Defense Industry Daily

Americas

• Performance Aircraft Services is being contracted for repair work on the Navy’s fleet of E-6B aircraft. The $57 million firm-fixed-price, indefinite-delivery/indefinite-quantity contract provides for the removal and replacement of sealant on fuel cells and aircraft surfaces, as well as on the internal surface of wing fuel tanks for up to 16 aircraft. The USA’s E-6 Mercury “survivable airborne communication system” airplanes support their Navy’s SSBN ballistic missile submarine force and overall strategic forces. The 707-300 derivatives have a range of about 5,500 miles and can easily carry 23 crew members. The E-6 flies independent random operations from various deployed sites for approximately 15-day intervals. Each deployed crew is self-supporting except for fuel and perishables, and the mission requires a 24-hour commitment of resources (alert posture) in the Atlantic and Pacific regions. Work will be performed in Waco, Texas and Oklahoma City, Oklahoma. It is expected to be completed in May 2023.

• Northrop Grumman is being tapped for work in support of the Navy’s PMS 408. The firm-fixed-price, cost-plus-fixed-fee modification is valued at $96,5 million and provides for the production for the Joint Counter Radio-Controlled Improvised Explosive Device Electronic Warfare Increment One Block One systems. PMS 408 is the Navy program management office for explosive ordnance disposal (EOD), counter radio controlled improvised explosive device electronic warfare (CREW), and anti-terrorism afloat (ATA) systems. The modification is for Counter Radio-Controlled Improvised Explosive Device Electronic Warfare (CREW) systems that provide combat troops protection against radio-controlled improvised explosive devices (RCIEDs). They are high-power, modular, programmable, multiband radio frequency jammers designed to deny enemy use of selected portions of the radio frequency spectrum. They come in 3 varieties – fixed, mounted, and dismounted. CREW systems are designed to provide protection for foot soldiers, vehicles and permanent structures. The Joint CREW Increment One Block One system is the first-generation system that develops a common open architecture across all three capabilities and provides protection for worldwide military operations. Work will be performed in San Diego, California and Sierra Vista, Arizona, and is expected to be completed by April 2020.

• BAE Systems Land & Armaments is being awarded a contract modification for the production of the Mk 38 mod 3 machine gun system. The modification is valued at $33,2 million and sees to fulfill specified requirements and technical performance requirements for the Mk38 mod 3 25mm MGS ordnance alteration. The Mk38 provides ships with defensive and offensive gunfire capability for the engagement of a variety of surface targets. Designed primarily as a close-range defensive measure, it provides protection against patrol boats, floating mines, and various shore-based targets. The gun is visually distinctive from previous versions with its stealthy housing, which also protects the gun from weather and allows for easier access to internal components through large access panels. The Mod 3 mounts a larger Mk44 II 30 mm cannon for a 500-meter range increase, as well as a coaxial .50 caliber machine gun. Elevation is increased to +75 degrees for engaging UAVs and helicopters, and ammunition storage is greater at 420 30 mm rounds. Work will be performed in Haifa, Israel and Louisville, Kentucky. It is expected to be completed by June 2020.

Middle East & Africa

• The government of Lebanon is set to receive several UASs as part of a US foreign military sale. The $8,2 million deal between the US DoD and Insitu provides for the production and delivery of six ScanEagle UASs to Lebanon. The contract also includes related support equipment, training, site activation, technical services, and data for the government of Lebanon. One UAS typically comprises up to 12 air vehicles as well as associated pneumatic launchers and Skyhook recovery apparatus, meaning that this latest contract could cover as many as 72 ScanEagle unmanned aerial vehicles (UAVs). The ScanEagle is solidly based on Insitu’s original “Insight” platform, with different variants distinguished by their payloads and accompanying equipment rather than their aerodynamic design. These UAVs fill a niche between hand-launched mini-UAVs and runway-capable tactical UAVs. Lebanon is understood to have received an initial batch of ScanEagle UASs in 2015, although no details were disclosed at the time or since. Work is expected to be completed in June 2020.

• Israel Aerospace Industries (IAI) is adding a new missile to its Barak family. The Barak-MX is a modular and scalable networked air/missile defense system that links various sensors, launchers and Barak effectors in a single architecture that can be scoped and optimized to meet specific customer mission requirements. Barak MX is essentially a building block solution. It enables one to retain the central C2 capability but adds longer-range air defense sensors and Barak effectors to scale up the system. The Barak Battle Management Center (BMC), which creates and manages a unified multi-senor aerial picture, coordinates the force operation networks and manages the launch arrays. Barak BMC is available in mobile, transportable and stationary versions. The interceptors are vertically launched and support 360° coverage, quick reactions, short minimal ranges and active high-end RF seekers for targets with low radar cross sections and high maneuverability.

Europe

• The Czech Ministry of Defense intends to move ahead with the acquisition of two additional C-295 transport aircraft in support of its troops. The Czechs currently have four tactical transporters, they are flying since 2010. The new C-295 is a stretched derivative of the CN-235 transporter, with characteristic high-wing, rear-loader design. The aircraft is noted for its short take-off and landing capability on semi-prepared runways and for the large payload capacity of 20392 lb. The landing and take-off run of just 350 yd. and 732 yd. allow the aircraft access to runways close to operational or crisis areas or where supplies and troops are needed. The new C-295s are expected to replace two obsolete Russian-made Yakovlev Yak-40 jet airliners, deliveries are expected by 2020.

Asia-Pacific

• The government of Japan is selecting Lockheed Martin in support of its multibillion-dollar missile defense system. The Asian nation plans to deploy to Aegis Ashore batteries by 2023. The two Aegis Ashore sites will likely cost around $4 billion, almost twice the amount previously expected. Lockheed will provide a version of its Long-Range Discrimination Radar (LRDR) in support of the defense efforts. LRDR combines proven solid-state radar technologies with proven ballistic missile defense algorithms, all based upon an open architecture platform. The radar provides precision metric data to improve ballistic defense discrimination. The missile defense upgrade is a clear message towards China and North Korea. Japanese military planners still see North Korea as an immediate danger. They also view China’s growing military power as a long-term threat.

Today’s Video

• A-10 Warthog prepares for combat patrol over Afghanistan.

ScanEagle launch
(click to view full)

ScanEagle’s base Insight UAV platform was originally developed by Washington state’s Insitu, Inc. to track dolphins and tuna from fishing boats, in order to ensure that the fish you buy in supermarkets is “dolphin-safe”. It turns out that the same characteristics needed by fishing boats (able to handle salt water environments, low infrastructure launch and recovery, small size, 20-hour long endurance, automated flight patterns) are equally important for naval operations from larger vessels, and for battlefield surveillance. A partnership with Boeing took ScanEagle to market in those fields, and the USMC’s initial buy in 2004 was the beginning of a market-leading position in its niche.

This article covers recent developments with the ScanEagle UAV system, which is quickly evolving into a mainstay with the US Navy and its allies. Incumbency doesn’t last long in the fast-changing world of UAVs, though. Insitu’s own RQ-21 Integrator is looking to push the ScanEagle aside, and new multiple-award contracts in the USA are creating opportunities for other competitors. Can Insitu’s original stay strong?

The ScanEagle Family

ScanEagle BCAS launch
(click for alternate view)

The ScanEagle is solidly based on Insitu’s original “Insight” platform, with different variants distinguished by their payloads and accompanying equipment rather than their aerodynamic design. The UAVs are launched by catapult, and autonomously recovered using a folding “skyhook” and catch-line. These UAVs fill a niche between hand-launched mini-UAVs like Aerovironment’s RQ-11 Raven or Elbit’s Skylark I, and runway-capable tactical UAVs like Textron’s RQ-7 Shadow, Aeronautics DS’ Aerostar, or IAI’s Searcher II. Its long endurance is actually superior to its tactical UAV competitors, but its payload weight limit is significantly smaller.

ScanEagle has been demonstrated or used from a wide variety of ship classes and types, and the family includes a number of specialty variants from sniper locator, to bio-warfare agent detection (BCAS). The base UAV has even been used successfully as a firefighting aid. A NightEagle conversion kit adds a different front end with thermal imaging sensors, and allows field conversion of ScanEagle aircraft in 2-3 hours. More drastic modifications are found in the ScanEagle Compressed Carriage (SECC), whose smaller fold-out wings allow it to be launched from an aircraft pylon, or a submarine.

Setup & use
click for video

In October 2014, Insitu introduced a new model, the ScanEagle 2. Compared to the original ScanEagle, v2.0’s most obvious physical difference is the payload holder at the front, which borrows from the larger NightEagle configuration and can combine day and night sensors with a laser marker. Wingspan is still about 10.2 feet, but the UAV is longer (5.1 feet to 5.6 feet) and heavier (base weight rises, payload beyond the sensor set rises from 7.5 to 7.7 pounds, max. takeoff weight rises from 48.5 to 51.8 pounds). Speed is unaffected (50-60 knot cruise, max. 80 knots), but endurance drops from 24 hours to just 16 hours for ScanEagle 2.

In Exchange, ScanEagle 2 features the first reciprocating internal combustion propulsion system designed and manufactured specifically for small UAVs, with real-time diagnostics built in. Inside, the UAV has an Ethernet-based architecture, a fully digital video system, upgraded navigation systems, and improvements that reduce electromagnetic interference to enable more sensitive payloads. Electric power available to those payloads rises from 60W to 100-150W.

