007, a $44,102,000 increment as part of a $269,143,489 cost-plus-award-fee contract for a within scope change to the Warfighter Information Network – Tactical System Development and Demonstration.

Work will be performed in Taunton, MA (50%), and Gaithersburg, MD (50%), and is expected to be completed by June 30, 2007. Contract funds will not expire at the end of the current fiscal year. This was a sole source contract initiated on Jan. 5, 2007. The U.S. Army Communications-Electronics Command, Fort Monmouth, NJ, is the contracting activity (DAAB07-02-C-F404).

Sept 1/06: General Dynamics C4 Systems, Taunton, MA, was awarded on Aug. 28, 2006, a $7,259,000 increment as part of a $202,503,038 cost-plus-award-fee contract for an engineering change to the Warfighter Information Network – Tactical System Development and Demonstration.

Work will be performed in Taunton, MA (50%), and Gaithersburg, MD (50%), and is expected to be completed by Jan. 31, 2007. Contract funds will not expire at the end of the current fiscal year. This was a sole source contract initiated on Aug. 1, 2006. The U.S. Army Communications-Electronics Command, Fort Monmouth, NJ, is the contracting activity (DAAB07-02-C-F404).

June 3/05: General Dynamics C4 Systems, Taunton, MA, was awarded on June 2, 2005, a $7,632,000 increment as part of a $126,672,195 cost-plus-fixed-fee, cost-plus-award-fee, and time and materials contract for a further development of an initial architecture for the Warfighter Information Network Tactical Communication System.

Work will be performed in Taunton, MA (75%) and Gaithersburg, MD (25%), and is expected to be completed by Jan. 9, 2006. Contract funds will not expire at the end of the current fiscal year. There were an unknown number of bids solicited via the World Wide Web on April 8, 2002, and three bids were received. The U.S. Army Communications-Electronics Command, Fort Monmouth, NJ, is the contracting activity (DAAB07-02-C-F404).

Nov 12/04: General Dynamics C4 Systems, Taunton, MA, was awarded on Nov. 10, 2004, a $14,987,144 increment as part of a $112,579,352 cost plus fixed fee, cost plus award fee, and time and materials contract for development of an initial architecture for the Warfighter Information Network Tactical Communication System.

Work will be performed in Taunton, MA (75%) and Gaithersburg, MD (25%), and is expected to be completed by Jan. 9, 2006. Contract funds will not expire at the end of the current fiscal year. There were an unknown number of bids solicited via the World Wide Web on April 8, 2002, and three bids were received. The U.S. Army Communication-Electronics Command, Fort Monmouth, NJ, is the contracting activity (DAAB07-02-C-F404).

Aug 9/02: General Dynamics Government Systems Corp., Taunton, MA, is being awarded a $3,000,000 increment as part of a $72,294,296 cost-plus-fixed-fee and time and materials contract for development of an initial architecture for the Warfighter Information Network – Tactical communication system.

Work will be performed in Taunton and is to be completed by Jan. 9, 2006. Contract funds will not expire at the end of the current fiscal year. There were an unknown number of bids solicited via the World Wide Web on April 8, 2002, and three bids were received. The U. S. Army Communications-Electronics Command, Fort Monmouth, NJ, is the contracting activity (DAAB07-02-C-F404).

Additional Readings

• US Army PEO C3T – Project Manager WIN-T

• General Dynamics – WIN-T mini-site.

• US Army STAND TO! via WayBack – Capability Set 13 Fielding. 1st set with WIN-T Increment 2.

• Lockheed Martin – Warfighter Information Network – Tactical (WIN-T)

• Harris – Warfighter Information Network—Tactical (WIN-T)

• Global Security – Warfighter Information Network-Tactical (WIN-T)

News & Views

• DID – Taming the UAV Data Explosion

• Taunton Daily Gazette (Aug 30/13) – Guest Opinion: General Dynamic’s WIN-T program a good example of a good investment. By Sen. Elizabeth Warren [D-MA]. Given that it’s centered in her state, she’s hardly going to rubbish it…

• AFCEA’s SIGNAL Magazine (July 2012) – WIN-T Marches Forward. Very good overview.

• General Dynamics, via WayBack (June 5/09) – General Dynamics to Boost Military Satellite Communications Capacity with $119 Million Army WIN-T Satellite Terminal Award

• US Army 2008 Posture Statement Information Papers, via WayBack – Warfighter Information Network-Tactical

• C4ISR Journal (Sept 1/08) – Incremental improvement: Keeping tabs on U.S. Army’s reborn tactical network

• DID (May 23/06) – Platoon-Level IP: $73M to Datapath for Joint Network Node Support. Describes the JNN, which became WIN-T Increment 1.

• Federal Computer Weekly, via WayBack (April 2/07) – WIN-T to LOST-T? Compares and contrasts WIN-T with the success of JNN (which became WIN-T Inc 1). “WIN-T is intended to provide tactical units on the battlefield with broadband, IP-based voice, video and data communications, a job performed quite well during the past few years by the Joint Network Node at about a tenth of the cost of using commercial gear, including satellite terminals from DataPath and routers and voice-over-IP systems from Cisco.”

• Fort Monmouth Team C4ISR Knowledge Center, via WayBack (March 17/06) – Communications system developed here named winner

• Army Communicator, via Highbeam (Winter 2005) – Providing the bridge to the future network with commercial wideband SATCOM

• C4ISR Journal, via WayBack (Oct 29/04) – Joint Network Node Gives Soldiers More Mobile Communications, Increased Bandwidth

• Federal Computer Weekly, via WayBack (Nov 22/04) – Iraq-bound 3rd Infantry ready to share

• Military Information Technology, via WayBack (Oct 19/04) – Interim Mobile Communications System Readied for Iraq

Americas

The Air Force is procuring a number of high-definition targeting systems for its MQ-9 Reaper UAVs. Raytheon will produce 127 AN/DAS-4 Multi-Spectral Targeting System Model B (MTS-B) turrets and will upgrade 40 DAS-1A to DAS-4 turrets. The predominantly fixed-price-incentive contractual action for FY 2017 – FY 2018 has a value of $281.9 million. Raytheon’s MTS-B is an electro-optical infrared (EO/IR) and laser detecting-ranging-tracking set. The EO/IR system provides long-range surveillance, high-altitude target acquisition, tracking, range-finding, and laser designation for the Hellfire missile and other laser-guided munitions. MTS-B has been adapted for the high-altitude MQ-9, which has a flying ceiling of 50,000 feet. Work will bet performed at Raytheon’s facility in McKinney, Texas, and is expected to be completed by September 30, 2020.

More USMC AH-1Z Super Cobras will be equipped with new target sight systems. Lockheed Martin will manufacture a total of 5 AN/AAQ-30s under this $11.8 million firm-fixed-price modification. The Hawkeye XR is a third generation, state-of-the-art FLIR targeting system developed for the AH-1Z and fully integrates into the helicopter’s fire control system and TopOwl HMD. It provides range and optical line-of-sight data for all weapons, even AIM-9M Sidewinder air-to-air missiles. Work will be performed at the contractor’s facilities in Orlando, Florida and in Ocala, Florida. The contract is expected to end by January 2022.

The US Army is upgrading parts of its 2nd Cavalry Regiment in Germany. The Regiment will receive a new Common Remotely Operated Weapon Station configuration for its Stryker combat vehicles. From now on soldiers will be able to launch Javelin missiles from within the light-armored vehicle. Until now, if infantry troops wanted to engage mechanized targets, the Stryker would have to stop, the soldier would get out, fire the missile, and then jump back on. This upgrade is a US response to continuing Russian aggressions in Eastern-Europe. The integration of the Javelin into the RWS now puts the Stryker on par with Russia’s BMP-3 tracked infantry fighting vehicles.

Middle East & Africa

Kuwait is receiving technical support for its PATRIOT system as part of a US FMS. Raytheon is being awarded with a $9.8 million contract modification that provides for technical assistance, planning, training, maintenance and sustainment. The Phased Array Tracking Radar Intercept On Target missile system is a mainstay in many military inventories. At present, 12 nations have chosen it as a key component of their air and missile defense system. Kuwait currently has the latest PAC-3 configuration deployed. Work will be performed at Raytheon’s facility in Andover, Massachusetts and is estimated to be completed by end of December, 2019.

Europe

An Italian F-35A will be deployed to Belgian, where it will be presented in a static exposition at the Belgian Air Force Days. Italy is a Tier 2 partner in the JSF program and will likely buy up to 131 fighter aircraft. The Lightning II is currently competing against the F-16 and the Eurofighter, in a competition launched in 2017 by the Belgian Government to buy 34 new combat aircraft at an initial price of $3.1 billion.

Asia-Pacific

Jane’s reports that Indonesian state-owned aircraft manufacturer PT Dirgantara (PTDI) is currently developing a gunship variant of the CN-235 twin-engine multipurpose aircraft. Aerial gunships are extremely useful in a number of military scenarios, but most involve internal security, counter-insurgency, and special forces work. The new variant will be equipped with one 30mm DEFA 553 aircraft cannon and EO/IR targeting systems. A flying demonstrator is currently being manufactured and is slated to conduct its first flight in 2019.

The Russian Navy is currently conducting early research on engine designs for its Project 23000E Shtorm. Behind this ominous name hides a new nuclear-powered super-carrier, one of Russia’s most ambitious military programs. The principal design work for the new carrier is being undertaken by the St. Petersburg-based Nevskoye Planning and Design bureau, Russia’s primary designer of large surface warships. Project Shtorm was shrouded in mystery for several years until an initial concept was unveiled by the Krylovsky State Research Center (KRSC) back in 2015. The new super-carrier would displace close to 100.000 tons, 330 meters long, 40 meters wide and could launch 80-90 aircraft with an EMALS system. Considering the estimated program cost of $9 billion, it seems quite unlikely that economically weakened Russia will move beyond the design stage.

The Japanese government plans to spend about $118 million on missiles for its new guided missile destroyer Maya. The Aegis-equipped Maya will be commissioned in 2020 and will receive several SM-6 missiles. SM-6 integration is part of Japan’s Integrated Air and Missile Defense initiative that will intercept missiles through the integrated use of Aegis vessels, early-warning aircraft, radars and other equipment, mainly in view of the threats posed by cruise missiles owned by China and under development by North Korea. The SM-6 is the latest variant of Raytheon’s combat proven missile system. Integrated with the Aegis BMD the missiles provide protection against anti-ship and ballistic missiles.

Today’s Video Today’s Video

Watch: German Navy frigate cruises off the US coast

Americas

The US Navy is moving ahead with its planned acquisition of the MQ-25A UAV. Boeing is being awarded with an initial fixed-price-incentive-firm-target contract for the delivery of four unmanned aerial vehicles. The MQ-25A is a UAV tanker that is expected to reach its initial operational capability including the integration into the carrier air wing by 2024. A carrier-based UAV tanker would allow the USN to extend the range of its manned aircraft, including the F-35 Lightning II, F/A-18 Super Hornet and EA-18G Growler. The company will provide the design, development, fabrication and all necessary certification for the next generation aircraft. Work will be performed at multiple locations in the US, including Boeing’s facilities in St. Louis, Missouri and San Diego, California, and is scheduled for completion in August 2024.

Lockheed Martin is being awarded with a multi-million contract in support of the F-35 Lightning II aircraft. The modification has a value of $250 million and defintizes the pricing for the JSF Lot 11 production. The Lot 11 production contract sees for the delivery of 141 F-35s. Flight Global estimates that the current cost per unit of the F-35A Lot 11 is about $89 million. This contract combines purchases for the Air Force ($86.3 million), Marine Corps ($44.8 million), Navy ($36.8 million) and international FMS partners ($41.2 million). Work will be performed a multiple locations inside and outside the continental US. Locations include Lockheed’s facilities in Fort Worth, Texas and El Segundo, California, as well as locations in Norway and United Kingdom.

The Navy is stocking up on spares to keep its fleet of F/A-18 Super Hornets flying. The undefinitized contractual action delivery order with a one five-year option period has a value of $128.9 million. The F/A-18 series of multirole fighters is capable of operating from airstrips and aircraft carriers. It is designed for both air-superiority and land attack missions, and can carry a variety of ordnance ranging from air-to-air missiles and precision-guided bombs to standoff munitions. Work will be performed at Boeing’s facility in St. Louis, Missouri and is scheduled to run through November, 2021.

The USS Michael Monsoor is ready to sail again. Shipbuilder Bath Iron Works recently completed the replacement of one of the massive turbines needed to power the DDG-1001. The Navy decided to replace the unit after it noticed an unusual vibration during sea trials and discovered afterward that a foreign object had damaged some of the blades. The Zumwalt class destroyers are powered by two Rolls-Royce MT30 turbines, similar to those used on Boeing 777 passenger jets.

Middle East & Africa

The armed forces of Afghanistan will continue to receive ground vehicle support as part of a US FMS. The contract modification awarded to PAE Government Systems is valued at $138.5 million. The United States has been training and equipping the Afghan military and security forces since the early days of Operation Enduring Freedom, including thousands of light utility trucks and Humvee fighting vehicles. Work will be performed in HKIA, Afghanistan, with an estimated completion date of August 2022.

Israeli defense contractor Rafael is developing a new, fifth-generation version of its Spike-ER multipurpose precision-guided missile system. The 170 mm Spike ER2 will equip attack helicopters, combat vehicles, and small boats. The Spike ER2 is an upgrade of the 8-km Spike ER (Extended Range) missile. The missile also includes a new RF datalink variant to maximize the missile’s energetic range for enhanced stand-off launch from rotary platforms, enabling its 16-km range. It also contains an advanced seeker with high-resolution IR and day sensors for extended range target acquisition, and a multispectral target tracker, enabling sensory data fusion. Rafael plans to offer the Spike ER2 for the German Tiger Program.

Europe

Germany is determined to actualise its own version of a Defense Advanced Research Projects Agency. On Wednesday, the German government agreed to create a new cybersecurity agency tasked with innovating technology for defense purposes.The agency will be headed jointly by the Defense and Interior ministries and will eventually employ 100 people. The new shop is slated to get a budget of $230 million between 2019 and 2022. The German parliament, the Bundestag, will debate the proposal in the upcoming months. Once the funding is cleared, analysts will begin their work in earnest next year.

Asia-Pacific

The Taiwanese Navy plans to build brand-new fast-attack missile boats as an effort to strengthen the country’s asymmetric warfare capabilities in the face of a growing military imbalance in the Taiwan Strait. Shifting from its past heavy reliance on conventional forces, Taiwan will now focus on “quality, efficiency and precision over quantity”, an anonymous defense official told CAN. The 50-ton vessels are small, fast, agile and can be armed with anti-ship missiles, like the Hsiung Feng II. The development program has an overall value of $1.03 billion.

Today’s Video

Watch: German paratroopers jump from an A400M

Americas

Raytheon is being tapped to provide the US Navy with logistics services needed to maintain the night-vision systems installed on its rotor and tilt-rotor aircraft. The five-year performance-based logistics contract amounts to $59.7 million and sustains the availability of the Forward Looking Infrared (FLIR) systems installed on the CH-53 and V-22. The US Marine Corps currently has 165 CH-53 Super Stallions in service. The helicopter is equipped with the lightweight, high performance AN/AAQ-29A FLIR on a 12 inch turret. The FLIR pod helps helicopter pilots with low-level navigation to high altitude long-range targeting. The V-22 Osprey has a nose-mounted AN/AAQ-27 FLIR that provides navigation and target recognition capabilities in darkness and low-visibility conditions. Work will be performed at Raytheon’s facilities in McKinney, Texas; El Segundo, California and in Jackson, Florida.

The US Army is spending $491 million on generators. The firm-fixed-price contract awarded to Cummins Power Generation provides for the production of several Advanced Medium Mobile Power Sources (AAMPS). AAMPS has been developed under the Army’s Advanced State of the Art Power Components Program, which was devised to sustain a reliable electrical power availability on the battlefield. The current family of AMMPS consists of five versions: the 5 kW, 10kW, 15kW, 30kW, 60kW generators. In Afghanistan this new generation of generators saves about 300,000 gallons of fuel each month. The Army needs a reliable power network to control its tanks, aircraft and battle formations which heavily relies on electrical powered communication technologies. The contract is set to run until August 2022.

L-3 Communications will produce a number of Electro-Optic/Infrared/Laser Designator payloads for the US Army’s RQ-7Bv2 Shadow UASs. The firm-fixed-price contract is valued at $454 million and is expected to be completed by August, 2023. The Shadow v2 is the latest model of the Shadow series. It is an all-digital system, optimized for new multi-mission, single-sortie profiles and manned/unmanned teaming. The UAS has a wingspan of 20ft, and can provide a 9 hour coverage at altitudes of up to 18.000ft. L-3s payload will provide near-real-time reconnaissance, surveillance and target acquisition, as well as intelligence and battle damage assessment capabilities.

Aviall Services, a subsidiary of Boeing will provide the US and Australian Navies with essential components for the P-8A Poseidon. The $23.7 million firm-fixed-price contract procures six quick engine change & engine build up components. The engine’s used on the P-8 are designed so that the whole assembly can be removed from and replaced in the vehicle as a unit. Under the Quick Engine Change concept, if a unit requires a major engine job, the power plant can be removed and another one quickly installed. The Poseidon is powered by a CFM56-7B27AE engine is produced by CFM International belongs to the family of high-bypass turbofan aircraft engines. Work will be performed at the company’s facilities in Everett, Washington and Dallas, Texas. The US Navy and Australia will pay $15.8 and $7.9 million respectively. The contract expected to be completed in May 2020.

Middle East & Africa

The United Arab Emirates will receive a number of sensors, designators and processors for its AH-64E Apache helicopters as part of a US Foreign Military Sale. Lockheed Martin will produce modernized day sensor assembly (M-DSA) kits, laser range finder designators, and flight code processors at a cost of $44.8 million. The M-DSA, also known as Arrowhead, is an electro-optical and fire control system that the Apache helicopter pilots use for combat targeting of their Hellfire missiles and other weapons, as well as flying in day, night, or bad weather missions. Tin 2010, the UAE bought a total of 60 Apaches in a $5 billion deal. Work will be performed at the contractor’s location in Orlando, Florida and is scheduled for completion by the end of April, 2022.

Reuters reports, that Yemen’s Houthi rebels launched two Zelzal-1 missiles towards Saudi Arabia. The Zelzal-1 is part of Iran’s short-range missile systems. It is a solid-fuel heavy artillery rocket, that carries a 300 lb. warhead to a range of up to 100 miles. Saudi Arabia is leading a western-backed alliance of Sunni Muslim Arab states trying to restore the internationally recognized government of Yemeni President Abd-Rabbu Mansour Hadi, ousted from the capital Sanaa by the Iran-aligned Houthis in 2015.

Europe

One Hellenic Air Force pilot was killed when his T-2 Buckeye aircraft crashed during a routine training flight. The T-2 was once the Navy’s primary early flight training and carrier indoctrination aircraft. Every jet-qualified Naval Aviator and virtually every Naval Flight Officer from the late 1950s until 2004 received training in the T-2 Buckeye, a length of service spanning four decades. Greece bought a total of 40 T-2s. A statement by the Greek Air Force said the aircraft crashed due to mechanic failure 2 nautical miles south of the airport in Kalamata. The co-pilot survived by parachuting to safety. In the US, the Buckeye was replaced by the T-45 Goshawk.

Jane’s reports that the French SF 1/67 Pyrénées Helicopter Squadron is currently training with a new 20mm cannon installed on its multi-mission Caracal helicopters. The Caracal is a special variant of Eurocopter’s EC725 Cougar, specifically designed for or Combat Search and Rescue (CSAR) missions. Typically they are equipped with MAG 58 machine guns, which limit the helicopter’s in-air refueling capability. Nexter’s SH-20 retractable door mounting is built around the M621 cannon, and is designed to provide the Caracal with an air-to-ground fire-support capability. The unit expects to reach an operational capability in the coming weeks.

Asia-Pacific

China’s People’s Liberation Army Air Force (PLAAF) will soon receive the last batch of ten Sukhoi Su-35S from Russia. The Su-35s is Russia’s most advanced fighter aircraft, which can compete with America’s upgraded ‘teen series’, the JAS-39, the Rafale and the Eurofighter. The per-unit cost of the fighter jet, is estimated to be about $85 million. The Diplomat notes, that Russia was initially reluctant to sell the fighter jets to China as it feared Chinese reverse engineering the plane’s powerful thrust-vectoring engine. In 2015, China became the first international customer of the Su-35S when it ordered 24 jets for a total of $2.5 billion.

Today’s Video

Watch: When you should expect the Air Force to announce its next trainer aircraft

AH-64 & Arrowhead
(click to view full)

For much of the post-WWII era, US helicopter pilots have been trained to fly “low and fast.” This was based on combat experience in Korea and Vietnam. In the urban environments of Iraq and Afghanistan, however, flying low and fast has made helicopters more vulnerable to a number of threats: terrain, wires/powerlines, rocket propelled grenades, small arms fire, and shoulder-fired missiles.

Enter the Arrowhead system. Arrowhead is an electro-optical and fire control system that AH-64 Apache helicopter pilots use for combat targeting of their Hellfire missiles and other weapons, as well as flying in day, night, or bad weather missions. The system also provides accurate targeting at high altitudes, a practice that also has its drawbacks. This free-to-view Spotlight article covers the Arrowhead’s characteristics, components, contacts, consequences, and contracts.

Challenges of Urban Warfare

Flying Low and Fast
(click to view full)

“Low and fast” has been the mantra of US helicopter pilots for much of the post-war era. Flying low and fast enabled pilots to avoid radar-guided missiles and anti-aircraft artillery. Low-level flying also improved the survivability of the crew when something went wrong. If the helicopter had a mechanical problem or was hit by enemy fire, the pilot could ditch the helicopter more easily at a low altitude.

However, flying low and fast has made helicopters more vulnerable to a number of urban combat threats: terrain, wires/powerlines, rocket-propelled grenades, small arms fire, and MANPADS.

Losses suffered early on in Operation Iraqi Freedom (OIF) convinced the US Army that flying low and fast was contributing to high helicopter losses. For example, in the first 3 months of OIF, 12 US Army helicopters were shot down, all at 400 feet or below.

Instead, maintaining a high altitude allows pilots to avoid many of the urban combat threats. Staying above 500 feet enables pilots to avoid wires and power lines; above 1,500 feet, RPGs; and above 3,000 feet, small arms and light machine gun fire.

Fighting in an urban environment increases the need to carry out nighttime operations because insurgents often use nighttime maneuver for cover. Also, urban combat can involve operating in smokey environments caused by the enemy purposively setting fires to provide a smoke-filled veil or as a result of fires started in buildings from weapons.

As a result, the US military realized that helicopter pilots need the ability to see and target at a distance, through smoke and obscurants, and at night.

The Arrowhead Advantage

Apaches need arrowheads
(click to expand)

To provide these capabilities, the Army turned to Lockheed Martin to develop the Arrowhead sensor system. Arrowhead – also known as the Modernized Target Acquisition Designation Sight/ Pilot Night Vision System (M-TADS/PNVS) – is an electro-optical and fire control system that the Boeing-built AH-64 Apache helicopter pilots use for combat targeting of their Hellfire missiles and other weapons, as well as flying in day, night, or bad weather missions. The system enables pilots to target accurately at high altitudes. Check out this Discovery Channel video of the Apache with the Arrowhead system in action.

The Arrowhead system is provided as original equipment on new Apache helicopters, or as retrofit kits that upgrade the older version TADS/PNVS systems. Lockheed Martin rolled out the first Arrowhead system to the US Army in May 2005 and completed integration on the first Apache helicopters in June 2005. Over 1,000 Arrowhead systems will have been delivered with the completion of the Lot 7 contract, which extends production through April 2013. For details on the Lot 1-7 contracts, check out the Contracts and Key Events section below.

The Arrowhead system has 2 turrets [PDF]. The lower turret contains the targeting system, with day and night sensor assemblies. The day sensor assembly [PDF], which is undergoing modernization, incorporates a laser rangefinder designator, TV sensor, and laser spot tracker components.

The night sensor assembly includes the forward-looking infrared (FLIR) sensor that can see through haze and smoke and at night. The FLIR sensor has three fields-of-view, a multi-target tracker, multiple-code laser spot tracking, and internal boresight. Arrowhead’s electro-optics replace the older version TADS/PNVS direct-view optics with a TADS electronic display and control (TEDAC) unit.

The upper turret houses the pilot night vision system, which provides a long-wave, high-definition FLIR sensor with 52-degree wide field of view optics. The system’s processing algorithms give pilots sufficient resolution to avoid obstacles (including wires and trees) during low-level flight and at night.

Digital data from the FLIR sensor is displayed in the cockpit and on the pilot’s helmet-mounted display, providing high-resolution images. Arrowhead also has an image-intensified TV camera to aid aircraft pilotage in thermal environments and urban scenarios. The TV camera enables the pilots to see ground tracers, laser points and other signals from the ground. The system’s software combines imagery from the TV and the FLIR sensor into one multi-spectral image for the pilot and crew.

Particularly relevant for high-altitude flight is the Arrowhead system’s range for identifying targets. The system provides aircrews with a clear FLIR image at ranges greater than 5 miles. This range enables helicopter pilots to maintain an altitude above 2,500 feet and still provide firepower support to US soldiers on the ground.

Arrowhead also helps Apache pilots cope with brownout, which is reduced visibility caused by blinding sand and dust clouds churned up by the helicopter’s rotors. The US Army has lost 27 helicopters in brownout accidents since 2002, including the October 2009 crash of a special operations H-47 Chinook helicopter, which hit a hidden obstacle and crashed with 10 lives lost.

Commenting on the ability of Arrowhead to aid Apache pilots in brownout situations, Col. Mark Hayes, capabilities manager for the US Army Training and Doctrine Command, told the Army Times in April 2008:

“With MTADS [Arrowhead] we have far fewer challenges with obscurants than we had because the acuity of the system is so good. For example, it will see through rain. It will see through light fog. It will see through a certain amount of smoke.”

VNsight and Pathfinder

Pathfinder
click to play video

To provide enhanced night vision capabilities, Lockheed Martin offers the VNsight add-on for both the Arrowhead system and the Pathfinder system, which is a version of the Arrowhead system adapted for cargo and utility helicopters. VNsight provides enhanced visible light/ near infrared sensor capabilities that complement the long-wave infrared wavelength of the FLIR sensor.

Using the composite of VNsight and FLIR imagery, pilots can see cultural and military lighting (lasers, markers, beacons, tracer rounds, etc.) registered with the thermal image over the 30 by 52 degree field of view of the sensor. This improves situational awareness in low-light conditions and situations where existing light sources cannot be imaged by the FLIR. The capability to image all light sources with the VNsight sensor allows pilots to see laser pointers used to target laser-guided munitions.

As noted, the Pathfinder [pdf] system is a version of Arrowhead adapted for cargo and utility helicopters. The high-resolution FLIR imagery is projected onto the visor of the pilot’s helmet while the turreted sensor assembly is slewed to the helmet and is coordinated with the pilot’s head movements.

The Pathfinder system displays flight information on the helmet visor so that the pilot can maintain a head-up, eyes-out posture when operating in low visibility conditions. This approach maximizes the pilot’s unobstructed visibility (invisible cockpit), facilitates detection and avoidance of obstacles at lower altitudes and higher airspeeds; and provides the ability to identify and react to threats.

The Pathfinder turret mounts on the helicopter’s chin using a kit consisting of 3 line-replaceable modules. Eleven of the 14 line-replaceable modules are common with the Arrowhead. This creates synergy with the established Arrowhead production line and performance based logistics.

Lockheed Martin notes that Pathfinder is currently the only IR sensor system designed and developed specifically to support terrain flight (low level, contour, and nap-of-the-earth) and terminal operations in unimproved landing areas during reduced visibility conditions.

High-Flying Drawbacks

AH-64 Apache Flying High
(click to view larger)

The Arrowhead sensor enables Apache helicopters to maintain high altitudes, which allow crews to remain out of range of a number of urban combat threats.

However, high-altitude flight doesn’t come without problems. In a USMC Command and Staff College paper, Capt. A. C. Schilleci said that high-altitude flight prevents pilots from feeling and absorbing the intangibles of urban ground combat.

Also, he noted that if helicopter pilot training and experience focuses on high-altitude attack enabled by Arrowhead in an urban environment, the pilots might lose the ability to be effective in large-scale anti-armor missions, which could become the Achilles heel for attack aviation:

“The attack helicopter community must combine the fundamental tank killing successes achieved in Operation Desert Storm with the insurgent exploitability learned and gained in OIF/OEF with the M-TADS. Once this evolution is completely implemented and properly standardized throughout Army attack aviation, the ability to surgically strike our future armored enemies becomes limitless.”

Col. Jim Slife, a USAF special ops pilot, in a 2007 Armed Forces Journal article identifies a number of other high-altitude flight issues:

• Some helicopter missions, such as close air support (CAS), require low-altitude flight. With training, pilots could fly CAS missions from altitudes above 3,000 feet. This altitude would eliminate the environmental obstacles, as well as threats from small arms, light machine guns, rocket-propelled grenades, and the scourge of helicopter pilots, MANPADS.

• Flying at high altitudes can make it more difficult for helicopters to maintain visual contact and stay in formation, particularly if there is heavy cloud cover.

• Many helicopter countermeasure systems are optimize for operation at low altitudes and may not provide cover at high altitudes. Existing countermeasure system might have to be modified.

• A helicopter’s lifting performance is reduced with altitude. Helicopter engines run hotter at higher altitudes, which reduces performance. Also, the aerodynamic performance of rotor systems decreases in thinner air.

• At high altitudes, there is a blind spot under the helicopter that can’t be visually scanned. This makes the helicopter’s underbelly vulnerable to attack.

These disadvantages are obviously not a problem with the Arrowhead system per se, but an issue for high-altitude helicopter flight in general.

But the advantages of high-altitude flight, reducing the number of helicopters and crewmembers lost in combat, far outweigh the problems. And the Arrowhead system, with its targeting range and night time/bad weather viewing capabilities, enable pilots to opt for high-altitude and/or night flying, if the situation requires it.

Contracts and Key Events

Unless otherwise noted, Arrowhead contracts are awarded to Lockheed Martin Missiles and Fire Control in Orlando, FL, by the US Army Aviation and Missile Command in Redstone Arsenal, AL.

FY 2011 – 2018

August 31/18: UAE The United Arab Emirates will receive a number of sensors, designators and processors for its AH-64E Apache helicopters as part of a US Foreign Military Sale. Lockheed Martin will produce modernized day sensor assembly (M-DSA) kits, laser range finder designators, and flight code processors at a cost of $44.8 million. The M-DSA, also known as Arrowhead, is an electro-optical and fire control system that the Apache helicopter pilots use for combat targeting of their Hellfire missiles and other weapons, as well as flying in day, night, or bad weather missions. Tin 2010, the UAE bought a total of 60 Apaches in a $5 billion deal. Work will be performed at the contractor’s location in Orlando, Florida and is scheduled for completion by the end of April, 2022.

April 02/18: Egypt-FMS Lockheed Martin Corp. will provide Arrowhead upgrade kits in support of the Egyptian Air Force AH-64 Apache helicopter fleet. The contract modification is valued at $7.7 million. Work will be performed in Orlando, Florida and is scheduled for completion by October 2022. The AH-64A/D Apache has become a dominant attack helicopter around the globe, in service abroad with Britain, Egypt, Greece, Israel, Japan, Kuwait, the Netherlands, Saudi Arabia, Singapore, and the UAE. All are strong candidates for AH-64E upgrades at some point, and some have already placed formal export requests. The Arrowhead system is an electro-optical and fire control system that Apache helicopter pilots use for combat targeting of their Hellfire and other weapons, as well as flying in day, night, or bad weather missions. The system also provides accurate targeting at high altitudes. Egypt operates at least 45 Apache helicopters to help counter jihadists operating in the Sinai desert.

January 4/18: Egypt-FMS Egypt’s AH-64 Apache helicopter fleet will be fitted with Modernized Target Acquisition Designation Sight/Pilot Night Vision Sensor System (M-TADS/PNVS) kits, following the award of a foreign military sales (FMS) contract modification by the US Department of Defense (DoD) to Lockheed Martin. Work on the $25 million contract, which includes spares, will take place at Orlando, Florida, with an estimated completion date of April 30, 2020. The M-TADS/PNVS system is designed to integrate onto the AH-64 Apache, giving operators a long range, precision engagement and pilotage solution for day, night, and adverse weather missions. Egypt operates at least 45 Apache helicopters following orders in 2003 and a follow on order in 2009—the latter delivered in late 2014 to help counter jihadists operating in the Sinai desert after the sale was suspended after the military ousted the elected president Mohamed Morsi.

Sept 9/13: South Korea. The Longbow LLC joint venture in Orlando, FL receives a $51.1 million firm-fixed-price contract for 6 Longbow fire control radars, plus associated parts, spares and support. It’s part of Korea’s 36-helicopter buy, which has already seen orders for 36 helicopters, their engines, MTADS-PNVS surveillance and targeting turrets, and now a limited number of Longbow radars. Total announced so far: $1.236 billion, out of a $1.6 billion budget.

The Republic of Korea is the Longbow radar’s 10th international customer, and production under their order is scheduled through 2016. Work will be performed in Orlando, FL; Ocala, FL; and Baltimore, MD. US Army Contracting Command, Aviation at Redstone Arsenal, AL acts as South Korea’s agent (W58RGZ-13-C-0105). Sources: Pentagon | NGC & Lockheed releases, Sept 12/13.

South Korea: 6

Aug 8/13: 1M hours. Lockheed Martin and the U.S. Army officially celebrate 1 million flight hours for the M-TADS/PNVS “Arrowhead” system since 2005, during ceremonies held at Lockheed Martin’s Orlando, FL final assembly facility. The firm claims that:

“M-TADS/PNVS enhances system performance and reliability by more than 150 percent, reduces maintenance actions by nearly 60 percent, and will save the U.S. Army nearly $1 billion in operation and support costs over its 40-year system life.”

Aug 1/13: South Korea. Lockheed Martin Missiles and Fire Control in Orlando, FL receives a maximum $223.3 million contract to buy M-TADS/PNVS systems for South Korea (q.v. April 17/13). Lockheed Martin later confirms that this is the 1st announced contract in their 36-machine AH-64E order, covering 36 Arrowhead systems and spares, with production and delivery extending through 2018. Electronics assembly will take place at the Ocala, FL facility, with final assembly performed in Orlando, FL.

South Korea becomes the system’s 12th international customer. Oddly, the Pentagon release says that 3 bids were solicited, with 3 bids received. The system only has 1 manufacturer, and it would be very expensive to integrate a different system on the AH-64. US Army Contracting Command in Redstone Arsenal, AL acts as South Korea’s agent (W58RGZ-13-C-0104). Lockheed Martin.

March 8/13: Support. A $6.6 million firm-fixed-price contract to support the MTADS/PNVS. Work will be performed in Orlando, FL with an estimated completion date of Feb 28/14. One bid was solicited through the Internet, with 1 bid received (W58RGZ-13-C-0029).

Feb 13/13: Upgrades. Lockheed Martin announces 2 US Army production contracts totaling $161.7 million, to continue upgrades of the Modernized Target Acquisition Designation Sight/Pilot Night Vision Sensor (M-TADS/PNVS Arrowhead) program. This will continue production at Lockheed’s Ocala, FL facility until Q3 2016.

The Lot 2 and Lot 3 contracts cover 482 Modernized Day Sensor Assembly (M-DSA) Modernized Laser Rangefinder Designator (M-LRFD) kits and spares. 1st deliveries of the M-DSA and M-LRFD will happen in early 2013, as the result of the US Army’s February 2012 order. Lockheed Martin.

Dec 20/12: Support. A $96.7 million firm-fixed-price contract modification to support MTADS/PNVS. This is the 1st of 3 options under the July 26/12 contract, whose maximum 4-year value is apparently $375 million. Note the use of a fixed-price contract for support, in order to drive reliability and maintainability improvements.

Work will be performed in Orlando, with an estimated completion date of Dec 31/15. The bid was solicited through the Internet, with 1 bid received (W58RGZ-12-C-0009). See also Lockheed Martin.

Nov 1/12: An $18.3 million firm-fixed-price contract modification to buy MTADS/PNVS “Arrowhead” units. Work was performed in Orlando, FL; the listed completion date was Oct 22/12. One bid was solicited, with one bid received (W58RGZ-11-C-0120).

July 26/12: It’s announced as a $65.3 million firm-fixed-price contract “for the services in support of the Apache helicopter,” but that’s completely misleading. It’s actually the base award for a contract that could be worth up to $375 million over about 3 1/2 years, to provide fixed-price support for “Arrowhead” MTADS/PNVS units.

Work will be performed in Orlando, FL, with an estimated completion date of Dec 31/15. The bid was solicited through the Internet, with 1 bid received (W58RGZ-12-C-0009).

Multi-year support

Jan 5/12: Saudi Arrowheads. Lockheed Martin Missiles and Fire Control in Orlando, FL received a $66.6 million firm-fixed-price and cost-plus-fixed-fee contract. The award will provide for the procurement of AH-64D Apache M-TDAS/PNVS (“Arrowhead”) systems and spares for the Saudi Arabia National Guard. Work will be performed in Orlando, FL, with an estimated completion date of March 31/15. One bid was solicited, with 1 bid received by US Army Contracting Command in Redstone Arsenal, AL as the Saudi’s FMS agent (W58RGZ-11-C-0120).

This is one of several ancillary contracts supporting reports that Saudi Arabia has signed a deal to buy AH-64E helicopters. That deal wasn’t announced publicly, so it isn’t clear if other services may be covered. Beyond the SANG’s interest in buying 36 Apache Longbow Block IIIs, the Royal Guard wanted 10, and the regular Army wanted to add 24 AH-64Es to its existing fleet of 12 AH-64D Block IIs. See the Oct 20/10 DSCSA request for more.

Saudi buy

Dec 30/11: A $7.8 million firm-fixed-price and cost-plus-fixed-fee contract, buying Modernized Laser Range Finder Designator Lot 1 kits and associated spares. The contract is Arrowhead’s, and the system does use an LRFD module.

Work will be performed in Orlando, FL with an estimated completion date of April 30/14. One bid was solicited, with one bid received (W58RGZ-11-C-0120).

Nov 21/11: Support. Lockheed Martin Corp. in Orlando, FL received a $45.8 million firm-fixed-price contract for MTADS/PNVS support. Work will be performed in Orlando, FL, with an estimated completion date of Dec 31/12. One bid was solicited, with one bid received by the U.S. Army Contracting Command at Redstone Arsenal, AL (W58RGZ-12-C-0009).

Nov 9/11: Lot 8. A $163.7 million firm-fixed-price and cost-plus-fixed-fee contract modification buys more M-TADS/PNVS “Arrowheads”. Based on past contracts, this is Production Lot 8, and it will buy 110-140 systems.

Work will be performed in Orlando, FL, with an estimated completion date of Nov 30/14. One bid was solicited, with one bid received (W58RGZ-11-C-0120).

Lot 8?

Sept 7/11: Lockheed Martin Missiles and Fire Control in Orlando, FL receives a $15.3 million firm-fixed-price contract modification, buying M-TADS/PNVS “Arrowhead” surveillance and targeting turrets.

Work will be performed in Orlando, FL, with an estimated completion date of Nov 30/13. One bid was solicited, with one bid received, by U.S. Army Contracting Command at Redstone Arsenal, AL (W58RGZ-06-C-0169).

June 3/11: Support. A $48.8 million firm-fixed-price contract extends another 6 months of spares support for the AH-64 Apache’s original TADS/PNVS and modernized MTADS/Arrowhead.

Work will be performed in Orlando, FL, with an estimated completion date of Dec 31/11. One bid was solicited, with one bid received (W58RGZ-07-C-0058).

March 4/11: RESET. A $9.3 million firm-fixed-price contract for RESET support to include inspection, refurbishment, and removal of sand, dust and foreign material intrusion to the Apache Arrowhead sight. Work will be performed in Orlando, FL, with an estimated completion date of Feb 28/12. One bid was solicited with one bid received (W58RGZ-10-C-0023).

Dec 28/10: Retrofits. A $14.9 million firm-fixed-price contract for “the modification and application of B-kit to legacy and modified-legacy components of the [MTADS/PNVS].” A subsequent Lockheed Martin release explains this more clearly, as 1st Lot production of 65 VNsight visible/near infrared sensors for Arrowhead’s modernized pilot night vision sensor, plus spares. Upgrades will be performed as field retrofits, and the contract will equip 2 American AH-64 Apache helicopter battalions, plus an initial quantity of cameras and spares to outfit an unidentified foreign customer.

Work will be performed in Orlando, FL, with an estimated completion date of Dec 31/11. One bid was solicited with one bid received (W58RGZ-10-C-0023).

Dec 17/10: Support. A $48.8 million firm-fixed-price contract to support both legacy TADS/PNVS and Arrowhead systems. This includes tier 2/3 repair and maintenance of line replaceable units and line replaceable modules, to support the Apache’s sensors flying hours program. Work is to be completed in Orlando, FL, with an estimated completion date of June 30/11. One bid was solicited with one bid received (W58RGZ-07-C-0058).

Nov 1/10: Retrofits. Lockheed Martin announces a $65 million contract to modernize the day sensor assembly and associated electronics on the Apache’s M-TADS/PNVS (Arrowhead) system. The modernization includes upgrades to the multi-mode laser rangefinder/designator, visible color sensor, laser spot tracker, inertial measurement unit, modernized day sensor structure assembly and a potential for future laser pointer marker compatibility.

FY 2008 – 2010

 

Aug 17/10: Lot 7. Lockheed Martin announces a $260 million follow-on production contract for Production Lot 7 of the M-TADS/PNVS (Arrowhead) system. The Lot 7 contract includes new systems, Arrowhead kits that modernize existing TADS/PNVS turrets, and spares, for delivery to U.S. Army and “several international customers.” By the end of Lot 7, which extends production through April 2013, over 1,000 kits will have been delivered. Bob Gunning, Lockheed Martin Missile and Fire Control’s VP of Apache Fire Control was predictably enthusiastic, but with some content to it:

“Field Commanders describe Arrowhead as a game-changing system in combat. Maintenance time is down and operational time is up; reports from users are that performance has been terrific. We have a great team working the program for us as the Army prepares to modernize the remaining legacy components of the original TADS/PNVS system.”

Lot 7

April 14/10: A $46.2 million firm-fixed-price contract for the purchase of Arrowhead sensor systems for AH-64 Apache attack helicopter for several international customers. The orders are destined for Saudi Arabia, Egypt, and the Netherlands, which have all submitted requests to buy the Arrowhead systems via the US Defense Security Cooperation Agency (DSCA).

FMS buys

March 11/10: Retrofits. A 3-year, $36.8 million contract to upgrade existing TADS/PNVS systems on AH-64 Apache helicopters with the Arrowhead system. Work will performed at Lockheed Martin’s Arizona Support Center. The contract includes fielding activities, such as sending teams of support technicians to US Army Apache locations worldwide.

Feb 22/10: Support. A follow-on performance-based logistics (PBL) contract worth up to $90 million to support the existing TADS/PNVS and the Arrowhead M-TADS/PNVS systems on the AH-64 Apache helicopter. This is the 3rd option for the original PBL contract awarded in 2007 (see May 11/07 entry). Under the PBL contract, Lockheed Martin provides post-production supply chain management, including spares planning, procurement, repairs, maintenance, modifications and inventory management of fielded systems. The combined value of the initial PBL contract, and the first 2 options was $283.4 million.

Brit Apaches in Afghanistan
click to play video

Feb 16/10: UK Support. Lockheed Martin announces that AgustaWestland awarded the company a $49.5 million sustainment and support contract for the TADS/PNVS and M-TADS/PNVS systems on the UK Apache AH Mk-1 helicopter. Under the contact, Lockheed Martin will provide post-production services, including spare parts, in-country repair and technical services, as well as logistics, engineering and depot repair support. AgustaWestland provides support services for the UK Apache fleet to the UK Ministry of Defence. Support under this contract will continue through March 2014.

Britain: multi-year support sub-contract

July 27/09: A $142 million follow-on production contract (Lot 6) for the Arrowhead system. The contract includes 55 Arrowhead kits to update the TADS/PNVS systems on US Army Apache helicopters and “Apache helicopters for several international customers.”

With the completion of Lot 6, which extends production through December 2011, over 850 Arrowhead systems will have been delivered to the US Army and international.

Lot 6

July 14/09: Support. A follow-on performance-based logistics (PBL) contract worth up to $89 million to support the existing TADS/PNVS and the Arrowhead M-TADS/PNVS systems on the AH-64 Apache helicopter. Under the PBL contract, Lockheed Martin will provide post-production supply chain management, including spares planning, procurement, repairs, maintenance, modifications, and inventory management of fielded systems. The value of the original PBL contract was $117.8 million and the 1st option year contract was worth $76.6 million.

Dec 3/08: Upgrade. A 3-year, $16.9 million contract to modernize the laser transceiver in the Apache helicopter’s day sensor assembly (DSA) located in the Arrowhead’s lower turret (targeting system). The complete day sensor modernization program will be composed of 2 phases, with a separate contract for development and production in each phase. Phase 1 will complete modernization of the laser rangefinder/ designator and associated electronics, while Phase 2 will include modernization of the remaining DSA elements. Work will be performed in Orlando and Ocala, FL, with an estimated completion date of 2011.

July 14/08: Pathfinder. Lockheed Martin announces that its Pathfinder flight team established operations at Felker Army Airfield, Fort Eustis, VA, in preparation for the system’s developmental and limited-user evaluation by the US Army’s Aviation Applied Technology Directorate. Army aircrews will evaluate the Pathfinder system’s performance on an Army Reserve HH-60L Black Hawk MEDEVAC helicopter. Lockheed Martin will lead an industry team that includes BAE Systems, Elbit-Fort Worth and Thales.

July 9/08: Industrial. Lockheed Martin Missiles and Fire Control announces the opening of its Arizona Support Center to integrate Arrowhead M-TADS/PNVS systems into AH-64D Apache helicopters. The center will also provide repair services for the Arrowhead system and legacy TADS/PNVS systems.

April 7/08: A $172 million follow-on production contract (Lot 5) for the Arrowhead systems. The Lot 5 contract authorizes production of 126 Arrowhead kits and/or equivalent unit spares, foreign military sales kits and ground support equipment. With options, this will bring the total number of Arrowhead kits and/or systems to 785 to date.

Lot 5: 126

FY 2001 – 2007

 

May 11/07: Lockheed Martin announces a $380 million performance-based logistics (PBL) contract to support the TADS/PNVS and Arrowhead M-TADS/PNVS systems, worth up to $380 million over 4 years. The contract provides complete post-production supply chain management, including spares planning, procurement, repairs, maintenance, modifications and inventory management of fielded systems.

Support under this 4-year contract will continue through 2010. The first year’s contract value is expected to be approximately $123 million.

Multi-year support 2007-2010

March 5/07: A $311 million follow-on production contract (Lot 4) for the Arrowhead system for the AH-64 Apache helicopter. The Lot 4 agreement authorizes production of 158 Arrowhead kits for some of the remaining US Army and foreign military sales inventory, as well as Arrowhead systems for new wartime replacement helicopters, and spares for both types.

Lockheed Martin will produce Lot 4 in Orlando and Ocala, FL. The final deliveries for Lot 4 production will occur in December 2009.

Lot 4: 158

June 26/06: A $385.6 million follow-on production contract (Lot 3) for the Arrowhead system for the AH-64 Apache helicopter. The Lot 3 contract authorizes production of 219 Arrowhead kits plus spares for the US Army and foreign military sales.

Lockheed Martin will produce the Lot 3 systems in Orlando and Ocala, FL, with final deliveries of the upgraded helicopters in December 2010.

Lot 3: 219

Oct 3/05: Lockheed Martin announces delivery of its first 8 Arrowhead systems for the US Army’s AH-64D Apache helicopters.

The Lockheed Martin Arrowhead team outfitted the 8 helicopters at Boeing’s Apache production facility in Mesa, AZ. The Arrowhead-equipped Apache helicopters departed for Fort Hood in 2 flights beginning June 23/05.

1st deliveries

Aug 5/05: +13. A $75 million firm-fixed price contract for 13 modernized Arrowhead target sights & pilot’s night-vision sensors.

The work will be performed at Lockheed Martin’s Orlando, FL facilities and will be complete by Jan 13/08. The U.S. Army Aviation and Missile Command at Redstone Arsenal, AL manages the contract (W58RGZ-04-C-0302).

May 25/05: Lockheed Martin announces a $212 million contract from AgustaWestland to supply Arrowhead kits for the UK’s Apache AH Mk-1 helicopters.

The first UK Arrowhead kit will be delivered in April 2007. Flight testing is scheduled to begin in late spring 2007. Integration of Arrowhead on the first 4 UK helicopters is scheduled for completion in January 2009, and retrofit of the entire UK fleet is scheduled for completion by the end of 2010.

British retrofit buy

May 2/05: A $262.4 million Lot 2 modification to a firm-fixed-price production contract for Arrowhead units, with accompanying initial spares. Discussions confirmed that this is a finalized version of Lockheed Martin’s Feb 17/05 announcement, which had pegged the contract at $247 million for 97 Arrowhead systems, on behalf of the U.S. Army and Foreign Military Sales customers.

The subsequent Aug 5/05 announcement appears to bring the Lot 2 contract to $337.4 million for 110 MTADS/PNVS.

Work on Arrowhead production will be performed in Orlando, FL, and is expected to be complete by Oct 31/07. This was a sole source contract initiated on June 8/04 by US Army Aviation and Missile Command in Redstone Arsenal, AL. (W58RGZ-04-C-0302).

The Lot 2 deliveries will begin in July 2006. The Army’s first unit equipped with Arrowhead will be fielded in June 2005. Currently, the U.S. Army intends to buy 704 Arrowhead systems to outfit its AH-64 Apache fleet by 2011.

Lot 2: 110

Dec 8/03: A $260 million production contract (Lot 1) to supply Arrowhead systems for the AH-64 Apache helicopter fleet.

The Lot 1 contract is for 55 Arrowhead systems and initial spares, for the US Army and Foreign Military Sales customers, with deliveries beginning in March 2005.

Lot 1: 55

July 27/01: Lockheed Martin and Boeing announce the signing of an agreement to cooperate on the incorporation of the M-TADS/PNVS systems into AH-64 Apache helicopter. Boeing is the prime contractor on the multi-role combat helicopter while Lockheed Martin is developing Arrowhead for the Apache Longbow.