ScanEagle 2 uses the same Mark 4 catapults, SyHook recovery system, and Insitu Common Open-mission Management Command and Control (ICOMC2) as the RQ-21 Integrator/ Blackjack.

Versatility
(click for alternate view)

The ScanEagle family’s combination of versatility, long endurance, and small size appears to be succeeding in the global defense marketplace, without really impairing the market for tactical UAVs.

Boeing has had field representatives in theater for a few years now to support and operate the ScanEagle UAV from ships and ashore, receiving high battlefield praise and a fairly regular stream of contracts from the USA and Australia. Canada and Malaysia have also signed on for battlefield surveillance services, the Colombian, Iraqi, Tunisian, and UK Royal navies are using ScanEagle, and so are the Czech Republic, Italy, Lithuania, Poland, Romania, Singapore, and Yemen. The Dutch are using ScanEagle as an interim UAV, Japan is testing it, and other customers wait in the wings. Reported interest includes France, Pakistan, Kuwait, and other Gulf States.

Competition from Without – and Within

Aerosonde 4.7
(click to view full)

The UAV field continues to change quickly. The latest US Navy ISR contract will have ScanEagle competing against the Aerosonde-G for naval buys of UAV services, and against both AAI’s Aerosonde G and Arcturus’ T-20 for land-based surveillance missions. SOCOM’s MEUAS contracts have also become a de facto competition with AAI’s Aersonde.

Insitu’s flagship product will also have to contend with an internal competitor. The firm has begun to offer a next-generation “Integrator” platform, which was picked as the US Navy and Marine Corps’ next-generation RQ-21A Blackjack Small Tactical Unmanned Aircraft System (STUAS-II). It’s also reported that service contracts with other countries will begin incorporating the RQ-21, either as a main UAV or as a switch-in option.

The RQ-21A Integrator boosts endurance to over 24 hours, and raises maximum payload to about 50 pounds / 23 kg. Wingspan rises to 15.8 feet/ 4.8m, and body length rises to 7 feet/ 2.1m. Its sensor package will be a bit more versatile, too, with TV zoom and mid-wave infrared cameras, plus an infrared marker and a laser rangefinder (but not, yet, a target designator), all in a single package instead of the original ScanEagle’s swap-in options. Launch and recovery methods are the same as the ScanEagle’s, and use the same Mark 4 and ICOMC2 equipment.

Integrator will not be covered in this article except for contracts that shift away from the ScanEagle to the new platform, and equally significant milestones that affect ScanEagle’s future.

Contracts and Key Events: 2008 – Present

Eye in the Sky

Unless otherwise noted, contracts are issued by the Naval Air Systems Command in Patuxent River, MD. As of July 2008, Insitu Inc. is a Boeing subsidiary. Note that RQ-21A Integrator contracts won’t be covered here, unless they have a substantial impact on the ScanEagle’s future.

FY 2016 – 2018

 

ScanEagle 2
(click to view full)

July 4/18: FMS to Lebanon The government of Lebanon is set to receive several UASs as part of a US foreign military sale. The $8,2 million deal between the US DoD and Insitu provides for the production and delivery of six ScanEagle UASs to Lebanon. The contract also includes related support equipment, training, site activation, technical services, and data for the government of Lebanon. One UAS typically comprises up to 12 air vehicles as well as associated pneumatic launchers and Skyhook recovery apparatus, meaning that this latest contract could cover as many as 72 ScanEagle unmanned aerial vehicles (UAVs). The ScanEagle is solidly based on Insitu’s original “Insight” platform, with different variants distinguished by their payloads and accompanying equipment rather than their aerodynamic design. These UAVs fill a niche between hand-launched mini-UAVs and runway-capable tactical UAVs. Lebanon is understood to have received an initial batch of ScanEagle UASs in 2015, although no details were disclosed at the time or since. Work is expected to be completed in June 2020.

May 9/18: Spares for the Integrator UAV manufacturer Insitu has been awarded a firm-fixed-price delivery order against a previously issued basic ordering agreement. The $11 million contract provides for the procurement of spare and sustainment parts to maintain the RQ-21A Blackjack unmanned aircraft system in support of the Marine Corps. The RQ-21A is the internal competitor to Insitu’s flagship product, the ScanEagle. The RQ-21A Integrator is the company’s next-generation UAV platform. It boosts endurance to over 24 hours and raises maximum payload to about 50 pounds. Its wingspan rises to 15.8 feet and body length rises to 7 feet. Its sensor package will be a bit more versatile, too, with TV zoom and mid-wave infrared cameras, plus an infrared marker and a laser rangefinder, all in a single package instead of the original ScanEagle’s swap-in options. Launch and recovery methods are the same on both platforms. Work will be performed in Bingen, Washington, and is expected to be completed in January 2019.

March 30/18: Dolphin hunter goes inland The US government is procuring 8 ScanEagle unmanned aircraft systems (UAS) in support of the government of the Islamic Republic of Afghanistan. Insitu Inc. has been awarded a contract valued at over $47 million. ScanEagle’s base Insight UAV platform was originally developed by Washington state’s Insitu, Inc. to track dolphins and tuna from fishing boats. Its characteristics make it equally suitable for naval operations and for battlefield surveillance. A partnership with Boeing took ScanEagle to the defense market. The ScanEagle is launched by catapult, and autonomously recovered using a folding “skyhook” and catch-line. These UAVs fill a niche between hand-launched mini-UAVs like Aerovironment’s RQ-11 Raven and runway-capable tactical UAVs like Textron’s RQ-7 Shadow. The drone can be modified to speciality variants, from sniper locator, to bio-warfare agent detection. The ScanEagle is currently in service in Canada, Malaysia, Colombia, Iraq, Tunisia, the United Kingdom, the Czech Republic, Italy, Lithuania, Poland, Romania and Singapore. The deal also includes spares, other support equipment, 17 field services representatives plus site surveys and activation teams. The majority of work (95%) will be performed in Afghanistan with the remaining 5% being completed in Bingen, Washington. Work is scheduled for completion in March 2019.

March 15/18: Scanning the Philippines The US Embassy to the Philippines has overseen the transfer of a Boeing Insitu ScanEagle Unmanned Aerial System (UAS) comprising of six drones to the archipelago nation. The transfer was overseen by US Ambassador Sung Y. Kim and Philippine Secretary of National Defense Delfin N. Lorenzana during a ceremony at Villamor Air Base, Pasay City on March 13. An Embassy statement said the package is worth $13.2 million and is financed by the Foreign Military Financing grant program. The ScanEagle system will be operated by the 300 Air Intelligence and Security Wing (AISW), out of Antonio Bautista Air Base, Palawan.

February 26/18: Scanning the Seven Seas An anonymous source in the Indonesian Navy has said the service will receive four ScanEagle unmanned aerial vehicles (UAVs) this summer, Jane’s reports. The UAVs along with their support equipment are being procured by a grant provided by the US government under a capacity building program for allied Southeast Asian navies and coastguards known as the Maritime Security Initiative (MSI), with Vietnam, the Philippines, and Malaysia also involved. The scheme aims to help boost these nation’s capabilities to defend and survey their maritime territories and economic resources, as well as allowing them to better contribute to regional maritime security.

July 28/17: Insitu has been contracted by the US DoD to deliver five ScanEagle UAS systems, along with their support equipment, operators, spare parts, site activation services and management for the operation of the UAS for the government of Afghanistan. The work will primarily be conducted in Afghanistan and Bingen, Wash. with a projected completion date of April 2018. The $19.6 million order is being covered under Afghan Security Forces funding. ScanEagles provide intelligence, surveillance, target acquisition, and reconnaissance data with high endurance of over 24 hours.

January 12/17: UAV manufacturers are off to a busy 2017, with branches of the US Armed forces commissioning new orders and sustainment works. Washington firm Insitu has been contracted $70 million for the provision of six additional Lot I RQ-21A Blackjack unmanned aircraft systems to the Navy, comprised of unmanned aircraft, ground control stations, multi-mission plug-and-play payloads, and additional supporting equipment. The Army, meanwhile, has contracted Textron to perform sustainment services for the Army’s RQ-7 Shadow tactical unmanned aircraft system. Valued at $ 206 million, Textron will provide engineering, logistics, field service operations, depot materiel repair and post-production software support to the Army’s fleet of 117 Shadow aircraft.

July 18/16: Maritime surveillance capabilities of the British Royal Navy are to experience a setback in 2017 due to budget constraints. It’s been reported that the service will lose its ScanEagle capability and Type 23 warships will not have any UAVs on board. It had been hoped that UAVs could have been procured under the Flexible Deployable Unmanned Air System (FDUAS) program but failed to secure funding in this year’s budget cycle.

April 21/16: Afghanistan’s National Army has launched its first ScanEagle unmanned aerial vehicle (UAV). The first operational site is in the often volatile Helmand province, and there will be a total of eight sites situated across the country. The systems will provide the Afghan National Army with airborne intelligence, surveillance, and reconnaissance (ISR) capabilities as it conducts security missions against militants operating within its borders.

January 22/16: The USMC has declared that the RQ-21A Blackjack UAV has achieved Initial Operational Capability (IOC) with deployment of the system to commence this summer. Formerly known as the Integrator, the Blackjack has been developed by Boeing as part of a low rate production of a small tactical unmanned air system (STUAS) for the US Navy, and uses the same same launcher and recovery system as the Scan Eagle system. One hundred systems of five vehicles each are planned for the USMC by 2017.

November 30/15: Afghanistan has ordered eight sets of the Insitu ScanEagle UAS from Boeing worth $70 million. The sets contain 65 of the ScanEagle UAVs and work is expected to be completed by 2018. Initially developed to track dolphins and tuna from fishing boats, the ScanEagle is operational in several countries and provides a range of surveillance, tracking and mapping abilities. The purchase comes at a time of increased defense spending from Kabul who has spent $1.8 billion this year. It is expected defense spending will reach $3.4 billion by 2020.

FY 2015

ScanEagle 2 unveiled.

July 27/15: Also announced on Friday, the Navy awarded a $78 million contract modification for six low rate initial production RQ-21A Blackjack UAVs. Also known as the ScanEagle, the Boeing-owned manufacturer Insitu Inc. unveiled a new version of the UAV in October last year, the ScanEagle 2. The first version has seen significant export success, in countries as diverse as Colombia, Yemen, Japan and the Netherlands, with Iran producing an unlicensed version known as the Yasir.

Oct 29/14: ScanEagle 2. Insitu unveils the ScanEagle 2 at Euronaval 2014. It features the first reciprocating internal combustion propulsion system designed and manufactured specifically for small UAVs, with real-time diagnostics built in. Inside, the UAV has an Ethernet-based architecture, a fully digital video system, upgraded navigation systems, and improvements that reduce electromagnetic interference to enable more sensitive payloads. Electric power available to those payloads rises from 60W to 100-150W.

Compared to the original ScanEagle, v2.0’s most obvious physical difference is the payload holder at the front, which standardizes on the larger NightEagle configuration that can combine day/night sensors and a laser marker. Wingspan is still about 10.2 feet, but the UAV is longer (5.1 feet to 5.6 feet) and heavier (base weight rises, payload rises from 7.5 to 7.7 pounds, max. takeoff weight rises from 48.5 to 51.8 pounds). Speed is unaffected (50-60 knot cruise, max. 80 knots), but endurance drops from 24 hours to just 16 hours for ScanEagle 2.

ScanEagle 2 uses the same Mark 4 catapults, SyHook recovery system, and Insitu Common Open-mission Management Command and Control (ICOMC2) as the RQ-21 Integrator/ Blackjack. Sources: Insitu, “Insitu Announces ScanEagle 2 – the Next Generation of the ScanEagle Platform” | Defense News, “Insitu Launches New ScanEagle 2 UAS” (incl. existing customer list).

ScanEagle 2

FY 2014

Buyers: Yemen, Iraq; Opportunities: Japan, UAE partnership, USCG; Fielding in UK Royal Navy; New CEO.

Australian report
click for video

Sept 29/14: Yemen. Insitu Inc. in Bingen, WA receives an $11 million firm-fixed-price delivery order from Yemen for 9 ScanEagle Electro-Optics and 3 NightEagle UAVs. This order also provides for one 12-month/3,600 flight-hour sustainment package with acceptance testing, spares, technical manuals, and training; a site activation team; field service representative; and protection for the support team. All funds are committed immediately.

Work will be performed in Bingen, WA (50%), and Sanaa, Yemen (50%), and is expected to be complete in September 2015. The US Navy’s Naval Air Warfare Center Aircraft Division in Lakehurst, NJ acts as Yemen’s contract agent (N68335-11-G-0009, DO 0007).

Yemen buys

Sept 29/14: Czech. Insitu, Inc. in Bingen, WA receives a $6.8 million firm-fixed-price delivery order from the Czech Republic for 7 ScanEagle electro-optics and 3 NightEagle UAVs, to be used by their troops in Afghanistan. All funds are committed immediately.

Work will be performed at Bingen, WA (50%), and Afghanistan (50%), and is expected to be complete in September 2015. The US Navy’s Naval Air Warfare Center Aircraft Division in Lakehurst, NJ acts as the Czech Republic’s contract agent (N68335-11-G-0009, DO 0006).

Czech Republic buys

Aug 6/14: Leadership. Insitu CEO Steve Morrow (q.v. April 28/11) is retiring, so Boeing names SVP Insitu Programs Ryan Hartman as the new President and CEO, effective immediately. Sources: Insitu, “Boeing Names Ryan Hartman Insitu President and Chief Executive Officer”.

New CEO

June 22/14: UK. The Royal Navy is now using drones from its ships on operations:

“Just 7 months after the Ministry of Defence ordered the system from Boeing Defence UK, footage released today, 22 June, shows ScanEagle taking flight from [the Type 23 frigate] HMS Somerset in the [Persian] Gulf.”

Sources: UK MoD, “Royal Navy’s new eyes in the sky”.

June 2014: USCG. The ScanEagle’s performance with the US Coast Guard may yet make it the service’s 1st ship-borne UAV, after successful drug busts aboard one of the new frigate-sized National Security Cutters:

“At a joint House Transportation and Foreign Affairs Committee hearing looking at maritime drug interdiction efforts, Adm. Robert Papp, commandant of the Coast Guard prior to his retirement in May, said the service is continuing to test ScanEagles…. The Coast Guard will pursue an acquisition program, he confirmed.”

Sources: NDIA National Defense magazine, “Coast Guard Closer to Acquiring Ship-Based Drones”.

May 13/14: Firefighter. Insitu Pacific touts a successful ScanEagle demonstration for the Australian New South Wales Rural Fire Service over the Wollemi National Park, 150 km northwest of Sydney, where fires have burned more than 35,000 hectares of bushland since December 2013.

The trial was trial a collaborative effort between Insitu Pacific and General Dynamics Mediaware, whose D-VEX next-generation video exploitation system streamed full-motion video imagery alongside geo-location information in near real time. This combination was used to monitor and report on the movement of the fire front at night, which is generally done at low altitudes that are unsafe for manned aircraft. It’s also possible to do this job using more advanced sensors on full-size UAVs like the MQ-9 Reaper, but ScanEagle is a far more affordable option. Sources: Insitu, “Insitu Pacific Demonstrates Fire Management Assistance with ScanEagle Unmanned Aircraft”.

Jan 12/14: Japan. Japan’s Maritime Self-Defence Force is looking for ways to improve surveillance, in the wake of Chinese provocations and aggressive territorial claims. Their constitution bars aircraft carriers, but they’d like to try small UAVs that can be launched from destroyers. ScanEagle is already being trialed in Japan, which makes it the natural choice if Japan wants to trial live flights during the FY 2014 budget request’s YEN 2 million research (about $23,600) research phase.

If the JMSDF goes ahead, they’ll buy up to 19 systems. Textron’s Aerosonde can offer a competitor, Northrop and Raytheon have BAT UAVs, and even Boeing has a 2nd UAV up their sleeve in the RQ-21 Integrator. Sources: Japan Times: “MSDF looks to deploy drones on destroyers”.

Jan 7/14: Iraq. Now that Prime Minister Maliki’s sectarian approach to governing has produced predictable rebellion and insurgency in Sunni areas, the USA is shipping Iraq some weapons and equipment, even as heavier equipment finds itself blocked by Sen. Menendez [D-NJ], and many other senators are voicing concerns. Army Col. Steven Warren:

“We’re expediting delivery of 10 operational ScanEagles for part of the original purchase, as well as an additional four nonoperational ScanEagles, which will be sent to help facilitate maintenance of the original 10.”

They’ll act as Iraq’s high-end UAV, compared to the 48 Raven mini-UAVs slated for delivery in the spring. Sources: Pentagon, “DOD Speeds Delivery of Surveillance Assets to Iraq” | The Daily Beast, “Congress to Iraq’s Maliki: No Arms for a Civil War”.

Nov 19/13: UAE. Tawazun subsidiary Abu Dhabi Autonomous Systems Investments (ADASI) expands on a previous marketing and training teaming agreements with Boeing Insitu (q.v. Feb 18/13, Nov 15/11), and taken the next step: they’ll be able to operate and maintain Boeing’s ScanEagle and its larger Integrator UAVs as a service for the UAE military, and for “neighbouring allies.” That gives them complete service authority with the UAV, from marketing, to training, to operation.

ADASI aren’t newcomers to the UAV world. Under the UAE’s Al Sabr program, the firm performed final assembly of the country’s Schiebel S-100 Camcopter small helicopter UAVs, have been conducting R&D to expand the VTUAV’s range of carrying platforms, and service the UAE’s fleet. Sources: ADASI release, Nov 19/13.

FY 2013

SOCOM MEUAS contract; UK buys ScanEagle; Japan begins trial; Iran copies it from crashed UAVs; Kestrel agreement solidifies moving target detection; Sensor cueing from land robots; Launch & recovery improvements.

Small boat pickup
(click to view full)

Sept 17/13: Poland. Insitu Inc. in Bingen, WA receives $7.3 million for a firm-fixed-price delivery order covering ScanEagle system hardware repairs and modifications for Poland. It includes spares, operations and maintenance training, and technical UAS publications.

Work will be performed in Bingen, WA and is expected to be complete in September 2014. US Naval Air Systems Command in Patuxent River, MD acts as Poland’s agent within the FMS framework (N00019-12-G-0008, #0016).

Sept 16/13: SOCOM. A maximum $300 million, 3-year firm-fixed-price, indefinite-delivery/ indefinite-quantity contract for ScanEagle UAVs, operator services, and maintenance services in support of US SOCOM’s naval special warfare operators.