Cooperation agreement with Boeing

Additional Readings

• Lockheed Martin – M-TADS/PNVS (Arrowhead). Surveillance, targeting, and pilot vision system.

• DID – AH-64E Apache Guardian: The Once and Future Attack Helicopter. Will also be equipped with the Arrowhead.

• DID (June 9/06) – The Well-Equipped Apache: Longbows, Arrowheads & Hellfire

• Deagel.com – Arrowhead XR

• Wikipedia – Target Acquisition and Designation Sights, Pilot Night Vision System

• Aviationnews.eu (Feb 24/10) – Lockheed Martin Awarded Apache M-TADS/PNVS Performance Based Logistics Follow-On Contract

• Army Times (April 8/08) – Army vows infrared sensors for Longbow

• Armed Forces Journal (June 2007) – Shootdown solution

• MANPRINT newsletter (Spring/Summer 2007) – A MANPRINT Success Story: The Modernized Target Acquisition Sight/Pilot Night Vision Sensor

• Avionics magazine (Feb 1/07) – Arrowhead’s Vision Enhancement

• Army magazine (January 2006) – Modernized Target Acquisition Designation System Pilot Night Vision Sensor for the Apache

• USMC Command and Staff College (2005) – A Deadly Combination: Integration of the AH-64D M-TADS and High Altitude Tactics on the Modern Urban Battlefield [pdf]

• National Defense (July 1/01) – Gunship Sensors Optimized for Urban Warfare

Americas

Phoenix International Holdings is being tapped to provide the US Navy with the continued maintenance and operation of its Submarine Rescue Diving and Recompression System (SRDRS). The awarded cost-plus-fixed-fee modification has a value of $29.9 million and ensures that the rescue systems are maintained in a high state of readiness so that they can be rapidly deployed on a 24/7 basis. The SRDRS is a tethered, remotely-operated vehicle that is placed into the water and attaches to the disabled submarine’s hatch. It can be transported via sea, air and land, and doesn’t need a mother submarine or dedicated surface support ship, making it more more mobile than its predecessor. The system includes an air transportable rapid assessment/underwater work system, a decompression chamber system and a pressurized rescue module. The SRDRS was first delivered to the US Navy in 2008. Work will be performed at the contractor’s location in San Diego, California and will run through August 2019.

Jane’s reports that the US Navy plans to fast-track the integration of a new gun system onto the MH-60S. The MH-60S entered service in 2002 as a replacement for the US Navy’s Boeing CH-46D Sea Knight. Its roles encompass troop transport, search and rescue, and other standard roles. However their weapons package either includes the GAU-17 M134 Minigun or the GAU-21 .50 calibre heavy machine gun limiting the helicopter to either perform SAR or SUW missions. The new externally mounted gun system (EMGS) will bridge this gap, essentially making the MH-60S capable to simultaneously perform defensive air patrols while maintaining its SAR capability. Five n-flight live trials are planned for later this year.

The USS Abraham Lincoln is currently hosting several F-35Cs from the Strike Fighter Squadron 125. The pilots and aircraft are currently conducting their Operational Test-1 (OT-1) phase, which evaluates if the JSF is ready to operate within a carrier air wing. The C-variant of the JSF is the most expensive one and features 30% more wing area, larger tails and control areas and wingtip ailerons. Its structure is strengthened so that it can withstand hundreds of launch and recovery rounds. The F-35C is expected to be the US Navy’s high-end fighter, as well as its high-end strike aircraft. OT-1 helps give the Navy an assessment of how the aircraft would perform on deployment. Rear Adm. Dale Horan, director, Joint Strike Fighter Fleet Integration Office is asking, “Can we maintain it? Can we get the parts? Can we get it airborne? Can we repair it if it has a problem? ” Those are the kinds of things the Navy will have to figure out in the coming days and weeks.

Middle East & Africa

Qatar is currently in the process of building a new airbase. A senior Qatari Amiri Air Force official said that the new Tamim Airbase will host the country’s new Rafale, F-15s and Typhoons. Since 2014 the country’s airforce underwent a major modernization and overhaul process including the introduction of modern technology, upgraded airfields, the first class of female fighter pilots and the acquisition of new jets. Qatar has purchased a total of 35 F-15QAs at a cost of $12 billion, 24 Rafale jets for $7.8 billion and 24 Typhoons for $6.7 billion. In the coming years the Qatar Air Force will grow its fleet to a total of 96 aircraft, which is a significant leap from its current of 12 Mirage-2000s.

Europe

Defense News reports, that the US Air Force may soon deploy some of its MQ-9 Reapers to Romania’s 71st Air Base at Campia Turzii. According to a Air Force document the service is building a new $950 million hangar that will be able to house medium-altitude, long-endurance drones. The UAV in its ISR configuration will likely conduct support intelligence-gathering operations around eastern Europe and the Black Sea. The upcoming deployment of the Reapers will help the US to generate a real-time picture of Russian activities in the Black Sea. The UAVs will assist in monitoring what ships are moving in and out and can provide early warning of hostile activities.

The Czech Republic is set to boost its inventory with 62 Titus armored vehicles. The Titus is the result of a cooperation between Tatra Trucks and Nexter Systems. The Titus looks quite similar to other MRAP models with the engine at the front, the crew compartment in the middle and the troop’s area at the rear. The vehicle is highly adaptable and can be outfitted with any kind of RWS from 7.62mm to 20mm, and 40mm grenade launcher. Its 500hp engine powers it to a maximum speed of 64 mph and to ranges of up to 434 miles. According to a company press release, there is a number of versions of the vehicle available, ranging from a classic IFV through a mobile command post, armoured ambulance to communications, maintenance and evacuation vehicles. For police purposes, there are a number of modules, which can be used to quickly prepare a vehicle to fulfil specific roles, such as the SWAT module, the WCT module (Water Cannon Tank) or the riot control module. The deal has a total value of $303.1 million, with delivers expected for the years 2020-2025.

The UK Royal Marines are currently embarking their new Commando Merlin HC4 helicopters on HMS Queen Elizabeth as part of the carrier’s four-month ‘Westlant 18’ deployment. In the upcoming months the helicopters will be provide a SAR capability in support of F-35B trials. The UK is currently in the process of upgrading a total of 55 helicopters at cost of $3 billion. Of which, 25 AW101s are refurbished to the Merlin HC4 configuration, which includes cockpit modernizations and minor redesigns, plus standard naval changes like a folding rotor head, strengthened landing gear, deck lashing points, and a fast roping point for the Royal Marines.

Asia-Pacific

Russian daily newpaper Kommersant claims, that Algeria has voiced its intent to purchase 14 MiG-29M fighter jets. The new planes are set to replace the country’s Soviet-era MiG-29s. Over the last decade the Algerian Air Force was an avid costumer of Russian equipment. So far it bought 44 Su-30MKAs, 14 Mi-26T2s helicopters, 16 Yak-130 trainers and 42 Mi-28NE combat helicopters. The MiG-29 Fulcrum is a single-seat, highly maneuverable fighter aircraft designed to engage airborne targets such as aircraft, UAVs and cruise missiles and was designed as Soviet counterpart to US F-15s and F/A-18s. The upgraded M-version features a longer range, an in-flight refueling system, state-of-the-art equipment, redundant fly-by-ware system for improved safety and reliability, and higher weapon load. The potential deal has a value of $700-800 million.

Today’s Video

Watch: The Harrier – RAF’s Top Warplanes

Americas

Leidos is set to support the US Army’s Saturn Arch program. The company is being awarded with a $26.8 million contract modification that provides for a Quick Reaction Capability (QRC) Aircraft. Saturn Arch is the Army’s answer to an ever evolving threat posed by IED’s. It essentially is an effort to implement ISR capabilities to a special aircraft fitted with state of the art sensor technology to identify and assist in removing explosives from the battlefield. Aircraft used under Saturn Arch often include Bombardier Dash-8 planes that are outfitted with radar, imagers, and signal intelligence capabilities. Work will be at the company’s facility in Bridgewater, Virginia and is scheduled for completion in September 2019.

Raytheon is being contracted by the US Navy for work on the MQ-4C Triton UAS. The cost-reimbursable job order is valued at $9.3 million and allows for the production and fleet integration of the Triton multi-spectral targeting system (MTS). The MTS is a turreted EO/IR sensor used in maritime and overland ISR missions. According to a DoD notice, the sensor system will augment existing sensors that will enhance navigation as well as CSR, observation and interception missions. The system also provides long-range surveillance, target acquisition, tracking, range finding and laser designation for the Griffin and Paveway missiles and other forms of munitions. The Triton will have a minimum mission radius of 3,000 nautical miles, with a 10 hour time to on-station at 2,000 nmi mission radius, and autonomous flight through moderate icing or turbulence. Work will be performed at Raytheon’s facility in McKinney, Texas, and is expected to be completed by August 2020.

PeopleTec is being awarded with a $33.6 million contract for engineering and support efforts by the Missile Defense Agency. The contract has a two-year base value o $9 million and covers advisory and assistance services for international programs in the Ballistic Missile Defense System. These services also cover BMDS development, test, operations, infrastructure and acquisitions. Work will be carried out at multiple locations including the company’s location in Huntsville, Alabama and in Tel Aviv, Israel. Israel currently fields the Arrow-3 missile defense system that is a collaboration project between Boeing and IAI. The contract is set to run through September 2023.

Middle East & Africa

Israeli newspaper Haaretz reports that the country is moving ahead with the purchase of advanced ground-to-ground missiles that can reach ‘anywhere in the Middle-East’. The project was announced by Defense minister Avigdor Lieberman back in February and included an initial budget of $500 million to set up a new unit within the IDF’s ground forces. The new missile system will fill an operational gap that cannot be bridged by the US-made MLRS. The project could cost up to $2 billion, spread out over a decade, depending on the number of missiles the Israeli military will acquire. The focus on developing new ground-to-ground capabilities stems from an ever increasing threat to Israeli aircraft by advanced air-defense systems deployed in Syria and elsewhere.

It seems that Turkey will be banned from purchasing the F-35s for the foreseeable future. The latest bill was put forward by Maryland Senator Chris Van Hollen and prohibits the transfer of the fighter jets to Turkey as long as it cannot be guaranteed that the country will not be purchasing the S-400 air-defense system from Russia. As Jane’s notes, US defense officials are concerned that Turkey operating the S-400 in the vicinity of the F-35 would compromise the aircraft’s security, including its stealth capabilities, and represent a strategic threat to the United States. Turkey is a Tier 3 partner in the JSF program and initially planned to order about 100 F-35As as replacement for its 240-plane F-16 fleet. The overall program is expected to cost around $16 billion. Currently it is uncertain if the Van Hollen’s amendment will become law.

Europe

The Romanian government is moving ahead with its planned acquisition of anti-ship missiles that are to be deployed to the country’s Black Sea coast. Potential bidders include Boeing, MBDA, Kongsberg and Saab, which are offering the Harpoon, Exocet MM40, the NSM and RBS-15 Mk3 respectively. The sub-sonic, sea-skimming GM-84 Harpoon is the standard anti-shipping missile used by the US Navy, and its variants are in service with 27 navies around the world. The MM40 missile is an upgraded version of the MM38 that began development in 1976, it has an inertial navigation system, an active radar seeker, and is equipped with a high explosive fragmentation warhead. The stealth-enhanced NSM aims to be a germination beyond the Harpoon, an air-launched version is being developed for the F-35. RBS-15 fire-and-forget missiles have a longer reach and heavier punch than counterparts like the Harpoon. The contract has a value of $159 million and is scheduled to be financed in the years 2018-2023.

European NATO members are currently stockpiling air-to-ground precision guided munitions with the help of the US. The project is being run by the NATO Support and Procurement Agency (NSPA) and will reduce dependence on the US in the case of prolonged air-operations. The initial order of $20 million JDAM and Paveway kits are part of a larger US FMS worth about $231 million. During the 2011 intervention in Libya several countries ran out of munitions and found it difficult to use those of other air forces.

Asia-Pacific

The Australian Ministry of Defense is confirming that it will arm its Boxer combat reconnaissance vehicles with the Spike LR2. The country is procuring a total of 211 Rheinmetall Boxers under its Land 400 Phase 2 program. The Spike LR2 is produced by Israeli defense contractor Rafael and is the latest member of the multi-purpose missile family. The missile has the capability to destroy a number of different targets including MBTs with reactive armor and fortified structures. The LR2 is equipped with a passive and uncooled multi-band seeker that integrates both thermal and HD imagery and includes a smart target tracker with AI features, allowing the missile to track and target automatically.

Today’s Video

Watch: PAF JF-17 performs at Radom airshow

ADM-160B/C MALD
(click to view full)

The Bosnian “Nighthawk Down” incident in 1999 showed that even old air defense systems could still be dangerous, and that smart tactics and selective use could keep those systems alive against heavy opposition. The challenge is finding them and targeting them. Against truly advanced air defense systems like the Russian SA-20 family, however, the challenge is survival. Advanced stealth technologies, advanced anti-radar weapons, and successful electronic jamming are required.

Air-launched decoys can help, and they are not a new concept by any means. The same technologies used in cruise missiles allow construction of “stealth in reverse” decoys that fly long distances along pre-planned flight patterns, carrying radar reflectors that simulate the radar return of fighter or bomber aircraft. Enemy air defenses see them as incoming aircraft, and must decide to either shut down and hide, or activate and reveal their position. If American aircraft are flying behind a wave a decoys, either option can be dangerous. The USAF’s ADM-160B/C Miniature Air-Launched Decoy (MALD) program began as a DARPA effort in 1996, but made it all the way into production, and is branching out into new fields. The US Navy already has their own ITALD, but they liked one of the new MALD variants enough to add it, too.

MALD and Its Variants

MALDs, loading

The ADM-160 MALD has changed over its program lifespan. One big change was required range, which forced the Air Force to move to a larger decoy. That led to a re-compete, which Raytheon won from original incumbent Northrop Grumman in 2003. Prices have increased along with size and capability, from $30,000 to $120,000 per decoy. This is still much cheaper than a $70 million fighter. Range for the 300 pound system has also increased, to 500 nm/ 575 miles, with the ability to loiter over targets.

With its range and loiter time, however, MALD lends itself to other uses as well. One obvious use is to install radar jamming equipment, instead of radar reflecting equipment. The resulting system can add realism to an incoming wave of MALD decoys while neutralizing specific threats, or fly ahead on a mission of its own. The “MALD-J” electronics will have to be powerful enough to be useful, however, while remaining small and light enough to fit into a 300 pound MALD decoy.

MALD, JSOW & HARM

The USAF wants to explore those possibilities. Raytheon received a 2-year, $80 million US Air Force contract for MALD-J Phase II risk reduction in April 2008, and MALD-J received its milestone C go-ahead into low-rate production in November 2011. Deliveries begun in the fall of 2012, for use with USAF F-16 fighters and B-52H bombers. Meanwhile, the US Navy is working to integrate it with its regular F/A-18E/F Super Hornet fighter fleet, as a lower-end alternative to its dedicated EA-18G Growler electronic attack variant.

A 3rd MALD type, MALD-V, would have an open payload space for insertion of modular surveillance gear, jammers, or other equipment. This may provide the go-forward architecture, and give customers the option of turning MALD into a UAV, or even a hunter-killer that homes in and destroys radars targeting it. But after several test failures in 2010/11, the Air Force clipped the program’s wings by terminating research on MALD-J Increment II.

Program Timeline

Industrial Team

More than 125 Raytheon employees design and build the MALD and MALD-J in Tucson, AZ; Goleta, CA; and El Segundo, CA. Key suppliers for MALD and MALD-J components include:

• AUSCO in Port Washington, NY
  
• Advanced Industries Inc. in Wichita, KS
  
• CEI in Sacramento, CA
  
• Celestica in Austin, TX
  
• Eagle Pitcher in Joplin, MO
  
• EDO in Bohemia, NY
  
• Enser in Pinellas Park, FL
  
• Engineered Fabrics Corp in Rockmart, GA
  
• GDOTS in Redmond, WA
  
• Hamilton-Sundstrand in Rockford, IL & San Diego, CA
  
• LaBarge in Joplin, MO
  
• Moog in East Aurora, NY
  
• Tecom in Westlake Village, CA
  
• Teledyne Microelectronics in Los Angeles, CA
  
• Daico, in Carson, CA
  
• Cobham in San Diego, CA

Boeing and Lockheed Martin don’t supply components, but will be responsible for making MALDs work with their respective aircraft.

Contracts and Key Events FY 2018

DOTE not sure about navigational accuracy. Lot 7 and beyond. Radio link.

August 28/18: Decoys The US Strategic Capabilities Office (SCO) has achieved a milestone in its Miniature Air-Launched Decoy X (MALD-X) development. MALD-X decoys are mini-cruise missiles, which are used to distract and deceive an enemy air defense system so that a real strike package can succeed and survive. The ‘stealth in reverse’ decoys fly long distances along pre-planned flight patterns, carrying radar reflectors that simulate the radar return of fighter or bomber aircraft. MALD-X enhances the modular nature of the mini cruise missile with the ability to accommodate different electronic warfare payloads that are more advanced than those found on its predecessors. A series of flight demonstrations were recently held at Naval Air Warfare Center Point Mugu, with additional tests to take place next year. Raytheon was awarded $34.8 million by the USAF to develop a new version in 2016.

FY 2014 – 2016

July 12/16: Raytheon has secured a $34.8 million USAF contract to modify its ADM-160 Miniature Air-Launched Decoy (MALD) for carriage on the Navy’s F/A-18E/F. Used currently on USAF F-16 and B-52s, the MALD deceives adversaries by replicating the signature of friendly aircraft, and the new development will see it receive an improved electronic warfare payload, the ability to carry out low-altitude flight, and an enhanced net-enabled datalink. The development will last for 24 months and see two demonstrations of the system.

September 11/15: Raytheon and the Navy have demonstrated the use of electronic warfare payloads fitted to the Miniature Air Launched Decoy – Jammer (MALD-J), with the system tested through a dozen different mission profiles. Known as Cerberus, the open architecture system was tested during Exercise Northern Edge in June. The tests showed how the payloads could be swapped into the MALD-J vehicle rapidly, using adapted motor sport technology.

Dec 9/14: data link. Almost 6 years after a January 2009 award to study the feasibility of adding a data link to MALD-J, Raytheon announces that it has conducted successful tests of that capability with the US Marines in Yuma, AZ. The benefit is to allow in-flight targeting adjustments.

Oct 15/14: Lot 9-11. The Air Force intends to award multiple sole source contracts for a total of $471M to Raytheon Missile Systems (RMS) for MALD-J lots 9-11; parts obsolescence management, sustainment, aircraft integration, non-warranty repair, technical support, and development of any future variants based on the MALD design.

June 30/14: USAF procurement. The Air Force releases a justification & approval document dated Oct. 31/12 that explains how lots 7 to 10 plan to procure 200 units each year from 2014 to 2017, on a Firm Fixed Price basis. Lots 7 and beyond should be contracted under a 10-year warranty, like lots 5 and 6, vs. 15 years for the first 4 lots. Source: FBO [PDF].

June 27/14: Lot 7. RMS is awarded a $80.8 million firm-fixed-price and cost-plus-fixed-fee contract for the Lot 7 Miniature Air Launched Decoy Jammer (MALD-J) missile that includes data, mission planning, process verification program, and operational flight software. Work will be performed at Tucson, AZ, and is expected to be completed by June 30, 2016. Fiscal 2012, 2013 and 2014 procurement and operations and maintenance funds are being obligated in the amount of $79,112,476 at time of award. Air Force Life Cycle Management Center/EBJM, Eglin Air Force Base, FL, is the contracting activity (FA8682-14-C-0004).

shoot these drones

May 2014: state of program. Raytheon says it has delivered a total of 1,000 MALD-Js, and all 33 flights performed during the past 2 years were successful, without elaborating on the success criteria.

January 2014: DOTE. The Pentagon’s Office of the Director, Operational Test and Evaluation, released its FY2013 report, with a section on problem discovery affecting OT&E. On MALD-J:

“All MALD-J vehicles launched during developmental testing performed within the navigational accuracy requirements. During IOT&E at an open-air flight test range (a more challenging operationally representative environment), several MALD-J vehicles experienced unexpected navigational accuracy issues. There were several different causes of the navigational errors, all classified, but all arose from technical performance issues that should have been uncovered during developmental testing.”

There is also a dedicated brief [PDF] on the program that details test activity so far.

FY 2011 – 2013

Milestone C for MALD-J; Lot 4-6 orders are all MALD-Js; Work begins to add MALD-J to MQ-9 UAVs, F/A-18E/F Super Hornets, and transport aircraft; MALD-J Increment II terminated; MALD-V for surveillance? IOT&E.

MALD CONOPS

April 22/13: Lot 6. Raytheon announces a USAF contract for 202 more MALD-Js and containers as Production Lot 6. It was exercised as an option under the Lot 5 contract “in Raytheon’s first quarter of 2013.”

As usual, contract work will take place primarily at Raytheon’s missile facility in Tucson, AZ.

Feb 13/13: MQ-9 UAVs. Raytheon Company and General Atomics Aeronautical Systems, Inc. announce that they’re working to integrate MALD/MALD-J decoys onto the MQ-9 Reaper UAV. The Reaper’s slow speed means that their use would need to be timed well, and arranged carefully so as not to make their mission obvious. On the other hand, the Israelis have made an art form out of using drones to provoke air defense batteries into using their radars and communications, then harvesting the emissions for analysis and counter-programming. Enough of that in advance, and the MALDs could just look like the big killer strike wave has finally arrived.

Ground Verification Test phase completed in November 2012 at GA-ASI’s Gray Butte Flight Operations Facility in Palmdale, CaA. Integration is estimated to conclude in 2013.

Aug 22/12: Lot 5. An $81.8M firm-fixed price contract for MALD-Js, to be completed by the end of August 2014 (FA8682-12-C-0002). FBO.gov.

July 6/12: F/A-18E/Fs. Raytheon announces that the MALD-J has begun integration with the US Navy’s F/A-18E/F Super Hornets. That will involve additional tests and demonstrations once work is finished to tie it into the Super Hornet’s systems. Meanwhile, the USAF is preparing to begin receiving MALD-Js for its F-16s and B-52s by the end of 2012.

The dedicated EA-18G Growler electronic warfare fighter doesn’t have the space to add MALD-J without badly compromising its range, but MALD-Js on regular Super Hornet fighters will give the US Navy additional electronic attack options beyond the Growler fleet.

June 01/12: In an interview with Defense Daily, Raytheon business development manager Jeffrey White defends the program, thanks to several successful tests so far this year. He adds that swarms of up to 192 decoys can be loaded on and dumped from heavy transport aircraft (see May 25/11 entry on MCALS). Now wouldn’t that be nice for business?

March 29/12: GAO report. The Government Accountability Office reviews the Pentagon’s airborne electronic attack efforts and starts its section on underperforming programs with MALD/MALD-J:

“In September 2011, citing ‘successful completion of MALD-J engineering and manufacturing development activities,’ the Air Force exercised a priced option to upgrade 240 of its planned MALD units to the MALD-J configuration, subsequently decreasing MALD quantities to 596. Because all future production lots are now planned as jammer-configured decoys (MALD-J), the 596 total represents the full MALD procurement – without the program having ever met the criteria necessary to proceed into full rate production. Since the MALD and MALD-J designs are identical – except for the addition of a jammer module to MALD-J–the absence of a proven manufacturing process for MALD introduces schedule risk to production of MALD-J.”

February 27/12: The FY 2013 President Budget terminates work on MALD-J Increment II. The USAF had previously planned to spend $272 million in order to develop this new version, which was intended to improve sensitivity and jamming power.

No MALD-J Increment II

Dec 2011: DOTE. The Director, Operational Test & Evaluation, issues its annual report [PDF]. They are satisfied by the Air Force’s follow-up on past recommendations, but urge a change to the Concept of Operations (CONOPS) so that some decoys can be used during exercises and training. The current CONOPS doesn’t allow that because of the device’s expendable nature. Overall, 2011 has been a better year for MALD-J than MALD.

Nov 29/11: Raytheon announces that the USAF has approved the MALD-J jammer variant for Milestone C, clearing it to enter Low Rate Initial Production. They also exercised a $5 million contract option, to convert Lot 4 production of the baseline MALDs into MALD-Js.

Milestone C

Sept 6/11: Raytheon touts a successful test with multiple MALD-Js in both free-flight and carry modes, simulating an electronic attack. That’s the last major hurdle toward a Functional Configuration Audit, and once that’s official, the USAF could authorize Milestone C and begin production by the end of 2011.

June 29/11: Boeing touts the first MALD-J powered launch “earlier this month” from a B-52 flying over the Gulf of Mexico, at the Eglin Air Force Base, FL test range. Boeing designed the avionics software on board the B-52 that controls and launches Raytheon’s MALD-J. Boeing.

May 27/11: LRIP-4. Raytheon Missile Co. in Tucson, AZ receives an $83 million firm-fixed-price contract modification MALD low rate initial production lot four (LRIP-4) production.

Work will be performed at Tucson, AZ. The contract is managed by the AAC/EBJM at Eglin Air Force Base, FL (FA8682-10-C-0007, PO 0019).

May 27/11: MALD-J/V. A Flight International article discusses US Navy interest in the USAF’s jammer variant, and notes work on a MALD-V, with an empty payload compartment that could carry surveillance payloads as well.

May 25/11: MALD MCALS. Raytheon announces that they’ve launched two MALD “instrumented shapes” from the ramp of a C-130 Hercules, using the new Raytheon-funded MALD Cargo Air Launched System (MCALS).

Adding cargo aircraft as a platform would offer many more options for using MALDs, on both combat strike and cargo missions. MCALS’ steel, birdcage-like framework body sits on a standard cargo pallet, and can hold as many as 8 MALDs. At a pre-determined altitude, the ramp is opened and MCALS rapidly ejects the MALDs, which then initiate a standard wing deployment and engine ignition sequence.

March 10/11: The US Navy posts FedBizOpps notice #N0016411RWS47: “14–SOLE SOURCE – MINIATURE AIR LAUNCHED DECOY (MALD)/ MINIATURE AIR LAUNCHED DECOY JAMMER (MALDJ)”:

“Naval Surface Warfare Center (NSWC) Crane Division plans to enter into a five year Basic Ordering Agreement (BOA) with Raytheon Missile Systems… ceiling in the amount of [$12.5 million, for] engineering, logistics and test support, test item hardware and software, support equipment hardware and software, prototypes, test and assembly fixtures, repair services, training, and various data products. This requirement will be negotiated on a sole source basis in accordance with the statutory authority 10 U.S.C. 2304(c)(1) as implemented by FAR 6.302-1… The POC for information regarding this requirement is Mr. Matthew Lucas, Code CXMN, telephone (812)854-8864, fax 812-854-3805 or send a request via e-mail (E-MAIL preferred)…”

FY 2006 – 2010

MALD-J: From initial R&D to EMD contract and free flight; MALD free-flight from F-16; USAF reaches initial target level for MALDs.

MALD
(click to view full)

May 5/10: LRIP-3. Raytheon Co. in Tucson, AZ receives a $96.7 million MALD low rate initial production contract for a 24-month effort, to include operational test and evaluation. Raytheon expects to supply 300 MALD decoys. At this time, $89.8 million has been committed by the 692th ARSS/PK at Eglin Air Force Base, FL (FA8682-10-C-0007).

Raytheon has already delivered more than 100 units to the USAF, and this Lot-III order for 300 is nearly equal to the total of Lots I and II combined. Additionally, the contract requires the delivery of the MALD-Jammer, in preparation for the MALD-J initial operational test and evaluation phase. Raytheon release

April 30/10: MALD-J EMD. Raytheon Co. in Tucson, AZ receives a $53.1 million contract to develop the MALD-J active jamming variant. This includes the associated engineering, program management, supportability, mission planning, modeling and simulation, hardware fabrication, production readiness, software and testing efforts. At this time, $24.5 million has been committed by the 692th ARSS/PK at Eglin Air Force Base, FL (FA8682-10-C-0010).

During EMD, Raytheon will put MALD-J through an aggressive series of free-flight and captive-carry tests, in order to meet the required operational availability date of 2012. Raytheon states that MALD-J has successfully completed all 27 test events so far, culminating in a free-flight test in December 2009, and a 2nd free-flight test April 27/10. Production is expected to begin in 2011. Ken Watson, the U.S. Air Force’s MALD program manager, explains the stakes:

“In executing the MALD-J program, Raytheon has been ahead of schedule and under budget for 39 months in a row… The success of this program is crucial because it will reduce or eliminate the need for manned stand-in jamming aircraft.”

MALD-J EMD

March 31/10: MALD. Raytheon announces that they have now delivered “an operationally significant quantity” of MALD decoys to the USAF, allowing the service to reach its “required assets available” as scheduled. Raytheon had committed to a 2010 delivery schedule in 2003.

Raytheon will continue to deliver additional MALDs to the U.S. Air Force, and expects to deliver its first system to the U.S. Air Force in 2012. It also says that it “continues to make progress developing a jamming variant of the MALD.”

Feb 18/10: MALD-J. Raytheon announces that the USAF completed a critical design review (CDR) for the MALD-J variant. Passing the CDR follows completion of the 1st MALD-J free-flight test in December 2009. This sets the stage for a final system design and development and low rate initial production.

MALD-J CDR

Jan 13/10: MALD-J. Raytheon announces that the USAF completed the 1st free-flight test of the MALD-J variant. The test demonstrated that the MALD-J has reached a technology readiness level 7 and sets the stage for the system to enter engineeing and manufacturing development. The Feb 18/10 announcement notes that the free-flight test was conducted in December 2009.

June 14/09: MALD-J. Raytheon announces that the company and the USAF completed a preliminary design review of the MALD-J variant.

MALD-J PDR

March 17/09: MALD-J. Raytheon announces that the USAF accepted delivery of the 1st MALD low-rate initial production unit. With this delivery, Raytheon said that it is on schedule to meet the USAF required asset availability date of March 2010.

1st MALD-J delivery

Jan 15/09: Datalink? Raytheon announces that it received a $12.2 million USAF contract to study the feasibility of increasing power and adding a data link capability for the MALD-J. The contract requires Raytheon to integrate a data link and more powerful jammer amplifiers into the baseline MALD/MALD-J vehicle. Raytheon will also determine the technical feasibility and performance capability of MALD-J Block II prior to building and flight testing the new vehicle.

April 9/08: MALD-J. Raytheon announces that it received a 2-year, $80 million contract from the USAF for Phase II risk reduction for the MALD-J. The contract calls for Raytheon to further develop, integrate and test the MALD-J variant.

MALD-J Phase II Dev

Feb 26/08: MALD. Raytheon announces that MALD completed government and Raytheon verification team flight testing on Jan 11/08. This sets the stage for MALD to enter low-rate initial production later in 2008. The testing, which began in June 2007, put the MALD through a series of flight profiles including jettison and powered flight tests from both F-16 and B-52 aircraft.

MALD flight testing

Oct 24/06: MALD. Raytheon announces that a series of MALD vehicles have demonstrated successful separation when launched from an F-16 fighter. The flight tests took place at Eglin Air Force Base, FL, under a development contract managed by the 728th Armament Systems Group. In total, 9 free-flight launches took place from May to July 2006 at Eglin.

Additional Readings

• Raytheon – Miniature Air Launched Decoy. See also brochure [PDF]

• GlobalSecurity.org – Miniature Air-Launched Decoy

• Deagle.com – MALD-J

• Wapedia – ADM-160 MALD

• Designation Systems – Northrop Grumman (Teledyne Ryan) ADM-160A MALD/ Raytheon ADM-160B/C MALD

L12 & LCVPs
(click to view full)

The 22,500t HMS Ocean is similar to some of the smaller LHD designs like the 21,300t French Mistral Class. Built to commercial standards, LPH01/ L12 carries a crew of 255, an aircrew of 206, and 480 Royal Marine Commandos; an additional 320 marines can be accommodated in a short-term emergency. The ship has capacity for 40 vehicles, but its 4 Landing Craft Vehicle Personnel (LCVP) Mk 5s aren’t designed to handle heavy vehicles like tanks. Its main assets are up to 18 helicopters: usually 12 transport (EH101 Merlins or H-3 Sea Kings), and 6 smaller maritime/ scout/ attack helicopters (multi-role Lynx variants, and/or WAH-64D Apache attack helicopters). H-47 Chinooks can be refueled and serviced on deck.

HMS Ocean’s primary role is as an amphibious support vessel. Secondary ship roles include training, a limited anti-submarine warfare role, humanitarian assistance, and acting as a base for anti-terrorist operations. The 2011 campaign over Libya added a strike carrier role of sorts, using the WAH-64D. Those kinds of events have forced the ship to remain at sea near more distant shores, and on longer voyages, than originally anticipated. Hence the priority on crew-related modifications. Not to mention some of the other changes being made under recent refits.

Contracts and Key Events

HMS Ocean
(click to view full)

HMS Ocean [L12] was built on the Clyde by Kvaerner Govan, launched in October 1995, named by Her Majesty the Queen on Feb 20/98, and commissioned in September 1998 in her homeport of Devonport.

August 28/18: Sailing for Brazil Jane’s reports, that the Brazilian Navy’s newest ship is dropping anchor in Rio de Janeiro. The PHM Atlantico was bought from the UK Royal Navy earlier this year as part of Brazil’s ‘Obtaining Full Operational Capability’ program. The deal has an estimated value of $108.7 million. While sailing for the UK the ship had the name HMS Ocean. The ship has a 22.500 t displacement and offers pace for a crew of 255, an aircrew of 206, and 480 marines. The vessel’s primary role is as an amphibious support vessel. Secondary ship roles include training, a limited anti-submarine warfare role, humanitarian assistance, and acting as a base for anti-terrorist operations.

April 16/17: The UK and Brazilian governments are in talks over the potential sale of the Royal Navy helicopter carrier, HMS Ocean, for the reported price of $100 million. Designed to support amphibious landing operations, the vessel was commissioned in 1998 but had been designated in 2015 for decommissioning in 2018 with no plans for a like-for-like replacement. Brazil’s interest in the vessel comes as their Navy decided to abandon the refit of the aircraft carrier Sao Paulo and decommission the vessel after a series of technical issues and accidents.

Dec 12/12: Refit. The UK MoD announces another refit for HMS Ocean. Her 15-month, GBP 65 million (about $105 million) upgrade will be carried out in the newly developed 10 Dock facility at Babcock’s Devonport Royal Dockyard in Plymouth. The work will secure about 300 jobs in Devonport, plus another 300 or so jobs with over 70 contractors who are set to be involved in the project.

Defensive upgrades include the new Type 997 “Artisan” Medium Range Radar system; 4 automated 30mm cannons and 20 km of accompanying power and control cabling to replace existing 20mm manned guns, and complement the ship’s 3 MK15 Phalanx advanced 20mm close-in weapon systems; a new fire detection system; the new multi-service Defence Information Infrastructure (Future) (DII(F)) communications system; and the DNA(2) Command System.

Mechanical and crew improvements include a first-of-class ballast water treatment system, and a first-of-class Membrane Bio-Reactor (MBR) system to treat waste water and sewage. They’ll ensure compatibility with environmental legislation and permit discharge at sea. Represervation work on the ship, and numerous improvements to crew quarters and facilities, round out major requirements. In all, about 1.2 km of new pipework will be installed; over 100 pumps, motors and valves will be overhauled in Babcock’s main factory, and around 100,000 litres of paint will be applied; and major structural modifications will be made to the interior of the ship.

Babcock has also introduced a number of improvements and new processes of its own to optimise delivery of this upkeep, including a new organisation structure in the form of zone management to further improve the planning and execution. Royal Navy | Babcock International.

Sept 21/12: The Royal Navy recounts HMS Ocean’s central role during the 2012 Olympic Games in London. The ship steamed up the Thames and moored in the middle of the river, becoming a visible attraction of her own. She embarked 450 soldiers from a mixture of Army units for venue security at Greenwich Park, whilst simultaneously supporting Fleet Air Arm (FAA) and Army Air Corps (AAC) helicopters – with Royal Marine and RAF Regiment snipers in the back – in order to assist the Metropolitan Police. Royal Navy.

Feb 18/09: Fleet return. HMS Ocean deploys as part of TAURUS 09, steaming in the Royal Navy’s Amphibious Task Group through the Mediterranean, the Arabian Sea, the Indian Ocean and the Far East. Royal Navy.

Oct 13/08: Trials done. HMS Ocean has successfully conducted 2 weeks of sea trials. HMS Ocean will return to sea again to resume her program of sea trials, before embarking on operational sea training in November 2008. UK MoD | Just Plymouth.

Aug 22/07: Refit. The UK MoD announces HMS Ocean’s GBP 30 million (about $59.5 million) refit, and provides details. The work is part of the developing Surface Ship Support Alliance, a new contracting approach that was a pre-requisite to approval of the Royal Navy’s new 65,000t CVF Queen Elizabeth Class carriers.

The year-long refit of HMS Ocean will involve the fitting of new main propulsion shaft sections, extensive improvements in accommodation (including mess-deck dining areas in troop accommodation areas, storage for troop equipment, improvements to the galley and accompanying food storage areas), and an upgrade to the ship’s aviation support facilities to improve support to the Army’s WAH-64D Apache attack helicopters. Work is expected to start in September 2007 and, the ship is expected to return to service in September 2008 after a set of sea trials.

HMS Ocean participated Iraqi operations near Al-Faw in 2003, and her most recent assignment involved deployment to the Caribbean to counter drug smuggling (see video – at GBP 29 million, the value of seized drugs was about equal to the present refit costs), work with US Marine Corps’ HMM-774 “Wild Geese”s and their CH-46E Sea Knight helicopters in a joint training deployment, and offer humanitarian assistance to hurricane victims. In her absence, Britain’s 20,000t escort carrier and fleet flagship HMS Ark Royal will take on HMS Ocean’s role, embarking the helicopters and Royal Marines and serving as a less-optimized backup.

RBS-70, Australian Navy
(click to view full)

The domain of man-portable air defense missile systems (MANPADS) has 4 major competitors around the world. Saab’s RBS-70 is used by 18 countries, and Finland continues to raise its order. Sweden’s Nordic next-door neighbor uses the RBS-70 in 2 modes: as a dispersed, soldier-carried system, and as a vehicle-mounted VSHORAD(Very Short Range Air Defense) system.

A 2009 purchase will complement these dispersed, short-range RBS-70 systems with a wider air defense net based on Sentinel radars, and ground-launched AMRAAM missiles. This combination is intended to make Finland’s airspace dangerous enough to deny enemies full air dominance, while its difficult terrain and mobile land forces bleed any future invasion until it quits. If that strategy sounds improbable, recall that Finland forced Stalin’s Russia to settle for a qualified draw in the 1939 Winter War, when Hitler’s ally attacked Finland per the terms of the Molotov-Ribbentrop Pact.

• The RBS-70
  
• Contracts & Key Events
  
• Additional Readings
  

The RBS-70

Man-portable, sorta
(click to view full)

Unlike competitors such as Raytheon’s FIM-92 Stinger, MBDA’s Mistral, or KBM’s SA-18 Igla, the RBS-70 is an ‘unjammable’ laser beam-riding missile with no seeker head at the front. The RBS-70 is a bit heavy for shoulder firing, and is handled from a tripod. The system can be carried in its component parts by 3 infantry soldiers. Target acquisition includes an IFF (Identification, Friend or Foe) phase, but once fired, the missile locks on and vents its propulsion exhaust through the mid-section. This allows the laser beam riding system to fit in the tail, where it is extremely difficult to jam.

Its GlobalSecurity.org entry adds that the RBS-70 Mk 2 uses the Linear Quadratic Method based on the Kalman Theory for missile guidance, whereupon it delivers a 1-2 punch using a shaped charge surrounded by more than 3,000 tungsten pellets.

The Bolide missile is an RBS 70 Mk 2 upgrade that is faster (Mach 2 vs Mach 1.6), with a range up to 8 km (4.8 miles), an adaptable proximity fuse that gives it full effectiveness against a wider variety of targets, and new reprogrammable electronics. The 4th generation system incorporates the BOLIDE all-target missile, BORC clip-on thermal imager, a digital IFF Interrogator, a PC-based training simulator, and an external power supply for training. These improvements reportedly allow the RBS-70 Bolide to be deployed against surface targets as well, which makes it an especially interesting choice for naval use given the proliferation of small fast attack boat threats.

In a complete air defense system configuration, up to 9 RBS-70 firing tripods can be connected to a surveillance radar like Ericsson’s Giraffe 75, enabling all C3I functions. If the missile firing positions are set 4 km apart, the resulting networked VSHORAD (Very SHOrt Range Air Defense) battery protects an area of 175 square kilometers. A number of radar options are available for the RBS-70, including automatic threat evaluation, autonomous operations, et. al.

RBS-70 Bolide, cutaway
(click to view full)

Beyond Sweden, RBS-70 sales have been made over the years to Argentina, Bahrain, Brazil, Indonesia, Iran, Republic of Ireland, Norway, Pakistan, Singapore, Tunisia, and the United Arab Emirates. All together, Saab says that more than 16,000 missiles have been produced over 4 product generations.

In the last 3-4 years, the Australians have retired their Rapier systems in favor of the RBS-70 system (SEK 600M, incl. SEK 150M for 170 new Bolide missiles). Lithuania received RBS-70 missiles as a gift from Norway to protect critical infrastructure like the Ignalina nuclear plant, while Latvia (ex-Swedish launchers, unspecified missiles for SEK 185M) and the Czech Republic (SEK 204M, 16 launchers & 200 missiles) have also purchased the RBS-70.

Beyond confirmed customers, The SIPRI (Stockholm International Peace Research Institute) “Register of the transfers of major conventional weapons from Sweden 1995-2005” [PDF] also lists Mexico (100 missiles, supplier uncertain in 1993) and Thailand (85, in 1996 & 2001) as having these missiles in inventory. GlobalSecurity.org adds Venezuela’s Air Force, and the FAV Club site claims that an RBS-70 was successfully used to shoot down an OV-10 during a 1992 coup attempt.

Contracts & Key Events

RBS-70 fired from
ASRAD-R test vehicle
(click to view full)

August 28/18: Lithuanian upgrades Swedish defense manufacturer Saab confirms that Lithuania is upgrading its RBS-70 MANPADS. The company is being awarded with two contracts providing for the delivery of improved missiles and BORC night-capability sights. The two orders have a value of $10.9 million. The RBS 70 missile can be operated independently in stand-alone mode or can be configured with several firing units linked with a surveillance radar to form an anti-aircraft battery. Unlike competitors such as Raytheon’s FIM-92 Stinger, MBDA’s Mistral, the RBS-70 is an ‘unjammable’ laser beam-riding missile with no seeker head at the front. The BORC clip-on thermal sight allows the laser guidance beam from the day sight to pass without distortion to the missile for a jam proof accurate guidance. According to Saab, 19 nations have procured more than 1,600 RBS 70 systems, including more than 18,000 missiles.

October 26/15: Latvia has ordered more missiles for its RBS-70 MANPADS very short range air defense systems. The country has been looking to bolster its air defense capabilities in recent months, installing new air surveillance radar in May and ordering three more TPS-77 Multi Role Radar systems earlier this month. The country is also thought to have signed for FIM-92 Stinger MANPADS in August. Deliveries of the new RBS-70 missile will take place over the next year.

July 2/15: Saab has signed a $32.5 million contract with an undisclosed customer for RBS-70 Man Portable Air Defense Systems (MANPADS), with these due for delivery by 2016. Previous customers include Finland and Brazil, with the latter signing a $12.2 million contract with the company last year.

Jan 27/10: Saab announces a SEK 260 million (about $35.6 million) follow-on contract for further RBS-70 deliveries to the Finnish Army. First deliveries under the new contract are scheduled for 2011. Saab Group.

Jan 7/10: Germany’s Rheinmetall Defence Electronics has commenced an arbitration process against Finland, concerning the delayed delivery of its anti-aircraft defense system to the Finnish Defence Forces. Finland’s MoD says that this is the first time that arbitration has been filed against the Finnish Defence Forces, and adds that they see the allegations as groundless. Finnish Forsvarsministeriet.

Jan 18/07: Saab Bofors Dynamics announces a SEK 600 million (about $85.4 million) contract for the RBS-70 short-range, man-portable air defense system (MANPADS) with the Finnish army, including missiles and maintenance equipment. First delivery is expected at the end of 2008, and the order secures production of the RBS-70 until 2010. Saab release.

Aug 6/02: Finland signs a contract for an unspecified number of RBS-70 MANPADS, and 18 ASRAD-R mobile systems, with a coalition that includes Saab Bofors Dynamics, Germany’s STN ATLAS (now part of Rheinmetall) and Ericsson Microwave Systems (now part of Saab Group). These systems will include the new RBS-70 BOLIDE missiles, and a new RBS-70 night sight. The ASRAD-R systems will be mounted on Unimog 5000 trucks. First deliveries were in 2004, and were completed in June 2008.

STN ATLAS was the prime contractor for the EUR 120+ million contract, of which about EUR 30 million was for Saab Bofors Dynamics’ share. Saab Group.

Additional Readings

• Saab – RBS 70

• Army Technology – RBS 70 Short-Range Anti-Aircraft Missile, Sweden

• Army Technology – LeFlaSys (ASRAD) Light Mechanized Short-Range Air Defense System, Germany

• FAV Club – This page has photos of Venezuelan RBS-70 systems.

Americas

The US Air Force plans to integrate a new IRST system on its fleet of F-15C aircraft. Boeing will provide the Air Force with engineering, manufacturing, and development efforts of the F-15 Legion Pod. The contract has a value of $208.2 million and will run through November 2020. The Legion Pod is being developed in conjunction with Lockheed Martin. The pod features Lockheed’s IRST21 infrared sensor and advanced data processing capabilities. This multi-function sensor system has been designed to provide long-range detection and tracking of airborne threats in radar-denied environments. The common interface of the Legion pod allows it to be easily integrated onto any aircraft without affecting the aircraft’s operational flight programme. Work will bet performed at Boeing’s facilities on St. Louis, Missouri and Orlando, Florida.

The Navy is stocking up on spares for its Evolved Sea Sparrow Missile. Raytheon is receiving a firm-fixed-price contract that provides for the provision of ESSM Block I life-of-type-buy and assembly-level spares at a cost of $25.1 million. The RIM-162 is used to protect ships from attacking missiles and aircraft, and is designed to counter supersonic maneuvering anti-ship missiles. The ESSM Block I is a semi-active radar homing missile that depends on reflected radiation from the ship’s radar to see its target. Work will be performed at multiple locations inside and outside the US, including Andover, Massachusetts; Hengelo OV, Netherlands and Richmond, Australia. Work is scheduled for completion by June 2021.

The US Army is modernizing its stockpiles of Javelin missiles. Raytheon and Lockheed Martin will conduct a holistic engineering development to modernise the Javelin Weapon System under this $14.3 million contract modification. The FGM-148 Javelin is a man-portable anti-tank missile used to destroy moving vehicles, fixed fortifications, troops in the open and low-flying helicopters. It can be used for direct fire or in a pop-up mode that allows it to hit tanks from above to take advantage of their thinner top armor. Work will be performed in Tucson, Arizona and is expected to be completed by September, 2020.

The US Strategic Capabilities Office (SCO) has achieved a milestone in its Miniature Air-Launched Decoy X (MALD-X) development. MALD-X decoys are mini-cruise missiles, which are used to distract and deceive an enemy air defense system so that a real strike package can succeed and survive. The ‘stealth in reverse’ decoys fly long distances along pre-planned flight patterns, carrying radar reflectors that simulate the radar return of fighter or bomber aircraft. MALD-X enhances the modular nature of the mini cruise missile with the ability to accommodate different electronic warfare payloads that are more advanced than those found on its predecessors. A series of flight demonstrations were recently held at Naval Air Warfare Center Point Mugu, with additional tests to take place next year. Raytheon was awarded $34.8 million by the USAF to develop a new version in 2016.

Jane’s reports, that the Brazilian Navy’s newest ship is dropping anchor in Rio de Janeiro. The PHM Atlantico was bought from the UK Royal Navy earlier this year as part of Brazil’s ‘Obtaining Full Operational Capability’ program. The deal has an estimated value of $108.7 million. While sailing for the UK the ship had the name HMS Ocean. The ship has a 22.500 t displacement and offers pace for a crew of 255, an aircrew of 206, and 480 marines. The vessel’s primary role is as an amphibious support vessel. Secondary ship roles include training, a limited anti-submarine warfare role, humanitarian assistance, and acting as a base for anti-terrorist operations.

Middle East & Africa

Russian media reports that the east African nation of Burundi is considering purchasing the Pantsir-S1 air-defense system. The system is produced by Russia’s KBP and features a fire-control radar and electro-optical sensor, two 30-mm cannons and up to 12 57E6 radio-command guided short-range missiles. It is designed to protect vital small-size and big military areas, industrial targets and land forces units and reinforced the air defense units responsible for the protection of troops and military installations against precision-guided air attack from low and extreme low altitudes. The Burundi National Defense Force has currently a variety of air-defense weapons in its inventory, ranging from SA-7B Grail MANPADS to M-1939 anti-aircraft guns.

Europe

Swedish defense manufacturer Saab confirms that Lithuania is upgrading its RBS-70 MANPADS. The company is being awarded with two contracts providing for the delivery of improved missiles and BORC night-capability sights. The two orders have a value of $10.9 million. The RBS 70 missile can be operated independently in stand-alone mode or can be configured with several firing units linked with a surveillance radar to form an anti-aircraft battery. Unlike competitors such as Raytheon’s FIM-92 Stinger, MBDA’s Mistral, the RBS-70 is an ‘unjammable’ laser beam-riding missile with no seeker head at the front. The BORC clip-on thermal sight allows the laser guidance beam from the day sight to pass without distortion to the missile for a jam proof accurate guidance. According to Saab, 19 nations have procured more than 1,600 RBS 70 systems, including more than 18,000 missiles.

Asia-Pacific

The French Air Force is currently conducting a large-scale humanitarian relief mission in Asia. Operation Pegase, includes a fleet of three Rafale B fighter jets, an A310 transport plane and a C-135 refuelling tanker. Most recently the mission was joined by a A400M that flew 25 tons of aid from Jakarta to Lombok, the Indonesian island devastated by a series of powerful and deadly earthquakes. The airlifted ferried food supplies, two ambulances, building material, and NGO medical staff to the island just east of Bali. Operation Pegase, with its aircraft and about 100 flight crew members will now spend a couple of days in Vietnam.