Work will be performed in Bingen, WA, and the contract will run until September 2016. $85 million in operational and supplemental/OCO funds are committed immediately, and will expire by Sept 30/13. Interestingly, the Pentagon says that the “contract was not competitively procured pursuant to FAR 6.302-1,” which is the “only 1 responsible provider” exemption. That significant language, because Textron subsidiary AAI’s Aerosonde 4.7G won the MEAUS-II competition (q.v. March 5/12). ScanEagle pushed back in with a $190 million, 25-month “unusual and compelling urgency” MEAUS contract in February 2013, and this award appears to firmly nail down its position as SOCOM’s go-to UAV (N00019-13-D-0016).

US SOCOM

July 26/13: FAA. The US Federal Aviation Administration issues its 1st UAV Restricted Category Type Certificates, which include the ScanEagle X200. A “major energy company” wants to fly ScanEagle in international waters off of the Alaska coast, surveying ocean ice floes and migrating whale patterns, in order to assess potential Arctic oil exploration areas.

Experimental Airworthiness Certificates have been used for non-government UAV operations in the past, but they don’t allow commercial use. The FAA says that US military acceptance of the ScanEagle and Puma designs was an important factor in granting the new Restricted Category certificates, which do allow commercial operations.

That’s going to be a hotter area for UAV manufacturers over the next few years, and for the FAA as well. The Federal Aviation Administration Modernization and Reform Act of 2012 mandated that the FAA integrate UAVs into domestic airspace by 2015, but a key deadline establishing 6 pilot sites by August 2012 wasn’t met. These type certificates are a small step forward, within a larger framework. Sources: US FAA | NDIA’s National Defense magazine | Seattle Times.

(Restricted) Commercial USA in USA

July 12/13: Industrial. Insitu breaks ground on a new 120,000-square-foot production facility near its headquarters in Bingen, WA. The building is expected to be done in August 2014. Sources: Insitu, July 12/13 release.

July 2/13: USCG. The Coast Guard has been pondering its UAS options and requirements for years (vid. Dec 1/09 entry). They recently completed the 2nd of 3 planned demonstration phases. They used a ScanEagle during a 2-week deployment aboard the Bertholf cutter. That led to 90+ hours of flight time, during which the UAV helped with a the interception of a cocaine-loaded vessel. That gave them the opportunity to test the daytime camera, the combination electro-optical/infrared camera, and auto detection software.

The 3rd phase will gather quantitative data aboard a National Security Cutter in early 2014. USCG.

June 20/13: Britain. The Royal Navy signs a GBP 30 million (about $46.9 million) contract to buy ScanEagle UAVs, for use from Royal Fleet Auxiliary ships like the Bay Class amphibious landing ships, as well as surface combatants like Britain’s frigates, destroyers, and helicopter carriers. This is the Royal Navy’s 1st sea-launched UAV, and it will be a big help to a fleet whose number of ships has dwindled, even as it abandoned maritime patrol aircraft.

ScanEagles can also serve as targeting assets for the Royal Marines, and for Navy ships if Britain buys naval weapons that use laser precision guidance. Raytheon’s new Excalibur laser/GPS guided shell is one such naval option. MBDA’s proposed maritime adaptation of the British Army’s Fire Shadow loitering missile is another. UK MoD.

Britain’s Royal Navy buys in

May 14/13: Japan. Insitu Pacific delivers a ScanEagle Unmanned Aircraft System (UAS) to its partner Mitsubishi Heavy Industries (MHI) of Japan, for a 12-month operational evaluation by the Japanese Ground Self Defence Forces (JGSDF, see July 11/12 entry). Insitu.

April 24/13: OEF, etc. A $7.8 million firm-fixed-price contract modification to exercise an option for ScanEagle/ Nighteagle services until March 2014, in Afghanistan and around the world. $3.6 million is committed immediately.

Work will be performed in Bingen, WA, using FY 2013 Navy wartime supplemental operations and maintenance funds (N00019-11-C-0061).

April 24/13: NanoSAR next. ImSAR LLC in Springville, UT receives an $8.8 million cost-plus-fixed-fee contract modification, for “research services in support of the ultra-small aperture radar” (q.v. May 29/12 entry). This brings the contract’s cumulative value to $32.8 million.

ImSAR are the makers of the NanoSAR and Leonardo radars. US Army Contracting Command in Natick, MA manages this contract (W911QY-12-D-0011, 0006).

March 8/13: OEF. Insitu, Inc. in Bingen, WA receives a $7.8 million firm-fixed-price contract modification, exercising an option for ScanEagle operational and maintenance services in Afghanistan, including both day and night operations.

Work will be performed in Bingen, WA, and is expected to be complete in January 2014. $3.6 million is committed immediately, all of which will expire at the end of the current fiscal year on Sept 30/13 (N00019-11-C-0061).

Feb 18/13: UAE. Boeing broadens their ScanEagle support and sustainment agreement with the UAE’s ADASI (vid. Nov 15/11 entry), adding marketing services within the Middle East and North Africa, training services, and the new Integrator UAV. Boeing VP Debbie Rub reiterated to Gulfnews that this is:

“Not a contract but an agreement to work together. No particular value right now but the region needs this capability so they are working together so that we can grow this sort of business. There are intensions [sic] with Adasi to establish this as the centre in the Middle East for the ScanEagle and Intergrator contracts.”

See: Boeing | Arabian Aerospace | Gulfnews.

Feb 8/13: Iranian copies. The regime’s PressTV is now showing photos of a production line for ScanEagle UAV knock-offs.

Back on Dec 17/12, Commander of the Islamic Revolution Guards Corps (IRGC) Navy Rear Admiral Ali Fadavi had said that Iran was producing copies of the ScanEagle, based on drones it had captured. The Iranian regime says a lot of things about its military capabilities, most of which are fodder only for comedians and the credulous. This report, on the other hand, was plausible.

Iran has significant aerospace reverse engineering expertise, which it has built up to keep its fleet of American fighters and helicopters in the air. They also have some UAV expertise, and Iranian UAVs launched from Lebanon have been shot down over Israel. Iranian copies may not have the same performance and features as ScanEagle, but it’s reasonable to conclude that for once, Iran is making a military claim in line with its demonstrated capabilities. Iran’s PressTV.

Feb 6/13: MEUAS, Too. Insitu Inc. in Bingen, WA receives a 25-month Mid-Endurance Unmanned Aircraft System (MEUAS) indefinite-delivery/ indefinite-quantity contract from US SOCOM, worth $1 million – $190 million. MEUAS involves contractor-owned and operated equipment on the front lines. Work will be performed in Bingen, WA, and “overseas.” US Special Operations Command at MacDill AFB, FL manages the contract (H92222-13-D-0005). FBO.gov justifications for the award shed some light on the contract, which is pursued under FAR 6.302-2, “Unusual and Compelling Urgency”:

“Due to unforeseen circumstances beyond the Government’s control, there is an immediate requirement to mitigate a critical ISR services gap. This proposed contract action is to ensure continued operational capability.”

The interesting question is whether this new contract also provides for RQ-21 Integrator services, to match the USMC’s new STUAS-II UAV buys. Insitu was asked, but said that they were unable to comment. Meanwhile, there has also been a steady expansion and extension of Insitu’s original H92222-09-D-0015 MEUAS ScanEagle contract, when it became clear that its $250 million would run out long before April 27/14. FBO.gov announced on Feb 7/13 that:

“Program efforts were initiated in October 2010 to establish the competitive follow-on MEUAS II contract. A Justification and Approval (J&A) document was approved on 10 June 2011 to increase the existing contract ceiling by $50,000,000 for a revised contract maximum of $300,000,000. This allowed for the continuation of mission essential operations during the source selection process of the MEUAS II follow-on requirement. A second J&A was approved and issued on 16 July 2012. This action increased the contract maximum by $35,000,000 for a revised contract maximum of $335,000,000. This was to assure continuous operational capability during the transition from the MEUAS contract to the MEUAS II [won by AAI’s Aerosonde UAV] …. [Now we’re announcing a raised] dollar ceiling of the MEUAS contract (H92222-09-D-0015) by $10,000,000 for a revised contract maximum of $345,000,000.”

Bottom line? MEUAS could end up being worth as much as $535 million to Insitu, more than double its original amount. From the government’s point of view, it now has 2 MEUAS vendors, with contracts that will both expire in March 2015. FBO.gov re: Revised Contract | FBO.gov re: revised contract maximum | Insitu.

US SOCOM MEUAS

Nov 16/12: OEF. Insitu Inc. in Bingen, WA receives a $12.1 million firm-fixed-price contract modification for pre and post deployment operations and services involving ScanEagle UAVs in Afghanistan. The contract mentions both electro-optical and mid-wave infrared imagery, and in 2013 the new MWIR/EO turret will let the company offer both of those options, without requiring the UAV to land and switch (q.v. Aug 7/12 entry).

Work will be performed in Bingen, WA, and is expected to be complete in August 2013. All contract funds will expire at the end of the current fiscal year, on Sept 30/13 (N00019-11-C-0061).

Nov 16/12: AOL Defense calls attention to Insitu’s business model of providing turnkey services, as the US military prepares to cut in-theater deployments and surveillance, standardize its UAVs, and bring operations and maintenance in house.

Meanwhile, the civilian market isn’t ready yet. That’s partly because of issues around certification in civil air space, and partly because all Insitu UAVs must be sold as weapons through the USA’s ITAR process. As an example, oil companies who want to use ScanEagle are told that they can’t have any non-US citizens aboard the operating platform. Things are going well in Australia with government agencies and civil fight authorities, but that won’t be enough.

Insitu is trying to get a version of the ScanEagle designated as a commercial commodity, and they estimate that the RQ-21A Integrator program will be worth $500 million over 10 years. Even so, AOL Defense is probably right that the Boeing subsidiary is about to take a financial hit.

Oct 30/12: UAV + UGS. Insitu Pacific in Queensland, Australia announces that integration between ScanEagle and McQ’s iScout Unattended Ground Sensor (UGS)/ OmniWatch technologies is complete. McQ’s UGS is in widespread service with the U.S. Department of Defense, Department of Energy and “a range of international customers.”

The project enables UGS target detection alerts to be automatically displayed within ScanEagle’s Insitu I-MUSE multiple UAS controller software. The iScout sensor automatically sends a notification to I-MUSE, displaying the target location, detection type (seismic, magnetic, acoustic or infrared) and other relevant information. The operator is then able to automatically focus the ScanEagle’s sensors on the new contact to verify the data provided by iScout and OmniWatch, and to continue to track the target once it has moved beyond the OmniWatch camera range. Insitu.

Oct 23/12: Kestrel agreement. Insitu Inc. announces a long-term licensing agreement with Sentient in Melbourne, Australia, to integrate Kestrel land and maritime automated detection software into Insitu’s ScanEagle and Integrator systems.

Kestrel software is currently deployed as a separate add-on that specializes in detecting moving targets within the field of view of the UAV’s electro-optical (EO) and infrared (IR) sensors. There are land and maritime versions, which have been used by the U.S. and its allies in Iraq and Afghanistan. Insitu | Sentient.

Kestrel MTI agreement

Oct 10/12: Compact CLRE. The US Office of Naval Research is funding tests of the ScanEagle Compact Launch and Recovery System (CLRE), which combines the Skyhook recovery system with a compressed air launcher for the UAV. The end result is more compact than the traditional piston launcher/ skyhook combination, which is a big advantage for smaller boats and ships. ONR adds that:

“The system currently is trailer mounted for testing and ease of towing behind ground vehicles, but Insitu is exploring modifications of this version for rapid deployments. Its turntable base allows for mounting to a variety of integration structures.”

2012

New USN contract introduces competition, but assures ScanEagle’s future; Key US SOCOM loss; Wins in Singapore & Malaysia; Dutch buy ScanEagle services, but look to Integrator; Japanese evaluation; Integrator gets closer; Research into new tiny ground-scanning radar.

Skyhook recovery
(click to view full)

Sept 26/12: Upgrades. Boeing subsidiary Insitu, Inc. in Bingen, WA receives a $12.4 million delivery order for the hardware required to modernize the ScanEagle and its ancillary equipment. See Aug 7/12 for more details of what the upgrades entail; the hardware contract also includes replacements, using upgraded air vehicles and components.

Work will be performed in Bingen, WA, and is expected to be complete in May 2013. All contract funds will expire at the end of the current fiscal year, which is almost immediately. The Naval Air Systems Command, Patuxent River, Md., is the contracting activity (N00019-12-G-0008).

Sept 17/12: OEF. Insitu Inc. in Bingen, WA receives a $7.7 million firm-fixed-price contract modification for pre and post deployment operations and services involving ScanEagle UAVs in Afghanistan. The contract mentions both electro-optical and mid-wave infrared imagery, and in 2013 the new MWIR/EO turret will let the company offer both of those options, without requiring the UAV to land and switch (q.v. Aug 7/12 entry).

Work will be performed in Bingen, WA, and is expected to be complete in August 2013. All contract funds will expire at the end of the current fiscal year, on Sept 30/12 (N00019-11-C-0061).

Aug 21/12: OEF. Insitu in Bingen, WA, is awarded a $23.4 million firm-fixed-price contract modification for additional ScanEagle operations and maintenance in Afghanistan, using both daytime EO and IR night sensors. Work will be performed in Bingen, WA and is expected to be complete in August 2013 (N00019-11-C-0061).

Aug 9/12: Netherlands. A Dutch ScanEagle is launched on its first anti-piracy operation in the Gulf of Aden, from the amphibious ship HNLMS Rotterdam. The LPD embarked the UAVs, catapult, and command station, plus a 19-soldier Army contingent. Dutch MvD [in Dutch].

Aug 8/12: Comms. relay. Boeing touts a smaller, lighter version of its Tactical Compact Communications Relay (TCCR). The 1.6-pound TCCR extends the range of line-of-sight military handheld radios from under 10 nautical miles to more than 150, and has been operating in Afghanistan. The new 1-pound version does the same, and will fit into a 5″ x 5″ x 1″ slot in the ScanEagle’s payload bay.

The new TCCR has been tested on several other UAVs, including the Schiebel Camcopter S-100, and Boeing plans to demonstrate a civilian set that could support emergency response or other commercial applications.

Aug 7/12: Netherlands. Insitu Inc. announces that the Dutch military can now fly the ScanEagle under a limited military aircraft type-classification certificate from the Military Aviation Authority (MAA) of the Netherlands.

The Dutch needed that, because they intend to operate the UAVs over their own country as well as abroad. Both sides were motivated, so the certification milestone was achieved in just 4 months. Note that this isn’t a full civilian certification, but it will definitely help. Insitu.

Aug 7/12: Sensors. Insitu Inc. announces that it’s conducting field evaluations of 2 new turrets for ScanEagle. Both turrets will be available in the first half of 2013, and better power draw will help make switch-ins easier.

The new Hood Technology Corp. Vision MWIR/EO turret means customers won’t have to choose any more between zoom cameras or mid-wave infrared thermal imaging on their ScanEagles. Insitu’s larger RQ-21A Integrator was already offering both modes, and competitive pressure makes it an important advance.

Hood’s SuperEO turret has already been in service for about a year, providing 5x better stabilization than its predecessor. The newest SuperEO Enhanced turret lets operators track, zoom and focus while maintaining positive identification, thanks to a sophisticated gimbal mechanism and a picture-in-picture display. Losing the target of interest when the camera moves has long been an annoying problem for many UAVs, especially small ones.

July 12/12: Australia. The Army’s contract for ScanEagle services has ended, but the Navy is interested. Insitu Pacific in Queensland, Australia is still using the Army’s contract, just extended and expanded to include trials with the Royal Australian Navy (RAN). ScanEagle will be installed on a number of RAN vessels, and a first-of-class flight trial from a Frigate is expected in September 2012.

The RAN’s endorsed Aviation vision, NA2020, is to have a UAS dedicated unit by 2020. That’s awfully slow, given the pace of change, but the embarked trials will begin moving them in that direction. As American experiences have shown, UAVs as a service can work as a shipboard offering. If the RAN decides to adopt ScanEagle as an “interim UAV” service, there would be almost no changes from the arrangement it has just signed. Insitu.

RAN extends Army deal

July 11/12: Japan. Insitu Pacific in Queensland, Australia announces a contract from Mitsubishi Heavy Industries, Ltd. (MHI), to deliver ScanEagle systems for comprehensive operational evaluation by the Japanese Ground Self-Defense Force (Army).

It’s more than just an evaluation, as the ScanEagles will be operated by the JGSDF during this period to assist in disaster recovery, as well as intelligence, surveillance and reconnaissance (ISR) missions. Having said all that, it isn’t a long-term win yet, either.

July 9/12: Singapore. Insitu Pacific in Queensland, Australia announces a contract from the Republic of Singapore Navy (RSN), to equip its 6 Formidable Class (Lafayette Class derivative) missile frigates with ScanEagle systems. Insitu Pacific will also provide training, logistics and ship installation, as well as specialist in-country maintenance support.

This decision has been a while in coming, vid. the March 2/09 entry detailing ship trials. Insitu.

Singapore

May 29/12: NanoSAR next. ImSAR LLC in Salem, UT receives a $24 million firm-fixed-price and cost-plus-fixed-fee contract to build, test, and assess a lightweight ultra wideband Synthetic Aperture Radar for use on small unmanned aerial vehicles. ImSAR makes the NAnoSAR, and this looks like the contract to develop its successor.

Work will be performed in Salem, UT with an estimated completion date of May 31/17. One bid was solicited, with one bid received by US Army Contracting Command in Natick, MA (W911QY-12-D-0011).

May 20/12: Iraq? Reuters confirms that Iraq will be using UAVs to protect its southern port and associated oil platforms. The logical candidate is Insitu’s ScanEagle, which is already operating in this role (vid. Feb 9/12 entry):

“Iraq’s navy has purchased US drones to protect the country’s oil platforms in the south, from where most of Iraq’s oil is shipped,” said an official from the Office of Security Cooperation in Iraq, which is part of the US embassy. The OSCI did not give further details of the number or type of unmanned aircraft. But Iraqi security officials confirmed plans to use drones to protect oil infrastructure.”

Iraq?

May 15/12: Insitu, Inc., Bingen, WA receives a $35.5 million firm-fixed-price contract modification for additional ScanEagle and NightEagle services in Afghanistan.