Today’s Video

Watch: RMAF’s A400Ms take off from Subang

Americas

The US Marine Corps’ H-1 upgrade program is set to receive another major financial boost. Bell Helicopters will manufacture and deliver 29 newly built Lot 15 AH-1Z attack helicopters at a cost of $509.7 million. The contract modification also provides for long lead material and components for an additional seven Lot 16 aircraft. The H-1 program, is the USMC’s plan to remanufacture older helicopters into new and improved UH-1Y utility and AH-1Z attack helicopters. The Viper will receive a new newly designed “Integrated Avionics System” cockpit, including a Thales’ TopOwl helmet-mounted display system and the AN/AAQ-30 FLIR system. Work will be performed at Bell’s facilities in Fort Worth, Texas and Amarillo, Texas, and is scheduled for completion in February 2021.

The Navy is contracting Technical Systems Integration for the provision of necessary overhaul and modification work on the USMC’s Mk-105 minesweeping system. The firm-fixed-price, indefinite-delivery/indefinite-quantity contract has a value of $10.5 million, but also includes options, which if exercises, would bring the face value to roughly $54 million. The Mk-105 Magnetic Influence Minesweeping System is a catamaran hydrofoil which is towed behind the MH-53E Sea Dragon helicopter. It is used to detect mines that use magnetic sensors to target the metallic hulls of ships before detonating. The twin magnetic tails, consisting of open-electrode magnetic sweeps, are towed behind the sled, detonating mines to clear the water for safe shipping. Work will be performed in Panama City, Florida, and is expected to be completed by August 2019.

Raytheon is being tapped to progress with the re-certification of the Navy’s Tomahawk Block IV cruise missiles. The cost plus-fixed-fee delivery order is valued at $9.3 million and provides validation and verification and cost risk analysis. The key to the next set of Tomahawk improvements is actually a warranty. The missile has a 15-year warranty and a 30-year service life, the re-certification process will keep the Tomahawk cruise missile flying through 2040. To keep the missiles up-to-date, Raytheon will add a newly developed ability to strike targets at sea. Work will be performed at multiple locations inside the continental US, including Walled Lake, Michigan; Tempe, Arizona and Albuquerque, New Mexico. The contract is expected to be completed in August 2019.

Middle East & Africa

The Israel Defense Force will receive new thermal weapon sights for its M-16 and M-4 rifles as part of a US Foreign Military Sales. FLIR Systems will deliver a number of Milsight T75 long-range thermal weapon sights, materials and training at a cost of $14 million. The ThermoSight T75 weapon sight that doubles as a portable reconnaissance scope, is designed to interface with scopes such as the Trijicon ACOG for the M-4, M-16, and similar weapons. The sight is compatible with any 1913 Mil-Std Rail System. It has three zoom capabilities, 1X, 2X, and 4X, for long range ID and engagement. It can be clipped-on to day-sight/RCO or use as stand-alone thermal sight for mission flexibility and works with all combat optics and rapidly adaptable to various weapon platforms. Work will bet performed at the company’s facility in North Billerica, Massachusetts. The sights are expected to be ready for delivery by end of December 2019.

Europe

The government of France is increasing its remote strike and surveillance capabilities. The European nation is ordering an unspecified number of MQ-9 UAVs from General Atomics. The firm-fixed-price, cost-plus-fixed-fee contract has a value of $123 million and involves foreign military sales to the government. France introduced the Reaper in 2013, when it requested the purchase of 16 MQ-9 aircraft and associated equipment at a cost of $1.5 billion. The drone s designed primarily for attack missions but can also be used for surveillance, close air support and reconnaissance. The MQ-9 has a a high cruise speed, a flight ceiling up to 40,000 feet and can carry a larger sensor and weapons payload than its predecessors. The Reapers can be armed with laser-guided missiles and bombs like the Hellfire and GBU-12 Paveway, as well as GPS-guided GBU-38 JDAMs. Work will be performed at GA’s facility in Poway, California and is expected to be completed on May 1st, 2020.

The French Air Force is finishing its deployment to Estonia, and will be replaced by the German Luftwaffe. From now on, four German Eurofighter Typhoons will take on the NATO air policing duties. There are currently NATO air and land forces from the Netherlands, Spain, the US, the UK deployed in the northeastern Estonian town of Tapa. They are part of NATO’s Enhanced Forward Presence mission. Germany bought a total of 140 Eurofighters, equipped with IRIS-T short-range air-to-air missiles, Meteor long-range air-to-air missiles and a Captor radar.

Asia-Pacific

The Indian Ministry of Defense clears a major defense acquisition with a total value of $6.5 billion. The biggest chunk of the procurement will be the purchase of 111 naval utility helicopters. They will be built by an Indian company at a cost of $3.1 billion. $3.4 billion are earmarked for a variety of missiles and 150 Indian-made 155mm artillery gun systems. The Indian Navy will also replace its 12 outdated Seaking multi-role helicopters with 24 US-made MH-60Rs. This deal is expected to be worth about $1.8 billion. The MoD will further procure total of 14 Vertically Launched Short Range Missile Systems which will increase the capability of warships to shoot down and destroy incoming anti-ship missiles.

Today’s Video

Watch: A Jordanian fighter pilot was killed in a helicopter crash in Texas

UH-1Y and AH-1Z
by Neville Dawson

The US Marines’ helicopter force is aging at all levels, from banana-shaped CH-46 Sea Knight transports that are far older than their pilots, to the 1980s-era UH-1N Hueys and AH-1W Cobra attack helicopters that make up the Corps’ helicopter assault force. While the tilt-rotor V-22 Osprey program has staggered along for almost 2 decades under accidents, technical delays, and cost issues, replacement of the USMC’s backbone helicopter assets has languished. Given the high-demand scenarios inherent in the current war, other efforts are clearly required.

Enter the H-1 program, the USMC’s plan to remanufacture older helicopters into new and improved UH-1Y utility and AH-1Z attack helicopters. The new versions would discard the signature 2-bladed rotors for modern 4-bladed improvements, redo the aircraft’s electronics, and add improved engines and weapons to offer a new level of performance. It seemed simple, but hasn’t quite worked out that way. The H-1 program has encountered its share of delays and issues, but the program survived its review, and continued on into production and deployment.

DID’s FOCUS articles offer in-depth, updated looks at significant military programs of record. This article covers the H-1 helicopter programs’ rationales and changes, the upgrades involved in each model, program developments and annual budgets, the full timeline of contracts and key program developments, and related research sources.

The H-1 Helicopters

TopOwl
(click to view full)

For pilots, both H-1 helicopters will incorporate a newly designed “Integrated Avionics System” cockpit designed by Northrop Grumman, including dual mission computers, GPS navigation, moving map displays, and other modern aids. Pilot workload will be improved further by using Thales’ TopOwl helmet-mounted display systems (HMDS), to offer flight and targeting data no matter where the pilot looks.

FLIR Systems’ BRITE Star NTIS will handle targeting and surveillance on the UH-1Y Venom. The UH-1Y is currently slated to use only machine guns and 70mm rockets, but a March 2012 decision has added laser-guided APKWS rockets to its arsenal.

The AH-1Z Viper will use the more advanced Lockheed Martin/ Wescam/ Kollsman AN/AAQ-30, which is fully integrated into the AH-1Z fire control system and TopOwl HMD. It provides range and optical line-of-sight data for all weapons, even AIM-9M Sidewinder air-to-air missiles. TSS features a large-aperture, 3rd-generation staring mid-wave FLIR derived from Lockheed’s fighter-borne Sniper targeting pod; a 640 x 512 day/night TV with automatic video tracker and continuous zoom from high magnification to wide field of view; a laser spot tracker; an on-gimbal inertial measurement unit (IMU) for accurate line-of-sight pointing and geolocation of targets; coupled with a Kollsman laser designator/rangefinder with an eyesafe mode. The AAQ-30’s wide Field-of-View (FoV) optics also provide a secondary navigation capability when light levels are low, and night vision goggles are ineffective. All of this is packed into a stabilized L-3 Wescam turret.

Overall, the AH-1Z Viper will have a wider array of weapons to choose from, and it will become the Navy’s initial platform for the dual-mode radar/laser guided JAGM missile if the weapon makes it into production.

Neither helicopter uses extensive armoring for protection, as is the case with the AH-64 Apache, for instance. Instead, efforts like infrared-reducing paint and exhausts, design for low profiles, and some protection to key systems like energy-absorbing landing gear, self-sealing fuel systems and a fuel vapor inerting system are used. Troops riding in the UH-1Y will especially appreciate the energy attenuating seats that reduce the effects of G-forces in the event of a crash, or hard landing; in the UH-1N, they just had to sit on the floor and receive the full shock. Both helicopters will also rely on a common set of advanced defensive systems:

• ATK’s AN/AAR-47 missile approach warning system – will become JATAS
  
• BAE’s AN/ALQ-144 infrared (IR) jammer and AN/ALE-47 decoy dispensing system, serves as central ECM hub
  
• Northrop Grumman’s AN/APR-39A(V)2 radar warning receiver
  
• UT Goodrich’s AN/AVR-2A laser warning receiver
  
• A Directed InfraRed CounterMeasures (DIRCM) system of some kind may be added to the AH-1Z in particular

UH-1Y & AH-1Z: Performance Issues

AH-1Z, testing
(click to view full)

Some issues do remain with the helicopters. One is that the 2 engines provide almost 3,660 shp, but the aircraft’s transmission is flat-rated for 2,350 shp. That doesn’t matter as much at altitude or in very hot weather, or above 180 knots airspeed where drag becomes the limiting factor, so it was deemed acceptable.

For the AH-1Z, potential issues include a lack of robust armor – a characteristic it shares with earlier AH-1 models, but not with the Army’s heavily armored AH-64 gunship. The exception is the flight controls and some engine sections, which can withstand cannon fire up to 23mm. This is more of a design choice than a manufacturing flaw, but it does affect the helicopter’s usage.

A second AH-1Z design issue involves communications. Statements by H-1 upgrade program manager USMC Col. Harry Hewson seem to indicate that the older AH-1Ws will initially be more advanced in this area. The AH-1Zs will have secure voice communications only, while the upgraded AH-1W includes the tactical video data link (TVDL) that can broadcast sensor data to a ground controller with a ROVER system, or receive video from other helicopters or Marine aircraft with LITENING pods. As of 2014, a full-motion video project is in the works for the AH-1Z, but hasn’t been fielded yet.

On the manufacturing side, as of December 2010, several rotor components were falling far short of the original 10,000 hour reliability goal. Unfortunately, efforts to redesign the rotor head’s cuff and yoke weren’t going to provide enough improvement to justify the costs. NAVAIR says that current efforts involve improved tooling design and manufacturing processes for the existing design.

The H-1 Upgrade Program

UH-1N, Iraq
(click to view full)

It seemed fairly straightforward: update a pair of old USMC standbys in the UH-1N and AH-1W, creating a transport (UH-1Y Venom) and attack helicopter (AH-1Z Viper) backbone with maximum commonality, and minimum risk.

It hasn’t quite worked out that way.

The H-1 program is designed to resolve existing safety issues in both aircraft, reduce life-cycle costs, significantly enhance combat capability, and achieve 85% commonality between the 2 versions. Bell Helicopter believes this commonality can save up to $3 billion in operating and support costs over a 30-year lifespan, and the stated goal is airframes that will last through 10,000 flight hours of service life. Common components include the tail boom, engines, drive train, rotor blade, software controls, avionics, and displays.

Many of these helicopters will be remanufactured from the Marines’ old UH-1N Hueys and its AH-1W Super Cobra attack helicopters. Major modifications include a new 4-blade rotor system with semi-automatic blade fold, new composite main and four-bladed tail rotor, upgraded drive system and landing gear, and pylon structural modifications. The AH-1Z attach helicopter will also have 2,500 pounds of fuel instead of 1,900 (AH-1W), to extend strike range to over 170 miles. GE’s T700-401C engine will power both helicopters, giving them improved maneuverability, speed and range, and payload when compared to their UH-1N and AH-1W predecessors. The UH-1Y is touted as having 50% better range, a faster maximum speed, and 25% greater payload than its UH-1N predecessor. The AH-1Z is touted as almost doubling effective strike range over the AH-1W, or doubling weapons load carried to the same ranges. Maintainability is also being addressed, using embedded diagnostics that can provide warning of maintenance needs or impending faults.

H-1 Upgrade: Force Size & Structure Shifts

AH-1W, hard left
(click to view full)

The H-1 program has required substantial changes to both cost and schedule 4 times now, while addressing numerous technical issues. The UH-1Y/ AH-1Z upgrades program was originally structured as a remanufacturing effort, converting 180 AH-1W Super Cobras to AH-1Z Vipers, and 100 UH-1N Hueys to UH-1Y Venoms.

It didn’t stay that way.

The initial changes were prompted by 2 factors: effort and time.

The idea of remanufacturing the helicopters didn’t look so great once the true scope and expense of the work involved became clear. Worse, it involved taking each UH-1N Huey out of service for 2 whole years, in the face of ongoing demand from the front lines.

The program tried putting new UH-1Y nose sections into production earlier, and establishing a rotating pool of government-furnished equipment so a UH-1N doesn’t have to be taken out of service until a corresponding UH-1Y Venom is delivered. After the 1st 10 UH-1Y remanufactures, however, the rest were switched to new-build machines.

The next big change was the USMC’s Program Objective Memorandum for 2010, which raised the future fleet to 123 UH-1Ys and 226 AH-1Zs (58 new-build + 168 remanufactured), as part of a plan to grow the Marines by about 20,000 troops. Under this plan, the 58 new-build AH-1Zs would be delivered first, in order to maintain overall fleet availability by keeping existing AH-1Ws in service. Once the overall fleet had grown, AH-1Ws could be taken from the front lines and shifted into the remanufacturing program.

Subsequent shifts have pared back the number of AH-1Zs, and drastically reducing the number of remanufactured AH-1Zs, while increasing the number of UH-1Y Venoms. The legacy model is a USMC squadron of 18 AH-1Ws and 9 UH-1Ns, but the future will involve 15 AH-1Zs and 12 UH-1Ys in each squadron.

So, why the extra Venoms?

The UH-1Y’s extra power proved to be extremely useful in hot and high-altitude conditions, and the planned addition of guided 70mm rockets like APKWS and LOGIR would give them an attack punch comparable to previous AH-1 Cobras. The UH-1Y’s performance in Afghanistan using APKWS guided 70mm rockets has only reinforced these opinions.

The other question is, why did remanufactured AH-1Ws decline so sharply?

Heavy wartime use has increased the wear on existing AH-1Ws, which created a shortage of flyable attack helicopters, and made remanufacturing them more expensive. By FY 2013, cost estimates for new AH-1Z cabins offered an option that was now cheaper over the machines’ service life, while avoiding a critical USMC shortage by leaving AH-1Ws in the fleet.

H-1 Program: Budgets & Industrial Partners

Note that these years do not always correspond fully to Production Lot orders, though they can be used as a general guide. Since American supplemental funding bills are typically passed closer to mid-year, and not in conjunction with the baseline defense spending bills, aircraft appropriated under OCO/supplemental funding as war replacements are sometimes bought with the following year’s contract.

For instance, in 2009, the 11 baseline UH-1Ys, 5 baseline AH-1Zs, and 4 supplemental UH-1Ys were bought as Lot 6 (20 helicopters); but the program office didn’t have priced options for additional AH-1Zs negotiated for Lot 6. That’s why FY 2009’s 4 supplemental AH-1Zs were bought as part of Production Lot 7.

In FY 2010, those 4 Lot 7 supplemental AH-1Zs were added to FY 2010’s 18 UH-1Ys, 5 AH-1Zs, and 2 OCO funded new-build AH-1Zs, growing Lot 7 to 29 helicopters. The “29” total adds the 4 machines from FY 2009, but also omits the FY 2010 supplemental bill’s 1 UH-1Y and 1 AH-1Z. They’re part of Lot 8, because their bill’s timing prevented them from being added to Lot 7. And so it goes…

H-1 Upgrade Program industrial partners include:

Program Problems

UH-1Y & AH-1W,
in Afghanistan
(click to view full)

The original idea of remanufacturing existing helicopters, and adding some new performance enhancements, seemed like a low-risk program. Events have a vote, however, and the actual program has been much more challenging than expected.

In May 2005, the Navy warned Bell that the H-1 program was in serious jeopardy. The Texas-based company was described as failing to meet Navy needs, and the memo reserved the option of killing the program. It demanded “fundamental changes” in Bell Helicopter’s management processes as well as its production processes. Recertification in Earned Value Management, used to track program performance, was high on the list of “to-dos.”

Ultimately, changes were made – including some executive changes at the highest levels of Bell Helicopter Textron.

A May 31/06 Defense Acquisition Board process made the decision to proceed with the program. The UH-1Y and AH-1Z began Phase II of their Operational Evaluation (OpEval) in February 2008, and a full rate production decision was expected in August 2008.

After the management and process issues were sorted out, the UH-1Y did very well. Its Initial Operational Capability (IOC) came a month early, in August 2008, and it received a full production go-ahead in September 2008.

The AH-1Z has fared less well, thanks in part to issues surrounding the AAQ-30 surveillance and targeting system, and the TopOwl helmet-mounted display. Other issues included rocket gas ingestion by the engines, and problems with mission software. IOC for the AH-1Z was pushed back from FY 2008 to FY 2011, but the program is moving toward completion.

Contracts and Key Events

Unless otherwise noted, all contracts are issued by US Naval Air Systems Command (NAVAIR) in Patuxent River, MD to Bell Helicopter Textron, Inc. in Fort Worth, TX.

FY 2015 – 2018

August 27/18: More $ for the USMC The US Marine Corps’ H-1 upgrade program is set to receive another major financial boost. Bell Helicopters will manufacture and deliver 29 newly built Lot 15 AH-1Z attack helicopters at a cost of $509.7 million. The contract modification also provides for long lead material and components for an additional seven Lot 16 aircraft. The H-1 program, is the USMC’s plan to remanufacture older helicopters into new and improved UH-1Y utility and AH-1Z attack helicopters. The Viper will receive a new newly designed “Integrated Avionics System” cockpit, including a Thales’ TopOwl helmet-mounted display system and the AN/AAQ-30 FLIR system. Work will be performed at Bell’s facilities in Fort Worth, Texas and Amarillo, Texas, and is scheduled for completion in February 2021.

May 14/18: FMS-Czech Republic The Czech Republic will receive 12 UH-1Y Venom helicopters from Bell. The sale to the Eastern European country and NATO member have already been approved by the US government. The Armed Forces of the Czech Republic has a pressing need to replace many of its Warsaw Pact-era inventories, which include Mil Mi-2 ‘Hoplite’, Mi-8/17 ‘Hip’, and Mi-24 ‘Hind’ helicopters. The UH-1Y Venom is a product of the H-1 program, USMC’s plan to remanufacture older helicopters into new and improved utility and attack helicopters. The aircraft incorporate a newly designed “Integrated Avionics System” cockpit designed by Northrop Grumman, including dual mission computers, GPS navigation, moving map displays, and other modern aids. Pilot workload will be improved further by using Thales’ TopOwl helmet-mounted display systems (HMDS), to offer flight and targeting data no matter where the pilot looks. The UH-1Y utility helicopter provides command & control and assault support under day, night and adverse weather conditions.

April 30/18: FMS-Bahrain The US Defense Security Cooperation Agency (DSCA) has approved the possible foreign military sale of 12 AH-1Z Viper attack helicopters to the kingdom of Bahrain. According to the agency’s press release, the fleet will be armed with 14 AGM-114 Hellfires, and 56 Advance Precision Kill Weapon System II. The estimated cost of the acquisition is set at $911.4 million. The Viper’s manufacturer Bell, alongside Textron and General Electric have been listed as principal contractors on the sale.

February 20/18: Lot 16-Long-Lead Items Bell Helicopters will supply additional long-lead items for 27 Lot 16 AH-1Z Viper helicopters in support of the US Marine Corps. Valued at $37.6 million, work on the contract modification will be performed in Fort Worth, Texas, and Amarillo, Texas, and is expected to be completed in March 2019. Last week, USMC Vipers of the 1st Marine Aircraft Wing, met up with service members from seven full participating nations in advance of the start of the “Cobra Gold” exercise in Thailand—a co-sponsored event by the US and Thailand that seeks to advance regional security and ensure effective responses to regional crises. “The Marines of Marine Light Attack Helicopter Squadron 369 are here to promote multilateral training and deliver close air support for the participating nations such as the Kingdom of Thailand and Republic of Korea,” Maj. Kevin M. Keene, an operations officer and AH-1Z Viper pilot with HMLA-369, under the Unit Deployment Program with Marine Aircraft Group 36, 1st MAW, said in a press release. In addition to the Vipers, the USMC will use UH-1Y Venoms, along with CH-53E Super Stallions and KC-130J Hercules to provide aerial support for the exercise. The exercise will run until February 23.

October 25/17: The US State Department’s Defense Security Cooperation Agency (DSCA) has notified Congress of the potential foreign military sale of 12 Bell UH-1Y twin-engine, medium-sized utility helicopters to the Czech Republic. If approved, the Central European nation will be the first foreign operator of the rotorcraft. Valued at an estimated $575 million, the package includes 25 T-700 GE 401C engines, 13 Honeywell Embedded GPS/INS systems and 12 7.62mm M240 Machine Guns. Other items requested by Prague include the Brite Star II FLIR system, aircraft survivability equipment, the AN/AAR-47 missile warning and laser detection system, AN/ALE-47 counter-measure dispensing systems, and joint mission planning systems. Bell Helicopter, Textron and General Electric Company will act as principal contractors on the deal.

June 19/17: Bell Helicopters is considering a plan to manufacture AH-1Z Viper attack helicopters in Romania within the next 4-5 years. News of the deal comes almost twenty years after a previous attempt to assemble the AH-1 in the country fell through. The announcement follows Bells’ signing of a memorandum of understanding (MoU) with Romanian company IAR-Ghimbav Brasov Group last November that would see the local firm cover possible maintenance, repair, and overhaul (MRO) of the AH-1Z should it be procured by Bucharest. While Romania has yet to launch a formal tender for their replacement, Bell is just one of several manufacturers, including Airbus, who are positioning themselves for an anticipated requirement.

April 9/17: Bell Helicopters is scheduled to deliver the first three of 12 AH-1Zs to Pakistan this summer, with the remainder to be delivered next year after being handed over to the US government. Approval for the deal was granted by Washington last April. The sale comes as the company expects the signing of a second export order for the H-1 series UH-1Y Venom utility and AH-1Z Viper attack helicopters in the coming months.

March 2/17: After a few months of delay, the USAF may soon re-release a request for proposals for the replacement of the UH-1 Huey helicopter fleet. The delay originated after a number of manufacturers told the service their off-the-shelf solutions would not meet all of the proposed requirements, with only the Sikorsky HH-60U Black Hawk fitting the earlier requirements. Speaking on the matter, USAF chief Gen David Goldfein said that the “delay in the UH-1 replacement is actually based on the dialogue we’re having with industry and what they’re saying they can produce based on our RFP.” “We want to make sure when the RFP hits the streets it’s right,” he added. Alongside the Black Hawk, Boeing and Leonardo are looking to offer a militarized version of the Italian firm’s commercial AW139 helicopter. An attempt at providing a media flight for the MH-139, however, had to be cancelled following the malfunction of one of its modular avionics units.

February 10/17: Bell Helicopters will provide long-lead items and components for the US Navy’s AH-1Z aircraft. valued at $49 million, the agreement covers 27 Lot 15 AH-1Z Vipers operated by the USMC, and work is expected to be completed by March 2018. According to manufacturer Bell, the AH-1Z is the only helicopter in the world to feature air-to-air missile attack capabilities.

December 28/16: AH-1Z Cobra attack helicopters operated by the US Navy will receive Target Sight Systems provided by Lockheed Martin. Valued at $150 million, the deal also includes production orders for the government of Pakistan under the foreign military sales program. Options included in the contract could raise the value to $284 million. The Target Sight System is a large-aperture mid-wave forward-looking infrared sensor designed to identify and designate targets at maximum weapon range, increasing the Cobra operator’s survivability and lethality.

October 18/16: Bell Helicopters is keen to sell its AH-1Z attack helicopter as a solution to Japan’s AH-X program. As part of preparations the company has teamed with engineers from Fuji Heavy Industries on modification work to the helicopter aimed at improving transmission performance. If selected, between 60-70 of the Bell 412EPI-based helicopters would be produced locally in Fuji with the first slated to deliver in 2022. Civilian variants would also be produced in Fuji in an effort to help the production line attain scale.

April 22/16: Protests have arisen by some US lawmakers against the USAF’s UH-1N Huey helicopter replacement program. The helicopters, which protect US supplies of inter-continental ballistic missiles (ICBMs), are to be replaced via a sole-source contract due to a new urgency felt by air force brass in fielding the capability favoring Sikorsky’s UH-60 Black Hawk. This in turn has caused a group in Congress to rail back who now want a fair and open competition for the Huey’s replacement.

March 15/16: The US Navy has awarded Bell Helicopters a $461 million contract to supply the force with 12 Lot 13 UH-1Y and 16 Lot 13 AH-1Z helicopters. The contract includes the provision of 16 auxiliary fuel kits. Completion of the sale is expected by February 2019 as part of the Navy’s H-1 upgrade program. Bell Helicopters has also signed a teaming agreement with BAE Systems Australia to offer the AH-1Z as a potential replacement for the Australian Army’s Tiger fleet.

August 19/15: The H-1 helicopter fleet of both the Navy and Pakistan will receive a boost through a $85.5 million contract to develop weapons systems for the aircraft as part of its system configuration set (SCS). The SCS intends to create prototypes for emerging operational requirements, with the majority of this contract covering acquisitions for the US Navy, with the contract set to run to 2020.

FY 2014

 

UH-1Y from LHD 4
(click to view full)

Sept 5/14: A $41.8 million firm-fixed-price contract for 3 UH-1Y flight training devices (aka. simulators), 1 AH-1Z flight training device, aircraft and/or trainer driven revisions, aircraft common operational equipment, provisioned device spares, associated technical data required for operational and maintenance support, and 3 months of initial operation evaluation period for each flight training device. All funds are committed immediately, using FY 2012 Navy reserve and FY 2014 aircraft budgets.

Work will be performed at Broken Arrow, OK (46%); Fort Worth, TX (33%); St. Louis, MO (15%); and Austin, TX (6%), and is expected to be complete in June 2018. The contract was not competitively procured pursuant to FAR 6.302.1 by the Naval Air Warfare Center Training Systems Division in Orlando, FL (N61340-14-C-1000).

Aug 4/14: UH-1Ns. The USMC plans to retire the last of its 205 UH-1N Huey helicopters in September 2015. Of that total, 10 were upgraded to UH-1Ys. Another 5 upgraded HH-1Ns will continue to serve at MCAS Yuma, AZ, but they will retire in 2015. Sources: Navy League Seapower, “Marine Corps to Retire UH-1N Helicopters in September; HH-1Ns in 2015”.

June 20/14: Support. A $44.7 million modification, finalizing a previously awarded contract to a cost-plus-fixed-fee price contract to repair various parts for the UH-1Y and AH-1Z Upgrade Helicopters. FY 2014 US Navy budgets will be drawn on as needed.

Work will be performed in Hurst, TX, and work is expected to be complete by January 2017. No funds will be obligated at the time of award and contract funds will not expire at the end of the current fiscal year. This contract was a non-competitive requirement in accordance with 10 USC. 2304 (c)(1), managed by NAVSUP Weapon Systems Support in Philadelphia, PA (N00383-14-D-015N).

May 29/14: Sub-contractors. Northrop Grumman Guidance and Electronics Co. in Woodland Hills, CA receives a $25 million delivery order for 119 H-1 upgrade tech refresh mission computers. Those have been broken out into a separate purchase by the US Navy, as a way to improve costs. $10.9 million in US Navy FY 2013 – 2014 aircraft budgets is committed immediately.

Work will be performed in Woodland Hills, CA (79%); Salt Lake City, UT (13%); and Baltimore, MD (8%); it is expected to be complete in October 2017 (N00019-11-G-0016, DO 0002).

May 16/14: Lot 11. A $337.8 million contract modification finalizes the Lot 11 order for 12 new UH-1Ys and 12 new AH-1Zs, creating a fixed-price-incentive contract for the helicopters and a firm-fixed-price contract for the auxiliary fuel kits. See also May 28/13, which brings the total announced award to $388.4 million – but note that this contract adjusts the previous ratio from 15 UH-1Ys and 10 AH0-1Zs.

All funds are committed immediately, using FY 2013 & 2014 US Navy aircraft budgets, which makes sense. The final FY 2014 budget has cut buys to a base of 11 UH-1Ys and 10 AH-1Zs, and recall that annual contracts also tend to include supplemental funding purchases from the previous fiscal year. Work will be performed in Fort Worth, TX (60%) and Amarillo, TX (40%), and is expected to be completed in June 2017 (N00019-13-C-0023).

Lot 11 order

April 7/14: HMD. Thales Defense & Security Inc. in Clarksburg, MD received a $38.5 million firm-fixed-price, indefinite-delivery/indefinite-quantity contract for Optimized Top Owl (OTO) Helmet Mounted Sight and Display (HMSD) Sustainment Capability services. They’re replicating the facility, labor, materials, parts, test and tooling equipment from Bordeaux, France to the United States.

$1.8 million in FY 2014 Navy budgets is committed immediately. Work will be performed in Clarksburg, MD, and is expected to be complete in April 2019. This contract was not competitively procured pursuant to FAR 6.302-1 by NAWCAD in Lakehurst, NJ (N68335-14-D-0014).

March 28/14: Lot 12. Bell Helicopter Textron Inc. in Hurst, TX receives a $59.7 million contract modification, buying long-lead items for Lot 12’s 15 new-build UH-1Ys and 11 new-build AH-1Zs.

All funds are committed immediately, using FY 2014 Navy aircraft budgets. Work will be performed in Fort Worth, TX (60%) and Amarillo, TX (40%), and is expected to be complete in September 2015 (N00019-13-C-0023).

March 28/14: Support. Bell Helicopter Textron Inc. in Hurst, TX receives exercises an $11.4 million firm-fixed-price contract option for H-1 upgrade program systems engineering and program management support.

All funds are committed immediately, using FY 2014 USN aircraft budgets. Work will be performed in Hurst, TX, and is expected to be complete in December 2014 (N00019-12-C-0009).

March 4-11/14: Budgets. The US military slowly files its budget documents, detailing planned spending from FY 2014 – 2019. The numbers are featured in the charts above, and the detailed documents add this:

“FY 2015 Airframe cost increases account for prime contractor’s new Business System Modernization (BSM) accounting structure and increased internal research and development investment, Pension Protection Act pension harmonization and higher medical forecasts, and continued effects of large business base decline. Due to airframe cost increases and USMC priorities, the program… added one year of production. Compared to President’s Budget 2014, unit cost growth is a result of deferred aircraft to FY 2020…. electronics previously harvested from UH-1N and AH-1W aircraft at no-cost were procured new, at cost, for all future lots beginning in FY 2013…: CD-45/ALE-47(V) Chaff/Flare Programmer, ICS Boxes, MT-6711 TACAN Mount, RT-1798 TACAN Receiver, APR39 System, CP-1975/AAR-47(V)2 Central Processor, SU-211/AAR-47(V)2 Optical Sensor, AS-2728 Antennas AT-741B/A Antennas, EGIs, CV-20 Digital Converters. GFE Electronics increase in FY 2014 due to Mission Computer being provided as GFE instead of CFE.

All new engines are factored into the budget formulation for FY 2014 through the FYDP. The program prefers to procure new T-700-401C engines for higher maintainability and reliability, increased time on wing, and ultimately lower life-cycle costs. Refurbished T-700-401C engines are procured as budget constraints warrant and the H-60 B/F sundown schedule permits. An additional determining factor for refurb engine procurement is the repair (refurb) contract ceiling for H-1 with General Electric Engine Services (GEES), currently at sixteen engines per year. Due to funding constraints as a result of sequestration, program reductions, and airframe costs, 16 UH-1Y refurbished engines were procured in FY 2013.”

Jan 28/14: DOT&E Testing Report. The Pentagon releases the FY 2013 Annual Report from its Office of the Director, Operational Test & Evaluation (DOT&E). The H-1 upgrade program is included, and as of July 2013, Bell Helicopter has delivered 79/160 UH-1Ys and 32/189 AH-1Zs.

The big issue with the H-1s is software, and to a lesser extent support. The SCS 6.0 software has a critical flaw: if it detects a failure in any electronic warfare component, whether real or a “false positive”, the helicopter loses the entire EW display for all threat detection systems. That cost 2 of 23 missions during testing. This problem was detected during developmental testing, but DOT&E blandly says that “the operational implications of this loss of electronic warfare situational awareness were not apparent until operational testing.” Really?

They’re testing SCS 7.0, which hopes to correct this problem, and DOT&E concludes that “H-1 Upgrades units remain survivable against small arms and automatic weapons fire (up to 12.7 mm) and legacy Man-Portable Air Defense Systems.”

Meanwhile, they note that the test helicopters had problems with readiness rates because of long waits for repair parts. Tail and rotor systems were an especial problem, in part because operational units quite properly have priority. What they don’t say is whether the level of problems encountered are an indicator of larger issues.

Jan 22/14: Support. A $13.5 million cost-plus-fixed-fee delivery order for repair/overhaul work on 5 high priority UH-1Y/AH-1Z items.

$6.7 million in FY 2014 USN funds are committed immediately. Work will be performed in Hurst, TX, and the contract runs until January 2017. US Naval Supply Systems Command Weapon Systems Support in Philadelphia, PA manages the contract (N00383-14-D-015N, DO 0001).

Dec 19/13: Avionics. Northrop Grumman Guidance and Electronic in Woodland Hills, CA receives a $10.6 million firm-fixed-price contract for low rate initial production of 45 improved (“technical refresh”) AH-1Z and UH-1Y helicopters mission computers, which are now being bought direct (q.v. Dec 29/11 entry).

All funds are committed immediately, using FY 2012 USN aircraft procurement budgets, and will expire of Sept 30/14. Work will be performed in Woodland Hills, CA, and is expected to be complete in October 2015. This contract was not competitively procured pursuant to FAR 6.302-1 by the Naval Air Warfare Center Weapons Division in China Lake, CA (N68936-14-C-0020).

Dec 17/13: Sensors. Lockheed Martin Missiles and Fire Control in Orlando, FL receives a $34 million firm-fixed-price contract for the AH-1Z’s AN/AAQ-30(A) Target Sight Systems (TSS) and data. Based on past contracts, that’s about 12.

$31.2 million is committed immediately, using USN FY 2013 and 2014 aircraft procurement budgets. Work will be performed in Orlando, FL (80%), and Ocala, FL (20%), and is expected to be complete by May 2016. This contract was not competitively procured in accordance with 10 U.SC 2304(c)(1), as set forth in FAR 6.302-1(b)(1)(ii). The US Naval Surface Warfare Center in Crane, IN manages the contract (N00164-14-C-JQ65).

FY 2013

Orders; Loss in South Korea; Losing helicopters at program’s end?

AH-1Z, fully armed
(click to view full)

Sept 27/13: Training. Bell Helicopter Textron, Inc., Hurst, TX receives a $23.1 million firm-fixed-price contract modification to perform baseline configuration upgrades for 1 AH-1Z Full Flight Simulator, 1 UH-1Y Full Flight Simulator, and 1 UH-1Y Flight Training Device. All funds are committed immediately.

Work will be performed in Broken Arrow, OK (49%); Fort Worth, TX (35%) and St. Louis, MO (16%), and the larger contract runs until March 2017. The US Naval Air Warfare Center Training Systems Division, Orlando, FL manages this contract (N61340-12-C-0030).

Aug 27/13: Sensors. Lockheed Martin Missiles and Fire Control in Orlando, FL received a $34 million firm-fixed-price contract for the AH-1Z’s AN/AAQ-30 Target Sight Systems (TSS). All funds are committed immediately.

Work will be performed in Orlando, FL (80%), and Ocala, FL (20%), and is expected to complete by November 2015. The US Naval Surface Warfare Center in Crane, IN manages the contract (N00164-13-D-JQ43).

Aug 26/13: Sensors. FLIR Systems Inc. in Wilsonville, OR receives a 5-year sole-source $136.6 million firm-fixed-price, indefinite-delivery/ indefinite-quantity contract for BRITE Star Block II Systems (UH-1Y and MQ-8C), BRITE Star II’s class I engineering change proposal, plus BRITE Star I upgrades, cables, technical data, depot repairs, and engineering services. $4.2 million is committed immediately.

Work will be performed in Wilsonville, OR, and is expected to be complete by August 2018. The work was sole-sourced on the basis of FAR 6.302-1, “only one responsible source…” provision. The Naval Surface Warfare Center in Crane, IN manages the contract (N00164-13-D-JQ08).

July 15/13: Support. A $17.9 million firm-fixed-price, cost-plus-fixed-fee contract to add US Navy depot level maintenance infrastructure. Bell Helicopter will develop, test, and deliver 1 H-1 main rotor gearbox test stand, and 1 H-1 tail rotor/intermediate gearbox test stand. The contract includes logistics support, maintenance efforts, follow-on support, and associated data. This is unsexy, but experience in countries like Pakistan demonstrates that unless this infrastructure is in place and in use, helicopters will remain in place and not in use.

Work will be performed in Hurst, TX using FY 2011 procurement funds, and is expected to be complete in March 2017. All funds expire at the end of FY 2013, on Sept 30/13. This contract was not competitively procured pursuant to FAR 6.302-1. by the US Naval Air Warfare Center Aircraft Division in Lakehurst, NJ (N68335-13-C-0302).

June 18/13: Lot 10. A $38.8 million option order for 2 more new-build AH-1Z Vipers in Lot 10, whose main order was Dec 12/12. All funds are committed immediately, using FY 2013 procurement budgets. This brings that lot’s totals to 15 UH-1Ys and 12 AH-1Zs, with 1 AH-1Z option remaining.

Note that this doesn’t provide the full cost of 2 Vipers, and the USN places average flyaway costs for Lot 10 H-1 machines at over $26 million each. The difference will be made up via previous long-lead buys, and/or additional awards. Work will be performed in Fort Worth, TX (60%) and Amarillo, TX (40%), and is expected to be complete in September 2013 (N00019-12-C-0009).

June 18/13: Weapons. US NAVAIR touts the work of their PMA-242’s Crew Served Weapons Integration team, who redesigned the UH-1Y’s weapon mount to improve maximum elevation. That’s useful if you’re on or near the ground, being fired on from hills. In effect, the UH-1Y door gunner’s field of fire is now on par with the UH-1N in terms of overall range, azimuth and elevation.

Testing began in May 2013, and will continue at Pax River, MD for another 6 months or so. The USMC expects to deploy the new mounts to Afghanistan by the end of 2013. US NAVAIR.

May 28/13: Lot 11. Bell Helicopter Textron Inc. in Fort Worth, TX receives a $50.6 million advance acquisition contract modification for long-lead parts and components required for 25 Production Lot 11 helicopters: 15 UH-1Ys and 10 AH-1Zs, all new-build. All funds are committed immediately.

Work will be performed in Fort Worth, TX (60%) and Amarillo, TX (40%), and is expected to be complete in September 2014 (N00019-13-C-0023).

April 17/13: South Korea loss. South Korea announces that the AH-64E Apache Guardian has beaten the AH-1Z Viper and T-129 ATAK helicopters for a 1.8 trillion won ($1.6 billion), 36-machine order. The attack helicopter decision had been due in October 2012, but was put on hold until after the elections. The ROK hopes to have the helicopters between 2016 and 2018.

The AH-1Z would have represented continuity with the existing AH-1S fleet, and a DSCA export request was already approved (vid. Sept 25/12). The Italo-Turkish T-129 would have been a reciprocal deal with a major arms export customer. A DAPA official is quoted as saying that the AH-64E’s superior target acquisition capability, power, and weapons load gave it the edge, and so South Korea will begin the acquisition process. The weapons load issue is debatable, but the Apache is certainly much more heavily armored than its counterparts, and its combination of modernized optics and MMW radar or UAV control does give it an edge in target acquisition. Korea Herald | Reuters.

Loss in South Korea

April 10/13: FY 2014 Budget. The President releases a proposed budget at last, the latest in modern memory. The Senate and House were already working on budgets in his absence, but the Pentagon’s submission is actually important to proceedings going forward. See ongoing DID coverage.

The H-1 program is cut slightly from 26 total helicopters to 25 this year, as part of a longer-term set of slight reductions that will stretch out the program. FY 2014 drops from 26 – 25, FY 2015 drops from 27 – 26, FY 2016 drops from 31 – 27, and FY 2017 drops from 30 – 28. An order of 30 helicopters in FY 2018 leaves just 30 more to close out the program.

The key will be where reductions are focused. The AH-1Z is behind due to delays, so these and other cuts at the end of the program will force the Marines to decide whether they want fewer attack helicopters in the future force, as they contemplate adjustments to the production split. Especially if future budget pressures cut these planned numbers again. The alternative is to stretch production into later years, but that will raise total costs because the fixed costs come due for more years of work.

April 1/13: Lot 11 long-lead. A $13 million advance acquisition contract to provide long-lead parts and components required for Production Lot 11’s 15 UH-1Ys and 10 AH-1Zs. All are new-build helicopters – Lot 9 held the last remanufactured helicopters.

Work will be performed in Fort Worth, TX (60%) and Amarillo, TX (40%), and is expected to be complete in September 2014. All funds are committed immediately, using the FY 2013 Aircraft Procurement, Navy budget line. This contract was not competitively procured, pursuant to FAR 6.302-1 (N00019-13-C-0023).

Jan 16/13: Milestone. Bell Helicopter delivers the 100th H-1 upgrade helicopter to the US Marine Corps.

Bell Helicopter has since confirmed that it was a UH-1Y. Bell Helicopter | Fort Worth Star-Telegram Sky Talk.

#100

Jan 17/13: DOT&E testing. The Pentagon releases the FY 2012 Annual Report from its Office of the Director, Operational Test & Evaluation (DOT&E). The H-1 program is only included in passing, but it’s an interesting reference:

“The U.S. Army Aviation Applied Technology Directorate led a project to manufacture complex, curved ceramic armor for placement at strategic locations on aircraft, improving survivability with minimal weight impact. These installations protect flight-critical aircraft components that when damaged would lead to catastrophic aircraft loss. Due to their complexity, these structurally integrated panels required development of several cutting-edge material and processing technologies. Two implementations were demonstrated: the OH-58D Kiowa Warrior engine bay door and the AH-1Z Cobra helicopter flight control linkage bell-crank.”

Dec 27/12: Lot 10. A $418.9 million contract related to the FY 2012 order: 15 UH-1Y helicopters and 10 AH-1Zs. All helicopters will be new-build, and there are options for another 3 AH-1Zs. Two of those options were exercised on June 18/13, to make 12 AH-1Zs ordered.

The actual wording is “for the procurement of long lead parts and components required for the manufacture of…”, but NAVAIR has confirmed that this is the main Lot 10 order, covering FY 2013 helicopters for the most part. Work will be performed in Fort Worth, TX (60%) and Amarillo, TX (40%) and is expected to be complete in March 2016. All contract funds are committed immediately (N00019-12-C-0009).

Lot 10 order

Dec 20/12: Support. A $15.3 million firm-fixed-price, cost-plus-fixed-fee advance acquisition contract modification. Bell Helicopter will provide H-1 Upgrade Program systems engineering and program management services.

Work will be performed in Hurst, TX and is expected to be complete in December 2013. All contract funds are committed immediately (N00019-12-C-0009).

Dec 20/12: Support. A $12.3 million to a previously awarded firm-fixed-price, cost-plus-fixed-fee contract modification to support of the H-1 Upgrade effort. Work will include logistics management support, technical material for maintenance planning, design interface, supply/material support; support of support equipment/technical data, distribution and inventory management/packaging; handling, storage and transportation; logistics management information; supportability analysis and technical manuals.

All contract funds are committed immediately. Work will be performed in Fort Worth, TX, and is expected to be complete in December 2013 (N00019-11-C-0023).

Nov 20/12: HUMS. Simmonds Precision Products Inc. (dba Goodrich Sensors and Integrated Systems in Vergennes, VT) receives a $6.9 million modification to a previously awarded firm-fixed-price contract, exercising an option for 28 integrated AH-1Z/UH-1Y mechanical diagnostic and health usage monitoring system kits.

This would appear to cover FY 2013 production: 13 AH-1Zs and 15 UH-1Ys. HUMS systems are undervalued by causal observers, but they pay for themselves very, very quickly via more cost-effective maintenance and higher in-service rates.

Work will be performed in Vergennes, VT, and is expected to be complete in May 2014. All contract funds are committed. US Naval Air Systems Command, Patuxent River, Md., is the contracting activity (N00019-12-F-4003).

Nov 6/12: Mission Computers. Northrop Grumman Guidance and Electronics Co., Inc. in Woodland Hills, CA receives a $9.3 million firm-fixed-price modification for 54 GEN II mission computers and trays, per the new buying arrangements (vid. Dec 29/11 entry). They’ll be used in Production Lot 10, which is mostly FY 2013 buys.

Work will be performed in Salt Lake City, UT, and is expected to be complete in January 2015. US Naval Air Systems Command in Patuxent River, MD (N00019-11-G-0016).

Oct 16/12: Lot 9. A $391.4 million firm-fixed-price contract modification. As we saw on July 25/11, the Pentagon’s turgid language involving “definitization… to provide long lead parts” means that it’s the main Production Lot 9 (mostly FY 2012) buy, which is added to the previous contracts for long lead time components. US NAVAIR places the total Lot 9 contract at $447.8 million, plus any separately bought “government furnished equipment” like the T700 engines, mission computers (vid. Dec 29/11 entry), weapons and mounts, defensive systems, etc. Those “extras” add up.

The contract covers 15 new UH-1Ys (all new) and 10 AH-1Zs (3 remanufactured, 7 new). According to NAVAIR, Lot 9 will be the final production lot that will include remanufactured AH-1Z aircraft.

Work will be performed in Fort Worth, Texas (60%) and Amarillo, TX (40%), and is expected to be completed in July 2015 (N00019-11-C-0023).

Lot 9 order

FY 2012

Orders; AH-1Z competes in South Korea; AH-1Z maiden operational deployment; AH-1W swap to Turkey; UH-1Ys using precision rockets.

UH-1Y & AH-1Z
(click to view full)

Sept 25/12: South Korea. The US Defense Security Cooperation Agency announces [PDF] South Korea’s request to buy up to 36 AH-1Z Viper attack helicopters and associated equipment, parts, training and logistical support. The cost would be up to $2.6 billion, but this isn’t a contract. It doesn’t even mean that the AH-1Z is the ROK’s choice. South Korea is conducting a competition to replace its attack helicopters, and the DSCA request will make sure that everything the ROK wants is available if the AH-1Z is picked.

They appear to have picked the AH-1Z as the American contender, even though the AH-64D Apache Block III’s fuselage is made locally by KAI. That still leaves 2 more strong contenders. EADS Eurocopter is already producing Surion medium helicopters under a Korean Joint Venture, and is offering their EC665 Tiger attack helicopter. It’s in service with France, Germany, Spain, and Australia. The other contender is AgustaWestland/TAI’s T129, which is now a joint Italian/Turkish venture. Turkey is South Korea’s biggest defense export customer by far, and a loss could ruffle some important feathers. As for the AH-1Z, the DSCA request includes:

• 36 AH-1Z Viper attack helicopters
  
• 84 T-700-GE-401C Engines (72 installed and 12 spares)
  
• Integrated missile launchers
  
• 288 AGM-114K3 Hellfire laser-guided strike missiles
  
• 72 AIM-9M-8 Sidewinder air-air missiles. The missile’s range and performance are superior to weapons carried on other helicopters.
  
• AN/AAQ-30 Target Sighting Systems (TSS)
  
• APX-123 Identify Friend or Foe (IFF) Mode-4
  
• Electronic warfare systems: AN/ALQ-136 Radar Frequency Jammers, AN/AAR-47 Missile Warning System, AN/ALQ-144 Infrared Jammer, AN/ALE-47 Chaff and Flare Decoy Dispenser
  
• Communication and support equipment, spare engine containers, spare and repair parts, tools and test equipment, technical data and publications, personnel training and training equipment, and other US government and contractor support.

The prime contractors will be Bell-Textron Corporation in Amarillo, TX (helicopter), and General Electric in Lynn, MA (engines), though many of the ancillary items will come from firms like Lockheed Martin, Raytheon, BAE, et. al. Implementation will require multiple trips to Korea involving U.S. Government or contractor representatives on a temporary basis for program and technical support, and management oversight.

South Korea request

Sept 25/12: Training. A $44.7 million firm-fixed-price contract to buy 2 UH-1Y Flight Training Devices (simulators) for the US Marine Corps. In addition, this contract provides for the baseline configuration upgrade to create an AH-1Z FTD from the previous AH-1W simulator.

Work will be performed in Fort Worth, TX (46%); Broken Arrow, OK (32.4%); St. Louis, MO (16.2%); and Austin, TX (5.4%), and is expected to be complete in March 2015. $19.8 million will expire at the end of the current fiscal year, on Sept 30/12. This contract was not competitively procured pursuant to 10 U.S.C. 2304c1 by the US Naval Air Warfare Center Training Systems Division in Orlando, FL (N61340-12-C-0030).

April 3/12: Buy direct. US NAVAIR has made a slight acquisition shift, and is now ordering mission computers for the UH-1Y and AH-1Z directly from Northrop Grumman, instead of through prime contractor Bell Helicopter. Under the initial $8.9 million contract, Northrop Grumman will provide Gen II mission computers to the U.S. Marine Corps Light Attack Helicopter Program (PMA-276) directly, reducing the item’s price.

The dual mission computers are the heart of Northrop Grumman’s Integrated Avionics System (IAS) that powers the helicopters’ glass cockpits. Northrop Grumman.

Mission computers direct

March 2012: Laser-guided rockets. The APKWS laser-guided 70mm rocket is cleared for fielding by Marine Corps HQ, and shipped to Afghanistan. The rockets will initially be deployed in existing rocket launchers on USMC AH-1W Super Cobra attack helicopters, and UH-1Y Venom utility helicopters. It will be the UH-1Ys first precision-guided weapon, dramatically increasing its firepower.

BAE cites cite over 100 APKWS firings since 2007, with a 94% success rate, and an average distance from the center of laser spot to the impact point of less than one meter. US NAVAIR | BAE Systems.