Work will be performed in Bingen, WA, and will run to December 2012. All Contract funds will expire at the end of the current fiscal year, on Sept 30/12. US Naval Air Systems Command in Patuxent River, MD manages the contract (N00019-11-C-0061).

May 4/12: Over in Australia. The ScanEagle has made its last flight for Australia, and its leased services are being replaced with Textron’s RQ-7B Shadow UAVs bought under Project JP129.

While Boeing contractors provided assistance and operational services, about 180 Australian Defence Force personnel deployed in support of the ScanEagle, mostly from 20th Surveillance and Target Acquisition Regiment, with elements from 16th Air Defence Regiment, Defence Imagery and Geospatial Organisation, 1st Topographic Survey Squadron and 16th Aviation Brigade. During its 5 years in operation in Afghanistan, ScanEagles flew about 32,000 hours in more than 6,200 missions. Australian Army | Ottawa Citizen.

April 17/12: Malaysia. Insitu Pacific and Composites Technology Research Malaysia (CTRM) announce a contract for Insitu Pacific to deliver its ScanEagle to CTRM, to be operated by CTRM’s subsidiary Unmanned Systems Technology (UST).

Insitu Pacific has confirmed to DID that “CTRM will utilise the ScanEagle system to augment UAS Services provided to the Malaysian Defence Forces under an existing contract.”

Malaysia

April 4/12: Hydrogen-powered. Boeing’s Insitu announces that the ScanEagle has completed a hydrogen-powered test flight, using a 1,500-watt fuel cell by United Technologies and a hydrogen fueling solution by the US Naval Research Laboratory. They add that this ScanEagle is lighter than the traditional model, which means more room for equipment. On the other hand, the release didn’t discuss the effects on range and endurance, which are more critical traits for this UAV. Earth Techling.

March 19/12: Dutch contract. Insitu announces a contract with the Dutch MvD to use its ScanEagle “both domestically and abroad.” Specifically, they’ll provide:

“…an ISR capability during the second half of 2012, replacing a program [DID: Sperwer UAVs] that ended in the middle of 2011. Looking forward, Netherlands MOD and Insitu plan to continue to explore the potential for multi-mission ISR capabilities using a next-generation Insitu UAS that carries multiple ISR sensors and enables rapid, robust payload integration.”

Which is to say, their RQ-21A Integrator platform. Both of the interim ScanEagle systems (3 UAVs each) are expected to achieve operational capability by late 2012, with 1 available for overseas deployment, and the other used for training and domestic tasks.

The permanent Sperwer replacement will involve 5 systems, by late 2014: 3 for deployment, 1 for missions within The Netherlands, and 1 for training. The RQ-21A has the required integration with ScanEagle ground systems, and has been chosen to enter service with 107 Aerial Systems Battery in 2014. Insitu | Dutch Defence Press.

Netherlands

March 5/12: MEUAS-II loss. Textron’s subsidiary AAI wins the 3-year, maximum $600 million follow-on to US Special Forces’ MEUAS contract, using its Aerosonde 4.7G UAV. Insitu’s MEUAS contract had been slated to expire in 2014, but the somewhat-imprecise wording of public statements and solicitations suggest that MEUAS-II will fully replace the old contract.

With its technology validated by 2 huge American contracts, AAI’s Aerosonde UAVs can be expected to be a much more visible competitor around the globe. Meanwhile, ScanEagle has gone from the sole-source solution in 2 major American contracts, to forced competition in UAS-ISR and an uncertain position in MEUAS. ScanEagle UAV still has important advantages in its array of specialized variants, and the larger RQ-21A Integrator UAV is on tap as a follow-on offering. Even so, the MEUAS-II setback may leave Boeing and Insitu pondering the need for further investment in, and upgrades to, their core ScanEagle platform. Textron’s AAI | UV Online.

US MEAUS-II

Feb 29/12: USN ISR. US NAVAIR issues their 5-year, $864 million UAS ISR contract, which can include services for US military allies, alongside the US Navy and Marines. Insitu submits the ScanEagle instead of the RQ-21A Integrator, and their selection as an eligible bidder for task orders would seem to protect ScanEagle’s near term future.

On the other hand, the umbrella contract introduces competition to an area that ScanEagle used to have to itself. Textron’s Aerosonde G will compete with Insitu’s ScanEagle for naval and land task orders, while Saab’s small Skeldar heli-UAV will become a 3rd competitor on land. Read “ScanEagle, Aerosonde & Skeldar: The USN’s UAS-ISR Contract, 2012-2017” for full coverage.

USN ISR

Feb 9/12: Exports. An AOL Defense report offers an expanded list of ScanEagle operators, as well as 3 more potential export clients:

“Navy leaders are considering foreign military sales of the Scan Eagle to Kuwait, Pakistan and the Netherlands, according to a presentation by Marine Corps Col. James Rector, head of the small tactical unmanned aerial systems division at Naval Air Systems Command. Aside from the U.S. Navy, the Scan Eagle is being flown by naval forces in Colombia, Tunisia, Poland and Iraq, according to PowerPoint slides from Rector’s speech at the Association for Unmanned Vehicle Systems International’s annual program review in Washington yesterday.”

The Netherlands is already using ScanEagle as an interim UAV; presumably, Dutch discussions represent long-term lease or purchase options. Previous reports have suggested that Boeing is offering ScanEagle leases with provisions to switch part-way through, and use the larger and more advanced RQ-21 Integrator platform (vid. June 16/10 entry).

Jan 25/12: NightEagle. Insitu, Inc. in Bingen, WA receives an $20 million firm-fixed-price contract modification, exercising an option for ScanEagle operational and maintenance services. These services will provide electro-optical/infrared and mid-wave infrared (NightEagle) imagery in support of Marine Corps operations in Afghanistan. Work will be performed in Bingen, WA, and is expected to be complete in May 2012. All contract funds will expire at the end of the current fiscal year, on Sept 30/12 (N00019-11-C-0061).

Jan 22/12: Closing time approaches. First flight of an Early Operational Capability (EOC) RQ-21A STUAS Integrator UAV at the USMC’s Air Ground Combat Center in Twentynine Palms, CA, 16 months after the contract is awarded. USMC UAV Squadron VMU-3 will deploy the RQ-21A within the USA, while a government-contractor team works with the system, and develops tactics, techniques, and procedures on the way to formal Initial Operational Capability (IOC), and then Full Operational Capability (FOC).

As those milestones are reached, Insitu’s ScanEagle will fade from use. US NAVAIR: “RQ-21A will eventually replace the Navy and Marine ISR services contract in which current ISR missions are conducted in Iraq, Afghanistan and shipboard.”

2011

CEO shift; Dutch pick ScanEagle; Arctic & Libyan operations; Swarm flight; Comm relay test.

Aussie ScanEagle
(click to view full)

Nov 28/11: Insitu, Inc. in Bingen, WA receives an $12 million firm-fixed-price contract modification, exercising an option for ScanEagle operational and maintenance services. These services will provide electro-optical/infrared and mid-wave infrared (NightEagle) imagery in support of Marine Corps operations in Afghanistan. Work will be performed in Bingen, WA, and is expected to be complete in January 2012. All contract funds will expire at the end of the current fiscal year, on Sept 30/12 (N00019-11-C-0061).

Nov 15/11: UAE. Insitu Inc. announces a partnership with Abu Dhabi Autonomous Systems Investments Company (ADASI), to perform joint support and sustainment activities on Insitu’s ScanEagle and Integrator UAS.

Oct 6/11: Canada. Insitu Inc. announces that its Canadian clients have successfully used ScanEagle UAVs during Operation Nanook in Canada’s Northwest Passage. The exercise focused around an Arctic major air disaster (MAJAID) simulation, and ScanEagle was deployed by Insitu and its partner ING Engineering to identify traversable ground routes, watch for polar bear threats, and monitor day-to-day iceberg movements. Insitu and ING UAS operators launched and retrieved the aircraft, then handed control over to the Canadian Forces and stood by to provide technical assistance as needed. Commanders in tactical operations centers (TOC) at 74 degrees north and troops on the ground received real-time video.

The exercise itself is not as significant as ScanEagle’s proof of use in polar environments. Insitu | Canada DND on Operation Nanook 11 | Canada DND Nanook 2011 photos.

Sept 30/11: Insitu, Inc. in Bingen, WA received a $7.6 million firm-fixed-price contract for major end items and parts to be used in the ScanEagle system. Work will be performed in Bingen, WA, and is expected to be complete by January 2012. This contract was not competitively procured by the US Naval Surface Warfare Center Panama City Division in Panama City Beach, FL (N61331-11-C-0011).

August 15/11: Libyan operations. Insitu discusses ScanEagle’s performance over Libya, from the Arleigh Burke Flight II Class destroyer USS Mahan [DDG-72]. The operation began shortly after an Insitu team had been aboard Mahan to analyze the way ScanEagles were used, and made recommendation to expand its uses. Mahan put those suggestions into effect once Operation Unified Protector began, flying the ScanEagles in strong winds and forwarded secure imagery transmission to the task force used Boeing’s Secure Video Injection system:

“What happened over that period of time, no one expected,” said ScanEagle Detachment Officer in Charge Lt. Nick Townsend. “ScanEagle was locating contacts of interest that no one else could find. After the dust settled, ScanEagle was credited with locating a host of contacts of interest due to its ability to capture superior image quality and to operate covertly at relatively low altitudes.”… Later coordinating with an AWACS team, the USS Mahan ScanEagle team drew on ScanEagle’s 24-hour endurance to support additional phases of the mission, including battle damage assessment: ScanEagle delivered real-time, full-color imagery… “They (operational commanders) say ‘put the camera here’ and we put the camera there without going through layers of complex coordination. We get essential information directly to the decision makers fast,” said Insitu ScanEagle Site Lead Samuel Young.”