Feb 13/12: FY 2013 request. The Pentagon releases its budget. FY 2013 would see it spend up to $851.5 million to buy 15 new-build UH-1Ys, and 13 AH-1Zs (4 remanufactured, 8 new, 1 new combat loss replacement). Over the longer term, the H-1 Upgrades program also escapes budget cuts.

Feb 13/12: A $56.75 million advance acquisition contract to provide long lead parts and components required for the manufacture of H-1 upgrade Lot 10 UH-1Y (15) and AH-1Z (13) helicopters. As noted above, correspondences aren’t exact, but these are mostly FY 2013 helicopters.

Work will be performed in Fort Worth, TX (60%), and Amarillo, TX (40%), and is expected to be complete in September 2013. This contract was not competitively procured pursuant to FAR 6.302-1 (N00019-12-C-0009).

Dec 28/11: A $20.4 million firm-fixed-price, cost-plus-fixed-fee contract modification, exercising an option for H-1 upgrade program logistics management support; distribution and inventory management/packaging, handling, storage & transportation; logistics management information; technical material for maintenance planning; design interface; supply/material support; technical data, support of support equipment; technical data; supportability analysis; technical manuals and logistics/technical liaison support.

Work will be performed in Fort Worth, TX (96%) and Afghanistan (4%) and is expected to be complete in December 2012 (N00019-10-C-0035).

Dec 27/11: Northrop Grumman Guidance and Electronics Co., Inc. in Woodland Hills, CA received an $8.9 million firm-fixed-price delivery order for 52 GEN II mission computers, which will be used in H-1 upgrade production Lot 9 (mostly FY 2012). Work will be performed in Woodland, CA, and is expected to be complete in January 2014 (N00019-11-G-0016).

Dec 13/11: Bell Helicopter Textron, Inc. in Fort Worth, TX received a $13.9 million firm-fixed-price, cost-plus-fixed-fee contract modification for systems engineering and program management work related to AH-1Z and UH-1Y production aircraft. Work will be performed in Fort Worth, TX and will run to December 2012 (N00019-11-C-0023).

Dec 8/11: An $85.2 million cost-plus-fixed-fee, firm-fixed-price, indefinite-delivery/ indefinite-quantity contract for design, development, studies, and implementation of upgrades to existing H-1 software and ancillary hardware, and/or improved functionality and electronics obsolescence management. Since the H-1 upgrades are designed to use the same cockpit electronics, investments in upgrades can benefit the whole fleet. As noted above, Northrop Grumman in the main sub-contractor for all cockpit systems.

Work will be performed in Woodland Hills, CA (70%); Hurst, TX (25%); and China Lake, CA (5%), and will run to December 2014. This contract was not competitively procured pursuant to 10 U.S.C. 2304c1. The US Naval Air Warfare Center Weapons Division at China Lake, CA manages this contract (N68936-12-D-0003).

Dec 5/11: Lockheed Martin announces a pair of AN/AAQ-30 TSS spares and AH-1Z program support contracts from the US Naval Surface Warfare Center. Their release distinguishes these $30.6 million in support contracts for the AH-1Z’s surveillance and targeting turrets, from the TSS production contracts in March 2008, June 2010, and September 2011.

Nov 14/11: When USS Makin Island sailed on her maiden deployment, she sailed with the 1st operational deployment of AH-1Z Viper attack helicopters. The 4 AH-1s and 3 UH-1Ys function as a detachment of Marine Light Attack Helicopter Squadron 367 (HMLA-367). NGC put out the release, to tout the common “Integrated Avionics System” cockpits that equip both helicopters.

AH-1Z deployment

Oct 31/11: Turkish swap. With Turkey’s fleet of serviceable AH-1 Cobra attack helicopters dwindling, demands from the Army for helicopters to use against the Marxist Kurdish PKK in Turkey and Iraq, and no arrival of even its emergency configuration T129 attack helicopters before mid-2012, Turkey launches an official request [PDF] for 3 AH-1W Super Cobra attack helicopters from US Marine Corps stocks. They’ll also get 7 T700-GE-401 engines (6 installed/ 1 spare), plus inspections and modifications, spare and repair parts, personnel training and training equipment, publications and technical documentation, and U.S. Government and contractor support.

The estimated cost is $111 million, and all sale proceeds will be reprogrammed into the USMC’s H-1 helicopter upgrade program. Implementation of this proposed sale will require the assignment of approximately 5 contractor representatives to Turkey for a period of up to 90 days, for differences training between U.S. and Turkish AH-1Ws helicopters.

FY 2011

Orders; AH-1Z achieves IOC, bull Full Operational Capability not until 2020; AH-1Z approved for Full-Rate Production; AH-1Z export strategy.

UH-1Y, Afghanistan
(click to view full)

Sept 27/11: Sensors. Lockheed Martin Missiles and Fire Control in Orlando, FL receives a $16.7 million firm-fixed-price contract for 6 spare AN/AAQ-30 surveillance and targeting turrets for the AH-1Z Viper attack helicopter.

Work will be performed in Orlando, FL (90%), Ocala, FL (10%), and is expected to be complete by December 2014. This contract was not competitively procured by the US Naval Surface Warfare Center, Crane Division in Crane, IN (N00164-11-G-JQ97).

Sept 22/11: Rotor redesign. A $10 million cost-plus-fixed-fee delivery order to develop the H-1 cuff and yoke redesign, but not mass-produce it yet. These important parts of the rotor were falling well short of their expected service life, and this delivery order will include initiating the design-build-buy activities; part/drawing release; support analysis for detailed design, preparation, execution, and follow up for preliminary design review; process development for yoke full-scale process and drive system center; complete tooling conceptual designs and initiate tooling preliminary design; structural qualification; and flight test plans requirements.

Work will be performed in Fort Worth, TX, and is expected to be complete in May 2013 (N00019-11-G-0003). See also March 2/11 entry.

Aug 30/11: Sensors. Lockheed Martin Missiles and Fire Control in Orlando, FL receives a $50 million firm-fixed-price contract for 18 of the AH-1Z’s AN/AAQ-30 target sight systems (TSS). The DefenseLINK release identifies them as being specifically for the AH-1Z program; they are also found on armed C-130s operated by the USMC and US SOCOM.

Work will be performed in Orlando, FL (90%) and Ocala, FL (10%), and is expected to be complete by August 2014. The contract was not competitively procured, in accordance with 10 U.S.C. 2304c1 and FAR 6.203-1b-1-ii. The Naval Surface Warfare Center, Crane Division in Crane, IN manages the contract (N00164-11-C-JQ77).

Aug 25/11: Innovation. USMC Sgt. Zachary Lucas gets a Navy and Marine Corps Achievement Medal and a $5,000 check for inventing the “Lucas Seat” that’s now standard issue on UH-1Ys.

The helicopter’s 3 seats in the center were getting in the way of employing the door guns and tending the packs, so Lucas designed a 2-man bed seat while serving in Afghanistan, in 2009. It passed through some iterations on its way to becoming a Corps-wide issue, and the current configuration allows for a 3-man bench seat or a single seat.

Lucas’ peers are currently developing a hold-down map rack to install in the center area between pilots and the crew, making it easier for the crew to read them while the helicopter is in flight. Pentagon DVIDS.

The Lucas Seat

July 25/11: A $550 million firm-fixed-price modification that lists itself as being “for long lead materials and components associated with” the manufacture and delivery of 35 helicopters: 19 UH-1Y Lot 8 new-build, 8 AH-1Z remanufactured, and 6 AH-1Z Lot 8 new-build helicopters.

In reality, this modification is the “production definitization” of the Lot 8 Advance Acquisition Contract. In English: It’s the main Lot 8/ FY 2011 contract. Now, why couldn’t they just say that? See Feb 5/10 entry for the accompanying partial long lead-time items contract, of $50.4 million. That makes $600.4 million so far for 35 helicopters, not including items like key electronics, sensors, etc. Work will be performed in Fort Worth, TX (60%), and Amarillo, TX (40%), and is expected to be complete in February 2014 (N00019-10-C-0015).

FY 2011 order

June 6/11: FY 2012 lead-in. A $7.2 million contract modification to buy Lot 9 long-lead items for the USMC’s H-1 Upgrades Program. Per notes above, Lot 9 mostly involves FY 2012 purchases. See also March 14/11.

Work will be performed in Fort Worth, TX (60%), and Amarillo, TX (40%), and is expected to be complete in September 2012 (N00019-11-C-0023).

March 16/11: Sub-contractors. Simmonds Precision Products, Inc., dba Goodrich Corp. in Vergennes, VT receives a $7.4 million firm-fixed-price contract for 30 integrated mechanical diagnostic and health usage monitoring system (IMD/HUMS) units for FY 2011 “Lot 8 production upgrade aircraft”: 19 UH-1Ys and 8 AH-1Zs). Work will be performed in Vergennes, VT, and is expected to be completed in November 2012. This contract was not competitively procured (N00019-11-F-4002).

IMD/HUMS contracts aren’t very big by themselves, but their long term impact on a fleet’s readiness and operating costs is quite significant. They shift maintenance away from programmed formulas toward less expensive at-need practices, and are instrumental in tracing faults and spurring useful upgrades. As data accumulates, HUMS can even be used to make proactive predictions.

March 14/11: FY 2012 lead-in. A $48.4 million advance acquisition contract to provide long lead parts and components required for 26 Lot 9 (FY 2012) UH-1Y and AH-1Z helicopters for the Marine Corps: 15 UH-1Y build new aircraft; 4 AH-1Z remanufactured aircraft; and 7 AH-1Z new-build aircraft. That’s not quite in sync with the stated FY 2012 budget request (18 new UH-1Y, 2 AH-1Z remanufactured, 5 AH-1Z new-build incl. 1 supplemental), but as noted above, supplemental/OCO helicopters can end up under contract in the next year.

Work will be performed in Fort Worth, TX (60%), and Amarillo, TX (40%), and is expected to be complete in September 2012. Contract funds will not expire at the end of the current fiscal year, on Sept 30/11. This contract was not competitively procured (N00019-11-C-0023).

March 9/11: US NAVAIR announces that the AH-1Z Cobra achieved Initial Operating Capability ahead of [the new] schedule in February 2011, and will deploy to Afghanistan later in 2011.

U.S. Marine Corps Light and Attack Helicopters program manager, Col. Harry Hewson, reiterates the current program target of 131 remanufactured AH-1Zs from existing AH-1W helicopters, and 58 new AH-1Zs. Full operational capability, defined as when all AH-1Z maintenance and repair support, test equipment, and spares are in place to support active component force primary aircraft authorization, isn’t expected until 2020.

AH-1Z IOC, but FOC will be late

March 2/11: Rotor redesign. A $12.6 million cost-plus-fixed-fee order to support the AH-1Z and UH-1Y’s cuff and yoke redesign. The reason for this contract is that several rotor components are falling far short of the original 10,000 hour reliability goal. Work will be performed in Fort Worth, TX, and is expected to be complete in June 2013 (N00019-11-G-0003).

Feb 15/11: Engines. General Electric Engine Services, Inc. in Cincinnati, OH receives a $13.8 million firm-fixed-price, indefinite-delivery/ indefinite-quantity contract modification to repair 15 T700-GE-401 engines and 36 T700-GE-401C engines for the AH-1Z and UH-1Y helicopters. The -401C engines equip all UH-1Ys and new-build AH-1Zs, and may eventually be retrofitted to the remanufactured AH-1Zs; see Sept 15/09 entry for more details.

Work will be performed in Winfield, KS, and is expected to be completed in February 2012. Contract funds in the amount of $4,349,904 will expire at the end of the current fiscal year, n Sept 30/11 (N00421-09-D-0008).

Jan 14/11: Exports? Aviation Week says the AH-1Z is slated to deploy to Afghanistan in November 2011, and adds some insight on the export front:

“[Vice president of military business development at Bell, Richard] Linhart says Bell intends to underbid the current Apache model and Eurocopter Tiger HAD, which is being fielded in France and Spain. However, with the near-term focus on adding volume to the USMC fleet, production slots are not likely to emerge for foreign customers until 2012 at the earliest.”

There have been unconfirmed rumors, not reported by Aviation Week or other publications, that the AH-1Z was offered to Iraq, which held out for AH-64D Apaches but was refused.

Dec 30/10: Support. A $22 million firm-fixed-price, cost-plus-fixed-fee contract modification to exercise an option for logistics products and services in support of H-1 helicopter upgrade program. Services include logistics management support, technical material for maintenance planning, design interface, supply/material support, technical data, distribution and inventory management/packaging, handling, storage and transportation, logistics management information, supportability analysis, technical manuals, and logistics support/technical liaison support.

Work will be performed in Fort Worth, TX (96%), and Afghanistan (4%), and is expected to be complete in December 2011 (N00019-10-C-0035).

Dec 28/10: Infrastructure. A $13.5 million firm-fixed-price, cost-plus-fixed-fee contract modification, exercising an option for system engineering, and program management overseeing H-1 helicopters upgrade program production. Work will be performed in Fort Worth, TX, and is expected to be complete in December 2011 (N00019-10-C-0035).

Nov 28/10: The AH-1Z is approved for full rate production, as Under Secretary of Defense for Acquisition, Technology & Logistics, Dr. Ashton B. Carter issues a milestone III acquisition decision memorandum.

NAVAIR’s release reiterates that: “A total of 189 new and remanufactured AH-1Z helicopters are anticipated, with deliveries expected to be complete by the end of 2021.”

AH-1Z FRP

FY 2010

Orders; AH-1Z passes testing; GAO program review cites woes, progress; Manufacturing expansion.

AH-1Z: Hellfire test
(click to view full)

Sept 24/10: AH-1Z OpEval. The US Navy’s Commander, Operational Test and Evaluation Force, notifies NAVAIR’s H-1 Upgrades program office that the AH-1Z was found to be “operationally effective and suitable” during Operational Evaluation, and have been recommended for fleet introduction. Operational effectiveness means it can perform its missions. Operational suitability refers to the platform’s reliability and the service’s ability to support it.

That designation clears an important delay for the program, and NAVAIR adds that:

“A total of 189 new and remanufactured AH-1Z helicopters are anticipated, with deliveries expected to be complete by the end of 2021… The evaluation report noted that the AH-1Z fire control and additional weapons delivery modes allowed for improved weapons delivery accuracy, reduced pilot workload, and enhanced employment flexibility compared with the AH-1W. The H-1 Upgrade Program offers 84 percent “identicality” of parts shared between the AH-1Z and UH-1Y helicopters.”

AH-1Z passed OpEval

Sept 13/10: Sub-contractors. L-3 Platform Integration Crestview Aerospace in Crestview, FL announces [PDF] a follow-on contract from Bell Helicopter Textron to produce another 38 UH-1Y cabin assemblies between 2010 – 2013.

Under the preceding contract, L-3 Crestview Aerospace has delivered 35 cabin assemblies to Bell, with 5 remaining under contract.

June 16/10: Bell Helicopter Textron, Inc. in Fort Worth, TX is being awarded a $546 million firm-fixed-price, cost-plus-fixed-fee contract for Production Lot 7 UH-1Y and AH-1Z helicopters for the US Marine Corps: 18 new UH-1Ys, 9 remanufactured AH-1Zs; and 2 new AH-1Zs.

Work will be performed in Fort Worth, TX (60%), and Amarillo, TX (40%), and is expected to be complete in July 2013. This competition was decided long since, so the contract was not competitively procured (N00019-10-C-0035).

FY 2010 order

April 20/10: Sensors. Lockheed Martin Missiles and Fire Control in Orlando, FL receives a $44.4 million firm-fixed-price supply contract for 18 AN/AAQ-30 thermal sight system (TSS) and associated data, for use on AH-1Z helicopters. Work will be performed in Orlando, FL (90%), and Ocala, FL (10%), and is expected to be completed by October 2012. Contract funds will not expire at the end of the current fiscal year. The Naval Surface Warfare Center, Crane, IN manages the contract (N00164-10-C-JQ84). Lockheed Martin release

This is a follow-on order to the initial 16 system order placed March 28/08. The first production system was delivered on June 30/08, and see also the Sept 28/09 long-lead contract. Delivery of all systems contracted under Lot 6 and 7 low-rate initial production will be complete in 2011. Lockheed Martin’s TSS has had integration problems with Thales’ TopOwl helmet-mounted sight, but the Marines are hoping that their fixes will prevail during 2010 Operational Evaluations. If OpEval goes well, a contract for full-rate production of 226 total units is expected in fall 2010.

March 30/10: GAO Report. The US GAO audit office delivers its 8th annual “Defense Acquisitions: Assessments of Selected Weapon Programs report. Overall, the H-1 upgrade program has risen in both costs and quantity since the October 1996 baseline. As of December 2008, program R&D had risen from the $680.2 million baseline to almost $1.84 billion (170% growth), while total program cost has risen from $3.54 billion to about $11.52 billion. Part of that involves an original target of 284 helicopters jumping to 353 (+24.3%), but part of it involves issues that pushed procurement costs up by 239.2%, to $9.69 billion, and have delayed the program. GAO summarizes:

“In December 2008, the Navy reported a unit cost increase of 19 percent over the program’s then current baseline, breaching the significant cost growth threshold. Program officials stated this breach was due to growth in the cost of material, labor, government furnished equipment, and nonrecurring engineering. This breach followed four previous major restructuring efforts. The program’s new acquisition program baseline delays completion of operational testing for the AH-1Z by 28 months from March 2008 to July 2010 and establishes a new full-rate production decision review for the AH-1Z, which is planned for October 2010. The revised baseline also accounts for an almost 25 percent increase in planned procurement quantities from 280 to 349 aircraft (123 UH-1Ys and 226 AH-1Zs) to support the Marine Corps’ growth plans.”

In terms of program progress, the UH-1Y is already in full-rate production and operating on the front lines, and is demonstrating “3x normal operating rates” versus older Hueys, along with better ability to cope with the performance-draining effects of hot and/or high altitude conditions. AH-1Z risk reduction testing is complete, and the AH-1Z Operational Evaluation (OPEVAL) begins in spring 2010. The Navy says that “[p]reviously noted deficiencies with Target Sight System, rocket gas ingestion, helmet mounted sight system, and mission software have been corrected and will be formally assessed” in that OpEval.

Overall, “supplier base issues” have slowed production, and advance funding for long-lead items is expected to help resolve prior supply issues. At present, the GAO is concerned that Bell Helicopter has yet to demonstrate the 28 helicopters per year pace called for in the FY 2010 budget, and revised program baseline. On the other hand, 52 UH-1Y and 21 AH-1Z aircraft were on contract as of December 2009, with LRIP phase deliveries happening in accordance with the production ramp-up plan, and the last 13 helicopter deliveries coming ahead of schedule.

Feb 5/10: FY 2011 lead-in. An undefinitized advance acquisition contract with an estimated value of $50.4 million for long lead materials and components associated with the manufacture and delivery of 18 Lot 8 UH-1Y build new aircraft, 8 Lot 8 AH-1Z remanufactured aircraft, and 1 Lot 8 AH-1Z build new aircraft. Work will be performed in Fort Worth (60%) and Amarillo, TX (40%), and is expected to be complete in January 2014 (N00019-10-C-0015).

Dec 11/09: Support. A not-to-exceed ceiling-price $14.8 million contract for repair coverage for 8 “items required to support the H-1 aircraft.” Work will be performed in Fort Worth, TX, and is expected to be complete in December 2010. This contract was a sole source, with manufacturer Bell Helicopter deemed the “sole source responsible and responsive offeror.” The Naval Inventory Control Point in Philadelphia, PA manages the contract.

Oct 23/09: Industrial. A ceremony in Amarillo, TX marks breaks ground for a new 137,000 square foot H-1 Hangar at Bell’s Military Aircraft Assembly and Delivery Center. The hangar is slated to be complete in October 2010, and will be capable of housing up to 10 UH-1Y and AH-1Z helicopters at a time as the H-1 program’s annual production numbers grow.

Amarillo is also home for the final assembly of the V-22 Osprey tiltrotor aircraft, following its selection 11 years ago by Bell. Since then, public/ private partnerships between the city, Amarillo College, the Amarillo Economic Development Center and Bell have worked to provide both the infrastructure required, and a trained and capable workforce. Bell’s delivery goals for 2010 are 28 V-22 and 20 H-1 aircraft.Textron release.

FY 2009

Orders; 1st production AAQ-30 TSS delivered; Problem parts; Program change to more rebuilds.

AN/AAQ-30 TSS
(click to view full)

Sept 28/09: Sensors. Lockheed Martin Missiles and Fire Control, Orlando, FL is being awarded a $11.5 million firm-fixed-price contract for long lead time components for 8 of the AH-1Z’s target sight systems (TSS). Long lead material includes the gimbal assembly and laser designator, and the advance orders are used to reduce TSS production delivery time.

Work will be performed in Orlando, FL, and is expected to be complete by May 2011. Since the AN/AAQ-30 TSS has already been selected, this contract was not competitively procured by the Naval Surface Warfare Center in Crane IN (N00164-09-C-JQ82).

Sept 15/09: Engines. Bell Helicopter Textron, Inc. in Fort Worth, TX received a $35.8 million cost-plus fixed-fee delivery order against a previously issued basic ordering agreement to provide Phase 2 non-recurring engineering for the AH-1Z new-build helicopter airframe, and to develop an engineering change proposal related for incorporating the T700-401C engine.

The -401C engine is present in all new-build AH-1Zs, but at present it is not inserted into remanufactured helicopters, which use refurbished T700-401 engines from the existing AH-1Ws. At some point in the future, as funding allows, NAVAIR says that the Marines also plan to retrofit any remanufactured AH-1Zs that still have older engines with T700-401Cs. This ECP paves the way for that future change as well.

Work will be performed in Ft. Worth, TX (50%) and Amarillo, TX (50%), and is expected to be complete in April 2013. All contract funds will expire at the end of the current fiscal year (N00019-06-G-0001).

Aug 3/09: Bell Helicopter Textron, Inc. in Fort Worth, TX received a $6.3 million cost-plus-fixed-fee delivery order against a previously issued basic ordering agreement to provide 3D modeling in support of the AH-1Z new-build new program, including associated technical data for the Marine Corps.

Work will be performed in Fort Worth, TX and is expected to be complete in February 2010. All contract funds will expire at the end of the current fiscal year, on Sept 30/09 (N00019-05-G-0001).

June 30/09: Sensors. Lockheed Martin delivers its first AAQ-30 Target Sight System (TSS) production unit, at a ceremony held at its Orlando, FL, facility. USMC Col. Harry Hewson of PMA-276 is present. Production of the 16 systems ordered under the March 28/08 contract will take place at Lockheed Martin’s facilities in Ocala and Orlando, FL, and will be complete in 2010. Lockheed Martin release.

June 25/09: The US Senate Armed Services Committee issues Report 111-035. An excerpt concerns the UH-1Y/AH-1Z program:

“Fiscal year 2010 would be the first year of buying new AH-1Zs. Operational testing for the UH-1Y has been completed, which resulted in a positive Milestone B decision in September 2008. Operational testing for the AH-1Z has been delayed, mainly due to issues surrounding the targeting sight system. The program office now predicts that operational testing for the AH-1Z configuration will not be completed until late in fiscal year 2010. Also since last year, the Secretary of the Navy notified Congress that the Service Acquisition Executive had determined the program had breached the significant cost growth threshold of 15 percent, compared to the baseline average procurement unit cost.

The committee recommends a decrease of $282.9 million to keep the UH-1Y/AH-1Z program at the same level of effort as fiscal year 2009.”

In the end, it makes no difference. Section 211 of the S.1390 budget bill, which passes in the Senate on July 23/09, restores this funding.

June 15/09: Bad parts. Aviation Week reports that

“[USMC Lt. Gen. George J.] Trautman is also monitoring problems with recently delivered UH-1N and AH-1Z aircraft delivered to the Navy/Marine Corps from Bell. Bad parts from a subvendor caused problems with the transmission in these aircraft. Fixes are underway, and by mid-July, these helicopters will be back in service, he says.

The USMC is also planning to deploy the new Hueys to the Afghan theater later this year. Operational testing of the AH-1Z is expected to finish next year, Trautman says.”

April 22/09: Testing. The US Air Force discusses cooperative efforts with the Marine Corps to figure out exactly how to load the UH-1Y Venom and AH-1Z Viper into the C-5 Galaxy transport:

“…the Marines have been working with Air Force representatives for three months to find the best method of transporting their helicopters to the fight. According to John Buchanan, 60th APS cargo operations manager, they tried to use a C-17 Globemaster III first but found they had to strip too many parts off the helicopter. So the next logical step was to test the C-5 capability.”

These helicopters’ 4-bladed rotor doesn’t fully fold, which makes even the C-5 has been a challenge. At one point in the loading process, clearance for the UH-1Y helicopter is down to 3 inches.

April 7/09: Support. A not-to-exceed $14.6 million modification to a previously awarded cost plus fixed fee contract (N00019-06-C-0086) for H-1 Upgrade logistics products and services, including: logistic management support, technical material for maintenance planning, design interface, supply /material support, support of support equipment, technical data, distribution and inventory management/packaging, handling, storage & transportation, configuration management, supportability analysis, aircraft acceptance discrepancies, and contractor logistics support/technical liaison.

Work will be performed in Fort Worth, TX and is expected to be complete in May 2010.

April 6/09: Industrial. A $9.25 million cost-plus-fixed-fee contract to buy production rate tooling for the H-1 program. Work will be performed in Fort Worth, TX (70%) and Amarillo, TX (30%), and is expected to be complete in December 2011. This contract was not competitively procured (N00019-09-C-0023).

March 26/09: A $288.9 million firm-fixed-price contract for the FY 2009 (Lot 6) buy of 11 UH-1Y and 5 AH-1Z helicopters and associated technical data for the U.S. Marine Corps. Work will be performed in Fort Worth, TX (60%) and Amarillo, TX (40%), and is expected to be complete in October 2011. This contract was not competitively procured (N00019-09-C-0023). Bell Helicopter’s release adds:

“Bell is now on contract to produce a total of 65 upgraded H-1 aircraft for the Marines: 17 AH-1Z attack aircraft and 48 UH-1Y utility aircraft. So far, the company has delivered 23 upgraded H-1 helicopters: six AH-1Zs and 17 UH-1Ys.”

FY 2009 order

Jan 13/09: Sub-contractors. A Northrop Grumman release touts the role of its Integrated Avionics System (IAS), and the company’s efforts in preparing the UH-1Y Huey helicopters for initial deployment early in 2009 with the 13th Marine Expeditionary Unit.

Dec 18/08: Support. A $10.5 million firm-fixed-priced delivery order against a previously issued basic ordering agreement (N00019-06-G-0001). It covers Systems Engineering and Program Management (SE/PM) for Lot 6 production under the H-1 Upgrade program.

Work will be performed in Hurst, TX (79%); Amarillo, TX (15%); and New Bern, NC (6%), and is expected to be complete in December 2009.

Nov 12/08: Support. A $12.8 million modification to a previously awarded firm fixed price contract (N00019-06-C-0086) to prepare, validate and deliver revisions to organizational, intermediate and depot level technical manuals in digital format. Work will be performed in Fort Worth, TX, and is expected to be complete in May 2010. All funds will expire at the end of the current fiscal year.

Oct 27/08: More rebuilt AH-1Zs. Inside Defense reports that:

“The H-1 helicopter program has nearly cut in half the number of Marine Corps AH-1Z attack helicopters it plans to build from scratch in order to avoid a breach of the Nunn-McCurdy Act, which requires that the Pentagon notify Congress when a program exceeds certain cost thresholds, the program office acknowledged last week…”

Oct 7-16/08: The new Bell UH-1Y is tested as part of the Boxer Expeditionary Strike Group (BOXESG) integration exercise, flying from USS Boxer [LHD 4]. US Navy.

FY 2008

Orders; Marines want a larger program; UH-1Y reaches IOC; Why AH-1Z slipped.

UH-1Y on LHD 4
(click to view full)

Sept 30/08: A $210.2 million modification to a previously awarded firm-fixed-price contract . NAVAIR is exercising its contract option to make the FY 2008 purchase of 11 UH-1Y scout/utility helicopters, and 4 AH-1Z Viper attack helicopters.

Work will be performed in Fort Worth, TX (60%) and Amarillo, TX (40%), and is expected to be complete in January 2011 (N00019-06-C-0086).

FY 2008 order

Sept 29/08: FLIR systems receives a contract from the US Navy and Marines for 116 AN/AAQ-22E Brite Star II surveillance and targeting turrets, 25 upgrades from AAQ-22D to AAQ-22E status, and non-warranty repair and support for their BRITE STAR turret stocks. Purchases for the UH-1Y are included within this order.

Aug 22/08: More H-1s. Flight International reports that September 2008 will see the US Navy propose adding 69 aircraft to the Bell Helicopter H-1 upgrade program, despite a recent setback during an operational evaluation of the AH-1Z. Expanding from 280 to 349 helicopters (226 AH-1Zs and 123 UH-1Ys) would parallel the overall expansion of the US Marine Corps to 202,000 personnel. NAVAIR’s proposal will look to increase existing yearly orders, as well as adding to the back-end of the production schedule.

The combined proposal to restructure the program, again, will be presented for final approval on Sept 17/10 to John Young, undersecretary of defense for acquisition, technology and logistics.

Aug 18/08: The US DoD releases its latest Selected Acquisition Reports, and the H-1 program is included. The source of the AH-1Z program’s delays becomes a bit clearer:

“This SAR was submitted to report schedule delays of six months or more since the prior report. Specifically, the Operational Evaluation (OPEVAL) Phase I Complete (AH-1Z) slipped two years from May 2008 to May 2010 due to unresolved Critical Operational Issues related to the AH-1Z weapons employment. There were no cost changes reported.”

SAR – delays explained

Aug 15/08: Lt. Gen. George Trautman declares that the UH-1Y has reached the official “Initial Operational Capability” milestone, in a ceremony at Marine Corps Headquarters in Quantico, VA. This helicopter’s IOC was supposed to come in September 2008; it appears to be a bit early. NAVAIR release.

The 6 pilots, 6 crew chiefs, and 3 UH-1Ys of Marine Light Attack Helicopter Training Squadron HMLAT-303 have been training with the aircraft for over a year, They have now reported to the 13th Marine Expeditionary Unit in preparation for deployment, which is scheduled for January 2009 aboard the USS Boxer [LHD 4].

UH-1Y IOC

Aug 11/08: Inside Defense reports that:

“Bell Helicopter-Textron is expecting a delay in deliveries of UH-1Y utility helicopters due to a slippage in deliveries of cabins by a subcontractor, a company spokesman told Inside the Navy.”

Aug 1/08: Support. A $12.6 million modification to a previously awarded firm-fixed-price contract (N00019-06-C-0086) for H-1 Upgrade logistics products and services. Work will be performed in Fort Worth, Texas, and is expected to be complete in May 2009.

This modification includes logistic management support, technical material for maintenance planning, design interface, supply /material support, support of support equipment, technical data, distribution and inventory management/packaging, handling, storage & transportation, configuration management, supportability analysis, aircraft acceptance discrepancies, and contractor logistics support/technical liaison.

Aug 1/08: Support. A $6.5 million modification to a previously awarded firm-fixed-price contract (N00019-06-C-0086) for non-recurring engineering necessary to build, install and test of the combining Gearbox Test Stand in support of the H-1 Upgrades Aircraft. Work will be performed in Fort Worth, TX and is expected to be complete in June 2011.

July 11/08: Rotor redesign. Bell Helicopter Textron, Inc. in Fort Worth, TX received a $9.4 million cost-plus-fixed-fee delivery order against a previously issued basic ordering agreement (N00019-06-G-0001) for the H-1 program. The delivery order covers one-time engineering services to improve the new main rotor gearbox’s ability to “run dry”, i.e. without lubrication. This makes the aircraft more likely to survive if, for example, enemy gunfire severs key connections and leaves the main rotor gearbox without its usual lubrication.

Work will be performed in Fort Worth, TX and is expected to be complete in December 2012. Contract funds in the amount of $5.6 million will expire at the end of the current fiscal year.

April 22/08: More H-1s? Military.com reports that the initiative to expand the Corps by about 20,000 Marines may also grow the H-1 program from 100 UH-1Ys to 123, and 180 AH-1Zs to 226. The USMC has submitted their 2010 Program Objective Memorandum, which forecasts the service’s budget request for 2010, but that submission has not been approved yet by DoD officials.

The additional helicopters would also avert a potential shortage of AH-1 attack helicopters, by ordering the new-build helicopters first. This would enable the Marines to withdraw existing AH-1W Super Cobras from service for the 2-year overhaul program, without affecting the number of available machines.

March 28/08: Sensors. Lockheed Martin Missiles and Fire Control in Orlando, FL receives a $50 million cost-plus-fixed-fee contract for 16 AN/AAQ-30 Thermal Sight Systems (TSS) for the USMC’s AH-1Z Viper helicopter. Major subcontractors include L3 Communications/Wescam of Ontario Canada (turret assembly) and Elbit subsidiary Kollsman, Inc. of Merrimack, NH (Common Laser Designator Range Finder).

Work will be performed in Orlando, FL (86%); Ocala, FL (9%); and Santa Barbara, CA (5%), and is expected to be complete by October 2010. Bids were solicited via the Federal Business Opportunities and Navy Electronic Commerce Online websites, and 1 offer was received by the Naval Surface Warfare Center in Crane, IN (N00164-08-C-JQ24).

Feb 22/08: More H-1s? A Bell Helicopter release claims that:

“While the current contract calls 100 Yankees and 180 Zulus, the Marines have indicated a desire to increase the number of aircraft they will purchase in their total force plan.”

Feb 12/08: Phase II OpEval. The UH-1Y and AH-1Z begin Phase II of their Operational Evaluation (OpEval). A full rate production decision is expected in August 2008. Source.

Feb 11/08: A not-to-exceed $19.9 million cost-plus-fixed-fee delivery order against a previously issued basic ordering agreement for 2 non-recurring engineering (NRE) efforts associated with the manufacture of a minimum of 40 build new AH-1Z aircraft for the U.S. Marine Corps. Work will be performed in Fort Worth, TX and is expected to be complete in November 2009.

The first portion of the NRE effort includes tool design and loft for producing the tool proof cabin and other tool proof parts, and initiates manufacturing engineering and production planning. The second NRE effort will be issued to integrate and qualify the T700-401C engine for use in the new-build AH-1Z aircraft (N00019-06-G-0001).

Jan 3/08: FY 2008 lead-in. A $60 million not-to-exceed modification to a previously awarded firm-fixed-price contract for long-lead, time-critical parts in support of the Fiscal Year 2008 Lot V procurement of 11 UH-1Y Venom utility and 4 AH-1Z Viper attack helicopters.

Work will be performed in Hurst, Texas (80%) and Amarillo, Texas (20%), and is expected to be complete in July 2010 (N00019-06-C-0086).

Oct 1/07: Training. Bell Helicopter Textron, Inc. in Hurst, TX received awarded a $16.7 million fixed-price-incentive fee modification to a previously awarded firm fixed price contract for an AH-1Z Full Flight Simulator (FFS).

Work will be performed in Broken Arrow, OK (75%) and Hurst, TX (25%) and is expected to be complete in January 2010. The Naval Air Warfare Center Training Systems Division in Orlando, FL issued the contract (N00019-06-C-0086).

FY 2007

Orders.

UH-1Y, armed
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Sept 26/07: Spares. Bell Helicopter Textron in Hurst, TX received $5.6 million for ceiling priced order #GB4A under a previously awarded contract for spare components for the H-1 aircraft. Work will be performed in Hurst, Texas is expected to be complete December 2009. One company was solicited for this non-competitive requirement by the Naval Inventory Control Point in Philadelphia, PA (W58RGZ-06-G-0003).

Sept 21/07: Spares. A $32.1 million modification to a previously awarded firm-fixed-price contract (N00019-06-C-0086) for procurement of initial spares in support of the fiscal year 2007 Lot IV aircraft – 9 UH-1Y and 2 AH-1Z aircraft (see July 27/07). Work will be performed in Fort Worth, TX and is expected to be complete in April 2010.

July 27/07: A $162.3 million modification to a previously awarded firm-fixed-price, fixed-price-incentive fee contract (N00019-06-C-0086), exercising an option for the FY 2007 Low Rate Initial Production (LRIP) Lot IV procurement of 9 “Venom” UH-1Ys and 2 “Viper” AH-1Z aircraft.

Work will be performed in Hurst, TX (80%) and Amarillo, TX (20%), and is expected to be complete in October 2009.

FY 2007 order

July 6/07: Training. A $12.5 million modification to a previously awarded firm-fixed-price contract (N00019-06-C-0086) for the procurement of phases II and III of the Composite Maintenance Trainers (CMTs) effort, to include 2 UH-1Y trainers and 2 AH-1Z trainers. The CMTs will be based at Camp Pendleton, CA, and will be used to train personnel on the repair and maintenance of the H-1 Upgrades Aircraft. Work will be performed in Hurst, TX and is expected to be complete in August 2012.

Jan 30/07: Support. An $11.7 million modification to a previously awarded firm-fixed-price contract (N00019-06-C-0086), exercising an option for systems engineering and program management support for the UH-1Y and AH-1Z aircraft for Calendar Year 2007. Work will be performed in Hurst, TX (80%) and Amarillo, TX (20%), and is expected to be complete in December 2007.

FY 2005 – 2006

Orders.

UH-1Y ropedown
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Aug 11/06: Spares. A $31.7 million ceiling priced modification to a previously awarded firm-fixed-price contract for the FY 2006 lot III procurement of initial spare parts in support of the UH-1Y aircraft.

Work will be performed in Hurst, TX and is expected to be completed in December 2008 (N00019-06-C-0086).

July 20/06: Bell Helicopter Textron, Inc. in Fort Worth, TX received a $137.4 million firm-fixed-price, fixed-price-incentive fee contract for the fiscal year 2006 low rate initial production (LRIP) lot III procurement of 7 UH-1Y aircraft, 1 UH-1Y full flight simulator, and 4 composite maintenance trainers (Phase I) under the H-1 upgrade program.

Work will be performed in Hurst, TX (80%), and Amarillo, TX (20%), and is expected to be complete in September 2008. This contract was not competitively procured by the Naval Air Systems Command in Patuxent River, MD (N00019-06-C-0086).

FY 2006 order

May 2006: AH-1Z OpEval I. The AH-1Z, equipped with an AAQ-30 surveillance and targeting system, enters Operational Evaluation. Source.

Jan 31/06: Support. A $7.1 million modification to a previously awarded firm-fixed-price contract (N00019-04-C-0001), exercising an option for the logistics support, initial spares, build-to-print package, initial operational test and evaluation period, and helmet support for FY 2006 Flight Test Devices for the AH-1Z and UH-1Y Program.

Work will be performed in Camp Pendleton, CA (76%); Tulsa, OK (13%); and Fort Worth, TX (11%), and is expected to be complete in January 2007.

June 3/05: Spares. A $17.6 million not-to-exceed modification to a previously awarded firm-fixed-price contract (N00019-04-C-0001) for initial spare parts in support of FY 2005 Lot II UH-1Y and AH-1Z aircraft. Work will be performed in Amarillo, TX and is expected to be complete in September 2007.

May 26/05: An estimated $7.7 million modification to a previously awarded firm-fixed-price contract (N00019-04-C-0001) for the procurement of the non-recurring effort required to replace the remanufactured UH-1N or HH-1N structural parts with new structural parts used to manufacture a UH-1Y helicopter. Work will be performed in Fort Worth, TX, and is expected to be complete in December 2006.

April 4/05: A $104.2 million modification to a previously awarded firm-fixed-price contract (N00019-04-C-0001) for the H-1 upgrade program. The funds exercise an option for FY 2005 low rate initial production lot II procurement of 3 AH-1Z and 4 UH-1Y aircraft.

Work on this particular contract will be performed in Amarillo, TX and is expected to be complete in December 2007.

FY 2005 order

Feb 23/05: IAS. A $165.4 million cost-plus-award-fee contract for the development of Integrated Avionics Suite (IAS) software upgrades in support of the H-1 helicopter upgrade program. In addition, this contract provides for incorporation of the software upgrades into existing AH-1W Cobra attack helicopters and UH-1N transport helicopters, to convert them to AH-1Zs and UH-1Ys, respectively.

Work will be performed in Woodland Hills, CA (70%); Hurst, TX (25%), and China Lake, CA (5%), and is expected to be complete in February 2010.

IAS development

Dec 29/04: Avionics. A $35.3 million ceiling-priced modification to a previously awarded firm-fixed-price contract for the development of the Generation II Mission Computer for the AH-1Z and UH-1Y aircraft under the H-1 Upgrade Program. Work will be performed in Fort Worth, TX and is expected to be complete in September 2010 (N00019-04-C-0001).

Dec 8/04: Support. A $23.6 million modification to a previously awarded firm fixed price contract (N00019-04-C-0001) for the FY 2005 procurement of acquisition logistics support for Lot I and II Low Rate Initial Production (LRIP) AH-1Z and UH-1Y aircraft. Work will be performed in Hurst, TX and is expected to be completed in October 2007.

FY 1999 – 2004

Orders; AH-1Z Prototype rollout; Lockheed Martin’s TSS surveillance and targeting system picked for AH-1Z. N.B. incomplete.

H-1s on LHD 5
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July 20/04: SDD. A $15.9 million estimated value modification to a previously awarded cost-plus-award/incentive fee contract (N00019-96-C-0128) for the non-recurring development of a turned exhaust system for the AH-1Z helicopter. The turned exhaust system deflects exhaust gasses up into the rotor blades for dispersal, minimizing the helicopter’s infrared signature to enemy missiles etc.

Work will be performed in Amarillo, TX (53%) and Fort Worth, TX (47%), and is expected to be complete in March 2006. The Naval Air Systems Command issued the contract.

April 2/04: Spares. A $14.25 million delivery order under previously awarded basic ordering agreement (DAAH23-02-G-0008) for various spare items to support the low rate initial production (LRIP) for the H-1 upgrades program. Work will be performed in Hurst, TX and is expected to be complete by December 2006. This contract was not competitively procured by the Naval Inventory Control Point is the contracting activity (Order GB1C).

March 22/04: Support. A $13.1 million modification to a previously awarded firm-fixed-price contract (N00019-04-C-0001) for the FY 2004 procurement of acquisition logistics support for Lot I and II Low Rate Initial Production AH-1Z and UH-1Y aircraft. Work will be performed in Fort Worth, TX and is expected to be complete in October 2007.

March 5/04: Training. A $45.5 million modification to a previously awarded firm-fixed-price contract (N00019-04-C-0001) for the design, development, manufacture, and installation of 1 AH-1Z and 1 UH-1Y flight training device. Work will be performed in Arrow, OK (60%), and Fort Worth, TX (40%), and is expected to be complete in November 2006.

Dec 29/03: Bell Helicopter Textron Inc. in Fort Worth, TX received a $183.8 million firm-fixed-price contract for the low rate initial production of 3 Super Cobra helicopters (AH-1Z) and 6 Huey helicopters (UH-1Y).

Work will be performed in Amarillo, TX (53%), and Fort Worth, TX (47%), and is expected to be complete in January 2007. This contract was not competitively procured by the Naval Air Systems Command in Patuxent River, MD (N00019-04-C-0001).

FY 2004 order

Aug 15/01: Sensors. Lockheed Martin Missiles and Fire Control delivers its first Hawkeye eXtended Range (XR) Target Sight System (TSS) to Bell Helicopter during a brief ceremony in Orlando, FL. Lockheed Martin’s release adds that the Hawkeye TSS will be installed on an AH-1Z Cobra helicopter in early 2002. The first flight test of the TSS on an AH-1Z took place in August 2002.

Nov 20/2000: The rollout ceremony for the AH-1Z is held at Bell Helicopter Plant 6 in Arlington, TX. Lockheed Martin Missiles and Fire Control conducts public flight demonstrations of its Hawkeye Target Sight System (TSS, would become AAQ-30) at the Lockheed Martin release:

“Prospective customers from Turkey, Japan, South Korea, Taiwan, Greece, and Slovenia were given an opportunity for in-flight “hands-on” operation of the system that Lockheed Martin had installed on a Bell Model 222 helicopter. A real-time video downlink was also displayed.”

AH-1Z rollout

July 1998: Sensors. Bell Helicopter awards Lockheed Martin a $7.8 million Engineering and Manufacturing Development (EMD) contract for the [AAQ-30] TSS targeting and surveillance system. This would be followed by additional contracts covering Engineering Change Proposals. Lockheed Martin reportedly fabricates the whole nose section of the AH-1Z. Source.

Additional Readings & Sources

Thanks to Neville Dawson for the lead photograph, which is used with permission.

Helicopters & Ancillaries

• US Navy NAVAIR – USMC Light/Attack Helicopters.

• Bell Helicopter Textron – AH-1Z Zulu.

• Bell Helicopter Textron – UH-1Y Yankee.

• Lockheed Martin – TSS.

• Deagel – Hawkeye XR / AN/AAQ-30 GMS2 TSS. Hawkeye XR is related to the GMS2 system being fitted to AC-130U Spooky gunships.

• FLIR Systems – BRITE Star.

• DID – APKWS II: Laser-Guided Hydra Rockets in Production At Last.

• DID – JAGM: Joint Air-Ground Missile Again. If it debuts, the AH-1Z will be its initial Navy platform.

News & Views

• Flight International (Dec 20/10) – CUTAWAY: AH-1Z Viper enters production as substantially new aircraft.

• USMC (Dec 19/08) – Corps Cobra Receives New Fangs.

• Flight International (Aug 8/06) – Bell gets H-1 programme on track.

CH-53K concept
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The U.S. Marines have a problem. They rely on their CH-53E Super Stallion medium-heavy lift helicopters to move troops, vehicles, and supplies off of their ships. But the helicopters are wearing out. Fast. The pace demanded by the Global War on Terror is relentless, and usage rates are 3 times normal. Attrition is taking its toll. Over the past few years, CH-53s have been recalled from “boneyard” storage at Davis-Monthan AFB in Tucson, AZ, in order to maintain fleet numbers in the face of recent losses and forced retirements. Now, there are no flyable spares left.

Enter the Heavy Lift Replacement (HLR) program, now known as the CH-53K. It aims to offer notable performance improvements over the CH-53E, in a similar airframe. The question is whether its service entry delay to 2018-2019 will come too late to offset a serious decline in Marine aviation.

The HLR Program Lifts Off

Sikorksy on HLR, 2011

The $25.5 billion, 200-helicopter CH-53K program will define the long-term future of the US Marine Corps’ medium-heavy lift capabilities – and may be needed to save Marine aviation in the medium term.

On average, existing CH-53E aircraft are more than 15 years old, have over 3,000 flight hours under tough conditions, and are becoming more and more of a maintenance challenge with a 44:1 maintenance man-hours:flight hours ratio. Not to mention the resulting $20,000 per flight-hour cost ratio. According to Jane’s Defense Weekly, a 1999 analysis showed that the existing fleet has a service life of 6,120 flight hours, based on fatigue at the weakest point where the tail folds. The USMC expected that the existing fleet would start to reach this point in 2011, at a rate of 15 aircraft per year. The funding profile below suggests a problem for the Corps:

Excel
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The Marine Corps itself is the source of the disconnect. The HLR program initially called for 156 new-build helicopters derived from the CH-53E Super Stallion design, with initial flight tests in 2010-2011, and initial operating capability (IOC) in 2014-2015. IOC was defined as a detachment of 4 aircraft, with combat ready crews, and prepared to deploy with all required equipment and spares.

In 2010, however, the Marines grew the program plan to 200 helicopters, even as they pushed its initial flight back to FY 2013, and IOC back to FY 2018. The program wasn’t experiencing problems, and no reasons were given, beyond statements concerning the program’s aggressive schedule. Further slippage has occurred since. Here’s the full timeline:

Up, up, and…
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The current schedule creates a number of risks for the Marine Corps. There’s no question that pushing the CH-53K program back will leave the Marines with a dwindling heavy-lift helicopter fleet, whose size, capability, and safety are governed by mechanical realities rather than political diktat. In April 2010, the US military ran out of stored CH-53D/E airframes to refurbish and return to the front lines. In February 2011, the USMC retired its CH-53D fleet altogether.

The other risk is political. On the one hand, the CH-53K is a large program, and the farther the Marines push it away, the easier it is to cut amidst budget crises. With its heavy-lift fleet dwindling, that could be disastrous for the force. On the other hand, budgetary crises also look for programs that are late or experiencing problems, and the CH-53K is big enough to earn a lot of attention if it’s seen as screwing up. That fact that the original schedule was overly aggressive wouldn’t be remembered.

Was the move to push the CH-53K back an act of political negligence, to protect less critical programs like the V-22? Or was it an act of supreme prudence, which will lead to a strong program that survives precisely because it goes out and meets its targets? Opinions vary. Time will tell.

Current Status

Some assembly required
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US Navy PMA-261 is responsible for the CH-53K program. Sikorsky is currently working under a $3.5 – 4 billion System Development and Demonstration (SDD) contract, to include 4 SDD flight test helicopters, 1 ground test airframe, and associated program management and test support. As the development timeline stretched out, 6 System Development Test Aircraft were added to to that mix. To date, Sikorsky’s industrial partners include:

The CH-53X / CH-53K

Mission example
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The CH-53K’s maximum gross weight (MGW) will increase to 88,000 pounds with external loads, versus 73,500 pounds for the CH-53E. MGW with internal loads will be 74,000 pounds, compared to 69,750 pounds for the CH-53E. It’s being designed to carry a cargo load of 27,000 pounds (13.5 tons) 110 nautical miles, operating at an altitude of 3,000 feet and an ambient temperature of 91.5 degrees Fahrenheit. This is nearly double the capacity of the current CH-53E Super Stallions, all in a helicopter that’s roughly the same size.

Those altitude and temperature qualifications matter, too, because “hot and high” conditions lower aircraft load carrying capabilities and combat radius – especially for helicopters. This reduced performance has recently been a factor during operations in Afghanistan and relief efforts in Pakistan, for instance, and has been a factor with earlier models of the C-130 Hercules as well. Figures for the CH-53K operating entirely around sea level and in cooler temperatures would be higher, but would not be double that of existing CH-53Es.

As an example of these variables at work, Sikorsky’s CH-53K brochure states that the improved CH-53K will have a maximum external load of 16.3t/ 36,000 lbs. On the other hand, an operation that carries an externally-slung load from sea level to a point 3,000 feet above sea level, with a total range there and back of 220 nautical miles/ 407 km, and 30 minute loiter at the landing zone, would have a maximum mission load of only 12.25t/ 27,000 lbs.