Libya experience

May – August 2011: Comm relay. Boeing announces successful May and August demonstrations of ScanEagle’s new narrowband communications relay, using an Insitu ScanEagle and AeroVironment’s Puma AE mini-UAV. During the multiservice demonstrations, held in California, the UAVs flew at a variety of altitudes while linking handheld military radios dispersed over mountainous regions, extending the radios’ range tenfold.

Larger RQ-7B Shadow UAVs have also been used in this role, but those are generally controlled at the battalion level or above. Narrowband relays small enough to work on mini-UAVs would represent an important step forward, especially for Special Operations forces.

July 7-10/11: UAV Swarm. Boeing conducts successful autonomous UAV swarm missions over the rugged terrain of eastern Oregon, using 2 ScanEagles and a Procerus Unicorn UAV from The Johns Hopkins University Applied Physics Laboratory (JHU/APL). Boeing Advanced Autonomous Networks program director and team leader Gabriel Santander described it as “a milestone in UAV flight”; in this case, that’s a reasonable label.

The JHU/APL developed the UAVs’ Mobile Ad Hoc Network and swarm technology, which let them work together to search the test area through self-generating waypoints and terrain mapping, while simultaneously sending information to teams on the ground. A broader demonstration is planned for the end of September. Boeing.

Swarm flight

June 30/11: Netherlands. The Dutch will use ScanEagle UAVs as an interim front-line replacement for Sagem’s much larger Sperwer system, which has just been retired. Dutch MvD | Aviation Week

Dutch pick

May 31/11: Insitu, Inc. in Bingen, WA received a $46 million firm-fixed-price-contract to provide deployment services and flight hours, including electro-optical/infrared and mid-wave infrared imagery in support of Marine Corps operations in Afghanistan. In practice, this means both ScanEagle and NightEagle platforms; looks like the April 9/11 short-term contract went well.

Services will encompass both operation and maintenance of the ScanEagle UAS, to provide real-time imagery and data to USMC personnel. Work will be performed in Bingen, WA and in the field, and is expected to be complete in May 2012. All contract funds will expire at the end of the current fiscal year, on Sept 30/11. This contract was not competitively procured, pursuant to FAR 6.302-2 (N00019-11-C-0061).

June 2011: Insitu’s inception. The Smithsonian Institute’s magazine profiles the story behind Insitu and the ScanEagle, as part of a feature describing the evolution of UAVs toward civilian roles. Boeing bought the firm for about $400 million, in July 2008. Read “Drones are Ready for Takeoff“.

May 26/11: Insitu, Inc. in Bingen, WA received an $83.7 million indefinite-delivery/ indefinite- quantity contract for operations and maintenance services to support government-owned ScanEagle systems, including: multiple training courses ranging from system pilot training, maintenance and operations, to mission coordinator and payload operator; multiple kits for sustainment, payload and engine module kits; and multiple spare parts.

Work will be performed in Bingen, WA, and will run until May 2012. $62.7 million will expire at the end of the current fiscal year, on Sept 30/11. There’s only one ScanEagle manufacturer, and this contract was not competitively procured, pursuant to FAR 6.302-2 (N00019-11-C-0012).

April 28/11: CEO shift. Boeing executive Steve Morrow becomes Insitu’s new President and CEO, succeeding co-founder Steve Sliwa, who retired April 1/11. That’s always a big inflection point in a company’s history.

Morrow holds a B.Sc. (electrical) Engineering from the University of South Carolina, and an M.Sc. Aeronautical engineering from the Naval Postgraduate School in Monterey, CA. He most recently served as Director, Stand-off Strike, leading long-range weapons programs including

• GM-84 Harpoon and SLAM-ER missiles, the USAF’s Tomahawk ALCM, the Next Generation Cruise Missile, and Boeing’s portion of the Aegis Ballistic Missile Defense program. He joined Boeing in 2002 following his retirement as Navy program manager for Tomahawk-related programs. His Navy aviation experience came in P-3 sea control aircraft. Insitu.

New CEO

April 14/11: Insitu awards small business qualifier ArgenTech Solutions a contract to provide field service representative (FSR) services, at locations worldwide. It’s an initial 1-year contract that includes options for 2 additional years.

April 9/11: Boeing receives a $12.3 million firm-fixed-price contract modification for “additional Mid-Wave Infrared Unmanned Aerial Systems, intelligence reconnaissance surveillance services in for the 1st Marine Expeditionary Force combat missions in support of Operation Enduring Freedom.” Sounds like an order for NightEagle services in Afghanistan.

Work will be performed in Bingen, WA (65%), and St. Louis, MO (35%), and is expected to be complete in May 2011. The US Naval Air Warfare Center Aircraft Division in Lakehurst, NJ manages this contract (N00019-08-C-0050).

Feb 22/11: Boeing receives a $5.7 million firm-fixed-price indefinite-delivery/ indefinite-quantity contract modification for “additional persistent unmanned aerial vehicle intelligence, surveillance, and reconnaissance services in support of naval maritime missions.” ScanEagles featured prominently in the April 2009 rescue of an American vessel from Somali pirates, for example.

Work will be performed in Bingen, WA (65%), and St. Louis, MO (35%), and is expected to be complete in November 2011. All contract funds will expire at the end of the current fiscal year, on Sept 30/11 (N00019-08-D-0013).

2010

Polish order; New Integrator UAV for USMC; Weapons for ScanEagle?; FAA test; Heavy fuel; NanoSAR ready; ScanEagle SECC variant.

SECC test
(click to view full)

Dec 30/10: Boeing receives a $14.5 million firm-fixed-price contract modification for additional “persistent intelligence, surveillance, reconnaissance unmanned aerial vehicle services in support of Marine Corps combat missions.”

Work will be performed in Bingen, WA (97%), and St. Louis, MO (3%), and is expected to be complete in February 2011. All contract funds will expire at the end of the current fiscal year, on Sept 30/11 (N00019-09-C-0050).

Dec 28/10: A $68.3 million firm-fixed-price contract for “full-motion video from commercial un-manned air intelligence, surveillance and reconnaissance platforms across Iraq. Work will be completed in Baghdad, Iraq, with an estimated completion date of Dec 31/11. The bid was solicited through the Internet with 2 bids received by U.S. Central Command in Baghdad, Iraq (M67854-07-D-2052).

Dec 3/10: Weapons? Aviation Week reports that the US Navy is working on weapons that could give even the ScanEagle UAV hunter-killer capability. The 2 pound next-generation weapon management system (WMS GEN2) has been tested in the lab, and the development team is now looking at using the WMS GEN2 with the 5 pound NAWCAD Spike mini-missile, the Scan Eagle Guided Munition (SEGM), and a GPS-Guided Munition (G2M, likely the RCFC).

Sept 27/10: Boeing in St. Louis, MO receives a $5.7 million not-to-exceed indefinite-delivery /indefinite-quantity contract modification for 2,100 hours of persistent UAV intelligence, surveillance, and reconnaissance services in support of US Navy and USMC missions.

Work will be performed in Bingen, WA (94%, Insitu subsidiary) and St. Louis, MO (6%), and the contract will end in September 2011. All contract funds will expire at the end of the current fiscal year, on Sept 20/10 (N00019-08-D-0013).

Sept 23/10: It took a while, but Boeing subsidiary Insitu, Inc. in Bingen, WA gets a $7.2 million modification to an American firm-fixed-price contract (N00019-09-C-0005), for Poland’s order of 10 ScanEagle systems. ScanEagle would join Aeronautics’ Orbiter mini-UAV and Aerostar tactical UAV, as UAVs available to Polish forces.

Work will be performed in Bingen, WA, and is expected to be complete in September 2011. $3.5 million will expire at the end of the current fiscal year. US Naval Air Systems Command in Patuxent River, MD manages the contract on Poland’s behalf. See “Polish Equipment Issues and Consequences” for more in-depth coverage of the issues and pressures behind Poland’s purchase.

Poland

Aug 24/10: NightEagle. Insitu announces that its NightEagle conversion kit is now fully integrated into combat operations after successfully completing fielding of an upgraded mid-wave infrared (MWIR) imager payload. Insitu responded to an urgent, mission-critical request, using its deployed operations representatives to beat the schedule. The new configuration consists of upgrades to ground support equipment, new software, and specialized in-field training.

NightEagle

Integrator platform
(click to view full)

July 29/10: No ScanEagles for STUAS-II. Boeing subsidiary Insitu, Inc. in Bingen, WA wins a $43.7 million cost-plus-incentive-fee contract to provide its new Integrator UAVs under the USMC’s the small tactical unmanned aircraft system/Tier II unmanned aircraft system III (STUAS-II) competition. But the UAV that beats competitors like Raytheon’s KillerBee 4 is not a ScanEagle. Instead, it’s Insitu’s new Integrator UAV – which may herald the beginning of the end for ScanEagle. Integrator also uses catapult launch, and is recovered using the same Skyhook recovery systems as ScanEagle.