MRAP: RG-31, IEDed
(click to view story)

Even at sea level, however, increased lift capacity will be important. As the Hummer’s fundamental lack of survivability began to marginalize it on the battlefield, the Marines led the charge to field “MRAP” blast-resistant vehicle designs instead. While an up-armored HMMWV weighs about 9,100 pounds empty, the lightest Category 1 MRAP patrol vehicles check in at weights ranging from 16,000 – 31,000 pounds, and even the “light” JLTVs that will replace a large segment of the HMMWV fleet are expected to weigh 14,000 – 20,000 pounds.

Those weights mean that tactical operations to airlift mobile forces ashore beyond the beach, or within the zone of operations, will have only one helicopter available that can get the job done: the CH-53.

If the Marines think their CH-53 fleet is seeing heavy use now, just wait.

New Technologies

CH-53K concept
(click to view full)

In order to meet those requirements, the CH-53K will be depending on a number of new technologies. No one technology constitutes a big stretch, which is good news for the program. Instead, a host of technologies that have been developed since the CH-53E program will be refined, and used in inter-related areas. For the basic outlines of many low-risk CH-53X/CH-53K improvements, read “

/http://www.vtol.org/pdf/garmspring02.pdf">An Affordable Solution To Heavy Lift” [PDF] by Lt. Col. James C. Garman, an H-53 family pilot and Senior Preliminary Design Engineer in Sikorsky’s New Product Definition Group. See also this interview with former HLR program manager Col. Paul Croisetiere.

The most important new addition to the CH-53K will be its 7,500shp class GE38 / T408 engines, which have already hit 8,300 shp in ground tests. The military is hoping for 18% better specific fuel consumption than the similarly sized T64 engine, even though the engine would produce 57% more power. To improve maintenance and reliability, the GE38 is also expected to have 63% fewer parts.

Other technologies slated for the CH-53K include a “glass” [digital] cockpit that has high commonality and interoperability with existing Army and Navy helicopters, high-efficiency rotor blades with anhedral tips that have 12% (main) and 15% (tail) more surface area, plus different construction to handle higher loads; a composite cuff attachment that attaches the main blades directly to an elastomerically-articulated titanium rotor head, without the need for specialized tools or multiple redundant fasteners; a cargo rail locking system; external cargo improvements, survivability enhancements, and enhancements designed to extend service life.

Changes will be made as the program progresses, and engineers get a better sense of which technologies are ready, and which would create risks to the program. For example, the CH-53K was going to use a “viscoelastic lag damper” for the rotors, in order to minimize vibration and stress. It was removed in order to speed up deployment, and a modified version of standard linear hydraulic dampers will be used instead. The Navy hopes to achieve 2x reliability compared to the existing CH-53Es, but gave up the potential for 4x reliability, in exchange for less development risk.

Sikorsky on CH-53K

Given the CH-53E’s large maintenance ratio, reliability will matter. As former HLR program manager Col. Paul Croisetiere put it in a NAVAIR release:

“Given the CH-53E’s operational costs and maintenance demands, heavy lift has built its reputation for excellence on the backs of our maintainers… We are going to take our maintainers somewhere they’ve rarely been before. Home for dinner.”

Several decades of weapon program history suggest that the odds of meeting this goal are low. Instead, the trend is that these promises are made, but more advanced and complex weapons wind up having more points of failure, and require even more maintenance. If the CH-53K program can break that cycle, it would represent a landmark success in Pentagon weapons acquisition.

Contracts & Key Events

Unless otherwise noted, all contracts are issued by US Naval Air Systems Command in Patuxent River, MD.

FY 2014 – 2018

 

Takeoff?
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August 27/18: Keep’em sweeping The Navy is contracting Technical Systems Integration for the provision of necessary overhaul and modification work on the USMC’s Mk-105 minesweeping system. The firm-fixed-price, indefinite-delivery/indefinite-quantity contract has a value of $10.5 million, but also includes options, which if exercises, would bring the face value to roughly $54 million. The Mk-105 Magnetic Influence Minesweeping System is a catamaran hydrofoil which is towed behind the MH-53E Sea Dragon helicopter. It is used to detect mines that use magnetic sensors to target the metallic hulls of ships before detonating. The twin magnetic tails, consisting of open-electrode magnetic sweeps, are towed behind the sled, detonating mines to clear the water for safe shipping. Work will be performed in Panama City, Florida, and is expected to be completed by August 2019.

May 01/18: IOC delays Bloomberg reports that the Sikorsky CH-53K King Stallion helicopter program may be falling behind schedule, as Pentagon officials have found that a significant number of components require redesign and re-qualification. While a spokesperson from Sikorsky’s parent-company Lockheed Martin said that most of these items are already “fixed and proven or are in process,” initial operational capability—originally scheduled for December 2019—could be delayed by as much as eight months. According to a Pentagon review prepared in February, four helicopters currently in the flight test program were operating at 69 percent effectiveness as of late last year, “well below” the 75 percent to 90 percent benchmark needed. 200 King Stallions have been ordered by the US Marin Corps in a $31 billion heavy-lift program with Lockheed chasing exports to potential operators such as Germany.

April 20/18: German Heavy-Lift-Industrialization plan Sikorsky, Lockheed Martin’s helicopter subsidiary, revealed on Wednesday its industrialization plan for competing in the German Air Force “Schwerer Transporthubschrauber” (STH) Program, or effort to buy new heavy-lift helicopters. Offering its CH-53K King Stallion, Sikorsky has already teamed up with German defense giant Rheinmetall Group—who will take care of in-service support if Berlin chooses the King Stallion—and the Sikorsky CH-53K team plans to host German companies in an industry chalet during the ILA Berlin Airshow April 25-29, where it will showcase plans for the long-term sustainment of the CH-53K by German aerospace industry. Companies expected alongside Rheinmetall include MTU, ZF Luftfahrttechnik GmbH, Autoflug, HYDRO Systems KG, Rockwell Collins Germany, Jenoptik, Hensoldt, Liebherr, and Rohde & Schwarz. Germany is looking to replace its legacy fleet of CH-53G, some of which have been in service since the mid-1960s, with a new capability. Facing off against the CH-53K is Boeing’s CH-47F Chinook.

March 6/18: Potential Sales-Partnerships Sikorsky has selected German engine manufacturer MTU to be its engine maintenance partner as the US helicopter firm builds up local partners to help its bid to supply CH-53K heavy-lift helicopter to the German Air Force. The agreement tasks MTU with providing maintenance, repair and overhaul services for the helicopter’s GE Aviation T408-GE-400 engines should Berlin order the King Stallion as the replacement for its ageing fleet of CH-53G/GA/GS helicopters. At present, MTU already have an 18 percent share of the T408’s engine program, producing its power turbine, exhaust casing and output shaft. Also included on the team for Sikorsky’s German bid is Rheinmetall.

February 16/18: Initial Production Orders The Pentagon awarded Tuesday, February 13, a $126.5 million US Navy contract modification to Sikorsky for initial production of CH-53K King Stallion helicopters. Under the terms of the deal, the Lockheed Martin subsidiary will secure “long lead items in support of the low rate initial production of seven Lot III CH-53K aircraft.” Work will take place at Stratford, Connecticut, with work running until January 2019. The US Marine Corps is scheduled to receive 200 King Stallions, replacing the service’s older E variants for its heavy-lift mission. The first units are expected to become operational by 2019.

February 8/18: German Heavy Lift-Partnership Lockheed Martin subsidiary Sikorsky has signed a strategic teaming agreement with German defense giant Rheinmetall, to offer Sikorsky’s CH-53K King Stallion helicopter to Germany’s upcoming heavy-lift competition. A Lockheed Martin press release stated that further German teammates will be announced in the coming weeks and “will leverage and build upon the deep knowledge and expertise of the German defense industry.” The statement added that the King Stallion “provides the German Armed Forces with a proven heavy lift helicopter that can be entered into service seamlessly without need for upgrades for the next several decades.” Facing the Sikorsky-Rheinmetall team will be Boeing’s CH-47 Chinook, whose MG-47 variant is the only model thus far capable of Germany’s fleet-wide aerial refueling capability requirement.

November 21/17: Contracts-Spares General Electric Aviation (GEA) has been awarded a $143.4 million US Navy contract to provide 22 low-rate initial production Lot 1 and 2 T408-GE-400 turboshaft engines for the CH-53K King Stallion helicopter. In additional to the engines, the sale will also include associated engine and programmatic support, logistics support, peculiar support equipment, and spares. Work will take place in Lynn, Massachusetts, and is expected to be completed in July 2021.

November 17/17: Airshow Debut Lockheed Martin’s CH-53K Super Stallion will make its international debut at the Berlin Airshow next April, sources close to the program told Reuters. Built for the US Marine Corps by Lockheed subsidiary Sikorsky under the Heavy Lift Replacement (HLR) program, the heavy-lift helicopter is being touted as a possible solution to Germany’s CH-53G replacement program, which will see the King Stallion face off against the smaller Boeing CH-47F Chinook in a $4.7 billion competition for about 40 units. However, an official start to the program—along with a formal structure to the competition—is unlikely to be unveiled until Chancellor Angela Merkel’s conservatives manages to negotiate a ruling coalition with the pro-business Free Democrats and the Greens—horse-trading that could take until the end of the year. Israel is also reported to be interested in the King Stallion, adding a potential 20 units to Lockheed’s order book.

September 04/17: Lockheed Martin subsidiary Sikorsky has been awarded a Low Rate Initial Production (LRIP) Lot 1 contract to deliver two CH-53K King Stallion heavy-lift helicopters to the US Marine Corps (USMC). Valued at $304 million, the firm will deliver the models by 2021 in addition to spares and support, with work to be carried out in Stratford, Connecticut. The US Department of Defense’s Program of Record remains at 200 CH-53K aircraft, with the USMC intending to stand up eight active duty squadrons, one training squadron, and one reserve squadron to support operational requirements. Designed to lift three times as much weight as its predecessor, the CH-53E Super Stallion, its increased payload capacity can internally load 463L cargo pallets, High Mobility Multipurpose Wheeled Vehicles (HMMWV) or a European Fenneck armored personnel carrier while still leaving the troop seats installed.

July 11/17: With CH-53K King Stallion helicopters recently completing their first long-range flight test from West Palm Beach, Florida to NAS Patuxent River, Maryland, where it will continue flight testing, manufacturer Sikorsky has begun courting German industry in an effort to line up orders for the new heavy-lift helicopter from Berlin. The two day event, held in West Palm Beach, saw the delegates told that if the King Stallion is selected, German suppliers would be responsible for the majority of the work when it comes to platform sustainment. Germany is expected to issue a request for proposals for the replacement of its fleet of 81 CH-53GA/GS helicopters, originally delivered in the 1970s, in mid-2018, with deliveries to commence in 2023. Boeing is also likely to pitch its CH-47 Chinook as the “proven” helicopter.

May 24/17: Sikorsky has been awarded a $55 million contract modification to a previously awarded contract for the long-lead support of low-rate production of four Lot II CH-53K King Stallion helicopters. An upgrade of the Sea Stallion heavy-lift helicopter, work on the King Stallion contract will be conducted at the Sikorsky plant in Stratford, Conn and is expected to be completed by March 2022. The helicopter is capable carrying up of 27,000 pounds of external sling load. It can carry artillery pieces and Humvee utility vehicles and it’s cabin is capable of carrying 463 pallets for cargo transportation.

April 6/17: Lockheed Martin subsidiary Sikorsky will proceed with low-rate production of the CH-53K King Stallion since the helicopter has received a Milestone C status by a US Defense Acquisition Board review. A total of 200 CH-53Ks are to be acquired by the US Marine Corps. The first six aircraft are under contract and are expected to be delivered starting next year. Long-lead procurement of parts and materials for the first two low-rate initial production helicopters is underway. The King Stallion is capable of lifting three times as much as its predecessor, the CH-53E, and can carry as many as three external loads at the same time.

March 29/17: The US Department of Defense is expected to award Lockheed Martin a multi-billion contract to start production of 200 new heavy cargo helicopters for the US Marines Corp by the end of the week. Colonel Hank Vanderborght, head of the Pentagon’s CH-53K King Stallion program, stated that each unit will cost $87 million on average and $105 million including spare parts and certain service contracts. The total value of the program is $27 billion. Developed by Lockheed’s helicopter subsidy Sikorsky, the CH-53K can lift 36,000 pounds and would replace the CH-53E Super Stallion, which has operated as the backbone of field logistics for the USMC since the mid-1980s.

October 24/16: The CH-53K King Stallion helicopter has completed its initial operational testing. A two-week trial period, known as the OT-B1, took place at Sikorsky’s Development Flight Center in West Palm Beach, Florida. Requirements asked of the helicopter included multiple external lift scenarios of 27,000 lb. (12,200 kg), in-hover, and 12,000 lb. (5,422 kg) 110 nautical mile radius missions.

June 29/16: Sikorsky has achieved a key USMC requirement with the CH-53K King Stallion by successfully flying 100ft above the ground with a 12,250kg (27,000lb) payload. Due to replace the CH-53E Super Stallion, the new helicopter promises better range and triple the E model’s payload in hot weather conditions, as well as flight-by-wire flight controls designed to reduce pilot workload in degraded visual environments. While successful testing has the CH-53K currently on track, it hasn’t always been plain sailing with gearbox trouble delaying its first flight for a year.

May 18/16: Pricing and availability for the Sikorsky CH-53K King Stallion helicopters is being sought by Germany to meet its heavy vertical lift requirement. Other options include Boeing’s CH-47 Chinook, however the US Marine Corps is keen to take advantage of the better pricing that could be achieved by adding a sizable King Stallion order at the front-end of the production ramp. The latest K-model has twice the max gross take-off weight of the legacy CH-53G operated by the Luftwaffe at 40t (88,000lb) with external loads compared to 19t (42,000lb).

April 22/16: A USMC test has seen a Sikorsky CH-53K complete its first external load flight test, lifting a 12,000 pound external load in a hover. The April 12 test will see further loads tried with external payloads of 12,000 pounds flown first in hover, then incrementally increasing speeds up to 120 knots, followed by 20,000 and 27,000 pound external payloads. The system features an electrical load release capability from the cockpit and cabin, and a mechanical load release capability at each of the pendant locations. An auto-jettison system is incorporated to protect the aircraft in the event of a load attachment point failure.

March 17/16: The second prototype of the CH-53K helicopter made its maiden flight in January according to Lockheed company Sikorsky. In addition, the first aircraft into the test program has achieved flight envelope expansion to 120 knots for the USMC’s CH-53K King Stallion heavy lift helicopter program. The two are the most heavily instrumented of the Engineering Development Models (EDM) and will focus on structural flight loads and envelope expansion. Two more will join the flight line later this year and will focus on performance, propulsion, and avionics flight qualification.

January 5/16: The USMC seems to have given the seal of approval to the latest CH-53 after the first marine pilot to test the helicopter commended its abilities. Lt. Col. Jonathan Morel tested the CH-53K King Stallion which is set to become the largest and heaviest helicopter in the US military. Two hundred of the rotorcraft will be procured by the USMC in a deal worth $25.5 billion.

October 29/15: The Sikorsky CH-53K King Stallion helicopter has flown for the first time, eleven months behind schedule. The new helicopter is intended to replace the Marine Corps’ fleet of CH-53E Super Stallion heavy lift helicopters, with the new design boasting three times the lift capability of the older model. The first CH-53K, known as Engineering Development Model-1 (EMD-1) will be joined by an additional three aircraft to undergo 2,000 flight hours of testing.

July 31/14: Engines. General Electric in Lynn, A receives a $68.6 million firm-fixed-price contract modification for 16 GE38-1B engines, closure kits, tooling, and associated systems engineering and program management in support of the CH-53K helicopter program’s Operational Evaluation phase. This is on top of the July 17/13 contract for “time critical parts”, and the $84.3 million total represents the first engine buy beyond the 20 covered by the System Development & Demonstration contract. $22.5 million in FY 2013 – 2014 US Navy RDT&E budgets are committed immediately.

Note that each CH-53K is equipped with 3 engines. Work will be performed in Lynn, MA, and is expected to be complete in January 2017 (N00019-13-C-0132). See also GE, “U.S. Navy Awards GE38 Engine Production Contract”.

June 9/14: Leadership. PMA-261 Program Manager U.S. Marine Corps Col. Robert Pridgen turns over command to Col. Henry Vanderborght, a long-time CH-53E pilot, former John Glenn Test Pilot of the Year, and former Light/Attack Helicopters (PMA-276) platform team lead for UH-1Y production and the UH-1N’s sundown. Vanderbought wasn’t actually a full Colonel until he was promoted on the morning of the change-of-command ceremony.

Pridgen will become the program manager for the Presidential Helicopters Program (PMA-274) in July 2014. Sources: US NAVAIR, “Heavy-lift helicopters program welcomes new program manager”.

May 5/14: Naming. Sikorsky officially unveils their CH-53K flight test helicopter EDM-2, and the USMC officially names the type “King Stallion”.

One can see the natural extension from the CH53A/D Sea Stallion and CH-53E Super Stallion, but there comes a point where one can push the boundaries in unintended directions. Maybe they were thinking of the 1942 movie with Chief Thundercloud. In the modern era, people are more likely to think that somewhere, an adult entertainer wants his name back. Sources, Sikorsky, “Sikorsky Unveils CH-53K Helicopter; U.S. Marine Corps Reveals Aircraft Name” | South Florida Sun-Sentinel, “Sikorsky introduces new ‘King Stallion’ helicopter” | Stamford Advocate, “Sikorsky unveils its new King Stallion heavy lift helicopter”.

“King Stallion”

May 1/14: Testing. Sikorsky announces that full testing is finally moving ahead with the non-flying GTV, including powered “light-off” with all 7 main rotor blades and 4 tail rotor blades spinning, and powered by its three 7,500 horsepower class GE engines. This begins a rigorous 2-year test program of the rotor blades, transmission, engines, and all subsystems using the GTV. Sources: Sikorsky, “Sikorsky Begins Powered Ground Tests of CH-53K Helicopter with Rotor Blades”.

March 31/14: GAO Report. The US GAO tables its “Assessments of Selected Weapon Programs“. Which is actually a review for 2013, plus time to compile and publish. With respect to the CH-53K, their top concern is that the USMC is scheduled to begin ordering helicopters before testing is done. Beyond that concurrency worry:

Nearly 9 years later the program’s two critical technologies – the main rotor blade and main gearbox – are approaching maturity. The program expects these technologies to be demonstrated in a realistic environment by its planned February 2016 production decision, a delay in 6 months over last year’s schedule. Program officials reported that they conducted a three-blade whirl test that produced results that exceeded required outcomes. Flight testing is expected to begin in late 2014.

March 4-11/14: FY15 Budget. The US military slowly files its budget documents, detailing planned spending from FY 2014 – 2019. The current Navy plan will begin buying production CH-53Ks with an order for 2 in FY 2017, followed by 4 in FY 2018 and 7 in FY 2019. That means production has been pushed back by about a year, because:

“Late delivery of components into qualification, and subsequent qualification challenges, have delayed Ground Test Vehicle (GTV) delivery, Flight Readiness Reviews (FRR – GTV & 1st Flight), Engineering Development Models (EDM) delivery and CH-53K 1st Flight, and have moved Milestone C (MSC) and other associated events to 3Q 2016. Budgetary constraints delayed start of the Aircraft Procurement (APN) program by one year. As such, Advanced Acquisition Contracts (AAC) and LRIP awards have been adjusted accordingly. In order to procure aircraft that effectively demonstrate manufacturing processes are both mature and under control, two (2) additional RDT&E,N-funded System Demonstration Test Articles (SDTAs) in FY15 with delivery in 4Q 2018 and 1Q 2019 were added to the program.”

Sources: USN, PB15 Press Briefing [PDF] and detailed budget documents.

Oct 31/13: Rotors. Sikorsky has completed initial tests of the CH-53Ks new rotor blades, including fatigue tests and whirl-tower balance tests. Additional blade qualification testing will continue for several years, in order to validate aspects like aerodynamic stability, tip deflection, and rotational twist. The next steps involve installation and testing on the stationary CH-53K GTV.

There’s a lot to test, because the rotors are new technology. The 35 foot span, 7-bladed main rotor has blade of almost 3 foot chord width, with new airfoil designs, twist, and taper to handle the engines’ 71% power increase. The new blade tips are designed to improve hover performance, and a composite cuff attachment allows attachment of each blade to the elastomerically-articulated titanium rotor head, without tools or redundant fasteners. The rotor hub itself is almost 9 feet in diameter, and the blade radius will be 39.5 feet when assembled, with 12% more total surface area than the CH-35E.

The 4-blade tail rotors are also new, with 10 foot blades and 15% more surface area compared to the CH-53E. Sikorsky says that the CH-53K tail rotor produce as much thrust as the main rotor blades on Sikorsky’s 5.5 ton S-76 medium helicopter, which is used in the offshore oil industry. Source: Sikorsky via PR Newswire, “Sikorsky Completes Initial Tests of First Rotor Blades for CH-53K Helicopter”.

Oct 11/13: EVM penalty. Bloomberg News:

“Sikorsky was notified Sept. 6 of three deficiencies on a contract for the Navy’s CH-53K heavy-lift helicopter related to guidelines for the recording of direct costs and material accounting, Navy Commander William Urban, a Pentagon spokesman, said in an e-mailed statement. A corrective action plan is expected from the company by Oct. 21, he said.”

While Bloomberg doesn’t say so, the issue in question relates to a quantitative approach to project tracking called Earned Value Management. Until they’re satisfied, the Pentagon is withholding the maximum 5% on payments. Sikorsky responds that 2 of the 3 issues are already resolved, and they don’t expect this to affect the program. Sources: For Dummies.com, “Earned Value Management Terms and Formulas for Project Managers” | Bloomberg, “Pentagon Withholds Sikorsky Payments for Business System Flaws”.

Oct 1/13: Sub-contractors. Kratos Defense & Security announces that an $8.5 million contract from Sikorsky to design and develop CH-53K maintenance trainers. The full-fidelity Maintenance Training Device Suite (MTDS) is meant to provide a true-to-life environment for maintenance training; as well as remove-and-replace training for avionics systems, electrical systems, hydraulic systems and many other mechanical subsystems.

The Helicopter Emulation Maintenance Trainer (HEMT) uses a 3D virtual environment to support maintenance training scenarios: functional tests, fault isolation, troubleshooting, and remove and installation for 27 subsystems. Sources: Kratos Oct 1/13 release.

FY 2013

SAR shows program cost increases; Ground Test Vehicle delivered; Flight test helicopters ordered.

CH-53K GTV
(click to view full)

Sept 27/13: Sensors etc. Raytheon in El Segundo, CA receives a $20 million firm-fixed-price delivery order for:

CH-53K, using FY 2013 USN RDT&E budget…

• 5 AAQ-29 day/night surveillance turrets
  
• 2 Memory Loader Verifier System cables
  
• Software update, system integration, and test support

USAF HH-60 search & rescue helicopters, using FY 2011 procurement budget…

• 25 AAQ-29 day/night surveillance turrets
  
• 25 L2G multifunction control units and 35 L2G system control units
  
• 1 technical data package
  
• 1 repair of repairables analysis

All funds are committed immediately, and $16.2 million expires on Sept 30/13. Work will be performed in McKinney, TX (92%) and El Segundo, CA, (8%), and is expected to be complete in September 2015. US Naval Air Systems Command in Patuxent River, MD manages the contract (N00019-10-G-0018).

Sept 23/13: IG OK. The Pentagon’s Inspector General submits a non-public report concerning the CH-53K program. Their public statement: the program has been managed appropriately, but it may not meet its February 2016 Milestone C decision date, or its revised costs.

The Acquisition Program Baseline was updated on April 24/13, to address cost growth and schedule delays. Contractor manufacturing delays and component testing failures, hence the risk of not being ready in time for the low-rate production decision, and not meeting even its revised costs. The Office of the Under Secretary of Defense for Acquisition, Technology, and Logistics is aware of these issues. Sources: OIG, “CH-53K Program Management Is Satisfactory, but Risks Remain (Project No. D2013-D000CD-0095.000)”.

July 17/13: Engines. General Electric Co. in Lynn, MA receives a $15.7 million cost-plus-fixed-fee contract to buy “time critical parts” for incorporation into the CH-53K’s T408-GE-400 gas turbine engine. All funds are committed immediately by the US Navy.

Work will be performed in Lynn, MA, and is expected to be complete in December 2016. This contract was not competitively procured pursuant to FAR 6.302-2-1(a)(1) by US Naval Air Systems Command in Patuxent River, MD (N00019-13-C-0132).

June 27/13: Sub-contractors. Boeing spinoff Spirit Aerosystems announces a $60 million sub-contract, as a result of the #435 million order for 4 System Demonstration Test Article helicopters (q.v. May 30/13). Spirit makes the base cockpit and cabin, essentially the body of the helicopter.

Spirit will begin work during 2013 at its Wichita, KS facility, with deliveries to Sikorsky’s CH-53K prototype assembly line in West Palm Beach, FL to begin in 2014. When the helicopters are finished, they’ll enter Operational Evaluation in 2017, to verify that their performance meets projections. The contract follows over $150 million in work on 7 structures, for the first 5 prototype test helicopters and the 2 ground test frames.

Spirit recently announced work with Spintech Ventures, of Xenia, OH on a set of trademarked products called Inflexion/ Smart Tooling. The technology uses re-formable, reusable mandrels that can change states through the layup and cure phases. That helps form complex, highly integrated composite structures into large and/or unusual shapes and configurations – like full integration of skins, stringers, and frames or ribs in one step. Spirit | Wichita Eagle | Spirit re: Inflexion.

May 31/13: Hostile IG Report. The Pentagon’s Inspector General issues a report under Audit Project No. D2012-D000CD-0037.000, telling the USMC that the CH-53K’s program increase to 200 helicopters isn’t justified. The Marines politely tell the IG to stick it where Chesty can’t find it.

The Inspector General’s statement that “the Marine Corps risks spending $22.2 billion in procurement and operating and support funding for 44 additional aircraft” is a blatant error – that’s the entire 2011 program cost for 200, plus R&D. Beyond that, they complain that the USMC:

• did not follow the Joint Capabilities Integration and Development System Instruction and obtain Joint Requirements Oversight Council [DID: JROC] approval for the increase;
  
• did not have requirement studies prepared to determine a procurement quantity in consideration of program affordability;
  
• incorrectly relied on a 2008 memorandum from the Deputy Commandant for Aviation directing the increase of the procurement quantity to 200 aircraft, without support;
  
• incorrectly used the 2010-2011 Force Structure Review’s war-gaming scenarios as justification for the quantity increase; and
  
• did not justify or appropriately consider the impact of the Marine Corps personnel reductions effect on Heavy Lift quantity requirements.

In response, the USMC Deputy Commandant says the existing analyses do justify it, and JROC approved the 200. Then the Milestone Decision Authority approves the Marine Corps’ request to rebaseline the program with a 54% procurement cost increase over the 2005 baseline (a jump from Dec 2011 figures, if true) and formally push the Milestone C decision from December 2012 to February 2016 (later than the current August 2015). The IG wants additional comments re: the re-baselining. Which is fine, as far as it goes, but the whole process seems like an ad for the Lexington Institute’s Daniel Goure, who argues that the Pentagon’s procurement processes are an out of control overhead burden. It’s all about paper, rather than the soundness of the conclusion. And you can’t use what you learn in war games to change procurement decisions? What idiot thinks that’s a good idea? Pentagon IG Report.

May 30/13: Sikorsky Aircraft Corp. in Stratford, CT receives a $435.3 million cost-plus-incentive-fee contract modification, to buy 4 CH-53K System Demonstration Test Article helicopters. The April 5/06 System Development & Demonstration contract already included 4 test helicopters, and US NAVAIR and Sikorsky subsequently confirm that these 4 SDTA helicopters are a different set that the Marines will test during operational evaluation. The buy is structured as an additional line item under the 2006 contract, and initial funding will use $48.1 million in FY 2013 RDT&E budgets.

Sikorsky CH-53K Program VP Dr. Michael Torok says the SDTA helos will be based on the configuration of the 4th and final flight test aircraft from the 2006 contract, which is currently being assembled on the prototype production line. To date, Sikorsky has delivered 2 non-flying SDD CH-53Ks: the Ground Test Vehicle and the Static Test Article. That leaves the 4 flight test prototypes, 1 stationary Fatigue Test CH-53K, and now the 4 SDTA helicopters. First flight of a CH-53K prototype is now expected in “late 2014” instead of Spring 2014, and this contract requires 1st SDTA delivery by September 2016. Final delivery is scheduled by the time OpEval begins in March 2017, with incentives for early delivery.

Work will be performed in Stratford, CT (17%); West Palm Beach, FL (17%); Wichita, KS (15%); Salt Lake City, UT (10%); St. Louis, MO (4%); Bridgeport, WVA (3%); Windsor Locks, CT (3%); Ft. Walton Beach, FL (2%); Redmond, WA (2%); Forest, OH (2%); Jackson, MS (2%); Cudahy, WI (2%); Irvine, CA (2%); Kent, WA (1.2%); Bristol, United Kingdom (1%); Phoenix, AZ (1%); Chesterfield, MO (1%); Los Angeles, CA (1%); Rochester, United Kingdom (1%); Buckinhamshire, United Kingdom (1%); Longueil, Quebec, Canada (1%); Cedar Rapids, IA (0.8%); Twinsburg, OH (0.8%); St. Clair, PA (0.5%), and various other locations (8.7%) (N00019-06-C-0081). See also US NAVAIR | Sikorsky

4 flight test helos

May 24/12: SAR. The Pentagon finally releases its Dec 31/12 Selected Acquisitions Report [PDF].

“CH-53K Heavy Lift Replacement Helicopter – Program costs increased $1,897.6 million (+7.1%) from $26,626.8 million to $28,524.4 million, due primarily to changing the cost estimating methodology from analogy-based to supplier bottom-up (+$1,796.6 million), use of commercial indices for materiel escalation costs (+$948.9 million), revised escalation indices (+$539.4 million), an increase in the production line shutdown estimate (+$120.7 million), and an increase in support equipment, repair of repairables, and spares costs (+$64.9 million). These increases were partially offset by decreases in other support costs (-$664.0 million), initial spares requirements (-$589.0 million), and the application of new inflation indices (-$385.3 million).”

To put the estimating into English, the program had estimated costs based on similar programs, but now they’ve gone through the chosen suppliers and built an estimate using actual costs for components and materials, plus commercial figures for raw materials etc. The result adds almost $2.85 billion to the program, and other cost jumps bring the total increase to $3.47 billion. The downward revisions to spares and support, and to inflation, prevent costs from rising over 13%.

Are the changes reasonable? We won’t know until flight testing is well underway and time has revealed real inflation costs, but there’s reason to be skeptical. It could be a case of “paper cuts now, then cost increases once production is underway and jobs in Congressional districts are committed.” We’ll have to talk to the program to even begin to judge.

SAR: program cost increases – questionable cuts?

May 17/13: General Electric in Lynn, MA receives a $7.6 million firm-fixed-price delivery order to buy critical hard tooling required to support the manufacture of the CH-53K’s GE38-1B engines. The current order involves GE38s for the CH-53K System Demonstration Test Article (SDTA) helicopters, and they’re the engine’s inaugural platform.

Work will be performed in Lynn, MA (20%); Morristown, TN (20%); Groton, CT (20%); Hooksett, NH (10%); Fort Wayne, IN (10%); North Clarendon, VT (10%); and Albany, OR (10%); and is expected to be complete in November 2014. All funds are committed immediately, using FY 2013 RDT&E budgets (N00019-10-G-0007).

March 28/13: GAO Report. The US GAO tables its “Assessments of Selected Weapon Programs“. Which is actually a review for 2012, plus time to compile and publish. Overall, expected costs have risen (q.v. March 30/12 entry), though the added cost per helicopter is only 5.6% above the baseline. The “ground test vehicle” non-flying model has been delivered, but issues with a test stand are delaying progress.

GAO points out that the design is released, but not necessarily finished. The big break in the program remains the April 2011 shift from a cost-plus award fee to cost-plus incentive fee contract, tied to specific cost and schedule goals, and associated with a much-delayed schedule. The next big event will be the beginning of system-level prototype testing in 2013.

Dec 4/12: Testing. Sikorsky delivers the 1st CH-53K Ground Test Vehicle (GTV) prototype. It won’t fly, just help test the performance of the rotor blades, transmission, and engines. The 4 follow-on flight test helicopters aren’t expected to fly until 2014-2015. Sikorsky.

GTV delivered

FY 2012

GAO report says development will need more $; Last CH-53D retired.

CH-53E lifts M113 APC

May 6/12: Sikorsky Aircraft Corp. in Stratford, CT receives a $7.8 million cost-plus-award-fee contract modification to incorporate CH-53K live fire test and evaluation. This is exactly what it sounds like – the Navy will shoot lots of holes in test platforms, and assess damage resistance.

Work will be performed at Naval Air Warfare Center Weapons Division, China Lake, CA (80%), and Stratford, CT (20%). Work is expected to be complete in December 2018 (N00019-06-C-0081).

April 12/12: Sikorsky Aircraft Corp. in Stratford, CT receives a $25.7 million cost-plus-incentive-fee contract modification, to provide detailed maintenance plans in support of the CH-53K helicopter program. Work will be performed in Stratford, CT, and is expected to be complete in December 2015 (N00019-06-C-0081).

March 30/12: GAO report. The US GAO tables its “Assessments of Selected Weapon Programs” for 2012. With respect to the CH-53K:

“Program officials reported that in July 2011, the contract’s estimated cost was increased by $724 million to $3.4 billion. According to Defense Contract Management Agency officials, the estimated contract costs increased because of several factors including the need for additional flight test hours and spare parts, increased material costs, and design complexity. The contract was also changed from cost-plus award fee to cost-plus incentive fee for the remaining period of performance. The incentive fees are tied to specific cost and schedule goals… According to Marine Corps officials, a force structure review has been conducted to assess the required quantity of aircraft and that review determined that the requirement for 200 aircraft is still valid despite the proposed manpower reduction.”

Feb 28/12: Avionics. Northrop Grumman announces a $5.6 million Phase II contract from US NAVAIR to modify existing software for the CH-53K’s LN-251 embedded GPS/fiber-optic inertial navigation system (INS). Northrop Grumman’s Navigation Systems Division will provide updated software and engineering support for platform integration and flight tests, to both NAVAIR and Sikorsky Aircraft.

Feb 24/12: Sikorsky Aircraft Corp. in Stratford, CT receives a $15.5 million cost-plus-incentive-fee CH-53K contract modification. The program needs a condition-based maintenance plus software toolset (almost certainly ISS – vid. Oct 26/11), to integrate the helicopter’s onboard prognostics and the Navy’s fleet common operating environment maintenance computers. The contract includes installation, operation, and recurring data analysis.

Funds and work will be assigned if and as needed, and work will be performed in Lexington Park, MD (90%), and Stratford, CT (10%). The contract is expected to run until February 2018. US Naval Air Systems Command in Patuxent River, MD manages the contract (N00019-06-C-0081).

Feb 10/12: USMC retires CH-53D. The USMC holds a “sundown ceremony” to retire its CH-53D Sea Stallion fleet, leaving only CH-53E Super Stallions. See also Aug 16/10 entry. US NAVAIR explains that the retirement isn’t immediate, but it is imminent:

“The Sea Stallion’s last mission is currently underway with Marine Heavy Helicopter Squadron 363 supporting Operation Enduring Freedom in Afghanistan. The helicopter will be flown from Marine Corps Air Station Kaneohe Bay to its final destination at the Pacific Aviation Museum, where it will be displayed.”

CH-53D retired

Dec 19/11: Sub-contractors. Northrop Grumman announces a follow-on contract from US NAVAIR in Patuxent River, MD to define system requirements for the integration of its LN-251 embedded global positioning system (GPS)/fiber-optic inertial navigation system (INS) on the new CH-53K.

The firm touts the LN-251 system as “the world’s smallest, lightest navigation-grade embedded GPS/INS unit in its class… [whose] modular, open architecture supports additional applications and evolving requirements.”

Oct 26/11: Recognition. The CH-53K Helicopter Systems Engineering Team wins a Department of Defense Systems Engineering Top 5 Programs Award, at the annual NDIA Systems Engineering Conference Award Luncheon in San Diego, CA. US NAVAIR.

Oct 26/11: ISS Patent. Sikorsky Aerospace Services’ Integrated Support System (ISS) aftermarket software suite has received a patent. ISS integrates onboard diagnostics (vid. Sept 26/08 HUMS entry) and usage data with ground-based troubleshooting and service information. This technology is part of Sikorsky’s efforts to move toward proactive diagnostics, and ISS platforms for the Sikorsky CH-53K and S70i are under development. Future plans include expansion to other aircraft types. Sikorsky.

Oct 11/11: Sub-contractors. Thermoplastic composites firm Fiberforge announces the addition of Njord A. Rota as its CH-53K Program Manager. They explain that the Lockheed Martin veteran will lead all management aspects of Fiberforge’s work for DRS Technologies Inc. Their work includes the design, development and production of the carbon fiber composite components within the CH-53K’s Internal Cargo Handling System. Helihub.

FY 2011

GE delivers 1st engine, sees GE38 civil and military market potential as $4+ billion; Sikorsky unveils virtual reality center, FAFO experimental assembly line.

August 2011: Re-baselined. The CH-53K program undergoes a major time shift. Delivery dates for engineering development models are moved, 1st flight is pushed back to 2014, and Initial Operational Capability is moved from 2015 to 2018 (later 2019). Source: GAO.

Contract rebaselined

GE38 engine
(click to view full)

Aug 4/11: Engine. GE has delivered the 1st GE38 engine, for use on the Sikorsky CH-53K Ground Test Vehicle. After 2 years of testing, GE touts 57% more power and 18% lower specific fuel consumption than the CH-53E’s similarly-sized GE T64, while using 63% fewer parts.

In addition to the CH-53K SDD program’s 20 flight engines, the GE38 testing program includes 5 factory-test engines that will accumulate more than 5,000 engine test hours by 2013. GE is pushing ahead on its engine despite CH-53K delays, and expects it to have applications in the fixed wing and naval markets, alongside its helicopter potential. They see a total civil and military market potential of $4+ billion. GE.

June 21/11: Industrial. Sikorsky announces that they’ve begun assembly of the CH-53K Ground Test Vehicle (GTV), which is currently in position 4 on the line. It’s the 1st of 5 prototype CH-53Ks to be assembled at the Sikorsky Florida Assembly and Flight Operations (FAFO) facility in West Palm Beach, FL, which opened in March 2011.

Another 2 GTVs will be assembled at Sikorsky’s main manufacturing plant in Stratford, CT, making 3 ground test and 4 flight test helicopters. CH-53K ground testing is scheduled to begin in early 2012, and flight testing during FY 2014. To give one a sense of the CH-53K, its rotor hub and transmission alone weigh 15,000 pounds – about the empty weight of a UH-60 Black Hawk.

April 2011: Restructuring. The CH-53K program undergoes a major shift. The SDD contract is changed from a cost-plus award fee structure to cost-plus incentive fee contract, which is tied to specific cost and schedule goals. Source: GAO.

Contract restructured

March 22/11: Industrial. Sikorsky officially opens its new 60,000 square foot Florida Assembly and Flight Operations (FAFO) campus, establishing experimental assembly line operations for the new CH-53K heavy lift helicopter. The FAFO line introduces a set of new manufacturing technologies. It’s equipped with wireless data connections to all operator plasma data screens, uses digital operation sheets, and is outfitted with overhead power and air dropdowns, new aircraft work stands, and overhead cranes. Sikorsky, incl. video.

Feb 16/11: Sub-contractors. Donaldson provides an update regarding its Engine Air Particle Protection System, which is a critical piece of equipment in desert or dusty environments. They received the contract in September 2007:

“We built the first full-scale EAPPS in just three months following the CDR, [DID: which was August 2010]” said Sheila Peyraud, General Manager, Aerospace and Defense at Donaldson. “Developmental testing began in November 2010 to support testing of the helicopter’s GE38-1B engine in 2011. We are pleased that initial results in this phase of the program are exceeding expectations originally set during the conceptual design phase. Qualification testing will begin in May 2011.”

Jan 14/11: Industrial. Sikorsky unveils a state-of-the-art virtual reality center for the CH-53K heavy lift helicopter program, attempting to help identify production and maintenance issues before the initial build takes place by using a 3-dimensional digital environment.

Located within the engineering labs at Sikorsky’s main manufacturing facility in Stratford, CT, the virtual reality center uses sophisticated software, along with 12 cameras, a head-mounted display headset, gloves, and a gripping tool. All devices are linked to 3 computers, which comprise the “command center” for operating the system.

Nov 19/10: Sub-contractors. ITT Corporation (formerly EDO) announces that after nearly 3 years of advanced design, development, testing and manufacturing, they’ve delivered the first pair of CH-53K sponsons to Sikorsky. Each sponson is 25 feet long by 4 feet wide and 5 feet high, and fits on the helicopter’s side to house landing gear, fuel, and other mechanical and electrical assemblies.

ITT used composite materials instead of traditional sheet metal for the sponsons, and hopes they’ll provide benefits in weight, corrosion resistance, and in-flight stress tolerance. To make that work, ITT has to use advanced manufacturing technologies like electronic model control, laser-ply projection, 5-axis computer numerically controlled machining, automated trimming and drilling, and laser and ultrasonic inspection of all subassemblies. The CH-53K parts will be built at ITT’s Electronic Systems facility in Salt Lake City, UT.

FY 2010

Why was the CH-53K program pushed back 2 years?; SAR raises plans to 200; Critical Design Review passed; AAQ-29 surveillance turrets for CH-53K; No more “boneyard” CH-53D/Es left.

CH-53Ds in Hawaii
(click for video)

Sept 6/10: Sub-contractors. GKN Aerospace delivers the first major CH-53K structural assembly to Sikorsky – an aft transition fuselage section that measures approximately 20′ x 9′ x 9′, built of an advanced hybrid composite, aluminum and titanium structure covered with external composite skins.

GKN Aerospace was accorded full design authority and manufacturing responsibility for the CH-53K helicopter aft transition fuselage section, cargo ramp, and overhead door structural assemblies in 2007. Structural design is carried out by the GKN Aerospace Engineering Development Center in Nashville, TN, and manufacturing of over 1,000 separate components takes place at the Company’s plant in St. Louis, MO. GKN Aerospace is employing manufacturing technologies including automated fibre placement (AFP), automated trim and drill, and digital inspection. GKN Aerospace.

Aug 16/10: CH-35D plans. DoD Buzz looks at the shifting plans to replace the USMC’s 30 CH-53D Sea Stallions. The original plan was to replace them with MV-22s. At some point in 2007/08, the Marine Corps formally decided replace their aging CH-53Ds with CH-53Ks. But now USMC Lt. General Trautman is saying that he wants an east coast and a west coast MV-22 squadron to replace the CH-53Ds in Afghanistan, and “When I can do that, that’ll be the start of getting CH-53 Delta out of the way.”

Exactly what “out of the way” means is ambiguous. If it means out of service, DoD Buzz correctly notes that this raises questions about the USMC’s support for the CH-53K, and would seem to be better news for the MV-22. If it means “shifted back to Hawaii while MV-22s serve in Afghanistan,” that would be something else. The exact meaning isn’t 100% clear in the article.

Aug 3/10: CDR. Sikorsky announces a successful Critical Design Review for its CH-53K, following a week-long meeting in late July that included representatives from the military, Sikorsky, and 21 industrial partners. At the review, the CH-53K team had to demonstrate that their design meets NAVAIR’s system requirements. System-level performance projections indicate that all 7 Key Performance Parameters (KPPs) will be achieved with adequate risk mitigation margin built-in. Over 93% of the design has been released for manufacturing, and the final design definition concludes, the next step involves initial prototypes and testing.

The overall program CDR follows previous efforts including a System Requirements Review (SRR), System Functional Review (SFR), System Preliminary Design Review (PDR), 77 supplier-level CDRs, 64 supplier and internal software reviews, and 16 sub-system CDRs. Sikorsky VP and CH-53K Chief Engineer Mike Torok offers an update of other preparations:

“Parts are being made throughout the supply base and at our new Precision Component Technology Center; test facilities are being fabricated and prepped for installation in our recently opened ground test facility; the integrated simulation facility is marching toward a late 2010 opening, already having received the first increment of software for the aircraft; and the final assembly facility in West Palm Beach is being prepared to start building the ground and flight vehicles early next year. It’s time now to prove out our design and show that this helicopter system will indeed meet the war fighting requirements of the USMC…”

CDR

June 28/10: Sub-contractors. Raytheon Co. in El Segundo, CA received a $26.5 million firm-fixed-price delivery order for 50 forward looking infrared devices that will be fitted to CH-53E (42) and CH-53K (8) helicopters. Discussions with corporate representatives confirm that these will be AN/AAQ-29 turrets, using a 480 x 640 element, 3-5 micron wavelength indium antimonite infrared detector, and a 2 field of view telescope on a 12-inch diameter turret.

This is a follow-on to a previous order. Work under this basic ordering agreement will be performed in El Segundo, CA, and is expected to be complete in June 2012. $530,000 will expire at the end of the current fiscal year, on Sept 30/10 (N00019-10-G-0018).

June 4/10: No more CH-53D/Es. US NAVAIR announces that it has delivered the last available CH-53s from storage at AMARG in Tucson, AZ. The last H-53E to come out of desert retirement was delivered to Marine Helicopter Training Squadron 302 on May 7/10, while the last CH-53D was delivered April 16/10.

Since the start of the program in August 2005, FRC East H-53 artisans have inducted and completed 10 of the heavy-lift helicopters. The team delivered 8 CH-53Es and 2 CH-53Ds, some of which had been idle for as many as 11 years, ahead of schedule and under budget. Each helicopter still took about 25,000 total work hours for all testing, modifications, and maintenance. Sikorsky ended CH-53 production in 1999, so AMARG was the last remaining source of airframes.

Boneyard out of CH-53s

May 10/10: Engine. Flight International reports that even though the CH-53E is delayed, GE remains committed to delivering the 7,500 shp class GE38-1 engine on schedule. The firm sees re-engining opportunities and related sales beyond the CH-53K, so they’ve begun delivering GE38s for ground tests years before airframes become available for flight test.

As of Feb 15/10, GE had recorded 176 engine starts and 177 operating hours, with sustained power of 7,760 shp and peak power of 8,300 shp. April 2010 saw delivery of a 2nd engine for ground tests.

The article is less positive about the CH-53K’s odds of winning the German/French heavy-lift helicopter program. Apparently, Germany wants a helicopter that will fit key vehicles internally, not underslung. Ultimately, the question will be whether Germany can afford to develop what it wants, can find it elsewhere, or is forced to remove some requirements.

April 29/10: Why the delay? DefenseTech reports that the USMC has pushed back the initial flight date of the CH-53K by 2 years to FY 2013, and Initial Operational Capability by 3 years to FY 2018, “with little concrete justification beyond an ‘overly aggressive initial program schedule’ “, and while stressing that the program has not run into technical problems. Craig Hooper writes:

“The CH-53K was an unsung showpiece for those preaching the virtues of incremental development, and, as a result, appetite for the platform has grown by about 30 percent, with the program of record expected to increase from 156 aircraft to 200. But, in the process, the CH-53K has become something of a MV-22-killer. Is this the problem?… In late 2009, the Marine Corps decided to go with the CH-53Ks to replace their 40-year old CH-53D fleet (MV-22 Ospreys were originally slated to replace the CH-53D). At about the same time, Israel decided to forego the Osprey for the CH-53K, killing the Osprey’s best hope of snaring an international buyer. And with the Osprey 65% availability and the MV-22s high operating costs of about $11,000 dollars an hour… worse, studies from the Pentagon demonstrated that a CH-53K-equipped big-deck amphib provided a lot more logistical support for embarked Marines than the MV-22… Slowing CH-53K development will… prevent real-data comparisons between platforms… [until] a second multi-year MV-22 contract gets signed in FY 2013. Even worse, slowing the CH-53K schedule raised the program price by at least $1.1 billion dollars, raising the per-unit price… Why slow a program that stands to be a high-demand showpiece with potential markets in Israel, Germany, France, Turkey, Singapore and Taiwan?”

Asked for a response, US MARCORSYSCOM said that US NAVAIR was the only agency that could respond; NAVAIR did not respond to DID’s simultaneous inquiry.

April 1/10: SAR – Program grows. The Pentagon releases its April 2010 Selected Acquisitions Report, covering major program changes up to December 2009. The CH-53K is included, because the Marines want more of them – but there’s a self-imposed catch:

“CH-53K – Program costs increased $6,817.8 million (+36.4%) from $18,708.3 million to $25,526.1 million, due primarily to a quantity increase of 44 aircraft from 156 to 200 aircraft (+$3,108.9 million), and increases in other support costs (+$749.7 million) and initial spares (+$456.2 million) associated with the quantity increase. Costs also increased due to a three-year delay in the procurement profile shifting initial purchases from fiscal 2013 to fiscal 2016 (+$1,148.4 million), schedule growth attributable to funding constraints (+$669.6 million), and an increase in the cost estimate for the development contract (+$611.2 million).”

Feb 22/10: Sub-contractors. Cobham announces [PDF] a sub-contract from Sikorsky to manufacture all leading and trailing edge details and precisely locate and bond the details onto the CH-53K’s main rotor blade spar.

The work will be done by its Antenna Systems unit, which has consolidated all composites-related operations within the company. Depending on how many CH-53K helicopters are eventually built by Sikorsky for the US Marine Corps, the contract could be worth up to $25 million.

Jan 22/10: Industrial. Sikorsky formally opens its new $20 million Precision Components Technology Center, as part of United Technologies Corp.’s $130 million investment the CH-53K program.

The center currently employs 8 people, and was designed to allow the development of new product lines with “zero setup time” and quick changeover from one component to another. The center will produce major dynamic components of the CH-53K helicopter such as rotating and stationary swashplates, main and tail rotor hubs, and main rotor sleeves. The equipment in the center has the capability to produce any precision rotor and drive system dynamic component, including earlier-model configurations, and forgings machined there can be up to double the size of previous on-site limits. Sikorsky release.

Jan 7/10: IDR. Sikorsky announces the wrap-up of its Integration Design Review for the CH-53K, in preparation for the Critical Design Review coming in 2010. The event included industrial team members , and personnel from US NAVAIR and the Office of the Secretary of Defense. Risk reduction initiatives on the critical split torque main gear box and the advanced main rotor blade are done, and 2010 will also hold a Technology Readiness Assessment. Initial Operational Capability is currently slated for early 2016.

Established features of the CH-53K helicopter currently include a joint-interoperable glass (digital screens) cockpit; fly-by-wire flight controls; 4th generation rotor blades with anhedral tips; a low-maintenance elastomeric rotor head; upgraded engines; a locking cargo rail system; external cargo handling improvements; survivability enhancements; and design for reduced operation and support costs. Sikorsky release.

FY 2009

CH-53s flying at 3x planned usage; 1st GE38 engine test; VELD removed from the design; Sub-contractors picked.

CH-53E, Cobra Gold 2002
(click to view full)

July 28/09: Engine. The GE38 team holds a ceremony at General Electric in Lynn, MA, celebrating the completion of the first full GE38 engine test. This first engine test, which began June 24/09, focused on basic engine checkout and risk reduction. All engine test parameters were within predicted values.

SDD phase testing will include 5 ground-test engines that will accumulate more than 5,000 engine test hours, plus production of 20 flight-test engines for the CH-53K development helicopters (each helicopter carries 3 engines). NAVAIR release.

May 7/09: Sub-contractors. Curtiss-Wright Corporation announces a contract from Sikorsky to develop and supply data concentrator units for the CH-53K. Curtiss-Wright’s system consists of 2 data concentrator units (DCUs) that will receive and provide various avionic and air vehicle discrete, digital and analog inputs for monitoring, processing data and controlling various CH-53K subsystem components.

Curtiss-Wright’s Motion Control segment will develop and manufacture the DCU systems at its newly-opened City of Industry, CA, facility. The initial contract runs through 2011 with the production phase starting in 2013. The contract has a total potential value of $22 million when development and all aircraft production options and phases are completed.

April 21/09: Sub-contractors. Curtiss-Wright Controls Inc., announces a contract from United Technologies subsidiary Claverham Ltd. (a Hamilton Sundstrand Flight Systems business unit) to provide multi-channel linear variable displacement transducers (LVDTs) for the fly-by-wire (FBW) systems controlling the main rotor and tail rotor on the Sikorsky UH-60M Upgrade and CH-53K helicopters.

The LVDTs are special pressure sealed linear displacement transducers that are embedded in Claverham’s Primary Flight Control Actuators. The transducers provide electrical signals that are proportional to the position of the hydraulic actuator rod, and the actuators change pitch angles on the main and tail rotors in response to the pilot’s commands.

These two programs have a potential contract value in excess of $20 million over a 15-year period, with shipments expected to begin in 2009. The company will supply these products from its Christchurch, UK operation.

March 30/09: GAO. The US GAO audit office delivers its 7th annual “Defense Acquisitions: Assessments of Selected Weapon Programs report, which looks at 47 programs including the CH-53K HLR. The CH-53K stands out, as one of the few programs to show lower R&D projections (from $4.23 billion to $4.17 billion) and estimated delivery time (2 months early) since its 2005 baseline. The truth is, the Marines have little choice. The time crunch has already begun:

“According to program officials, all available decommissioned CH-53E helicopters have been reclaimed… Currently deployed CH-53E aircraft are flying at three times the planned utilization rate… The program intends to manufacture up to 29 of the 156 total [CH-53K] helicopters (19 percent) during low-rate initial production at the same time that it is conducting initial operational testing. While concurrent testing and production may help to field the systems sooner, it could also result in greater retrofit cost…”

That’s likely, since a number of requirements and systems have been shelved, in order to deliver the helicopter on time:

“Both of the CH-53K’s current critical technologies, the main rotor blade and the main gearbox, are immature and are expected to be fully mature following the low-rate initial production decision in 2013. The program replaced a third technology, the viscoelastic lag damper, with a modified version of an existing [linear hydraulic damper] technology. During preparations for the preliminary design review, it was discovered that maturing system engineering tasks would potentially require additional cost and time. As a result, the program eliminated noncritical requirements to contain costs and delayed the preliminary and critical design reviews and low-rate initial production decision.”

Feb 8/09: Sub-contractors. BAE Systems announces contracts from Sikorsky Aircraft for development and initial deliveries of CH-53K Cockpit Seats and Cabin Armor Systems, and for integration of the CH-53K’s fly-by-wire flight controls. BAE Systems efforts will include design, development, testing, qualification, and delivery of initial systems to support the flight test and ground test aircraft. Follow-on contracts would be placed for production orders and spares.

The seats will be based on BAE Security & Survivability Systems S7000 armored, crashworthy seats, and first deliveries of both seats and cabin armor are scheduled for 2010. The total value of the programs is estimated at approximately $90 million through 2022, if 156 CH-53K aircraft are built.

FY 2008

PDR successful; Sub-contractors picked.

Iraq: CH-53E lifts UH-60
(click to view full)

September 2008: PDR. The CH-53K program conducts a successful Preliminary Design Review. Source.

PDR

Sept 26/08: Sub-contractors – HUMS. Goodrich announces that it has been picked to supply its IVHMS Health Usage and Monitoring Systems (HUMS) for the CH-53K. HUMS are embedded sensors within the aircraft’s key components, like engines. They monitor these systems, and can often tell if things are beginning to wrong inside before something actually breaks.

Avoiding breakdowns, and helping to pinpoint problems faster if something does break, saves money. Further savings can be had by using HUMS in conjunction with advanced maintenance and fleet management software. Once a baseline of good data is available, it becomes possible to switch from “do it just in case” maintenance and overhaul checklists, to “condition-based maintenance” that’s performed only when necessary, based on a combination of HUMS readings and predictive software.

Goodrich has carved out a strong market position in this area, supplying HUMS systems of varying complexity for a number of US military helicopters. IVHMS will supposedly build on earlier IMDS systems implanted in the CH-53E, but will be broader in nature, monitoring “the CH-53K helicopter’s entire mechanical drive train from the engines to the rotor system, and hundreds of aircraft systems.”

Sept 2/08: Sub-contractors. Breeze-Eastern Corporation announces that Sikorsky has picked them to provide the CH-53K’s Internal Cargo Winch System. The initial contract requires the delivery of 5 units for the System Design and Development phase.

Breeze-Eastern has worked with Sikorsky in this area to supply the S-92, and to retrofit USMC CH-53Ds. Bloomberg.

May 30/08: Camber Corp. in Huntsville, AL received an $8.6 million cost-plus-fixed-fee contract for program management, acquisition management, and engineering and technical services in support of the CH-53D, CH-53E, MH-53E, and CH-53K.

Work will be performed in Patuxent River, MD and is expected to be complete in November 2008. This contract was not competitively procured by the Naval Air Warfare Center Aircraft Division, Patuxent River, MD (N000421-08-C-0044).

Feb 18/08: Sub-contractors. Northrop Grumman Corporation announces that U.S. Naval Aviation Systems Command has picked their APR-39BvX radar warning receiver (RWR) integration program for the Navy’s CH-53K helicopter fleet. The APR-39 BvX upgrade, scheduled for completion and flight testing in late 2009 or early 2010, builds on the recently completed AvX program and includes new, faster processors and “massive” memory expansion.

Under the terms of the $17 million phase Phase 2 contract, Northrop Grumman will incorporate all electronic warfare (EW) integration capabilities of the APR-39Av2 and APR-39Bv2 versions, which are variants of the same system tailored to the kind of aircraft computer and cockpit interfaces in Navy/USMC aircraft. The APR-39BvX program will create one interoperable version for the forthcoming CH-53K fleet. This phase 2 program will include electronic warfare controller and integration interfaces to multiple missile and laser warning sensors, and also tie the APR-39 into Northrop Grumman’s Directional Infrared Countermeasures (DIRCM) systems onboard each of the helicopters. The intended result is a system providing warning and protection against electro-optical, infrared, and radar guided missiles, and electronic warfare threats. NGC release.

Nov 6/07: Sub-contractors. Sikorsky has selected fellow United Technologies Corporation subsidiary Eaton Corporation to design, develop and supply the CH-53K’s integrated fuel system. This is in addition to the contract for the helicopter’s hydraulic power generation system and fluid conveyance package awarded to Eaton in July 2007.

During the development phase of the program, which runs through 2014, Eaton will provide the integrated fuel system support hardware for 5 helicopter shipsets in addition to a number of system development test sets. “Based on expected production of more than 156 helicopters for the U.S. Marine Corps, the contract value is approximately $96 million and, when combined with anticipated foreign military sales, is expected to exceed $160 million over the approximate 12-year life of the program.” Eaton release.

FY 2007

Sub-contractors picked; Sikorsky opens CH-53K development center.

CH-53E Super Stallions:
2 HMMWVs, to shore
(click to view full)

Sept 25/07: Sub-contractors. Donaldson Company announces that Sikorsky has picked them to provide the CH-53K’s engine air particle protection system (EAPPS), which helps keep blown sand and other contaminants from gumming up the helicopter’s engines.

Sept 17/07: Sub-contractors. Fellow United Technologies’ subsidiary Hamilton Sundstrand announces that they’ve been selected to supply integrated secondary power systems for the CH-53K, consisting of the environmental control system, auxiliary power unit and main engine start system. The environmental control system (flight deck and avionics air conditioning, cabin ventilation and heating, engine bleed system, and supply air for the onboard inert gas generation system) and main engine start system will be built at Hamilton Sundstrand’s Windsor Locks, CT facility. The Auxiliary Power Unit will be built at the company’s San Diego, CA facility.

The contract includes design, development and production work; design and development will begin immediately with first hardware deliveries scheduled for 2009. Hamilton Sundstrand says that this agreement has a potential value of more than $400 million. The firm already holds contracts to supply the CH-53K’s fly-by-wire flight control computers, and primary main and tail rotor actuators. Hamilton Sundstrand release.

Sept 4/07: Sub-contractors. Sikorsky Aircraft Corporation has selected Goodrich Corporation to act as integrator for the CH-53K’s input and tail drive shaft system, as well as supplying the electrical power generation and distribution system (q.v. June 17/07).

July 12/07: Sub-contractors. Sikorsky Selects fellow UTC subsidiary Eaton to supply the CH-53K’s Hydraulic Power Generation System and Fluid Conveyance Package. During the development phase of the program, which runs through 2014, Eaton will provide support hardware for 10 aircraft shipsets. Based on expected production of more than 156 aircraft for the U.S. Marine Corps, as well as anticipated foreign military sales, the potential value of the contract over the life of the program is expected to exceed $200 million. Eaton release.

June 20/07: European HTL. France & Germany confirm their heavy-lift helicopter program, known as HTL in France and FHT in Germany. A full set of specifications have not been created yet, and the countries involved are still trying to decide whether to pay the price of a full R&D program to get exactly what they want, or base their helicopter on an existing design. Possible contenders include the CH-53K, Boeing’s CH-47F, and Rosvertol’s super-giant Mi-26T helicopter.

June 18/07: Sub-contractors. Canadian aerospace manufacturer Heroux-Devtek Inc.’s Landing Gear Division received a contract from Sikorsky to design, develop, fabricate, assemble, test and deliver the CH-53K’s landing gears and tail bumper during the SDD phase, which includes the production of landing gears and tail bumper assemblies for 8 systems. Total revenue for the SDD and the Production Phase, which will be awarded in a separate contract, is expected to exceed C$ 95 million (about $89 million). Rotor News.

June 17/07: Sub-contractors. Sikorsky Aircraft Corporation has selected Fortune 500 firm Goodrich Corporation to supply the electrical power generation and distribution system for the CH-53K program. Goodrich’s Pitstone Green, UK and Twinsburg, OH facilities will be involved in the development and delivery of a complete electrical power system for the aircraft, consisting of generators and controls; primary power distribution; AC/DC converters; battery; and external power controls.

Goodrich currently supplies power generation for the Sikorsky S-92/H-92 Superhawk, and has recently been selected to supply the DC power generation for the Sikorsky’s upgraded S-76D civil helicopter. Rotor News | Goodrich press kit release incl. pictures

May 9/07: Sub-contractors. Sikorsky Aircraft announces its selection of 4 subcontractors to design and fabricate the CH-53K’s major fuselage sections, “following an extensive solicitation and evaluation of multiple bids over a 12-month competition”: They include Aurora Flight Sciences in Manassas, VA; Bridgeport, WVA; and Columbus, MS; R&D in Cambridge, MA (main rotor pylon). EDO Corp. composites in Salt Lake City, UT; select resin transfer molding parts from Walpole, MA; and final assembly in North Amityville, NY (tail rotor pylon & side sponsons). GKN Aerospace in Nashville, TN & St. Louis, MO (aft transition). Spirit AeroSystems in Wichita, KS (cockpit and cabin).

Design will be conducted in a collaborative environment between supplier sites and Sikorsky’s Heavy Lift Development Center using model management systems linked to Sikorsky IT and data systems. Composite and titanium materials are being employed extensively to provide superior fatigue and corrosion durability at minimum weight, and state-of-the-art manufacturing processes such as co-curing, automated part fabrication, super high speed machining, and determinant assembly are being pressed into service to keep costs down. Sikorsky release.

Assemblies will initially be built for 7 test and certification aircraft (4 Engineering Development Models, 1 Ground Test Vehicle, 1 Static Test Article and 1 Fatigue Test Article.) The CH-53K SDD program schedule runs through the end of September 2015.

ADDENDA: GKN Aerospace’s release says that they’re contracted to deliver their 7 development ship sets to Sikorsky between 2009 – 2012, and estimates that this deal could be worth up to $70 million to them. Aurora Flight Sciences’ release clarifies that the Main Rotor Pylon (MRP) is one of 6 major fuselage sections; it is mostly made of composite materials, and houses the CH-53K’s Main Rotor Head, the No. 2 engine and other aircraft subsystems. EDO Release [PDF]

Feb 12/07: Manufacturing. Sikorsky Opens the CH-53K Development Center. The CH-53K program’s new Heavy Lift Development Center is a 106,000-square-foot office building in Stratford, CT, about 5 miles from Sikorsky’s main facility. It houses the CH-53K Program and Engineering staff, co-locating 500 team members consisting of Sikorsky, Naval Air Systems Command, Defense Contracting Management Agency personnel and subcontractors. These members work in Integrated Product Teams to design, develop, test and manufacture major systems and subsystems within the CH-53K.

Dec 22/06: Engine picked. Sikorsky Aircraft has selected General Electric Aviation to provide the new CH-53K heavy lift helicopter’s main engines. The GE38-1B engine planned for the CH-53K is a derivative of the CFE738 commercial turbofan engine used in the Falcon 200 business jet; the CFE738 was in turn derived from the T407 turboprop intended to power the US Navy’s updated P-7 Orion (that program was canceled and a competition restarted that left the 737-derived P-8A MMA as the winner). See also GE’s Feb 7/07 release.

According to this Flight International article, GE’s engine beat out Pratt & Whitney’s PW150 and a derivative of Rolls Royce’s AE1107 that powers the V-22 Osprey.

Oct 30/06: Rotor. Sikorsky Aircraft has submitted test results for its 4th Generation(TM) rotor blade, which builds on the work done for the Growth Rotor Blade(TM) (GRB) currently used on their new UH-60M and S/H-92 helicopters, using anhedral tips. The CH-53K model wind tunnel testing performed late in the summer of 2006 has reportedly shown a significant improvement in forward flight efficiency over the GRB. Earlier in the year, similar model rotor hover testing indicated large gains in hover efficiency. Read Sikorsky’s release.

FY 2004 – 2006

Program OK and $3 billion development contract; European HTL opportunity?

CH-53D at work
(click to view full)

July 19/06: European HTL. Jane’s reports that EADS Eurocopter is seeking partners for a “super lift” helicopter to be fielded around 2020 with the French & German militaries, and confirms that talks have been held with Sikorsky regarding a modified CH-53K with European avionics and a larger cabin.

The Germans apparently want to replace their CH-53Gs (actually modified CH-53Ds) around 2020, and will look for upgrade programs to bridge the gap. The French currently lack heavy-lift helicopters in the CH-53 or CH-47 class, though the supergiant Russian Mi-26 was evaluated recently. Eurocopter and Sikorsky recently partnered on the successful $3 billion LUH program, but the firm has said it is keeping all its options open and is making no commitments.

UPDATE: Germany is updating their CH-53Gs, and the 2 countries are also going ahead with the heavy lift helicopter program. The CH-53K is still a competitor. Where does it stand? Read “The European Heavy Lift Helicopter Program?”

April 5/06: SDD contract. Sikorsky Aircraft Corp. in Stratford, CT receives a $3.04 billion modification to a previously awarded cost-plus-award-fee contract (N00019-06-C-0081) for the System Development and Demonstration (SDD) of the CH-53K aircraft, to include 4 SDD aircraft, 1 ground test vehicle, and associated program management and test support.

Work will be performed in Stratford, CT and is expected to be complete in December 2015. See also NAVAIR release.

SDD contract

Dec 22/05: Green light. A formal decision by the Honorable Kenneth R. Krieg, US Undersecretary of Defense for Acquisition, Technology and Logistics, gives the estimated $4.4 billion HLR program the green light to proceed to the System Definition and Development (SDD) phase.

CH-53E Super Stallion
(click to view full)

August 25/05: Sikorsky Aircraft Corp. in Stratford, CT received a $43.3 million cost-plus-fixed-fee delivery order against a previous basic ordering agreement to perform requirements definition and engineering studies in support of the Marine Corps’ Heavy Lift Replacement (HLR) Program. Work on the requirements definition and engineering studies will be performed in Stratford, CT and is expected to be complete in April 2006.

Jan 6/05: Sikorsky Aircraft Corp. in Stratford, CT received an $8.4 million cost-plus-fixed-fee contract for preliminary design work in support of HLR, as part of the initial system development and demonstration of the Marine Corps’ CH-53X Heavy Lift Replacement (HLR) program. Work on the preliminary design contract (N00019-06-C-0081) will be performed in Stratford, CT and is expected to be complete in January 2008 (N00019-03-G-0003).

Dec 23/04: A $34 million time and materials delivery order, issued against basic ordering agreement N00019-03-G-0003, to perform requirements definition and engineering studies in support of the Marine Corps’ Heavy Lift Replacement Program. Work was performed in Stratford, CT, and was expected to be complete in May 2005.

This contract number is not exclusive to the CH-53K. Other awards under this particular contract covered the Presidential Helicopter program (Sikorsky lost) and other helicopter engineering.

Appendix A: Flying Between Scylla and Charbydis: Navigating the Political Shoals

JHL: QTR Concept
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DID’s coverage of the HLR program has also included a report about HLR’s potential merger with the US Army’s futuristic JHL program. The Joint Heavy Lifter (JHL) is imagined as an aircraft with cargo capacity that approaches a C-130 Hercules transport (about 20 tons), but with the ability to take off and land like a helicopter. No current US military helicopter platform even comes close. JHL’s competitors are deploying some radical and different technologies in their attempt to achieve these goals – from quad tilt-rotors to coaxial skycranes and even compound helicopters.

Marine Corps acquisition officials also weighed the option of participating in JHL. While Congress could always step in to force the issue – and may still do so – the Marine Corps note that this would be deeply unwise for a number of reasons:

“The Army’s proposed heavy lift requirement to transport the Future Combat System greatly exceeds our requirement,” said program manager, Col. Paul Croisetiere. “The actual aircraft hasn’t been designed yet, but initial analysis suggests the joint heavy lifter will be too large to operate from current and programmed amphibious shipping. We may have a use for it, but in more of a logistical role as a possible KC-130J [air tanker] replacement – we still need the CH-53K for tactical heavy lift.”

Joint Heavy Lifters may not be available any sooner than 2025, according to Croisetiere, which is more than 10 years after the Marine Corps will be forced to start retiring its current CH-53E fleet. Even if the Marines could use it, Croisetiere pointed out that as currently envisioned, JHL will be too big to operate from the Marines’ amphibious ships.

V-22 Osprey

This is a logical argument. However this rationale might sell better if the USMC hadn’t spent the last decade describing tilt-rotor technology as the necessary wave of the future that would make helicopters obsolete, in its quest to sell the $100 million per plane V-22 Osprey.

When budgets are also being squeezed hard by multiple cost overruns on a wide swath of programs, programs that appear to be similar to each other will become big targets for Congressional cuts and pressure to merge. The US Marines have been the leading service advocates of tilt-rotor technology as a transformational necessity. Having invested so much of their prestige and credibility in the V-22, some people on Capitol Hill seem inclined to view the Marines’ rejection of a program that includes similar Quad Tilt Rotor and OSTR (Optimum Speed Tilt-Rotor) options as inconsistent, and hence mere territoriality. If this view spreads, it will not bode well for the HLR Program’s political survival.

It certainly wouldn’t be the first time in US military procurement history that the promise of the shiny new thing has found itself in the way of fulfilling military necessities with cheaper, proven options.

MH-53J Pave Low IV
(click to view alt.)

The natural response to such pressures would be twofold. One track would emphasize the comparatively speculative nature of the JHL Program’s technologies and their uncertain development timelines. The other track would tout the value of cheaper builds of proven helicopters, in order to meet immediate needs and an uncompromising timeline for fleet airframe life. This is exactly what Col. Paul Croisetiere has done.

Making that argument, however, flies in the face of almost everything the USMC said when some in Congress pushed for immediately available conventional helicopter options to replace the Marines’ extremely aged Vietnam-era CH-46 Sea Knights. Options that would also have cost about half the price per aircraft. If the CH-46s could be patched together via life extension programs and extensive maintenance while the V-22s sorted out their difficulties and eventually reached production many years late, why not the CH-53Es? Especially if pursuing a similar tilt-rotor technology like the JHL’s QTR would reduce the V-22’s per-aircraft costs while increasing overall interoperability, and therefore easing long-term maintenance and logistics costs as well?

These arguments may or may not be considered valid. Nevertheless, they should absolutely be expected as the Global War on Terror, unexpected future contingencies, and a looming demographic shift put increasing pressure on US defense budgets. The US Marine Corps has certainly prepared the ground well.

The HLR program may have an eventful political journey ahead of it.

Appendix B: Interesting Ideas: The CH-53X Skycrane Concept

CH-53X Skycrane Concept
(click for details)

As a point of interest, this is one of the more innovative suggestions we’ve seen re: the next-generation CH-53X. It proposes turning the CH-53 into a “Skycrane” variant, and using it in conjunction with the trend toward “battle box” containerized forces, plus underslung light armor & vehicles.

The idea is that this would improve both the CH-53E’s capabilities (via reducing aircraft weight but not power) and the USA’s transformational deployability (via faster and more versatile load and ship that would also improve tactical surprise).

Additional Readings & Sources

• Sikorsky – CH-53K.

• GlobalSecurity.org – Heavy Lift Replacement [CH-53X].

• SLD (Oct 16/10) – Adding a Core USMC Capability: The CH-53K As A Logistical Force Multiplier. An Interview with Major Jeff “Kingpin” Davis.

• Sikorsky Frontlines, via WayBack (Q3 2009) – CH-53K Update [PDF].

• American Helicopter Society’s Vertifile Magazine, via WayBack (Spring 2002) – An Affordable Solution To Heavy Lift [PDF] by Lt. Col. James C. Garman, MH-53E pilot in HMH-772 and a Senior Preliminary Design Engineer in the New Product Definition Group, Sikorsky Aircraft Corporation. It describes the basic outlines of many low-risk CH-53X improvements.

• Naval Technology – CH-53E Super Stallion – Heavy-Lift Helicopter, USA.

• GE Aviation – GE38. CH-53K’s Engine, designated T408-GE-400 by the US Navy.

• MTU – GE38. The firms are partnering to develop it, with the German firm having an 18% stake; MTU will be licensed to offer it for any European FTH helicopter program.

• DID – Incoming & Hostile: The USN’s JATAS Aircraft Warning System. ATK picked, will be used on the CH-53K.

News & Views

• Flight International, via WayBack (May 10/10) – CH-53K delay will not hold up GE38 engine programme. Its potential uses go beyond helicopters, to include things like hovercraft, and GE sees its market potential as $4+ billion.

• Flight International, via WayBack (June 25/08) – GE plots GE38 engine’s future in emerging heavylift market. Offers further details re: the CH-53K’s planned engine.

• US DoD DefenseLINK: Transformation, via WayBack (Jan 9/06) – New Heavy Lift Helicopter Starts Development.

• US Navy NAVAIR, via WayBack (April 5/06) – $3B CH-53K contract awarded to Sikorsky.

• Jane’s Defense Weekly, via WayBack (Feb 24/06) – US heavy-lift aircraft will stretch state of the art. Full subscriber’s article includes JHL Program coverage as well.

• DID (Jan 9/06) – CH-53X (HLR) Program Moves Into SDD, Preliminary Design. An $8.6 million preliminary design contract is issued to Sikorsky, beginning the SDD phase. The CH-53X program is also redesignated CH-53K. Has the HLR program dodged the bullet?

• DID (Sept 27/05) – CH-53X HLR & JHL: Future Heli Programs on Collision Course? The shiny new (expensive, uncertain) thing may become the enemy of the necessary, proven thing in the US military’s procurement culture. Again.

• DID (Sept 21/05) – CSAR-X: And Boeing Makes 3…. The HLR program may be affected by the choices Sikorsky makes in the CSAR-X competition.

• DID (Aug 29/05) – HLR (CH-53X) Helicopter Program Moves Toward Milestone B Approval.

• Aviation Today, via WayBack (July 1/05) – Future Heavy Lift for the Marine Corps. An interview with Col. Paul Croisetiere, program manager for the U.S. Naval Air Systems Command H-53 Heavy Lift Helicopters Program PMA 261.

• Hill News, via WayBack (June 1/05) – House language could create friction over chopper programs.

• USMC, Leatherneck Magazine, via WayBack (May/05) – Heavy Lift Replacement: A Vital Marine Corps Program.

• American Helicopter Society’s Vertifile Magazine, via WayBack (Spring 2002) – From The Past To The Future Of Heavy Lift Part Three: Heavy Lift Helicopters [PDF].

Americas

The US Navy needs more support services to keep the fleet’s single combat system running. Lockheed Martin will provide additional engineering and technical services for the Submarine Warfare Federated Tactical Systems (SWFTS) program. This cost-plus-incentive-fee modification has a value of $13.5 million. SWFTS is an engineering and management program that consists of all submarine combat system subsystems, consultation, command, control, communications, computers, and intelligence to aid in integrating all systems into a single combat system for naval battle group interconnectivity. SWFTS essentially is a common architecture for the Navy’s five different classes of submarines, transforming the submarines from stand-alone vessels to nodes in combat networks. Work will be performed at Lockheed’s facility in Manasses, Virginia, and is expected to be completed by December, 2018.

The US Army is contracting General Atomics for further engineering services in support of its Gray Eagle UAS. The modification to previously awarded contract has a value of $11 million. The MQ-1C Gray Eagle is based on the MQ-1 Predator, but it is bigger, can carry more payload and has an engine that runs on the same kind of fuel that is used to power US Army vehicles. Its expansive mission set includes, but is not limited, to wide-area Intelligence Surveillance and Reconnaissance (ISR), convoy protection, Improvised Explosive Device (IED) detection and defeat, close air support, communications relay, and weapons delivery missions. The Gray Eagle, equipped with signal jammers, will likely be one of the Army’s primary electronic warfare platform. Work will be performed at the company’s location in Poway, California and is scheduled for completion by end of September, 2019.

Progeny Systems is set to supply the Navy and a number of US foreign military sales customers with a number of Mk-54 Mod 1 lightweight torpedo kits. The contract has a value of $40.6 million, but includes options which, if exercised, would increase the total face value of the contract to $303.2 million. FMS customers include Canada, Australia, the UK and Taiwan. The Mod 1 kit is an upgrade that adds a new sonar array assembly, and improved processing capability. The torpedo has a price-tag of $1 million per piece and is designed to work in both deep water and near-shore or shallow environments. Work will bet performed at multiple locations, including Charleroi, Pennsylvania; Salt Lake City, Utah and Manassas, Virginia.

Middle East & Africa

Jane’s reports, that Saudi Arabia is deploying one of its Patriot batteries to protect pilgrims in Mecca. Satellite imagery collected by DigitalGlobe shows that the missile launchers were aimed towards the Yemeni border, some 354 miles away. Houthi rebels have regularly launched ballistic missiles towards the kingdom, and targeted Mecca directly on October 9th, 2016. PAC-3 is the current standard, its enhanced capabilities allow it to be used for point defense against ballistic missiles. Saudia Arabia is believed to have ordered a total of 802 PAC-3 missiles at a cost of $7.15 billion since 2014.

Europe

The government of Bulgaria is inviting Russian and Belorussian companies to submit offers for a multi-million deal. The country urgently needs to overhaul its fleet of Russian-made Su-25s, a process that already is 10-years overdue. The Su-25 is a single-seat, close-support aircraft, known by the Nato reporting name Frogfoot. The plane is equipped with a 30mm twin-barrel gun, its wings have ten pylons for carrying a range of air-to-air and air-to-ground weapon systems selected for the mission. Bulgaria currently operates a total of 35 Su-25s, which entered service 1988. The planes were grounded in December 2017 because the Ministry of Defense did not have the resources to conduct necessary maintenance work. The modernization efforts will likely cost $24.2 million.

The Ukrainian military is currently testing a new domestically developed 80mm unguided missile. Tests are held at Chernihiv firing-range, to date a total of 300 RS-80 Oskol missiles were fired from a Mi-8 helicopter. The country is in the midst of a low-intensity conflict with pro-Russian separatists in its eastern Donbass region.

The Austrian Ministry of Defense plans to procure a number of new helicopters for the Air Force. The new aircraft are needed to replace Austria’s fleet of Alouette-IIIs, which are already over 50-years old. The Ministry is looking into a variety of platforms suitable to fill the role of the Alouette. Possible successors could be Leonardo’s AW-109, Bell’s 429 or Airbus’ H-145M. In addition, the Army plans to buy three overhauled Blackhawks. To guarantee the necessary funding, Austria’s quite limited military budget of $2,6 billion will be boosted with a $463 million special investment program.

Asia-Pacific

The Russian military will soon receive an upgraded variant of of the Mi-28NE Night Hunter combat helicopter. The Mi-28NE is designed to carry out search and destroy operations against tanks, armored and un-armored vehicles, and enemy personnel in combat, as well as low-speed airborne targets. Upgrades include an new external radar and the capability to fire new anti-tank guided missiles. The new ATGM is the latest variant of the 9M123M Khrisantema-VM, known by Nato as AT-15 Springer.

Today’s Video

Watch: Close up of an A-10 Warthog

ER/MP, armed
(click to view full)

Its initial battles were fought within the Pentagon, but the US Army’s high-end UAV has made its transition to the battlefield.

The ER/MP program was part of the US Army’s reinvestment of dollars from the canceled RAH-66 Comanche helicopter program, and directly supports the Army’s Aviation Modernization Plan. The US Air Force saw this Predator derivative as a threat and tried to destroy it, but the program survived the first big “Key West” battle of the 21st century. Now, the MQ-1C “Gray Eagle” is in production as the US Army’s high-end UAV. As CENTCOM’s wars end, however, the Gray Eagle may find that staying in the fleet is as hard as getting there.

This FOCUS article offers a program history, key statistics and budget figures, and ongoing coverage of the program’s contracts and milestones.

The MQ-1C Gray Eagle, and its Band of Brothers

Predator landing
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With General Atomics MQ-1A/B Predators, MQ-1C Gray Eagles, and MQ-9 Reaper UAVs all headed for the skies above the conflict zone, our readers have asked us to help them tell the difference. It’s clear that all 3 share a design philosophy, but their capabilities diverge in important ways.

View from the Air

The MQ-1 Predator is 27 feet long, with a 55 foot wingspan. Its maximum gross takeoff weight is 2,300 pounds, and it can carry 625 pounds of fuel, 450 pounds of internal payload (sensors), and another 300 pounds on its wings for up to 2 AGM-114 Hellfire anti-armor missiles or equivalent loads. Its service ceiling is 25,000 feet, which can keep it well above the 10,000-15,000 ft ceiling above which most guns are ineffective. The piston engine is a Rotax 914 turbo that runs on aviation fuel, and pushes the Predator at a slow speed of 120 KTAS. It’s controlled by UHF/VHF radio signals, and is designed to be flown by a pilot – without automated takeoff and landing.

The USAF also had an MQ-1B Block X/ YMQ-1C project underway, to develop a Predator system that would run on heavy fuel and carry up to 4 Hellfires. That project, and questions of cross-service compatibility, died when the USAF stopped buying MQ-1 Predators, and shifted its focus to the larger MQ-9 Reaper instead.

MQ-9 w. Paveways
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The MQ-9 Reaper, once called “Predator B,” is somewhat similar to the Predator. Until you look at the tail. Or its size. Or its weapons. It’s called “Reaper” for a reason – while it packs the same surveillance gear, it is much more of a hunter-killer design than its counterparts. The Reaper is 36 feet long, with a 66 foot wingspan. Its maximum gross takeoff weight is a whopping 10,500 pounds, carrying up to 4,000 pounds of fuel, 850 pounds of internal/ sensor payload, and another 3,000 pounds on its wings. The MQ-9 has 6 pylons, which can carry GPS-guided JDAM family bombs and other MIL STD 1760 compatible weapons, Paveway laser-guided bombs, Sidewinder missiles for air-air self defense, and AIM-114P Hellfire missiles or laser-guided Hydra rockets. With that arsenal the Reaper becomes the equivalent of a close air support fighter with less situational awareness, less speed and less survivability if seen – but much, much longer on-station time than its manned counterparts.

MQ-1 vs. MQ-9
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The Reaper’s service ceiling is 50,000 feet unless it’s fully loaded, but even the lower altitudes it usually flies at make a lurking MQ-9 very difficult to find from the ground, and the ability to drop GPS and laser-guided bombs makes high-altitude precision strikes fperfectly plausible. The engine is a Honeywell TPE 331-10T, which pushes it along at a rather speedier clip of 240 KTAS. Not exactly an F-16, or even an A-10, but the extra speed does get it to the problem area more quickly when a call comes in from the troops.

Several MQ-9 variants exist. An extended range variant adds fuel tanks, and lengthens the wingspan to 88 feet. US Special Operations Command (SOCOM) also flies the MQ-9 Reaper, and has its own MQ-1 Predator program, too. Both UAVs are referred to as Medium Altitude Long Endurance Tactical (MALET) platforms. If SOCOM has to bring the MALET to hammer a target down, or soften it up, they fly in enhanced variants with improved video transmission, infrared modifications, signals intelligence payloads, and “delivery of low collateral damage weapons.” The latter presumably includes precision mini-missile options like Raytheon’s Griffin, and precision glide bombs like Northrop Grumman’s GBU-44 Viper Strike and Lockheed Martin’s Scorpion, all of which allow a single Hellfire rail or weapon station to carry multiple weapons.

General Atomics’ Mariner maritime surveillance UAV and FAA-certified high-altitude Altair research UAV are both derived from the MQ-9 Reaper. So, too, is NASA’s Ikhana.

The Army’s MQ-1C Gray Eagle

The MQ-1C Sky Warrior/ Gray Eagle looks a lot like the Predator, but it’s a little bit bigger, can carry more weapons, and has an engine that can run on the same “heavy fuel” that fills up the Army’s land vehicles. The initial engine was Thielert’s 160hp Centurion, but the firm filed for insolvency after substantive revelations of accounting fraud (q.v. May 17/08), and in July 2013, its commercial assets were bought by China’s AVIC. Gray Eagles will continue to fly with existing stocks of the Thielert engine, but new UAVs will fly with Lycoming’s 250hp DEL-120.

Maximum operating altitude is 29,000 feet, at a speed of up to 135 knots. The sensor turret payload was initially Raytheon’s AN/DAS-2, but has shifted to the final “Army Common Sensor Payload” AN/AAS-53 variant. The Army also added a communications relay, and has been working to give the UAV “sense and avoid” capabilities for safety in crowded airspace.

An Improved Gray Eagle variant was introduced in July 2013, and this type has flown a 45 hour mission in unarmed configuration. It includes the new Lycoming DEL-120 engine, and a heavier airframe thanks to a deep belly design that raises internal fuel load from 575 pounds to 850 pounds. A 500-pound wet centerline hard point can be used to push the UAV’s fuel total to 1,350 pounds. The new MQ-1C IGE also has a maximum 540-pound internal payload capacity, compared to the MQ-1 Block 1’s 400 pounds. The end result is a maximum takeoff weight that rises from 3,600 pounds to 4,200 pounds.

Sensors and Add-Ons

ZPY-1 STARLite
click for video

Beyond its standard equipment, the US Army is also developing and qualifying new payloads for the MQ-1C fleet, thanks to efforts by Product Manager RUS (Robotic and Unmanned Sensors) and PM-ARES (Airborne Reconnaissance and Exploitation Systems).

AN/AAS-53 CSP+. Raytheon’s base Common Sensor Payload (CSP) is being upgraded, and CSP High Definition (HD) is planned for production cut-in in FY 2013. It adds high-definition Full Motion Video (FMV) in both the Electro-optical and Mid-wave IR spectrums. A retrofit plan will begin in FY 2014 to convert all MQ-1Cs to CSP HD. The Army sees CSP Target Location Accuracy (TLA) as the final upgrade, upgrading targeting accuracy to allow timely use of GPs-guided bombs and missiles. All Gray Eagles will eventually be equipped with CSP TLA.

AN/ZPY-1 STARLite-ER. Northrop Grumman’s Small Tactical Radar – Lightweight (STARLite) Synthetic Aperture Radar/ Ground Moving Target Indicator (SAR/GMTI) is a lightweight, high performance, all weather radar that can track small moving ground targets, down to small car size, even in bad weather. It cross-cues with the UAV’s cameras, and enhancements have been approved to extend its range, and detect man-sized targets. STARLite ER (Extended Range) has been cut into production since FY 2011, and began fielding and retrofitting in FY 2012. The Army plans to buy 1 STARLite ER system per UAV.

Sense and Avoid. Ground Based Sense and Avoid (GBSAA) is a system designed to be aware of other aircraft, especially in civil airspace, and help avoid collisions with the MQ-1C. The Phase 2, Block 0 system will provide the operator with an air traffic display, color-coded to reflect the highest-priority potential conflicts. The Block 1 system will add recommended maneuvers to avoid crashing into others. That isn’t the full sense-and-avoid you’d see on a commercial jet, but by 2015 it will let the Army fly the UAVs from Fort Hood, TX; Fort Riley, KS; Fort Stewart, GA; Fort Campbell, KY; and Fort Bragg, NC, through Class D military airspace, to nearby test ranges without a manned chase plane. As the acronym suggests, making this work requires certain equipment in place on the ground at those locations.

Traveler Pod. BAE’s pods are designed to find and eavesdrop on electronic emitters, identify them (enemy radio communications? radar? etc.), then offer aerial precision geolocation (APG) and copying. SIGINT/ELINT pods and equipment can already be installed in larger UAVs like the USAF’s RQ-4 Global Hawks, and aboard light surveillance planes like the Beechcraft King Air MC-12Ws. The challenge is to shrink them and their supporting systems within the MQ-1C’s weight and size limits.

NERO pod. Provides electronic jamming that can prevent remote detonation of land mines, giving the UAV a very useful convoy overwatch role. It can also disrupt enemy communications. Raytheon’s NERO is adapted from the CAESAR pod that equips manned C-12 (Beechcraft King Air) turboprops. Initial deliveries took place in 2013.

The Army’s ER/MP Program

Prep for flight
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The Gray Eagle began in August 2005, as “Team Warrior” won a $214.4 million contract to develop the Extended Range/ Multi Purpose Unmanned Aerial Vehicle System (ER/MP UAS). The Army wanted its ER/MP UAV to fill both surveillance and attack roles. General Atomics’ Sky Warrior, derived from their famous MQ-1 Predator, beat the Hunter II system offered by Northrop Grumman, Aurora Flight Systems, and IAI.

That was just the first step along the US Army’s $5 billion road to fielding a true Medium Altitude, Long Endurance, armed UAV, modified from the USAF’s famous MQ-1 Predator. Its position got a boost when a 2007 program restructuring short-circuited the Future Combat Systems Class III UAV competition, in favor of ER/MP. That decision has held, and the UAVs are now operated by the US Army and by SOCOM’s “Night Stalkers” regiment.

The Systems Development and Demonstration (SDD) phase of GA-ASI’s multi-year ER/MP contract began with 17 MQ-1C UAVs, and 7 One System Ground Control Stations (OSGCS). Those pre-production Block 0 Gray Eagles began flying on the front lines, in Quick Reaction Component (QRC-1, 1R, and 2) deployments which began in December 2009. QRC drones are unarmed, and lack other key capabilities. Even so, the Army has been very enthusiastic about their performance.

As of 2013, the current plan reorganized its 152 planned buys to equip 10 active duty divisions, 2 special operation units, 2 aerial exploitation units, and the National Training Center. Gray Eagle companies are equipped with 9 UAVs and 5 Ground Control Stations each. Only deployed units get the extra 3 aircraft, drawn from stateside units, to bring their division up to 12 MQ-1Cs. Gray Eagle companies fit within each division’s Combat Aviation Brigade (CAB), following a model initiated in March 2012 at the 1st Infantry Division. Once the division’s UAVs are broken down, each CAB would end up with 4 Gray Eagles, 8 smaller RQ-7B Shadows, and 35 mini-UAVs.

A few years after the ER/MP program began, General Atomics-ASI’s Steve May was already saying that “The Army is now as large a customer for us as the Air Force.” At the time, the firm saw a potential market for as many as 540 “Sky Warrior” UAVs – 45 sets of 12 UAVs each for each brigade, plus accompanying ground stations and crews. The Army’s production program grew five-fold, but it’s still only about 30% of that maximum prediction, and remains far behind the USAF.

Excel
download

As the MQ-1C transitioned into production, Pentagon documents began breaking the program out from its USAF counterparts. The total program, including both the initial development contract and follow-on production, looks like it will be worth almost $5 billion. Budgets from 2004-2017 include:

There’s also a manpower equation for the Army, which affects ongoing operating costs. Those aren’t found in these budgets, but they make up well over half of a program’s actual lifetime cost. Fully automated take-off and landing (ATLS) systems are becoming more common among UAVs, and the MQ-1C’s ATLS is an important difference from the USAF’s MQ-1 Predators, which have all flight operations handled by pilots. While the initial batch of Gray Eagle UAVs will be flown by Army aviators, the Army plans to assign future MQ-1Cs to non-pilot warrant officers with UAV training. That’s a less expensive proposition, in terms of both salary and training costs. It’s also less expensive in terms of lost UAVs, as ATLS seems to lead to fewer crashes.

Key MQ-1C industrial partners include:

Contracts & Key Events FY 2018

 

MQ-1 IGE
(click to view full)

August 24/18: Support Services The US Army is contracting General Atomics for further engineering services in support of its Gray Eagle UAS. The modification to previously awarded contract has a value of $11 million. The MQ-1C Gray Eagle is based on the MQ-1 Predator, but it is bigger, can carry more payload and has an engine that runs on the same kind of fuel that is used to power US Army vehicles. Its expansive mission set includes, but is not limited, to wide-area Intelligence Surveillance and Reconnaissance (ISR), convoy protection, Improvised Explosive Device (IED) detection and defeat, close air support, communications relay, and weapons delivery missions. The Gray Eagle, equipped with signal jammers, will likely be one of the Army’s primary electronic warfare platform. Work will be performed at the company’s location in Poway, California and is scheduled for completion by end of September, 2019.

FY 2016 – 2017

December 29/17: Contracts-Support & Services The US Air Force (USAF) has awarded General Atomics a $328.8 million contract for MQ-1 Predator and MQ-9 Reaper remotely piloted aircraft support and services. Under the terms of the agreement, GA will be tasked with “core management, logistics support, configuration management, technical manual and software maintenance, contractor field service representative support, inventory control point management, flight operations support, depot repair, and depot field maintenance,” according to the notice published on December 22. Work will take place at Poway, Calif., and is expected to be completed by December 2018.

October 13/17: General Atomics announced this week that it has officially switched production of its MQ-1C Gray Eagle UAV over to the longer-range variant, the MQ-1C ER Gray Eagle Extended Range. The new UAV will be tasked with long range intelligence, surveillance and reconnaissance (ISR) missions, in addition to aiding in communications relay and the delivery of weapons to assist ground forces. Recent endurance tests of the new long range drone saw it fly for 41.9 hours, significantly more than the 25-hour capability of the current variant. The firm said the first four MQ-1C ER aircraft are currently being used for developmental testing and will progress to follow-on operational test and evaluation next spring 2018, with customer deliveries of MQ-1C ER to proceed from summer 2018.

September 26/17: General Atomics Aeronautical Systems has been awarded a $27 million US Army contract modification for service support to the Gray Eagle unmanned aerial system program. Work will be performed in Poway, California, with an estimated completion date of March, 17, 2019. Derived from the Predator UAV, the Gray Eagle conducts intelligence, surveillance, reconnaissance (ISR) and strike missions. It has space for mounting electro-optical and infrared cameras for target detection and can mount up to four Hellfire laser-guided missiles. It can also carry its own laser designator for targeting of its own ordnance or for other platforms.

September 13/17:The US has deployed the MQ-1C Gray Eagle UAV to the island of Mindanao “in support of the Armed Forces of the Philippines (AFP) counterterrorism efforts.” The drone’s 25 hour endurance is expected to allow for “a larger area of reconnaissance and surveillance” on the island, where Manilla has been battling an islamist insurgency focused on the besieged city of Marawi. However, Philippines’ President Rodrigo Duterte continued his criticisms of Washington policy, reiterating his displeasure in receiving expensive second-hand equipment from the US. “For me, everything has to be brand-new. All the planes and helicopters will have to be brand-new. Your guns, I want just one source for it. I’m not going to mention what country it is but it’s just two — two countries.” He did not reveal who those two countries were.

February 26/17: After 21 years of service, the MQ-1 Predator UAV will be retired in 2018. The USAF will instead opt for a full MQ-9 Reaper fleet citing better equipment and overall operational capabilities such as bigger payloads, higher flight ceilings, and top speeds. As a result, the USAF will no longer have to maintain a training pipeline or equipment on two separate aircraft, which eliminates the cost of operating two different airframes. Speaking on the Reaper, 432nd Operations Group commander Col. Joseph said in a statement “I think when we look at the legacy of the MQ-1 we’re going to be scratching our heads wondering how we did so much with so little.”

December 28/16: General Atomics has been contracted to perform MQ-1 Predator and MQ-9 Reaper support services for the USAF. Under the $359 million contract, the company will be tasked with conducting logistics support, program and configuration management, depot repair, and additional services, with work to be completed in December, 2017. Both the Predator and its successor, the Reaper, have been used by the US and UK for intelligence gathering missions as well as targeted strike operations as part of counter-terrorism operations in the Middle East.

October 6/16: India is anxious to close a number of defense and nuclear related deals with the Pentagon as the Obama administration enters its final months. Deals including the purchase of 22 MQ-1 Predator UAVs are in advanced stages of negotiations and should be finalized within the coming months. But with a potentially radical regime change on the cards in Washington, New Delhi may want to capitalize on the good relationship between leaders Modi and Obama as the prospect of an “America First” Trump administration may spark a US pullback from Asia.

December 2/15: A US Air Force MQ-1 squadron has been deactivated in Djibouti, raising doubts over the continued use of UAVs in combat operations based out of the area. The 60th Expeditionary Reconnaissance Squadron had flown over 24,000 hours between November 2014 and October 2015. During this period, the MQ-1s neutralized 69 enemy fighters, including five high valued individuals. Based out of camp Lemonnier, the MQ-1s were involved in operations not only on the African continent, but in the Gulf region as well. It is unclear if other units are operating UAV missions from the base or its network of camps and outposts or if the 60th is to be replaced.

October 16/15: A $121.4 million order for 19 MQ-1C Gray Eagle UAVs back in June has now been revealed as the first order for the Improved Gray Eagle configuration, first introduced in July 2013. The new model uses a heavier airframe and a new engine to increase fuel capacity, range, internal payload weight and take-off weight. The Army is also now looking to introduce more weapon options and other improvements for the Gray Eagle.

October 15/15: As the Army looks to standardize equipment to better enable Manned-Unmanned Teaming (MUM-T), the datalink equipping AH-64E Apaches will be replaced by one capable of operating across a broad spectrum of bandwidths used by various UAV systems. L-3 was awarded a contract last month for the MUM-TX datalink capable of operating across this spectrum, with this set to equip the future Apache fleet. In June the Army carried out a MUM-T test involving an AH-64 Apache and a MQ-1C Gray Eagle, with the Apache demonstrating the ability to launch a Hellfire missile using data remotely received from the UAV’s sensors.

Meanwhile, the Army is looking to field a wider array of weapons on the MQ-1C, with a particular focus being given to cheap, small munitions to complement the expensive AGM-114 Hellfires to which it sis currently limited. The program office is also looking for subsonic, lightweight weapons weighing around 30lb. The Hellfire currently weighs in at 105lb, with the reduced weight allowing for more weapons to be carried by the UAV. The Army also wants to implement a host of other improvements to the Gray Eagle, including more jam-resistant datalinks and assured position navigation and timing.

FY 2014 – 2015

 

June 25/15: The Army has successfully conducted Manned Unmanned Teaming (MUM-T) involving an AH-64 Apache and a MQ-1C Gray Eagle UAV. The Gray Eagle was used to designate a target for the Apache, with the latter then firing a Hellfire missile using data from the UAV. The test has allowed the 3rd Combat Aviation Brigade to certify the Fort Stewart complex for live Hellfire tests, an important tool as access to training ranges in Afghanistan and Iraq has diminished.

In related news, the Army awarded a $121.4 million contract to General Atomics on Tuesday for nineteen MQ-1C Gray Eagle UAVs, with these set for delivery by 2018. This follows a comparable contract in March, also for nineteen Gray Eagles, with that contract valued at $133 million. The company was also awarded a $84.8 million contract in May for performance-based logistics to support the UAV.

March 17/15: 19 More.The Army awarded General Atomics a contract for 19 Gray Eagle UAVs, as part of a $132m contract which also included SATCOM terminals and support.

April 23/14: Sensors. Northrop Grumman Systems Corp. in Linthicum Heights, MD receives a $40.7 million firm-fixed-price multi-year contract to provide up to 94 STARLite ground-looking SAR/GMTI radar systems. A system consists of 1 Aviation (A-Kit) and 1 B-Kit.

All funds are committed immediately, using mostly FY 2013 funds and some FY 2014 funds. Work will be performed in Linthicum Heights MD, and the estimated completion date is April 22/17. One bid was solicited and 1 received by the US Army Contracting Command in Aberdeen, MD (W15P7T-14-C-C005).

March 31/14: GAO Report. The US GAO tables its “Assessments of Selected Weapon Programs“. Which is actually a review for 2013, plus time to compile and publish. The MQ-1C is a stable design, but:

“Program officials said they are considering a change to the aircraft tail, which would be costly and require retrofitting the entire fleet. The program is also developing a new ground control station which will not undergo operational testing until May 2015. In addition, a production readiness review conducted in support of the program’s full-rate production decision identified several high risk supplier base issues that pose uncertainty for the program’s cost and schedule.”

Supplier issues include the new engine, “…and the Defense Contract Management Agency are also tracking other risk items related to multiple suppliers’ financial concerns as well as quality control….” Program officials say that have mitigation strategies are in place if something goes wrong.

Finally, the Ground Control System has been criticized in past evaluations. The Army is moving to new hardware and software, with follow-on testing planned in May 2015. If it goes well, the Army would begin deploying the new GCS to new and fielded units.

March 4-11/14: FY15 Budget. The US military slowly files its budget documents, detailing planned spending from FY 2014 – 2019. FY 2015 is the last year of Gray Eagle production: 19 UAVs, 19 Satellite Airborne Data Terminals (SADT), Government Furnished Equipment (GFE), Ground Based Sense and Avoid (GBSAA) Block 1 software, and site preparation and fielding for 2 locations. Payloads and Universal Ground Control Station systems will still be bought for a few more years.

For R&D, the Army continues development and integration of changes to the the Universal Ground Control Station, the GBSAA system as an alternate means of FAA compliance in properly-equipped civil airspace, and a signals intelligence (SIGINT) capability.

Nov 19/13: SOCOM. The 160th Special Operations Aviation Regiment (“Night Stalkers”) receives the 1st of E-Company’s 12 MQ-1C Gray Eagles. Sources: The Aviationist, “Legendary U.S. Army Special Operations Force gets MQ-1C Gray Eagle drones”.

SOCOM’s 160th SOAR

Dec 13/13: Support. General Atomics Aeronautical in Poway, CA receives an $110.4 million cost-plus-fixed-fee contract for continuing MQ-1C support and spares services until Dec 15/14.

$8 million in FY 2014 operations and maintenance funds are committed immediately. Work will be performed in Afghanistan and Poway, CA. One bid was solicited with one received by the US Army Contracting Command (Aviation) in Redstone Arsenal, AL (W58RGZ-14-C-0008).

Oct 22/13: Engine. During AUSA 2013, General Atomics confirms to DID that the US Army will use its existing inventory of Thielert Centurion heavy fuel engines to keep the current Gray Eagle fleet running for now, rather than doing wholesale retrofits. One presumes that retrofits would follow if Centurion stocks or part inventories drop too low.

Oct 22/13: Testing. GA-ASI uses their own funds to conduct a 45-hour MQ-1C Improved Gray Eagle flight, in reconnaissance-only configuration. They also confirm that new Gray Eagle IGEs will be built with Lycoming’s 205hp DEL-120 heavy fuel engine, replacing the discontinued Thielert Centurion (q.v. July 26/13).

A 2nd demonstration, which is planned for later in 2013, will feature an MQ-1C IGE with a wing-mounted external payload and weapons. Source: GA-ASI, Oct 22/13 release.

FY 2013

Annual order; NERO jamming pods delivered; What now for the USA drone fleets?; The pilot issue; FRP decision.

MQ-1C: what now?
(click to view full)

Sept 26/13: Support. General Atomics Aeronautical Systems, Inc. in Poway, CA receives an $86.6 million cost-plus-incentive-fee modification to finalize FY 2013 Gray Eagle performance-based logistics product support. The contract covers both newer, armed Block 1s program and the initial few Block 0/ Quick Reaction Capability drones.

Work is performed from Poway, CA. The contract was solicited via the web with one bid received. The U.S. Army Contracting Command – Redstone Arsenal (Aviation), Redstone Arsenal, AL, is the contracting activity (W58RGZ-12-C-007, PO 0032).

Sept 24/13: Djibooted. The small but strategically critical African state of Djibouti has forced the US military to move its drones out of Camp Lemonnier, which serves as Africa Command’s main base. Their problem? Lemonnier’s runway is too close to the international airport, and 5 Predator drone crashes since 2011 have left the locals unwilling to continue done flights.

The Pentagon has moved its drone operations to a more remote base, and the Gray Eagle’s automatic landing equipment makes it rather less crash-prone than USAF Predators and Reapers. At the same time, it’s an issue that the Army’s fleet will also face. Operations over a war zone are one thing. ISR support operations to aid friendly countries that have national and international air traffic moving through their space are a totally different kettle of fish. Sources: Washington Post, “U.S. moves drone fleet from Camp Lemonnier to ease Djibouti’s safety concerns” | VOA, “US Military Relocates Drone Fleet From Djibouti Base”.

Sept 25/13: Support. General Atomics Aeronautical Systems Inc. in Poway, CA receives a sole-source $70.2 million cost-plus-incentive-fee contract to conduct MQ-1C Gray Eagle 4.3.2 software development and depot repair of related spares.

Work will be funded from FY 2012 and 2013 R&D funds. US Army Contracting Command – Aviation in Redstone Arsenal, AL manages the contract (W58RGZ-13-C-0136).

Sept 25/13: STARLite radar. Northrop Grumman Systems Corp. in Linthicum Heights, MD receives an $85.3 million cost-plus-fixed-fee, multi-year, indefinite-delivery/ indefinite-quality contract to provide STARLite system support, including the SAR/GMTI features. Performance location and funding will be determined with each order. See the “Sensors and Add-Ons” section for full details re: the ZPY-1 STARLite.

This contract was a sole-source acquisition, but its duration isn’t clear. US Army Contracting Command – Aviation in Redstone Arsenal, AL manages the contract (W15P7T-13-D-C118).

Sept 25/13: General Atomics announces that the Gray Eagle fleet has reached 20,000 successful launch and recoveries using their Automatic Takeoff and Landing System (ATLS). They hit the 10,000 milestone in June 2012.

ATLS has been deployed at 8 sites worldwide, including 3 overseas, with 4 additional sites planned by January 2015. Source: GA-ASI, Oct 23/13 release.

Sept 13/13: FY 2013. General Atomics Aeronautical Systems, Inc. in Poway, CA receives a sole-source $199.7 million firm-fixed-price contract to provide FY 2013 MQ-1C Gray Eagle production (19 UAVs), and “FY 2012 hardware backfill requirements.” General Atomics confirmed that the overall contract involves 19 UAVs, plus ground control equipment, automatic landing systems, SATCOM and data terminals, spares, and mobile maintenance facilities.

Work will be performed in Poway, CA. US Army Contracting Command, Aviation at Redstone Arsenal, AL manages the contract (W58RGZ-13-C-0109).

Aug 25/13: Help Wanted. The USAF has a pilot recruitment problem for drones, driven by lower recognition and a true perception that promotions are less likely in that service. The US Army has an easier time of things, because they tap enlisted and non-commissioned soldiers to fly their UAVs: 15W Operator and 15E Repairer are enlisted soldiers positions, and 150U technician positions involve a warrant officer. Here’s the USAF’s math:

The USA has 61 round-the-clock UAV Combat Air Patrols, and plans to increase that to 65 by 2015. That increase is now suspect. If it’s maintained, the Pentagon’s April 2012 “Report to Congress on Future Unmanned Aircraft Systems Training, Operations, and Sustainability” says the USAF will require, at minimum, 579 more MQ-1/9 UAV pilots from December 2011 – 2015. In 2012, the 40 USAF training slots attracted just 12 volunteers, and training attrition rates are 3x higher than they are for regular pilots. Unlike the USAF’s manned aircraft training slots, only 33 RPA (Remotely Piloted Aircraft) training slots were filled (around 82%), triggered in part by the correct perception that those who succeed will have less successful careers. Based on present rates, 13% fewer RPA pilots have become majors, compared to their peers.

Army schadenfreude aside, the Pentagon’s April 2012 report did say that the Army needed to add 820 more MQ-1C Gray Eagle positions between December 2011 – 2015. They can’t neglect this area, either. Sources: Stars & Stripes, “Unmanned now undermanned: Air Force struggles to fill pilot slots for drones” | See Additional Readings section for full Pentagon report.

Aug 22/13: Training. General Atomics Aeronautical Systems, Inc. in Poway, CA receives a maximum $30.5 million cost-plus-incentive fee, option eligible, multi-year contract for 1 MQ-1C Gray Eagle Composite Maintenance System Trainer (CMST) suite of equipment, plus Interim Contractor Support at Fort Huachuca, AZ. US Army Contracting Command Aviation at? Redstone Arsenal, AL manages the contract (W58RGZ-13-C-0127).

Aug 16/13: Support. General Atomics Aeronautical Systems Inc. in Poway, CA receives an $11.4 million cost-plus-fixed-fee, option-eligible, non-multi-year, contract modification.

The award exercises an option for additional MQ-1C engineering services, and the announcement’s confusing language is “$11,423,474.37 with a cumulative maximum value of $156,370,264”. We’ve added all awards under this contract, and so far, announced awards total $81.9 million. But General Atomics clarifies that (since Sept 2009) “we have received contracts that value $156.4 million for Gray Eagle engineering services, including the $11.4 million contract that was just announced.”

Work will be performed in Poway, CA, using FY 2013 “other funding.” One bid was solicited, and 1 receives by US Army Contracting Command (Aviation) in Redstone Arsenal, AL (W58RGZ-09-C-0136, PO 0094).

July 26/13: MQ-1 IGE. A successful first flight of the Improved Gray Eagle (IGE) derivative of the MQ-1C Block 1, at GS-ASI’s Adelanto, CA facility.

IGE is designed for increased endurance, thanks to its “improved Heavy Fuel Engine” and deep belly fuselage with over 50% more capacity. In the field, that translates into up to 23 more hours aloft on reconnaissance missions. Overall payload capacity also improves by 50%, with an upgraded centerline wet hardpoint that can mount a 500 pound external fuel tank or a 360 degree sensor payload. General Atomics also cites the “potential of incorporating lightning protection, damage tolerance, and Traffic Collision Avoidance System (TCAS) features.” Source: General Atomics, July 26/13 release.

Improved Gray Eagle introduced, flies

July 23/13: Engine out. State-owned Aviation Industry Corp. of China buys Thielert’s commercial assets out of insolvency, and folding them into its Continental Motors division. In order to get approval for the sale from the German government, however, the firm has to divest its military business. They elect to close it, leaving the MQ-1C Gray Eagle and Turkey’s Anka UAV without an engine. Sources: Bloomberg, “AVIC Buys Thielert to Shift Company to Planes From Drones” | Reuters, “China’s AVIC to buy German aircraft engine maker Thielert”.

Thielert to China

June 14/13: FRP. The Defense Acquisition Board approved Gray Eagle for Full Rate Production (FRP), which will lead to the purchase of an additional 49 aircraft over FY13-15. Because of the current budget constraints, the FY13 buy was reduced from 19 to 15. FY14 is planned for an additional 19, with a final 15 units in FY15.

Deputy Program Manager Jeff Crabb tells DID that the program was also moved from the ACAT 1D down to the ACAT 1C level, meaning the Army is now the Milestone Decision Authority (MDA), as opposed to the Office of the Secretary of Defense. This makes sense since close to 70 aircraft have already been delivered after 3 LRIP lots, out of a planned total of 152. Of these, 4 have been lost in combat so far.

The program’s next milestone is Follow-on Operational Test & Evaluation (FOT&E) in early 2015, mostly around the universal ground control station (GCS) which involves both hardware and software components.

FRP

May 14/13: NERO EW pod. Raytheon announces that they’ve delivered the first 2 Networked Electronic Warfare, Remotely Operated (NERO) pods, as part of a contract awarded by US NAVSEA-Crane in 2012 for use on the US Army’s MQ-1C Gray Eagle.

NERO is an airborne electronic attack system capable of jamming enemy communications systems, including remote detonators for land mines. It’s derived from the Army’s Communications Electronic Attack with Surveillance and Reconnaissance (CEASAR) program, which is mounted on MC-12W King Air manned turboprops. Moving to the Gray Eagle doubles or triples flight time, at a similar or lower operating cost. Raytheon.

May 7/13: Support. GA-ASI in Poway, CA receives a $110.3 million cost-plus-incentive-fee contract modification for MQ-1C support and fleet sustainment, driving the contract’s total cumulative face value to $354.7 million.

Work will be performed in Afghanistan, using FY 2013 Operations and Maintenance funds, and other Procurement fund. The US Army Contracting Command in Redstone Arsenal, AL manages the contract (W58RGZ-12-C-0075, PO 0032).

April 10/13: FY 2014 Budget. The President releases a proposed budget at last, the latest in modern memory. The Senate and House were already working on budgets in his absence, but the Pentagon’s submission is actually important to proceedings going forward. See ongoing DID coverage. For the Gray Eagle, the budget requests $627.1 million, of which just $10.9 million is RDT&E. That’s a cut of about $151.8 million from previous plans, and when combined with 2015 plans it cuts the program by $337.8 million. They’re still ordering the same number of UAVs, though.

The FY 2014 request covers continued development of the Universal Ground Control Station, a Ground Based Sense-and-Avoid system for flights at several US based locations (vid Aug 10/12 entry), 15 UAVs, 8 AN/ZPY-1 STARLite ER radars, 8 AN/AAS-53 Common Sensor Payload surveillance & targeting turrets, 16 Tactical SIGINT (TSP for signals interceptions) payloads, and 3 modular platoon sets of equipment.

April 2/13: What now? Defense News aptly summarizes the key question facing the USA’s large drones:

“On the one hand, the work in Mali shows that the signature weapon of the U.S. war in Afghanistan is outlasting that conflict. On the other, the detachment is a tiny fraction of the Predator/Reaper fleet – and just where are the rest of them going to go?”

With flights below 60,000 feet heavily restricted within the USA, there aren’t that many options stateside, and most of the MQ-9 fleet’s $8,000 per flight hour operations are funded by wartime OCO appropriations. AFRICOM may have the best combination of circumstances abroad, thanks to growing trouble in the Gulf of Guinea to the West, as well as the Indian Ocean to the East. Even a massive increase in surveillance can’t absorb all of the UAVs, and the $6,000 per flight hour manned MC-12s are a natural competitor.

FY 2012

Attack helicopter control MQ-1C in flight; Operational Testing & Evaluation; Approval sought to extend LRIP buys; Predator GCS virus won’t affect Army; SIGINT pod.

Gray Eagle in Iraq
(click to view full)

Unless otherwise specified, the U.S. Army Aviation and Missile Command in Redstone Arsenal, AL issues the contracts to General Atomics Aeronautical Systems, Inc. (GA-ASI) in Poway, CA.

Oct 2/12: Support. A $102.6 million cost-plus-incentive-fee contract for services to support the Gray Eagle UAS.

Work will be performed in Poway, CA, with an estimated completion date of May 7/13. One bid was solicited, with one bid received (W58RGZ-12-C-0075).

Oct 2/12: Engine retrofits. A $10.7 million cost-plus-fixed-fee contract modification to retrofit MQ-1C Block 0 UAVs with an alternate heavy fuel engine.

Work will be performed in Poway, CA with an estimated completion date of Sept 26/13. One bid was solicited, with one bid received (W58RGZ-12-C-0001).

Aug 27/12: A $25.9 million fixed-price-incentive contract modification will add “a platoon set of ground equipment.” Note that for these UAVs, a “platoon” is 12 MQ-1Cs.

Work will be performed in Poway, CA with an estimated completion date of June 30/15. One bid was solicited, with one bid received (W58RGZ-12-C-0057).

Aug 27/12: An $11 million fixed-price-incentive contract modification, to buy more universal ground data terminals. Work will be performed in Poway, CA with an estimated completion date of April 30/14. One bid was solicited, with one bid received (W58RGZ-11-C-0099).

Aug 10/12: Civil airspace. The U.S. Army has validated the design and functionality of a Phase 2 ground-based sense and avoid (GBSAA, see above) radar system that will support training flights of MQ-1C Gray Eagle UAVs in unrestricted airspace, beginning in 2014.

The baseline GBSAA system was demonstrated in June 2012 at Dugway Proving Ground’s unmanned aircraft systems (UAS) testbed, and the Army’s UAS Rapid Integration and Acceptance Center. The 2-week demonstration covered several “vignettes” involving live RQ-7 Shadow and RQ-5 Hunter UAVs as well as simulated UAVs and intruder aircraft. The testing also replicated the airspace over other military installations and used live and recorded air traffic data from Salt Lake City, UT and Boston’s Logan airports. AIN Online.

July 18/12: A $19 million cost-plus-fixed-fee contract modification for MQ-1C contractor logistics support. Work will be performed in Poway, CA with an estimated completion date of July 15/13. One bid was solicited, with 1 bid received (W58RGZ-11-C-0001).

July 11/12: A $411 million fixed-price-incentive contract for Gray Eagle systems, initial spares, and additional hardware. Work will be performed in Poway, CA with an estimated completion date of March 31/15. The bid was solicited through the Internet, with one bid received (W58RGZ-12-C-0057).

Looks like they got that authorization to continue Low-Rate initial Production.

July 2/12: Support. General Atomics Aeronautical Systems, Inc. in Poway, CA receives an $8.6 million cost-plus-fixed-fee contract modification for MQ-1C Gray Eagle engineering support.

Work will be performed in Poway, CA, with an estimated completion date of Sept. 30/13. One bid was solicited, with one bid received. The U.S. Army Contracting Command at Redstone Arsenal, AL manages the contract (W58RGZ-09-C-0136).

June 27/12: Reliability & report. The US Army has some good news, and some bad news.

The bad news is that Gray Eagles are flying at about 80% availability rates after 24,000 combat flight hours, instead of their target 90%. The problems are mostly traceable to software issues that arise when new sensors are added.

The good news? The program is under budget. The UAVs have added weapons, ground-looking radars, and communication relays to their payload. The Army likes them a lot, and thinks they’re making a big difference, so they’ve decided to focus on expanding Gray Eagle capabilities for now, rather than trying to reach 90% availability rates. Right now, there are a pair of platoon-size 4-UAV QRC units in Afghanistan, and the “Fox 227” full-size company of 12.

May 29/12: IOT&E funds. An $8.5 million cost-plus-incentive-fee contract modification supplies incremental funding to support MQ-1C operational test and evaluation. The program’s IOT&E was moved back from October 2011, and is now expected in August 2012 (a milestone that was indeed met at that date).

Work will be performed in Poway, CA, with an estimated completion date of Nov 30/12. One bid was solicited, with one bid received (W58RGZ-05-C-0069).

May 10/12: A $141.8 million cost-plus-incentive-fee contract, for services in support of the MQ-1C Gray Eagle. Work will be performed in Poway, CA, with an estimated completion date of May 7/13. One bid was solicited, with 1 bid received (W58RGZ-12-C-0075).

April 4/12: Plans. The US Army discusses its plans for the MQ-1C, which includes the addition of a new Synthetic Aperture Radar with Ground Moving Target Indicator, and the development of a Universal Ground Control Station, or UGS that can show video feeds from Gray Eagle, Shadow and Hunter UAS on a single system.

A full company of 12 Gray Eagle UAS have now deployed as part of a full-spectrum Combat Aviation Brigade, and a Pentagon Defense Acquisition Board meeting is planned for mid-May 2012, to approve another Low Rate Initial Production buy. Initial Operational Test & Evaluation is scheduled for summer 2012.

March 30/12: GAO Report. The US GAO tables its “Assessments of Selected Weapon Programs” for 2012. With respect to the MQ-1C, it mentions that the Army will be modifying the UAV’s tail rudder and elevator, and the GAO is now satisfied with the automatic take-off and landing system’s technical maturity:

“However, the tactical common data link is still not fully mature… its air data relay capability has been deferred until fiscal year 2012. The March 2011 accident involving an MQ-1C in testing has delayed several key program events… The Army now plans to start [IOT&E] operational testing in August 2012 [instead of October 2011, and a]… full-rate production decision was postponed from August 2012 to March 2013. The Army has already awarded two low-rate production contracts in 2010 and 2011 for 55 aircraft. To avoid a break in production, the Army is planning to seek approval to award a third low-rate contract for 29 aircraft in May 2012. Based on the current program schedule, the Army will procure more than half of the total planned aircraft before the system’s operational effectiveness and suitability is fully tested…”

Jan 26/12: Preliminary FY 2013 budget materials discuss coming shifts in Pentagon priorities, as the defense department moves to make future cuts. The USAF will get fewer MQ-9 Reapers, but the Army’s MQ-1C is protected:

“Unmanned Air Systems – fund enough trained personnel, infrastructure, and platforms to sustain 65 USAF MQ-1/9 combat air patrols (CAPs) with a surge capacity of 85; the Predator aircraft was retained longer than previously planned, allowing us to slow the buy of the Reaper aircraft and gain some savings; we also protected funding for the Army’s unmanned air system, Gray Eagle.”

See: Pentagon release | “Defense Budget Priorities and Choices” [PDF]

Jan 17/12: A $30.3 million cost-plus-incentive-fee contract modification to support the MQ-1C Gray Eagle Quick Reaction Capability drones in theater. Work will be performed in Poway, CA, with an estimated completion date of May 7/12. One bid was solicited, with one bid received (W58RGZ-09-C-0153).

Jan 5/12: SIGINT Pods. BAE Systems in Nashua, NH receives a $12.3 million firm-fixed-price and cost-plus-fixed-fee contract for T-Pod SIGINT Systems. on the MQ-1C Unmanned Aircraft System. A December 2011 expression of interest stated that the US Army was looking for up to 5 tested and calibrated Traveler Pods within 4 months for integration work on the MQ-1C, and within 6 months for deployment. The pods are designed to find and eavesdrop on electronic emitters, identify them (enemy radio communications? radar? etc.), then offer aerial precision geolocation (APG) and copying. Pods and equipment can already be installed in larger UAVs like the USAF’s RQ-4 Global Hawks, and aboard light surveillance planes like the Beechcraft King Air MC-12Ws. The challenge is to shrink them and their supporting systems so that it falls within the MQ-1C’s weight and size limits.

Work will be performed in Nashua, NH, with an estimated completion date of Dec 27/12. One bid was solicited, with 1 bid received by US Army Contracting Command at Aberdeen Proving Ground, MD (W15P7T-12-C-C009). See also FBO.gov.

Jan 5/12: A $20.5 million cost-plus-incentive-fee contract modification to pay for operational test and evaluation. It does not specify further, but the contract is the MQ-1C’s.

Work will be performed in Poway, CA, with an estimated completion date of Nov 30/12. One bid was solicited, with one bid received (W58RGZ-05-C-0069).

Dec 30/11: A $12 million cost-plus-fixed-fee contract for Warrior A/Block 0 support services. These are the Quick Reaction Capability drones. Work will be performed in Poway, CA, until Dec 17/13. One bid was solicited, with one bid received (W58RGZ-12-C-0001).

Dec 23/11: An $18 million cost-plus-incentive-fee contract. “The award will provide for the modification of an existing contract to allow for incremental funding of previous change order”; it does not specify further, but the contract is the MQ-1C’s. Work will be performed in Poway, CA; Hunt Valley, MD; Salt Lake City, UT; and Lake Forest, CA, with an estimated completion date of Dec 31/11. One bid was solicited, with 1 received (W58RGZ-05-C-0069).

Nov 10/11: A $15.2 million cost-plus-fixed-fee and cost-plus-incentive-fee contract modification, to support the MQ-1C QRC contingents. Work will be performed in Poway, CA, with an estimated completion date of Jan 7/12. One bid was solicited, with one bid received (W58RGZ-09-C-0153).

Nov 9/11: An AH-64D Apache Block III attack helicopter fitted with the Unmanned Aerial Systems Tactical Common Data Link Assembly (UTA) atop its mast has controlled the payload and flight of an MQ-1C Grey Eagle UAV, while both are in flight. This marks the 1st time an unmanned vehicle has been controlled from the cockpit of an Apache helicopter.

Lockheed Martin says that the test program proved the UTA’s design, adding that: “All goals of this phase of UTA testing were completed with 100 percent success.”

Oct 17/11: A $30.3 million cost-plus-fixed-fee contract modification for additional MQ-1C engineering services. Work will be performed in Poway, CA, with an estimated completion date of Aug 30/12. One bid was solicited, with 1 bid received (W58RGZ-09-C-0136).

Oct 7/11: Hacked. WIRED Danger Room reports that a “keylogger” virus has infected the USAF’s MQ-1A/B Predator and MQ-9 Reaper fleets:

“The virus, first detected nearly two weeks ago by the military’s Host-Based Security System, has not prevented pilots at Creech Air Force Base in Nevada from flying their missions overseas. Nor have there been any confirmed incidents of classified information being lost or sent to an outside source. But the virus has resisted multiple efforts to remove it from Creech’s computers, network security specialists say… “We keep wiping it off, and it keeps coming back,” says a source familiar with the network infection, one of three that told Danger Room about the virus. “We think it’s benign. But we just don’t know.”

Unlike the USAF, the Army’s philosophy is to operate its MQ-1C Gray Eagles in-theater. The virus doesn’t compromise Army UAVs, therefore, but it may indicate a similar vulnerability point in the Army’s network.

Oct 5/11: Support. General Atomics Aeronautical Systems, Inc. in Poway, CA receives an $84.8 million cost-plus-fixed-fee contract. The award will provide for the logistics and hardware services in support of Gray Eagle First Unit Equipped system hardware.

Work will be performed in Poway, CA, with an estimated completion date of March 27/13. One bid was solicited, with one bid received. The U.S. Army Contracting Command at Redstone Arsenal, AL manages the contract (W58RGZ-11-C-0143).

Oct 5/11: An $8.8 million cost-plus-fixed-fee contract will fund RESET efforts for the Warrior A/Warrior Block 0 Unmanned Aircraft Systems. RESET is a program for worn vehicles and aircraft, involving tear-down and comprehensive inspections, followed by replacement of any worn parts, and restoration to “like new” condition. The question is whether these initially-fielded “Quick Reaction Capability” UAVs will be upgraded to full operational MQ-1C Block 1 status, complete with weapons.

Work will be performed in Poway, CA, with an estimated completion date of June 30/13. One bid was solicited, with 1 bid received (W58RGZ-11-C-0001).

FY 2011

MQ-1C program ramp-up; USAF accepts last MQ-1B Predator; TRACER foliage-penetrating radar; Iraq quick reaction deployment discussed.

QRC-1 sunrise, Taji
(click to view full)

May 20/11: An $8.9 million cost-plus-fixed-fee, cost-plus-incentive-fee contract, that buys additional spare hardware under the MQ-1C Gray Eagle’s logistics support contract. Work will be performed in Poway, CA, with an estimated completion date of Jan 18/12. One bid was solicited, with 1 bid received (W58RGZ-09-C-0153).

May 10/11: Support. General Atomics Aeronautical Systems, Inc. in Poway, CA receives an $9 million cost-plus-fixed-fee contract May 6/11. The award will provide for MQ-1C Universal Ground Control Station integration.

Work will be performed in Poway, CA, with an estimated completion date of June 30/11. One bid was solicited, with one bid received. The U.S. Army Contracting Command at Redstone Arsenal, AL manages the contract (W58RGZ-09-C-0136).

April 25/11: An $8.3 million cost-plus-incentive-fee contract, providing incremental funding to cover an extension of the ER/MP system development and design contract. Work will be performed in Poway, CA, with an estimated completion date of Dec 31/11. One bid was solicited with 1 bid received by U.S. Army AMCOM Contracting Center in Redstone Arsenal, AL (W58RGZ-05-C-0069).

April 12/11: +26. $173.5 million of a $354 million fixed-price-incentive-fee contract, for MQ-1C Gray Eagle low rate initial production. Queries to GA-ASI indicate that the contract covers 2 Gray Eagle systems: 26 UAVs (12 aircraft per system, plus 2 spares for losses), 15 of AAI’s OneSystem Ground Control Systems, L-3 Communications’ Satellite Communications equipment, and other peripheral equipment to support the systems.

GA-ASI says that part of this contract is for FY 2010 buys, and part is FY 2011. Work will be performed at Poway, CA, with an estimated completion date of April 30/14. One bid was solicited and one received (W58RGZ-11-C-0099).

March 7/11: A $64.3 million cost-plus-fixed-fee, cost-plus-incentive-fee contract modification for MQ-1C Gray Eagle product support, logistical support and sustainment operations.

Work will be performed in Poway, CA; Adelanto, CA; Palmdale, CA; Salt Lake City, UT; and Hunt Valley, MD, with an estimated completion date of Nov 7/11. One bid was solicited with one bid received (W58RGZ-09-C-0153).

March 3/11: The USAF accepts delivery of its 268th and last Predator UAV, an MQ-1B, at General Atomics’ Gray Butte Aeronautical Systems’ Flight Ops Facility. The delivery leaves the US Army as the only customer for MQ-1 Predator UAVs, unless the RQ-1 Predator XP variant finds some export customers.

Col. James Beissner, Air Combat Command’s Chief Irregular Warfare Division, accepted the aircraft. Aeronautical Systems Center’s Chief of Medium Altitude UAS Division, Col. Christopher Coombs, cites fleet totals of over 900,000 hours since its 1st flight in July 1994, with mission capable rates over 90%. What he does not mention is a high accident rate, which accompanies UAVs without auto-takeoff and landing capabilities. The Army’s MQ-1C Gray Eagle does not suffer from the same officer pilot bias as the USAF, and has adopted these technologies. Wright Patterson AFB | General Atomics.

Milestone

March 2/11: +30. General Atomics Aeronautical Systems, Inc. in Poway, CA receives an announced $335.5 million fixed-price-incentive-fee contract for MQ-1C Gray Eagle systems. In-depth discussions with General Atomics place the order in its full context, which is somewhat complex.

In February 2010, General Atomics says the US Army placed a not-to-exceed $399 million contract, but did not appropriate any money. Their first step was the $195.5 million 49% funding contract in the May 19/10 entry. According to the firm, this award funds the remaining contract with another $115.1 million, to make a total of $310.6 million. This will include the LRIP Lot 1 order for 2 systems (24 UAVs + 2 attrition), plus the FY 2009 supplemental funding of 8 UAVs, and a sizable quantity of plus-up air, ground and communication equipment.

Work will be performed in Poway, CA, with an estimated completion date of Dec 31/12. One bid was solicited with one bid received (W56RGZ-10-C-0068).

Feb 14/11: Budget request. The Pentagon releases its FY 2012 budget request, which includes breakout information concerning the MQ-1C Gray Eagle program. The FY 2012 request is $805.8 million for 36 systems, which includes $137 million in RDT&E(Research, Development, Testing & Evaluation) funds.

Jan 18/11: Program ramp-up. A US Army release quotes Tim Owings, deputy project manager for Army Unmanned Aircraft Systems:

“We’re going to accelerate Gray Eagle yet again. We’re accelerating from two systems per year to three systems per year, which will result in seventeen systems being procured by FY 2014… Defense Acquisition Board in February of this year is expected to confirm the addition of two more Low Rate Initial Production Gray Eagle systems – each consisting of 12 air vehicles, five ground control stations and five additional attrition vehicles… The Army has already deployed two Gray Eagle “Quick Reaction Capabilities.” One QRC is now flying with Army Soldiers in Iraq and another is with U.S. Special Operations Forces in Afghanistan”

Nov 28/10: Iraq T&P work. A posting from the 1st Infantry Division discusses [Pentagon DVIDS | US Army] some of the work that goes into the Gray Eagle’s Quick Reaction Capability 1-Replacement 1 (QRC-1/R1) deployment in Iraq, which is working to pioneer Gray Eagle tactics, techniques and procedures before the UAVs are deployed throughout the Army. Some excerpts:

“The QRC1-R1 operators are working with aviators from the brigade’s Apache battalion to integrate their mission… The unit has flown nearly 7,000 accident free hours, more than 350 combat missions, produced over 16,000 surveillance-type images, and maintained a systems operational readiness rate of about 93 percent [in its first 6 months].

“…One of the biggest things we try to do is educate other units about our capabilities,” said [unit commander Capt. Michael] Goodwin. “A lot of units have the ability to use our assets, but they don’t know what we can do.” One of the most useful tools the unit offers ground troops is education on a portable system known as the OSRVT, or One Station Remote Viewing Terminal. “We’re finding that a lot of units have the OSRVT, but don’t know what it does for them,” said Goodwin. “Our company helps train the ground guys on the system, on how to access our feeds and use our aircraft to support them.” …The unit is working to prepare the aircraft to carry hellfire missiles, and is scheduled to conduct a live test of the missiles in Iraq this January.

Sgt. Brent Randal, a Gray Eagle operator deployed with QRC1-R1 and a native of Las Vegas, Nev., said that one of the aircraft’s best features is its new Synthetic Aperture Radar, or SAR. Mounted underneath the Gray Eagle’s nose, the SAR can compare high resolution images of a location taken at different times to determine whether objects have been removed from or placed at a scene… The Gray Eagle can also help ground troops communicate with their headquarters over long distances. The success of [Predator drones he flew for Task Force ODIN] helped pave the way for the Army’s acquisition of the Gray Eagle, said [former scout Staff Sgt. Raymond] Ballance.”

Nov 19/10: General Atomics Aeronautical Systems, Inc. in Poway, CA receives a $31.9 million cost-plus-incentive-fee contract, providing incremental funding to cover an extension of the ER/MP system development and design contract. Work will be performed in Poway, CA, with an estimated completion date of Dec 31/10. One bid was solicited with one bid received by U.S. Army AMCOM Contracting Center in Redstone Arsenal, AL (W58RGZ-05-C-0069).

Announced System Development & Demonstration contracts covered here, not including any UAV buys or any support contracts, now stand at $253.4 million.

Nov 8/10: STARLite radar. Northrop Grumman announces a contract for 40 more AN/ZPY-1 STARLite synthetic aperture ground-looking radars, bringing announced orders to 73. These lightweight radars include Ground Moving Target Indicator (GMTI) capabilities, and will equip the Army’s MQ-1C Gray Eagle UAVs,. Under the terms of the contract option, deliveries to the Army’s Product Manager Robotic & Unmanned Sensors Program Management Office will begin in March, 2011 and conclude in March, 2012.

Pat Newby, vice president of Weapons and Sensors for Northrop Grumman’s Land and Self Protection Systems Division. “STARLite completed all first article and government testing requirements, which led to this award. These systems are ready now for immediate deployment.” See Feb 11/10, Apr 28/08 entries for more.

Oct 27/10: TRACER radar. Lockheed Martin’s tree-penetrating Tactical Reconnaissance and Counter-Concealment-Enabled Radar (TRACER) flies for the 1st time aboard NASA’s Ikhana MQ-9, because the Army Gray Eagle MQ-1C fleet that will eventually host the external unpressurized TRACER pods are all busy on operations.

TRACER is a dual-band synthetic-aperture radar (SAR), designed to detect vehicles, buildings and other man-made objects that are buried, camouflaged or concealed under trees and other foliage. The flight tests on Ikhana focused on the radar’s performance in the harsh environment of the unpressurized pod, as the TRACER system will eventually be installed on a variety of manned and unmanned aircraft. Lockheed Martin.

FY 2010

ER/MP becomes “Gray Eagle”; Army hits 1 million total UAV hours; USAF bows out of Predator buys, ending UAV War; MQ-1C arming approved; Hellfire missile tests; 1st STARLite radars delivered.

MQ-1C test flight
(click to view full)

In 2010, the Army officially changed the planned number of production MQ-1C Gray Eagle Block I+ systems from 13 company-sized units of 12 aircraft, to 31 independent “UAS Platoons” with 4 MQ-1Cs each, plus Standard Equipment Package (SEP), and Ground Equipment. The main production program would also buy 21 UAVs to replace those lost, and 7 training UAVs, for a total of 152.

Oct 4/10: Support. General Atomics Aeronautical Systems in Poway, CA receives a $5.8 million cost-plus-fixed-fee contract modification for ER/MP engineering and integration support, integrated logistics support, and program management. It was actually issued at the end of FY 2009.

Work will be performed in Poway, CA, with an estimated completion date of Sept 30/11. One bid was solicited with 1 bid received by the US Army at Redstone Arsenal (W58RGZ-09-C-0136, PO 0018).

Sept 10/10: A $7.2 million cost-plus-fixed-fee contract modification for ER/MP Quick Reaction Capability contractor logistics support replenishment sustainment spares. Work is to be performed in Poway, CA with an estimated completion date of June 6/12. One bid was solicited with 1 bid received (W58RGZ-09-C-0153).

Aug 24/10: The ER/MP’s new name is confirmed during a US Army UAS panel discussion at AUVSI Unmanned Systems North America. US Army UAS US Army Project Manager Col. Gregory Gonzalez says that using both ER/MP and SkyWarrior had created name recognition issues, and the USAF had approved the name. US Army Training and Doctrine Command (TRADOC) Capabilities Manager Col. Robert Sova adds:

“That’s ‘Grey Eagle’ as ‘G-R-E-Y’… The naming nomenclature, of course, is usually after an Indian chief or Indian tribe and I would suggest that you look up ‘Grey Eagle,’ because there is a good history of that particular Indian chief and his lineage with the army and special operations. So it is not only a cool’ name, it has substance and meaning behind it.”

We’re not the only ones scratching our heads about this reference, which is probably a mistake that stems from believing too many things on the Internet. Though we do like Shephard Group | this Chief Gray Eagle.

Milestone

May 24/10: A $38.5 million cost-plus-incentive-fee/cost-plus-fixed-fee contract modification that pays for new contractor logistics support; a transition to performance-based logistics for the Quick Reaction Capability 1 (see December 2009 entry), QRC-1R, and QRC-2 UAVs; and a UAS training base in support of Operations Iraqi Freedom and Enduring Freedom.

Work is to be performed in Adelanto, CA (34%); Hunt Valley, MD (24%); Poway, CA (18%); Palmdale, CA (17%); and Salt Lake City, UT (7%). The estimated completion date is May 19/11. One bid was solicited with one bid received (W58RGZ-09-C-0153, #P00011).

May 19/10: +26. General Atomics Aeronautical Systems, Inc. in Poway, CA received a $195.5 million fixed-price-incentive-fee contract for MQ-1C supplemental hardware and low-rate initial production. Work is to be performed in Poway, CA, with an estimated completion date of Nov 30/12. One bid was solicited with one bid received (W58RGZ-10-C-0068).

General Atomics tells us that this is for the first half (49%) of the LRIP Lot 1 contract, and covers 2 full Sky Warrior systems (24 UAVs) and FY 2009 supplemental hardware (2 attrition UAVs). The rest of the funding is expected in a few months, and could drive this contract set to about $399 million for 34 Sky Warrior aircraft, 16 of AAI’s One System Ground Control Stations, L-3 Communications West’s airborne and ground Tactical Control Data Link (TCDL) equipment, and various other items to include automatic landing systems, spares, and ground support equipment. Beginning in December 2011, the company is scheduled to deliver over 2 MQ-1C aircraft a month through the end of 2012.

This award comes at the same time that the U.S. Army is celebrating the achievement of 1,000,000 flight hours for its entire unmanned aircraft systems fleet, of which GA-ASI Sky Warrior Alpha and Sky Warrior UAS have logged 145,000 flight hours. See also July 8/10 release.

May 7/10: Lynx radar. General Atomics announces that its Lynx Block 30 Synthetic Aperture Radar with Ground Moving Target Indicator (SAR/GMTI) has achieved over 1,000 collective mission hours on their 4 Sky Warrior Block 1 UAVs in Iraq. The radar has a broad area GMTI scanning mode for detecting moving vehicles in front and to either side, can cue the camera payload to things it “sees” by using the CLAW payload control software, and features very fast Coherent Change Detection (CCD) algorithms.

The US Army’s Quick Reaction Capability-1 (QRC-1) deployment began in December 2009. A second group of 4 Lynx Block 30 radars is scheduled to begin Limited User Testing with the Army later in May 2010, in support of this summer’s planned QRC-2 deployment. In addition to supporting QRC-1 operations with the Lynx radar, GA-ASI is providing full Contractor Logistics Support (CLS), including radar operation, image analysis, and maintenance support.

May 7/10: A $5.8 million cost-plus-incentive-fee contract for continued performance of the ER/MP’s SDD phase. Work is to be performed in Poway, CA, with an estimated completion date of Dec 31/10. One bid was solicited with one bid received by U.S. Army Contracting Command, AMCOM Constructing Center at Redstone Arsenal, AL (W58RGZ-05-C-0069).

May 6/10: A $15.2 million cost-plus-incentive-fee contract, exercising an option in support of the ER/MP production readiness test asset. Work is to be performed in Poway, CA, with an estimated completion date of April 09/11. One bid was solicited with one bid received by U.S. Army Contracting Command, AMCOM Constructing Center at Redstone Arsenal, AL (W58RGZ-09-C-0151). Asked about this contract, General Atomics spokespeople said that:

“…this is not the other half of the [April 22/10] PRTA contract, this is an additional amount for spares and ground support equipment.”

On other topics, they add that the ER/MP’s name change from General Atomics’ Sky Warrior designation to the US Army’s Gray Eagle designation is not official – yet.

April 29/10: 1,000,000 UAV hours. The US Army announces that April 2010 saw the 1,000,000th flight hour for its UAV fleets. That’s a dramatic change from the handful of Army RQ-7 Shadow and RQ-5 Hunter systems in 2001, to roughly 1,000 UAVs by 2010 that are logging up to 25,000 of UAV flight hours per month. It has taken 13 years to put together the first 100,000 hours, followed by 8.5 years to add the next 900,000. About 88% of these flight hours are from time in combat.

The Army now operates 6 MQ-5 Hunter systems that have recently been armed, 87 RQ-7 Shadow UAS systems that are likely to become armed MQ-7 variants son, 9 MQ-1C ER/MP variants, 1,300 Raven mini-UAV systems and 16 RQ-18 gMAV systems. Each system includes several UAVs, plus launch platforms if needed and associated ground control station and communications equipment. Tim Owings, deputy program manager, Army UAS:

“Ninety-five percent of what the Army has in its inventory today did not even exist at the beginning of the war… A lot of people liken Vietnam to a helicopter war – I liken these two wars as the unmanned systems wars because these are the wars where these systems hit the central axis of the way we fight and became part and parcel to the way the Army prosecutes wars… It has been absolutely amazing, no matter how many we have built there has always been a need for more.”??

A Quick Reaction Capability (QRC) of 4 unarmed MQ-1C Block 0s were deployed to Iraq in 2009 – and another ERMP QRC is slated for Afghanistan later in 2010, armed with Hellfire missiles. The idea of the QRC is to field technologies in service of the ongoing war effort as they are available while simultaneously developing a system as a program of record.

April 22/10: +4. A $17 million cost-plus-incentive-fee contract to finalize a contract for ER/MP production readiness test assets. Work is to be performed in Poway, CA, with an estimated completion date of Sept 30/11. One bid was solicited with one bid received (W58RGZ-09-C-0151). In response to a query, General Atomics tells DID that the contract includes:

“…4 Sky Warrior ER/MP aircraft, 2 ER/MP One System GCS, TCDL/GDT, SGDT, TALS, etc.). The [equipment is] to be used for the Initial Operational Test & Evaluation (IOT&E) phase that follows SDD.”

The other $23.4 million part of this contract, plus the May 6/10 contract, leaves the final price at $55.6 million for systems and support.

MQ-1C Sky Warrior
(click to view full)

March 30/10: GAO report. The US GAO audit office delivers its 8th annual “Defense Acquisitions: Assessments of Selected Weapon Programs report. With respect to the ER/MP:

“…a Secretary of Defense memorandum to field the capability as soon as possible… affected the program in several ways. According to program officials, it extended system development and demonstration by about 2 years and delayed the award of the low-rate initial production contract by over 1 year. In accordance with the Secretary’s direction, the Army fielded one “Quick Reaction Capability” system in 2009 and plans to field another in 2010. These systems lack the full capabilities planned.”

“…All four critical technologies are now mature and have been demonstrated on the final version of the unmanned air system… The ER/MP is expected to enter low-rate initial production in early 2010 with all its manufacturing processes demonstrated in a production representative environment… the program was approved in February 2010 for low-rate initial production, and they now anticipate changes in cost, quantity, and schedule. However, official, detailed information was not available in time for inclusion in this report… the Air Force has determined it will no longer acquire the MQ-1C Predator. The Army now anticipates a DOD acquisition memorandum closing the [DoD’s earlier] direction to combine the programs.”

Feb 19/10: General Atomics Aeronautical System in Poway, CA receives a $36.7 million cost-plus-fixed-fee contract, covering in-theater support for ERMP Alpha and Block 0 UAVs for the Iraqi and Afghan theaters of war. The contract will run until Nov 15/11. One bid was solicited, with one bid received (W58RGZ-10-C-0044).

Feb 18/10: Tests, and Milestone C. The US Army announces that the ER/MP has successfully completed a series of tests with the HELLFIRE II UAS missile variant, whose 360-degree targeting ability, allowing UAVs that lack a helicopter’s instant maneuverability to put missiles on target faster. Testing began on Nov 22/09, and took place at Naval Air Weapons Station, China Lake, CA, following cooperation from General Atomics-Aeronautical Systems, Inc.’s Software Integration Laboratory, the company’s El Mirage Flight Test Facility in El Mirage, CA, and Edwards Air Force Base, CA..

The tests began with dry runs and an inert test missile, followed by a successful “cold” pass using a live missile to verify lock-on, followed by “hot pass” firing. November and December involved testing in various conditions, from varying altitudes, against stationary or moving targets. Tests recorded 9 successful shots, which helped pave the way for the UAV’s February 2010 Milestone C approval.

Feb 13/10: The US military issues a FedBizOpps notice as it conducts market research seeking sources to provide in-theatre logistical support, to include field service representatives and maintainers to support sustainment of the AN/DAS-2 payload and the AN/AAS-53 sensor and target designation turrets. The usual winner in these cases is the contractor, especially when, as in this case, “The government does not own the technical data package for these payloads.”

The AN/DAS-2 equipped initial SkyWarriors. The day/night sensing and targeting turret contains a continuous zoom day camera, a thermal imager, a visible imager, a laser designator, and an eye-safe laser rangefinder, all packaged within a stabilized gimbal. The AN/AAS-53 “is planned to replace the AN/DAS-2 beginning in fourth quarter 2009.” FBO solicitation.

Feb 11/10: STARLite, express. Northrop Grumman announces the recent delivery of the first 2 production AN/ZPY-1 STARLite radars for the US Army’s ER/MP, under a compressed 18-month schedule. The STARLite radar is a 65 pound synthetic aperture radar (SAR) with ground moving target indicator (GMTI) capabilities. In SAR mode, the radar provides images along the aircraft’s flight path or along a path independent of the flight path. It can also provide a high-resolution image of a specific area on the ground. In the GMTI mode, the radar provides moving target locations overlaid on a digital map. It can see through battlefield obscurants at all times of day, and in all weather. It also has software that connects with the Army One Common Ground Station.

Northrop Grumman is working under a $78.5 million contract with the Army’s Robotics and Unmanned Sensors Product Office at Aberdeen Proving Grounds, MD, to provide a total of 33 STARLite radar systems by April 2011.

Feb 2/10: Milestone C. The Army’s ER/MP passes its Milestone C review, following success during the UAV’s Operational Assessment test phase, and a positive verdict regarding production readiness. The decision allows Low Rate Initial Production to begin. Tim Owings, the US Army Deputy Project Manager for Army UAS, states that Milestone C authorizes 2 complete systems of 24 total UAVs plus ground control and related equipment, plus 8 UAVs for training and war-loss replacement. US Army.

Milestone

Feb 1/10: The Pentagon releases its FY 2011 budget requests. For the ER/MP program, Research, Development, Testing & Evaluation would jump 45% to $123.2 million. Purchases would jump about 5% to $506.3 million for 29 UAVs, including 3 UAVs under OCO/war funding purchases.

Dec 11/09: Arming begins. Aviation Week reports that the Army is beginning to arm its MQ-1Cs as its pushes toward a “Milestone C” production decision. Tests at China Lake, CA began with 2 Hellfire shots in late November, and will continue until Dec 18/09.

“The soon to be re-designated Gray Eagle UAV, currently called the extended range/multi-purpose (ERMP) unmanned aircraft system by the Army, is being rushed into service with newly-formed quick reaction capability (QRC) units in Iraq and Afghanistan… the initial QRC-1 unit is now deployed in Iraq with four unarmed aircraft… The current weapons tests… form part of preparations to arm QRC-2 aircraft which will be deployed to Afghanistan in July [2010].”

Army UAS project manager Col. Gregory Gonzalez confirmed to Aviation Week that QRC-2 will have the first real weaponized MQ-1C system.

Oct 27/09: The DEW Line highlights a Raytheon Program Manager job ad that discusses possible improvements to the MQ-1C fleet:

“[Raytheon] has proposed a significant upgrade program to the baseline CSP configuration to include High Definition (HD) EO/IR capability and Target Location Accuracy (TLA) enhancements. This position is the program manager (PM) of the CSP TLA/HD (approx $30M) development program. The selected individual will be responsible for managing all aspects of the development program including start up, gate reviews, customer reviews, customer daily interface, supplier management, build of 6 integration and test systems, quality testing and flight testing. It is anticipated the CSP TLA/HD development program will result in retrofit of up to 100 baseline CSP systems and this position would manage the follow-on retrofit business. The TLA/HD upgrade program will be run in parallel with the CSP IDIQ base program and will require integration and leveraging with the on-going CSP production program.”

Oct 9/09: Support. General Atomics Aeronautical Systems in Poway, CA receives on Sept 30/09 a $16.8 million cost-plus-fixed-fee engineering services contract, to support product improvements and new technology insertions into the ER/MP UAS.

Work will be performed in Poway, CA, with an estimated completion date of Sept 29/12. Bids were solicited online, with 1 bid received. U.S. Army Aviation & Missile Command Contraction Center, Redstone Arsenal, AL, is the contacting activity (W58RGZ-09-C-0136).

FY 2008 – 2009

1st mission in-theater; GAO decision blasts GA-ASI; Insolvency & fraud scandal for engine-maker Thielert; UAV Wars.

MQ-1C, Block 0
(click to view full)

August 2009: QRC-1 deploys. Deployment of Sky Warrior Block 1 (ER/MP program version), as the Quick Reaction Capability-1 (QRC-1). Feedback from the field will be incorporated into the QRC-2 deployment as software and hardware upgrades, and tactical changes. Source.

March 2/09: +8. General Atomics Aeronautical Systems, Inc. in San Diego, CA received a $35 million cost plus incentive fee, definitization of a letter contract to acquire 8 ERMP Quick Reaction Capability UAVs, and associated support equipment. This acquisition is directed by the Joint Chief of Staff to accommodate a surge of UAVs in theater.

Work is to be performed at San Diego, CA (46%); Adelanto, CA (14%); Palmdale, CA (8%); Salt Lake City, UT (18%); and Hunt Valley, MD (14%), with an estimated completion date of Jan 15/10. One bid was solicited and one bid received (W58RGZ-05-C-0069).

Feb 5/09: No SAR. Jane’s Defence Weekly [site] reports that:

“The US Army is suspending a synthetic aperture radar (SAR) requirement for Warrior unmanned aerial systems (UASs) in order to… speed the Warrior’s deployment to theatre, where intelligence, surveillance and reconnaissance (ISR) assets are in great demand.”

USAF MQ-1A/Bs currently carry the AN/APY-8 Lynx ground-looking synthetic aperture radar, which gives them the ability to notice certain kinds of objects more prominently, and to see through some obscurants like low clouds, smoke, etc. On Feb 5/09, General Atomics tested a Lynx II dual-beam variant, with a Space Time Adaptive Processing (STAP) upgrade developed in cooperation with BAE Systems. The modifications cancel the main beam’s GMTI (ground moving target indicator) clutter, which helps the radar detect slow-moving objects more accurately and at longer ranges.

Sept 18/08: General Atomics Aeronautical System in San Diego, CA received a $37.2 million cost plus incentive fee price contract for incremental funding for systems development and demonstration (including integration of the Hellfire Missile) for the ER/MP. Work will be performed in San Diego, CA, Adelanto, CA, Palmdale, CA, Salt Lake City, UT, Hunt Valley, MD, and Huntsville, AL, with an estimated completion date of Aug 31/09. One hundred and twenty bids were solicited and 3 bids were received (W58RGZ-05-C-0069).

Aug 19/08: General Atomics Aeronautical Systems in San Diego, CA received a $7.9 million cost plus fixed fee contract to acquire 3 ERMP Block 0 Unmanned Aircraft in support of Operation Iraqi Freedom and Operation Enduring Freedom in Afghanistan. Work will be performed in San Diego, CA with an estimated completion date of March 31/10. One bid was solicited and one bid received (W58RGZ-06-C-0208).

Aug 8/08: GA-ASI issues. A US GAO decision denies Lockheed Martin’s bid protest over the BAMS maritime surveillance UAV contract – and cites ongoing performance issues with its key partner General Atomics as the reason. The GAO summary for Bid Protest B-400135 states that:

“Agency reasonably determined, in procurement for unmanned maritime surveillance aircraft, that awardee [DID: Northrop Grumman] had significant advantage over protester [DID: Lockheed Martin] with respect to past performance where: protester’s subcontractor [DID: General Atomics], responsible for approximately 50 percent of contract effort, had recent past performance history of being unable to resolve staffing and resource issues, resulting in adverse cost and schedule performance on very relevant contracts for unmanned aircraft; record did not demonstrate that protester’s subcontractor had implemented systemic improvement that resulted in improved performance; [in contrast] operating division of the awardee also had performance problems on very relevant contracts for unmanned aircraft, many had been addressed through systemic improvement; and overall performance of awardee’s team on most evaluated contract efforts was rated better than satisfactory, while the overall performance of protester’s team on 11 of 26 contract efforts was only marginal.”

The BAMS bid in question has been based on General Atomics’ Mariner, a variant of its larger MQ-9 UAV. The GAO decision then goes on to discuss these issues in more detail, including this passage:

“In contrast, however, GA-ASI’s contract performance was a matter of great concern to the agency. Specifically, while recognizing that GA-ASI had demonstrated a willingness and ability to respond on short notice to evolving Global War on Terror (GWOT) warfighter requirements, the SSEB found that GA-ASI’s performance demonstrated: inadequate staffing, resulting in performance problems on SDD contracts for the MQ-9 Reaper (a second-generation, Predator B model) and the MQ-1C Extended Range/Multipurpose (ER/MP) UAS (a second-generation Predator model); unfavorable schedule performance on four of seven relevant GA-ASI contracts, including very relevant contracts for the MQ-9 Reaper, UAS ground control stations, MQ-1C ER/MP, I-GNAT Extended Range UAS (a version of the Predator with some differences for the Army), and MQ-1 baseline Predator; poor performance in meeting technical quality requirements on three of seven GA-ASI contracts, including contracts for the MQ-9 Reaper, MQ-1C ER/MP, and I-GNAT Extended Range UAS; and workload exceeded the firm’s capacity on five of seven GA-ASI contracts, including contracts for the MQ-9 Reaper, UAS ground control stations, MQ-1C ER/MP, I-GNAT Extended Range UAS, and MQ?1/MQ-9 maintenance support. In summary, the SSEB found the overall performance of GA-ASI on its very relevant contracts for the MQ-9 Reaper (most delivery orders), UAS ground control stations, MQ-1C ER/MP, and I-GNAT Extended Range UAS to be marginal.”

June 12/08: 1st mission. General Atomics announces that 2 MQ-1C Block 0 UAvs are now operational in Iraq. The first mission for WY-201 occurred on April 18/08 and lasted 10.5 hours. MQ-1C #WY-202 was deployed at the end of April.

Milestone

May 17/08: Thielert scandal. Thielert Engines insolvency administrator Dr. Bruno M. Kubler discusses the current situation in a release, including some revelations with implications for customers like General Atomics. The statement notes that attempts are being made to keep Thielert as a an operating concern, with some flexibility shown by creditors and Frank Thielert may not be CEO, but he remains the personal holder of key permits and therefore remains involved. Meanwhile:

• German insolvency law does not permit the assumption of warranties or guarantees free of charge for products and services supplied prior to the declaration of insolvency. Parts supplied after insolvency can be warrantied, but the firm is in no position to do so. Dr. Kubler hopes that aircraft manufacturers will step in.

• Higher prices will be charged for engines and spares.

• Payment in advance is now required, but assurances are made re: delivery once payment is made.

• The firm’s #1 customer, Diamond Aircraft, has pushed for concessions and preferential deals with Thielert, using both private negotiations and public tactics. Relations are deteriorating, but the firms are still negotiating.

April 28/08: STARLite radar. Northrop Grumman announces that its STARLite has been selected by the U.S. Army Communication-Electronics Life Cycle Management Command to equip ER/MP UAVs. The initial $42 million contract will finalize development, and deliver 10 radars.

The ground looking SAR/GMTI (Sythetic Aperture Radar with Ground Moving Target Indicator) fills the niche that General Atomics’ own AN/APY-8 Lynx radar occupies on USAF MQ-1A/B Predators.

April 16/08: +8. General Atomics Aeronautical Systems in San Diego, CA receives $38.5 million cost-plus incentive fee contract for the acquisition of 8 ER/MP quick reaction capability unmanned aircraft vehicles and assorted support equipment.

Work will be performed primarily in San Diego, CA and is expected to be complete on May 15/09. One bid was solicited on March 17/08 (W58RGZ-05-C-0069).

April 10/08: Thielert insolvency. SkyWarrior engine maker Thielert issues a release concerning their “urgent liquidity crisis.” The act is not an isolated incident, but rather a culmination of trends that include formal charges of accounting fraud and falsification of documents.

It is followed by a declaration of insolvency in May 2008.

March 31/08: General Atomics Aeronautical Systems, Inc. flies the first Sky Warrior Block 1 UAV from the company’s El Mirage Flight Operations Facility in Adelanto, CA. GA-ASI release.

March 3/08: General Atomics Aeronautical Systems in San Diego, CA received an $18.7 million cost-plus incentive fee contract that provides incremental funding for system development and demonstration of the ER/MP UAV. Work will be performed in San Diego, CA; Adelanto, CA; Palmdale, CA; Salt Lake City, UT; Hunt Valley, MD; and Huntsville, AL; and is expected to be complete by Aug 31/09. There were 120 bids solicited on Sept 1/04, and 3 bids were received (W58RGZ-05-C-0069).

Feb 14/08: Raytheon announces 2 U.S. Army orders totaling $17.2 million for 18 common sensor payloads, as system design and development continues. The article does not give details that would confirm the Nov 7/07 entry as one of those contracts, but it is possible. The firm states that they’ve delivered 10 AN/DAS-2 sensors so far.

Nov 7/07: Raytheon Co. in McKinney, TX received a delivery order amount of $11 million as part of an $800 million firm-fixed-price and cost-plus-fixed-fee contract for common sensors for the ARH-70A helicopter and the MQ-1C Sky Warrior ER/MP UAV. Work will be performed in McKinney, TX and is expected to be complete by Oct. 31, 2016. Bids were solicited via the World Wide Web on April 24, 2007, and 5 bids were received by the U.S. Army Communications-Electronics Command in Fort Monmouth, NJ (W15P7T-08-D-S602).

Raytheon’s release adds that the program calls for design and development, testing and air vehicle integration of a variant of Raytheon’s Multi-spectral Targeting System, in a project could be worth up to $1.2 billion for 875 units, if all options are exercised. See also Raytheon Feature | Common Sensor Platform product page. Raytheon’s CSP completes its Predator family trifecta; it also supplies the AN/DAS-1 system that equips MQ-1 Predator UAVs, and the AN/AAS-52 on MQ-9 Reapers. With respect to deliveries to the Sky Warrior program thus far:

“The company has delivered 10 AN/DAS-2 electro-optical/ infrared/ laser designator sensors under a system design and development contract let in May 2005. At the beginning of this year, the Army ordered seven more systems under a low rate production option.”

Oct 19/07: General Atomics Aeronautical System in San Diego, CA received a $20.8 million increment as part of a $231.2 million cost-plus-incentive-fee contract for system development and demonstration for the ER/MP UAV Vehicle, including integration of the Hellfire Missile.

Work will be performed in San Diego, CA (43%), Adelanto, CA (14%), Palmdale, CA (8%), Salt Lake City, UT (18%), Hunt Valley, MD (14%), and Huntsville, AL (3%), and is expected to be complete by Aug 31/09. There were 120 bids solicited on Sept. 1, 2004, and 3 bids were received (W58RGZ-05-C-0069).

Oct 1-17/07: UAV Wars. DID talks to the US Army about the SkyWarrior program. Going forward, the USAF will manage the program according to jointly agreed requirements, but each service will maintain its own budget for the UAVs it wants.

A common version will be selected and approved by late 2008, but no decision has been reached re: which version will predominate: the MQ-1B Block X/MQ-1C with 4 missile pylons and a heavy fuel engine that can burn diesel, or the existing MQ-1 that burns aviation fuel and has 2 missile pylons.

Oct 1/07: General Atomics Aeronautical Systems in San Diego, CA received a $27.5 million modification to a cost-plus-fixed-fee contract for contractor logistics support for the Sky Warrior Block 0 Unmanned Aircraft System.

Work will be performed in San Diego, CA (80%); Hunt Valley, MD (10%); and Salt Lake City, UT (10%); and is expected to be complete by Sept. 27, 2008. This was a sole source contract initiated on Sept. 14, 2007 (DAAH01-03-C-0124).

FY 2005 – 2007

UAV Wars between US Army & USAF; Army Future Combat System changes improve ER/MP’s opportunity; 1st ER/MP flight; ER/MP development contract issued.

MQ-1C Sky Warrior
(click to view full)

Sept 28/07: UAV Wars. In its Daily Report for this date, the Air Force Association’s Air Force Magazine Online discusses the UAV executive agency issue:

“Defending the recent Pentagon decision not to give the Air Force executive agency over medium- to high-altitude unmanned aerial vehicles, Army Secretary Pete Geren told defense reporters Thursday that the Army’s modernization goals don’t fit with an executive agent approach. “The need for control with UAVs fits close to the individual soldier,” Geren said. Part of the Army’s Future Combat Systems program is to empower soldiers and give them greater control over assets such as UAVs. He noted that Army Chief of Staff Gen. George Casey and Air Force Chief of Staff Gen. Michael Moseley have met on the issue recently to work out disagreements. “Some of the disagreements have arisen because these issues have not been tackled at a high enough level,” Geren said. While sympathetic to the Air Force’s perspective, he noted that an executive agent approach that’s advocated by some would make sense if we were fighting a conventional war. “It’s a different debate when you’re talking about the kind of fight we are in today,” Geren declared.”

See also Military.com’s article re: the decision fallout.

Sept 13/07: UAV Wars. Deputy Defense Secretary Gordon England rejects Air Force efforts to become the executive agent for all medium- and high-altitude unmanned aerial vehicles, over objections from the Army, Navy, and Marine Corps. In his memo, England directed the Pentagon’s acquisition office to create a task force on UAV issues to “enhance operations, enable interdependencies, and streamline acquisition” of the drones. He also directed Pentagon officials to take other steps to foster cross-service collaboration on the UAV programs.

The Predator and SkyWarrior programs, however, have been merged. The exact meaning of that move remains to be seen – either to standardize the Predator on a similar SkyWarrior/MQ-1C version, or eliminate the Warrior variant and use existing MQ-1As. GovExec | The Hill.

Aug 22/07: A $5.15 million increment as part of a $215.4 million cost-plus-incentive-fee contract for system development and demonstration for the ER/MP UAV. Work will be performed in San Diego, CA (43%), Adelanto, CA (14%), Palmdale, CA (8%), Salt Lake City, UT (18%), Hunt Valley, MD (14%), and Huntsville, AL (3%), and is expected to be complete by Aug. 31, 2009. There were 120 bids solicited on Sept. 1, 2004, and 3 bids were received (W58RGZ-05-C-0069).

According to DID’s calculations based on DefenseLINK public announcements, about $167 million of the $215.4 million ER/MP program’s contracts have been issued as of this increment.

Aug 6/07: +2 YMQ-1C. General Atomics in San Diego, CA received a cost-plus-fixed-fee contract for $7.3 million to provide 2 Pre-Production YMQ-1C Block X aircraft. General Atomics has confirmed to DID that these are USAF versions of the Army Sky Warrior. See the May 7/07 entry and Appendix A for details; this award should be seen in the context of the USAF’s effort to take over UAV authority.

At this time, total funds have been obligated. Solicitations began in April 2006, negotiations were completed in July 2007, and work will be complete in January 2009 (FA8620-05-G-3028-0018).

July 5/07: General Atomics Aeronautical Systems in San Diego, CA received a $14.7 million increment as part of a $215.4 million cost-plus-incentive-fee contract for system development and demonstration for the ER/MP Unmanned Aerial Vehicle. Work will be performed in San Diego, CA (43%), Adelanto, CA (14%), Palmdale, CA (8%), Salt Lake City, UT (18%), Hunt Valley, MD (14%), and Huntsville, AL (3%), and is expected to be complete by Aug. 31, 2009. There were 120 bids solicited on Sept. 1, 2004, and 3 bids were received (W58RGZ-05-C-0069).

June 27/07: UAV Wars. Air Force Times report: With the question of whether there should be an executive agency in charge of medium- and high-altitude UAVs still hanging in the air, U.S. deputy defense secretary Gordon England wrote in a letter earlier in June to Army and Air Force leaders asking the services to collaborate on procuring and operating the Predator and Warrior UAVs. Army and Air Force officials were asked to submit briefings to England by the end of June 2007.

June 6/07: The first ER/MP Sky Warrior aircraft flew successfully from General Atomics’ El Mirage Flight Operations Facility in Adelanto, CA. The company-owned Block 0 aircraft completed all stated objectives for its maiden flight. General Atomics release.

Milestone

May 17/07: UAV Wars. The Congressional Government Accountability Office releases report #GAO-07-578, “Greater Synergies Possible for DOD’s Intelligence, Surveillance, and Reconnaissance Systems,” which explicitly discusses the possible merger of Warrior & Predator programs. It mentions that “The Air Force and the Army are currently working to identify program synergies in a three-phased approach:

• First, the Air Force will acquire and test two of the more modern Warrior airframes.

• Second, the two services will compare their requirements for ground control stations and automated takeoff and landing.

• Finally, the Army and Air Force plan to compare concepts of operation and training requirements for additional synergies.”

May 10/07: The JROC directs the USAF to flesh out its executive agency plan. No firm deadline is set, and no firm decision is taken.

May 7/07: “Predator Block X”. General Atomics in San Diego, CA received a $10.1 million cost-plus-fixed-fee contract from the USAF’s Headquarters Aeronautical Systems Center at Wright-Patterson Air Force Base, OH. This contract action will provide a series of required tasks to design, fabricate, integrate, and test the Predator MQ-1B Block X aircraft which will utilize a Heavy Full Engine (HFE), will support a 3,200 lbs gross take-off weight, and will carry 4 Hellfire missiles (2 on each wing). The Predator MQ-1B Block X shall leverage off technology from the existing Predator B (MQ-9) program, the Army’s ER/MP program, and on-going GA-ASI internal research and development efforts. At this time, total funds have been obligated. Solicitations began June 2006 and negotiations were complete April 2007 (FA8620-05-G-3028-0016).

It should come as no surprise to anyone that the ability to operate the engine on “heavy” fuels like diesel, and to carry 4 Hellfire missiles instead of 2, constitute the two biggest differences between the USAF’s MQ-1 Predator and the Army’s Warrior UAV. This award should be seen in the context of the USAF’s effort to take over UAV authority, vid. Appendix A.

May 7/07: UAV Wars. Officials with the DoD’s Joint Requirements Oversight Council (JROC) meet with Army and Air Force officials to discuss proposals to put all such UAVs under a single executive agency. See Appendix A for more background.

April 6/07: General Atomics Aeronautical System in San Diego, CA received a $5.3 million modification to a cost-plus-fixed-fee contract for ERMP Block 0 UAVs. Work will be performed in San Diego, CA (65%), Adelanto, CA (5%), Palmdale, CA (5%), and Salt Lake City, UT (25%), and is expected to be complete by Aug. 31, 2007. This was a sole source contract initiated on June 21, 2006 (W58RGZ-06-C-0208).

March 5/07: UAV Wars. US Air Force Chief of Staff Gen. T. Michael Moseley’s circulates a memo, proposing to name his service as the Pentagon executive agent for UAVs. See Appendix A for more background.

Feb 14/07: 4 more. General Atomics Aeronautical System in San Diego, CA received an $11.7 million modification to a cost-plus-fixed-fee contract for acquisition of 4 ERMP Block 0 UAVs, associated support equipment, and initial spares. This appears to be the initial installment on the test aircraft.

Work will be performed in San Diego, CA (65%), Adelanto, CA (5%), Palmdale, CA (5%), and Salt Lake City, UT (25%), and is expected to be complete by Dec. 18, 2007. This was a sole source contract initiated on June 21, 2006 (W58RGZ-06-C-0208).

Jan 9/07: FCS changes. The US Army restructures its $160+ billion Future Combat Systems program, and “delays”/ eliminates its Class II and Class III UAVs. The Warrior ERMP is expected to be one of the existing systems filling the Class III brigade-level gap.

Dec 22/06: General Atomics Aeronautical System, San Diego, CA was received a $63.1 million increment as part of “a $215.4 million cost-plus-incentive-fee contract for System Development and Demonstration for the Extended Range / Multi-Purpose Unmanned Aerial Vehicle.”

Work will be performed in San Diego, CA (43%), Adelanto, CA (14%), Palmdale, CA (8%), Salt Lake City, UT (18%), Hunt Valley, MD (14%), and Huntsville, AL (3%), and is expected to be complete by Aug. 31, 2009. There were 120 bids solicited on Sept. 1, 2004, and 3 bids were received by the U.S. Army Aviation and Missile Command in Redstone Arsenal, AL (W58RGZ-05-C-0069).

March 13/06: DID – Warrior UAV Program Underway. $67 million increment received for the Warrior program, as part of a “$214.3 million cost-plus-incentive-fee contract for System Development and Demonstration for the Extended Range / Multi-Purpose Unmanned Aerial Vehicle” (W58RGZ-05-C-0069).

Oct 6/05: DID – AAI Takes Another UAV Ground Control Project. A $30 million subcontract for the Warrior UAV’s ground control.

Aug 8/05: Winner! General Atomics Aeronautical Systems, Inc. in San Diego, CA has won a $214.4 million cost-plus-incentive-fee contract for research, development, test and evaluation of the Extended Range Multi Purpose Unmanned Aerial Vehicle system (ERMP UAV).

One hundred twenty bids were solicited on Sept 1/04, and 3 bids were received. Work will be performed at facilities in 6 locations: San Diego, Adelanto and Palmdale, CA; Salt Lake City, UT; Hunt Valley, MD; and Huntsville, AL, and is estimated to be complete by Aug. 31, 2009. The U.S. Army Aviation and Missile Command at Redstone Arsenal, AL issued the contract (W58RGZ-05-C-0069). The Army’s public affairs office can be reached at (256) 955-9174.

Milestone

Appendix A: US Army et. al. vs. USAF Over UAVs

US Army Air Corps

Faced with an aerial tanker fleet that’s 50+ years old, front line fighters under flight restrictions due to age and fatigue, and heavy strain on transport aircraft resources, the USAF has been making strenuous efforts to take over the UAV domain. At the moment, UAVs are bought by individual services: Army, Navy, USAF, Marines. The Army in particular has been using UAVs for reconnaissance and persistent fire support, as in-house assets that involve less organizational friction to deploy, and can be prioritized for purchase according to the needs of soldiers on the ground.

The USAF had asked for authority over all American UAVs before, but this was refused. The Pentagon’s JROC(Joint Requirements Oversight Committee) determined that an executive agent was not necessary. Instead, they created the Joint Unmanned Aerial Vehicle Center of Excellence at Creech Air Force Base, NV to share operational tips; and the Joint Unmanned Aerial Systems Materiel Review Board in order to work out best practices for materiel. There is also a US Army UAV Center of Excellence at Fort Rucker, AL.

The end of the argument? No, because of the organizational and budgetary threat that non-USAF UAVs represent.

Viper Strike
(click to view larger)

One measure of the potential threat can be inferred from usage figures. As of September 2007, MQ-1 Predator UAVs had reached 300,000 flight hours since inception around 2001, of which 80% were combat flight. Fully 1/3 of those flight hours were accumulated in the previous 12 months, and total fleet flying hours had risen to 10,000 hours/month. On Nov 9/07, Jane’s International Defense Review reported that by the end of the second quarter of Fiscal Year 2007, US Army UAVs had flown a total of 295,181 hours in Iraq, nearly 18% of the total hours flown by the army aviation fleet.

Well below a Predator’s size threshold, US Army RQ-7 Shadow battalion-level UAVs are racking up 8,000 flight hours per month in Iraq (almost equal to the Predators’ recent totals), accompanied by US Army RQ-5 Hunter aircraft that sit somewhere between a Predator and Shadow in size and are accumulating their own flight time. Smaller UAVs like the popular RQ-11 Raven, meanwhile, are racking up their own significant totals, with shorter flight times offset by much larger numbers in the field to produce 300,000 flight hours in 2007 alone. The Army reached 1 million UAV flight hours for its fleet of RQ-5 Hunter, RQ-7 Shadow, RQ-11 Raven, RQ-18 gMAV, and MQ-1C ER/MP UAVs in April 2010, and is adding to that at 25,000 hours per month.

The RQ-5 Hunters have been tested with Viper Strike mini-bombs, and the Shadows may be eligible as well if the Army wishes. Shadows will certainly be eligible for NAVAIR’s 5-6 pound Spike missile project (scheduled for an autumn 2007 UAV test), and all UAVs can provide targeting for M30 GPS-guided MLRS rockets, long-range ATACMS MLRS missiles, or the 155mm Excalibur artillery shells entering service in Q3 2007. Larger UAVs like the Sky Warrior add Hellfire II missiles, the 250 lb. Small Diameter Bombs, and 250 – 500 lb. GPS-guided JDAMs or laser-guided Paveway bombs to the mix.

With these fire support assets on the airframe or on call, most close air support functions encountered in counterinsurgency missions can be covered.

Manned fighters offer their own advantages: anti-air capabilities, a payload capacity several times a UAV’s, greatly improved panoramic visibility, no need for potentially vulnerable or limited-bandwidth long-range communications in order to fly, better intimidation presence via fast flyovers, and better survivability/ fewer crashes. In counterinsurgency scenarios, however, air threats are minimal to nonexistent, fighters are usually loaded with just a couple of weapons; and except for the A-10 or dedicated COIN (COunter-INsurgency) turboprops, the planes are moving so quickly that they must rely on targeting pods with the same narrow field of view as a UAV pilot’s. That still leaves intimidation and survivability advantages, but your average jet fighter is extremely expensive to buy, has a 7,000 – 10,000 hour airframe life, costs many multiples of dollars per flight hour to operate, and offers an on-station time that is usually less than half that of a Predator class MALE UAV.

Specialty close-support aircraft like the USA’s A-10, gunships like the AC-130s, and even COIN turboprops offer combinations of affordability and/or compelling advantages that keep them competitive in counterinsurgency scenarios. Can the same be said for the USAF’s F-16s, F-15… or its future F-35 Lightning II and F-22A Raptor fighters? In their January 2007 article “UAVs With Bite,” Air Force Magazine notes that:

“The Air Force now has provisional plans to buy some 170 Predator MQ-1s by 2010 and acquire 50 to 70 MQ-9s by around 2012, for a total of 220 or more of the combat-capable drones. At present, the service plans on retiring a comparable number of F-16s over the same period.”

MQ-1 Predator:
circling to kill?
(click to view full)

This calculus is why some observers saw the UAV fight as the “Key West Agreement” fight for the 21st century, with the outcome determining the future organizational backbone and role of the USAF – and other services besides.

Hence the USAF’s persistence. The USAF’s return foray in March 2007 involved a move to take over acquisition authority for all UAVs designed to operate at “medium or high altitudes.” Battalion-level UAVs like the RQ-7 Shadow 200 might or might not escape, but even so the maneuver would neatly strip away virtually all armed UAVs, and hence the bureaucratic threat of Army UAVs evolving toward the USAF’s close air support role. Besides, with the USAF re-organizing its ISR (Intelligence, Surveillance & Reconnaissance) assets into their own dedicated function, they can always come back for the rest later under a “unified ISR” claim, once a large portion of UAV acquisition and prioritization are already under their control.

The ER/MP Warrior program is obviously a front-line target in this fight, given its derivation from the MQ-1 Predator UAVs the USAF had already bought in quantity, before switching future orders to the larger MQ-9 Reaper.

Three broad-brush outcomes were possible:

# The US Army and USAF retain separate control of their UAVs, and continue to work out standards et. al. through the established joint centers of excellence; Warrior program unaffected.
# The USAF does NOT acquire executive authority over UAVs, but there is consolidation between the US Army and USAF MQ-1 variants/programs to a common version. This is the current state. The Warrior program survives only if it becomes that common version.
# The USAF acquires executive authority over “medium to high altitude” UAVs. The ER/MP Warrior UAV program is almost certainly canceled, future USMC programs are under threat, and the Navy will have to fight to maintain control of its own programs.

In the end, the answer was solution #1, with a twist. The USAF also switched its future UAV production plans from the Predator to the MQ-9 Reaper, whose high altitude performance and 3,000 pound ordnance load give it dramatically different capabilities.

There’s obviously a larger debate going on here. The Kasserine Pass disaster in World War 2, where commanders in quiet sectors refused to turn over their aircraft to units under fire, provided the impetus for today’s TacAir system, which puts airmen in charge of managing and allocating air assets in response to the needs of the ground commander. At some level, the USAF arguments hark back to that concept, and to the 1948 “Key West Accords,” which ended up turning Army Aviation into a helicopter force. There’s also a procurement angle, as noted during coverage of USAF Chief of Staff Moseley’s testimony on this issue before Congress:

“Without an executive agency, the services will likely continue their separate design and procurement efforts, and the DOD will have forfeited the considerable savings it could have realized. Additionally, DOD will have lost an opportunity to create and harness the interservice synergies that would result from building upon — rather than duplicating — each service’s strengths, General Moseley said.”

On the other hand, the US Army hasn’t always felt well served by the USAF’s procurement priorities, which many feel have tended to emphasize high-end USAF assets at the expense of some key roles (forward observation, light transport, close support) needed by troops on the ground. That fact that UAVs serve in a couple of the roles that have previously received short shrift doesn’t make the Army feel any better. They also worry that a service run by fighter jocks is likely to steer unmanned systems away from anything that might intrude on their established roles, or call high-ticket platforms into question. The last 40 years of organizational and political theory tends to support that worry.

Tim Owings, deputy project manager for the Army’s unmanned aircraft systems:

“From our perspective, consistently what has come out of theater is the need for our commanders to have direct control and ownership of the UAV application. That has played out in every theater that we have been in.”

In 2010, director of the Army Quadrennial Defense Review Timothy Muchmore brought the issue into sharp relief, when he was quoted as saying that:

“The air power provided by our sister services has dominated the third dimension, but the Army is unable to leverage that third dimension… We’ve had two combat outposts overrun by superior forces [during the past year]. Those are losses that we consider unacceptable, because we couldn’t see what was going on around the outposts.”

Anyone who has worked in a large organization can see the shape of the bureaucratic battle here. On one side, you have the staff department, preaching the benefits and savings of centralization and standards, and urging central control over the function. Some of those benefits may be real. Some of the “joint” and “team” rhetoric may also be real. But the real issue is control. On the other hand, you have the front-line business unit managers who want resources that are dedicated to their needs – and under their clear authority, in order to ensure required accountability and service levels. Some of that may be required. Still, the key is not so much the promised dedication as the control that guarantees it. Throw in a central department that has sometimes placed business unit needs lower on the priority scale than their own long term plans, add a dash of politics, and stir.

The US Navy, with a long history of running its own aviation programs, and the qualifying UCAS-D unmanned strike aircraft and BAMS maritime reconnaissance UAV programs underway, will not be watching idly. Nor will the US Marines, who also operate integrated aircraft and have UAV plans of their own.

There’s always a proper balance point in any organization, and points beyond which either central control or local control of key functions can become dysfunctional. The thing is, there’s no set recipe. It’s different in each organization, and depends on the situation, past institutional performance, and (legitimately) on the personalities involved at the time.

Where is that balance point for the US military and UAVs? Because there’s a larger issue a-wing beyond the ER/MP program – and this time, getting the answer right really is a matter of life and death.

• = DID is aware that the US Army Air Corps no longer exists.

Footnotes

fn1. A communication from General Atomics to DID referred to the platform as the “MC-1C”, a designation DID subsequently used in the article. Andreas Parsch of the fine site Designation Systems asked some questions about that, and the investigation revealed that it had been a typo. DID has corrected the article accordingly. Danke schön, Andreas.

Appendix B: Who Controls the UAVs? Readings & Primers

• Associated Press – Rise of the Machines: UAV Use Soars. Very interesting facts and figures concerning UAV use.

• US Army (April 29/10) – Army surpasses 1 million unmanned flight hours

• National Defense Magazine (April 2010) – Army on a Fast Track to Build its Own High-Tech Air Force

• National Defense (February 2010) – Army to Air Force: We Won’t Give Up Our Surveillance Aircraft. They back that up with anecdotes about USAF UAVs leaving enemies to plant land mines, and Army UAVs saving lives.

• National Defense (January 2010) – Air Force to Army: There Are Better Ways to Deploy Surveillance Aircraft. The Army disagrees.

• C4ISR Magazine (Nov 1/09) – Different courses: New-style UAV trainees edge toward combat

• General Atomics (Sept 15/08) – GA-ASI War Fighter Support Reaches Historic Proportions.

“Predator-series aircraft have amassed over a half-million flight hours and will soon complete 50,000 total missions, with 85-percent of that time spent in combat… Predator-series aircraft are now flying over 20,000 hours a month supporting U.S. coalition forces in combat and homeland security requirements… In the past year alone, monthly flight hours have doubled. Over 300 Predator-series aircraft have been produced to date”

• DID (Aug 29/08) – UAMS Experiment Brings Deconfliction Closer for Smaller UAVs. If efforts like UAMS succeed, the argument for single-service UAV control suffers a major blow.

• US Army (July 3/08) – Leaders discuss new joint unmanned aerial operations. “Army and Air Force leaders met Monday to discuss developing a new joint unmanned aerial system concept of operations…”

• NY Times (June 22/08) – At Odds With Air Force, Army Adds Its Own Aviation Unit. Project ODIN includes both manned C-12s and UAVs like SkyWarrior. “The work of the new aviation battalion was initially kept secret, but Army officials involved in its planning say it has been exceptionally active, using remotely piloted surveillance aircraft to call in Apache helicopter strikes with missiles and heavy machine gun fire that have killed more than 3,000 adversaries in the last year and led to the capture of almost 150 insurgent leaders.” See also…

• CASR (June 22/08) – Counterinsurgency Legacy – US Army Aviation Supports its Own: US Air Force turns out to be too Tardy to be Tactically Useful. Excerpts and background the NYT article. The US Army is reportedly seeking money to raise a similar unit in Afghanistan by late 2008/early 2009.

• Military.com (March 18/08) – Army Embarks on Ambitious UAV Program. Discusses key tactical and operational differences between the Army and USAF’s use of UAVs.

• US Air Force Association, Air Force Magazine (October 2007) – The Big Squeeze. Describes steps the USAF is taking to improve its ISR capabilities, the challenges, and some of the platforms involved. As recapitalization of major assets is pushed back, UAV/UAS options will grow in popularity.

• Lexington Institute (Sept 5/07) – Army Plans For Reconnaissance Drones Misuse A Vital Asset. Loren Thompson’s analysis explains the drivers at both ends of the UAV controversy without really addressing the implications of each, and without securing some underlying assumptions re: employment. Both sets of drivers and assumptions may even be true as written, and the question then becomes one of priorities:

bq. “Only 34 of the 1,200 drones U.S. forces are using in Southwest Asia can operate beyond the line of sight of ground controllers, so sometimes the wait for access to that handful of planes can be quite lengthy… Under the Army plan, if five divisions were deployed in Iraq (as is presently the case), their combined inventory of 60 Predators would be able to keep 12-15 aloft at any given time. In contrast, the approach used by the Air Force can keep nearly three times as many drones in the air because the availability of the fleet is not tied to rotation patterns and concentrating all the drones at a few sites permits maintenance efficiencies.”

• Air Force Magazine (July 2007) – The Drone War [PDF, see also Google HTML format]

• Congressional Government Accountability Office (May 17/07, #GAO-07-578) – Greater Synergies Possible for DOD’s Intelligence, Surveillance, and Reconnaissance Systems

• Defense News (May 14/07) – USAF Pushes Plan To Handle Pan-Service UAVs

• USAF Aim Points (April 27/07) – JROC wants Air Force to flesh out its UAV ‘Executive Agent’ proposal

• In From the Cold (April 27/07) – An “Executive Agent” for UAVs?

• USAF (April 20/07) – US Air Force official testifies on UAV executive agent issue

• US Army (April 16/07) – US military officials discuss executive agency for UAVs

• Aviation Week & Space Technology (April 2/07) – U.S. Army faults Air Force in UAV debate

• Defense Tech (Dec 13/06) – So Long, Key West

• DID (March 27/06) – USAF’s 25-Year Take on UAV Operations & Management

• DID (Aug 29/05) – USA’s Unmanned Aircraft Systems Roadmap, 2005-2030. That roadmap is already changing.

Additional Readings

Thanks to DID correspondent Trent Telenko for his assistance.

Background: Gray Eagle UAVs & Related Tech

• General Atomics Aeronautical Systems – Gray Eagle UAS

• Defense Update – Sky Warrior ERMP UAV System. Now the Gray Eagle.

• General Atomics Aeronautical Systems – Predator UAS. MQ-1B.

• General Atomics Aeronautical Systems – Predator B UAS. MQ-9.

• Air Force Technology – Predator RQ-1 / MQ-1 / MQ-9 Reaper – Unmanned Aerial Vehicle (UAV), USA

• Army Technology – IGNAT-ER Long Endurance Unmanned Air Vehicle, USA. The Predator’s precursor.

• DID – UAV Data Explosion & Management

Background: Sensors and Ancillaries

• Raytheon – AN/DAS-2 Common Sensor Platform product page

• General Atomics – Lynx multi-mode radar

• Northrop Grumman – AN/ZPY-1 STARLite Small Tactical Radar – Lightweight

Official Reports

• Pentagon, via WayBack (April 2012) – Department of Defense Report to Congress on Future Unmanned Aircraft Systems Training, Operations, and Sustainability [PDF]

News & Views

• War Is Boring (Sept 29/14) – Air Force Drone Crews Got So Demoralized That They Booed Their Commander. Mistakes for the Army to avoid, though having lower-ranking operators will help.

• US Army (Feb 5/13) – Divisions will get 9 Gray Eagles to train, but deploy with 12.

• US Army (June 28/12) – Army expanding, upgrading Gray Eagle fleet.

• Alter Net, via WayBack (Oct 16/11) – America’s Secret Empire of Drone Bases: Its Full Extent Revealed for the First Time.

• US Army (Jan 18/11) – Army expanding UAS fleet, speeding up delivery.

• Esquire Magazine, via WayBack (Oct 14/09) – We’ve Seen the Future, and It’s Unmanned.

• Federal Computing Weekly, via WayBack (Oct 9/09) – Army shows Air Force the way on unmanned aerial safety. Automated take off and landing seems to be a better way to go, however injurious to pilot egos.

• Strategy Page, via WayBack (April 30/09) – Cylons 1, Humans 0. “The army uses automatic landing software for its larger UAVs [including the MQ-1C], while the air force does not [using human pilots instead]. Thus the air force has lost about a third of its UAVs to various equipment problems and operator errors, while the army loss rate was less than half that.”

• US Air Force Association, Air Force Magazine, via WayBack (Jan 7/07) – UAVs With Bite. Places the Predator family, Reaper, et. al. in a larger context.

Americas

The US Army is modernizing one of its training systems. Lockheed Martin will provide the service with an upgraded Close Combat Tactical Trainer Manned Module (CCTT) under a $356.3 million hybrid contract. The CCTT is a computer-driven, manned-module simulator that replicates the vehicle interiors of close-combat units. integrates all facets of combat vehicle operations to immerse Warfighters in the scenarios they will face on the battlefield. Through the CCTT, units train and are validated in tactics, doctrine, weapons systems, mission planning and rehearsals. Crewed simulators, such as the Abrams MBT, the Bradley and the Humvee, offer sufficient fidelity for collective mission training. Work locations and relevant funding will be determined with each individual order. The modernization efforts are scheduled for completion by August, 2028.

The US Air Force is procuring an unspecified number of aerial target from Kratos. The contractor will provide the service with Lot 14-16 BQM-167A high performance, jet powered unmanned aerial target drone systems at a cost of $108.9 million. The Air Force uses the BQM-167A to test and evaluate air-to-air and surface-to-air weapons systems. The system is capable of speeds from 230 to 600 knots. The drone can achieve flight altitudes from 50 feet above ground level to 50,000 feet mean sea level. Maneuvers include G-turns up to 9G’s, and other aerial acrobatic turns. The UAV can carry a full range of current Air Force subscale target payloads which include a scoring system, infrared and radar enhancements, electronic attack pods and a chaff/flare dispenser set. Work will be performed at Kratos’ facility in Sacramento, California, and is expected to be completed by the end of 2022.

The US Marine Corps is adding more unmanned aircraft systems to its inventory. Insitu is being contracted to provide the service with four Lot 2 RQ-21A Blackjack drone systems. The firm-fixed-price contract also includes the delivery of eight attrition air vehicles, of which seven are reserved for the USMC and one for Poland, which will receive the vehicle as part of a US foreign military sale. The order has a total value of $53.9 million. The Blackjack belongs to the family of Small Tactical Unmanned Aircraft Systems (STUAS). The drone can be deployed in persistent maritime and land-based tactical intelligence, surveillance and reconnaissance, data collection, target acquisition and dissemination missions. One UAS consists of five air vehicles with multi-mission payloads, two ground control stations and ancillary equipment. Work will be performed at Insitu’s facilities in Bingen, Washington and Hood River, Oregon. The systems are expected to be ready for delivery by June 2019.

Middle East & Africa

Iran is showing off its ‘new’ fighter jet as the diplomatic relations with the US further deteriorate. The Iranian Ministry of Defense claims that Kowsar-88 is the first domestically produced 4th generation fighter jet. However, experts quickly noted that the unveiled jet looks quite similar to the 50s era US-made F-5F. The F-5 was sold to Iran in the 1960s and first entered service in the Iranian Imperial Air Force in 1965. During the jet’s presentation President Hassan Rouhani reasserted Iran’s political standpoint that it will not yield to diplomatic or economic pressure. He clearly stated that the country is readying itself to counter any foreign military powers that seek to take over Iran’s territory and resources, while adding that under President Donald Trump the United States was becoming isolated even from its own allies. Iran is currently in the process of building up its influence in the region. It has a significant amount of troops stationed in Syrian and is sponsoring Houthi rebels in Yemen. To date the claim that the Kowsar-88 is indeed a new fighter jet seems to be just a product for domestic propaganda rather than genuine information.

Europe

The Swedish Air Force needs a new fighter jet after one of its JAS 39 Gripen crashed yesterday, August 21. Shortly after take-off the aircraft collided with a bird and subsequently crashed in a forested area about five miles north of a military air base near the southern Swedish city of Ronneby. The Gripen multirole fighter aircraft, developed by Saab, was first flown in December 1988 and entered operational service with the Swedish Air Force in 1997. The JAS-39, is a canard-winged successor to the Viggen and one of the world’s first 4+ generation fighters. The Gripen remains the only lightweight 4+ generation fighter type in service, its performance and operational economics are both world-class, and it has become one of the most recognized fighter aircraft on the planet.

Russia’s influence in the Balkans is growing, as the Serbian Air Force is now flying two Russian MiG-29 fighter jets. During the handover ceremony Serbian President Aleksandar Vucic thanked Russian President Vladimir Putin for helping make Serbia’s armed forces stronger. Produced between 1989 and 1991, the warplanes are somewhat newer than Serbia’s four existing MiGs, which were delivered in 1987. Serbia claims military neutrality and formally wants to join the European Union. But it is also negotiating additional arms purchases from Russia, including attack and transport helicopters, Buk-M1 and Buk-M2 air-defense missile systems, and Tunguska antiaircraft systems. The small country received the second-hand fighter jets free of charge but will be responsible to pay about $213 million for upgrades and maintenance work on a total of six MiG-29s. Serbia faces a mini arms race with NATO-member Croatia, which has recently agreed to purchase 12 used F-16 fighter aircraft from Israel.

The Royal Navy is introducing a new mine countermeasures sonar to its service. Produced by Thales, the enhanced 2093 Wideband variant has been developed under the Royal Navy’s 2093 Capability Sustainment Programme (CSP). The system is currently installed on the Navy’s Sandown-class minehunter HMS Grimsby and was extensively tested off the coast of Scotland. Thales will also refit the Grimsby’s six sister ships as part of multi-million pound contract. Sandown-class minehunters are built almost entirely of non-magnetic materials and are designed to resist high shock levels. Their manoeuvrability is controlled, either manually or automatically, by using the Ship Position Control System (SPCS) developed by Vosper Thornycroft. The 2093 sonar transmitter and receiver are contained within a towed body which is lowered below the ship by automated winch of armoured cable, penetrating oceanic temperature layers which can block sonar signals. The system greatly improves the minehunters ‘coverage rate’ and ‘speed of advance’.

Asia-Pacific

The Japanese government is currently negotiating a potential development cooperation with Germany and France. Japan plans to sell its P-1 maritime patrol aircraft to the two European countries. The Japanese Ministry of Defense began the development of P-1 along with the C-X transport aircraft in 2001 to replace the ageing P-3C fleet. The aircraft built by Kawasaki Heavy Industries and is equipped with new acoustics and phased array radar systems with enhanced capabilities for detecting and tracking submarines and small vessels. Germany is currently in possession of P-3Cs, while France relies on Dassault’s Atalantic. The two countries will soon need to replace their ageing aircraft and are looking for offers that reduce procurement costs as much as possible, while Japan at the same time is heavily promoting the export of military equipment as means to revitalise its domestic defense industry. Germany and France will use the new patrol aircraft to monitor increased Russian submarine activity.

Today’s Video

Watch: Marine Corps infantry training

Americas

One of the Navy’s Ticonderoga-class guided missile cruises is getting an overhaul. BAE Systems Norfolk Ship Repair is being contracted to modernize the USS Gettysburg (CG 64) at a cost of $146.3 million. The company is responsible to provide the Navy with ‘long-term’ availability that combines maintenance, modernisation and repair work on the vessel. The Ticonderoga Class remains critical to American seapower, functioning as the fleet’s most powerful anti-air defense, and contributing substantial anti-ship and anti-submarine combat power to its assigned naval groups. The Cruiser Modernization program aims to improve the CG 47 Ticonderoga class by modernizing the computing and display infrastructure and the Hull, Mechanical and Electrical (HM&E) systems. Weapons and sensor sets will also be improved, in order to upgrade their anti-submarine capabilities, add short range electro-optical systems that can monitor the ship’s surroundings without the use of radar emissions, as well as routine machinery upgrades to improve all areas of ship functionality. The modernized cruisers are expected to become more cost efficient to operate, as their lives are extended to serve in the fleet through the year 2030. Work will be performed at BAE’s shipyard in Norfolk, Virginia and is expected to be completed by March 2020.

General Atomics Electromagnetic Systems is set to develop a new sensor for the Missile Defense Agency’s MQ-9 UAVs. The cost-plus-award fee contract has a total value of $133.9 million and provides for finalising the development, integration and flight testing of an advanced sensor. The sensor will be evaluated in realistic test scenarios, to be held at various locations inside and outside the continental US. The MQ-9 Reaper is an armed, multi-mission, medium-altitude, long-endurance remotely piloted aircraft that is employed primarily against dynamic execution targets and secondarily as an intelligence collection asset. The new sensor technology has been in the works for some time. It is designed to significantly improve the ability to track cold body targets through their time of flight and enhance discrimination. The MDA is also planning to equip the MQ-9 with high-energy laser systems that could destroy intercontinental ballistic missiles in the boost phase at long standoff ranges. The sensor will be manufactured at GA’s facility in San Diego California from August 2018 through October 2021.

Camber Corp is being tapped to support the USMC’s CBRN contingency efforts. The awarded $15.2 million cost-plus-fixed-fee modification allows the company to perform a variety of technical and engineering services in support of the Chemical, Biological, Radiological, Nuclear and High-Yield Explosive Consequence Management Program. CCMRF is a robust federal entry force that is scalable and task-organized to mitigate further loss of life and relieve suffering in response to a CBRNE disaster. It supports local and state requests for assistance as part of a federal response. The USMC’s Chemical Biological Incident Response Force is capable of deploying as a battalion task force consisting of two subordinate initial response forces (IRFs) with approximately 150 personnel each. In the event of a CBRNE attack, the battalion will deploy Marines who specialize in identification and detection, and they will gather the first wave of intelligence that will be used to define the manner in which the mission will be accomplished. Work will be performed in Washington DC until August 22nd, 2019.

Middle East & Africa

The Qatari Air Force is ordering 28 NH-90 helicopters from Italian defense contractor Leonardo. The deal has a value of $3.4 billion and includes 12 NFH naval helicopters, 16 TTH troop transports, and a number of training services. The NH-90 began life as a leap-ahead competitor that would create a compelling alternative to Sikorsky’s 1980-era H-60 family airframe designs. The NH-90 TTH is the base variant for land and air forces. The platform can carry 12-20 troops and can be configured to perform SOF, MEDEVAC and CSAR missions. The NH-90 NFH an be used as a utility helicopter like the TTH, or as an anti-submarine helicopter. In its ASW configuration the helicopter is equipped with a naval radar, a dipping sonar, sonobuoys, a magnetic anomaly detector, and up to 2 light anti-ship missiles or torpedoes on side pylons. The naval variant will be manufactured at Leonardo’s facility in Venice, while the troop transporters will be assembled at a non-disclosed Airbus location. The helicopters are scheduled for delivery between 2022 and 2025.

Europe

Norway is currently testing its newly acquired F-35 JSFs. Two of Norway’s F-35s recently competed against two US F-22 stealth fighters in a number of simulated dogfights. The F-22s are among 13 jets currently deployed in Europe. Norway is a Tier 3 partner in the JSF program, has ordered a total 52 aircraft and is developing a stealthy Joint Strike Missile with the F-35 as its explicit target. The JSM/NSM is produced by Kongsberg, it can strike land or sea targets and and can be carried inside the F-35A/C weapons bay. The Raptor is considered to be the first 5th generation fighter, even though the aircraft is out of production, the program itself will continue to attract spending on maintenance, spares, and upgrades. The F-22’s deployment is part of US efforts to reassure European allies after Russia’s 2014 annexation of Crimea.

Asia-Pacific

South Korea’s Navy is funding a research project to explore the possibility of operating F-35Bs aboard its amphibious landing ships. The project aims to devise a feasible and affordable options to remodel the country’s 14,000-ton Dokdo-class vessel. Necessary work is likely to include retrofitting the ship with a ski-jump ramp, similarly to the one seen on the Queen Elizabeth-class carriers, and adapting the flight deck so that used materials can withstand the high-temperatures caused by fighter jet operations. In 2014, South Korea decided to acquire 40 F-35As at a cost of $6.4 billion, some experts speculate that the country will also opt for a few F-35Bs as means to mitigate the dangers of a future shortage of warplanes caused by decommissioning its ageing fleet of F-4s and F-5s.

The Singapore Air Force is adding a new multi-role transport aircraft to its fleet. Recent social media posts indicate that the aircraft recently landed at Changi West Air Base. The Airbus A330 Multi-Role Tanker Transport (MRTT) was designed from the outset to be able to function as an aerial tanker and a transport aircraft at the same time. The A330 MRTT has a maximum fuel capacity of 246.000 lbs. and has the capacity to carry 43,000 kg of cargo, including up to 32 463L cargo pallets, or up to 272 passengers, while carrying a full fuel load. The aircraft is powered by two Rolls-Royce Trent 772B-60EP engines, has a hose-and-drogue refuelling pod on both wings and a refuelling boom. Singapore has five additional A330 MRTT’s on order.

Today’s Video

Watch: Russia’s 6th Gen. fighter jet