We won’t be covering other Integrator contracts in this article, just milestones that are relevant to ScanEagle’s future.

Work will be performed in Bingen, WA (46.7%), Hood River, OR (45.6%), and Melbourne, FL (7.7%). Work is expected to be completed in September 2012, but $788,931 will expire at the end of the current fiscal year, on Sept 30/10. This contract was competitively procured via an electronic request for proposals, with 4 proposals received by the Naval Air Warfare Center Aircraft Division in Lakehurst, NJ (N68335-10-C-0054). Insitu.

June 16/10: Poland. Reports surface that Poland has joined the customer list for Boeing’s leased ScanEagle UAV services, but details are scarce. At 15-20 hours endurance, ScanEagle offers longer on station time than leased Aeronautics DS’ Aerostars’ 8-12 hours. On the other hand, the Aerostar offers 110 pounds of payload, while ScanEagle offers just 13 pounds.

Shepard Group adds that Insitu has qualified a Mk4 catapult launcher, which will be compatible with both ScanEagle and Integrator, and is “ready to ship the launcher to an undisclosed customer in Afghanistan.” The Insitu spokesperson told them that around 35 ScanEagle systems of 5-10 UAVs each were operational with Australian, Canadian, Polish and US forces.

Aviation Week reports that Boeing is also in talks with a number of European countries to lease ScanEagle UAV services, with the option of an upgrade to their Insitu subsidiary’s slightly larger and more advanced Integrator UAV later on. Aviation Week | Shepard Group | StrategyPage.

June 12/10: Boeing receives a $59.5 million ceiling-priced modification to a previously awarded firm-fixed-price contract (N00019-09-C-0050) to provide 3,300 flight hours of persistent intelligence, surveillance, reconnaissance UAV services to the U.S. Marine Corps.

Work will be performed in Bingen, WA (97%), and St. Louis, MO (3%); and is expected to be complete in December 2010. $29.75 million will expire at the end of the current fiscal year, on Sept 30/10.

June 8/10: FAA tests. Boeing subsidiary Insitu Inc. signs a cooperative research development agreement with the USA’s Federal Aviation Administration (FAA), in order to guide the development of recommendations for UAV use in civil airspace. The research will be managed by the FAA’s Research and Technology Development Office and conducted at the William J. Hughes Technical Center in Atlantic City, NJ. Insitu | FAA Fact Sheet.

Insitu will provide a ScanEagle system, related support hardware and data, and UAV training for FAA pilots and maintenance staff. Insitu will also supply documentation related to ScanEagle, including an open invitation for FAA personnel to visit Insitu.

June 2/10: Canada. Insitu announces that its ScanEagle has logged more than 17,000 combat flight hours and 1,700 sorties with the Canadian Forces, as part of a “rent a drone” service operated by their Canadian partner ING Engineering. ScanEagle has been deployed with the Canadian Forces in theater since 2008 and has completed a successful maritime flight demonstration aboard the Kingston Class patrol vessel HMCS Glace Bay.

May 13/10: Insitu Inc. announces that it has demonstrated its heavy fuel engine-configured ScanEagle UAS to the U.S. Army Aviation Center of Excellence, in conjunction with the Joint Systems Integration Laboratory (JSIL). The tests at Fort Rucker, AL demonstrated interoperability between ScanEagle video with metadata and the U.S. Army’s One System Remote Video Terminal (OSRVT), a digital video encrypted data feed, a mid-wave infrared (MWIR) sensor for night scans, and Insitu’s stabilized airborne target tracking system.

May 12/10: SECC. Boeing tests its ScanEagle Compressed Carriage (SECC), whose 132-inch wingspan and folding aero surfaces let it be carried in a container and launched from an aircraft pylon, or a submarine. It’s recovered using the same SkyHook system as a regular ScanEagle.

ScanEagle SECC is powered by a 6 hp heavy-fuel engine. The test launched it from a ground vehicle, whereupon it flew an autonomous 75 minute flight plan at various altitudes, and provided streaming video to a nearby ground station. Boeing | Boeing feature w. video.

April 29/10: Insitu Inc. announces that its ScanEagle UAS recently exceeded 300,000 combat flight hours since its 1st operational flight in 2002, and accounted for approximately 22% of the 550,000 hours that American UAVs flew in 2009.

April 14/10: An $11 million modification to a previously awarded firm-fixed-price contract (N00019-09-C-0050) to provide 6,600 flight hours of persistent ISR (intelligence, surveillance, reconnaissance) unmanned aircraft vehicle services in support of naval maritime missions. Work will be performed in Bingen, WA (97%), and St. Louis, MO (3%), and is expected to be complete in June 2010. All contract funds will expire at the end of the current fiscal year.

March 16/10: Boeing subsidiary Insitu, Inc. in Bingen, WA received an $8.6 million firm-fixed-price contract for technical services, to support intelligence, surveillance, and reconnaissance services. In addition, this contract covers 6 critical spare kits and 9 SkyHook recovery system modifications.

Work will be performed in Bingen, WA, and is expected to be complete in December 2010. Contract funds in the amount of $8.4 million will expire at the end of the current fiscal year, on Sept 30/10. This contract was not competitively procured pursuant to FAR 6.302-2 (N00019-10-C-0045).

Feb 23/10: Sensors – NanoSAR. Insitu Inc. announces that after 4 years of work with ImSAR LLC and 2 years of flight testing, the NanoSAR ground-scanning radar has moved out of development, is now available as a payload for its ScanEagle dual bay and follow on “Integrator” UAVs. See May 28/08, Jan 7/08 entries.

NanoSAR

Feb 19/10: A $6.1 million not-to-exceed modification to a previously awarded indefinite-delivery/ indefinite-quantity contract (N00019-08-D-0013) to provide 300 hours of persistent UAV intelligence, surveillance, and reconnaissance services in support of naval maritime missions.

Work will be performed in Bingen, WA (65%) and St. Louis, MO (35%), and is expected to be complete in July 2010. All contract funds will expire at the end of the current fiscal year.

2009

US SOCOM MEAUS order; Canada SUAV order; Maersk Alabama rescue; E-737 AEW&C’s UAV control; ASW MagEagle?; Bandit & Enerlink datalinks.

ScanEagle UAV
(click for alternate view)

Dec 18/09: Bandit datalink. Boeing subsidiary Insitu Inc. announces that a flight test with L-3 Communication Systems-West’s Bandit digital data link worked “well in excess of range requirements.” Insitu is integrating the Bandit digital data link into its ScanEagle, NightEagle and Integrator UAVs. Bandit is Advanced Encryption Standard (AES) capable and ROVER 4/ 5 compatible. This test was conducted using the Integrator UAV, but tests also happened on a ScanEagle earlier in 2009.

Dec 1/09: USCG. Aviation Week reports that the US Coast Guard is still considering its UAV options:

“As part of its ongoing analysis, the service has participated in numerous exercises with other platforms [beyond the MQ-8B]… including Boeing’s A160 Hummingbird, an AeroVironment vehicle and ScanEagle tested on board a National Oceanic and Atmospheric Administration ship.”

Nov 25/09: The University of North Dakota (UND) receives its ScanEagle UAS, to be used in Department of Defense (DOD) contracted research providing data for UAS national airspace integration. UND is a designated State Center of Excellence for UAS Research, Education and Training, and funds for this project were provided by a USAF research contract. UND Associate Professor of Aviation and Director of Program Development for the UAS Center of Excellence, Douglas Marshall, in Insitu’s Press release:

“To date, the university’s only fully trained operators and maintenance technicians are UND employees and primarily flight instructors. We hope to integrate a ScanEagle system into our curriculum and allow students to fly the system against a radar test bed, while learning to operate the UAS itself.”

Nov 24/09: Canada. Boeing subsidiary Insitu Inc. announces a successful ScanEagle flight demonstration aboard Canada’s Kingston class coastal patrol vessel HMCS Glace Bay [MM 701]. The demonstration was conducted by the Canadian Forces Maritime Warfare Centre (CFMWC), and included an in-flight handoff of the ScanEagle by Canadian Navy personnel aboard HMCS Glace Bay to a ground control station (GCS) operated by Canadian Army personnel at Naval Base Halifax.

Oct 19/09: ScanEagle wins C4ISR Magazine’s 2009 C4ISR Platforms Category Award. Insitu release | C4ISR Magazine.

Sept 28/09: Sensors – MagEagle? Boeing receives a $275,000 contract from the US Naval Air Warfare Center Aircraft Division (NAWCAD) to study of the magnetic noise associated with the heavy-fuel propulsion system on Boeing’s MagEagle Compressed Carriage (MECC) ScanEagle variant. The MagEagle is being designed and built to be magnetically quiet, in order to help it locate, track and attack submarines using a magnetic anomaly detector (MAD) system that picks up the changes in earth’s magnetic field caused by large metal objects.

Boeing envisions MECC as another UAV extension of the manned P-8A Poseidon aircraft, launchable from the aircraft itself. They will begin testing the MECC sensor system, vehicle integration, and magnetic noise reduction in 2010. Boeing.

Aug 11/09: Insitu announces that ScanEagle recently surpassed the mark of 200,000 operational flight hours since 2004.

Aug 5/09: Insitu marks more than 2,500 combat flight hours and more than 300 shipboard sorties with its heavy fuel engine (HFE) ScanEagle since flight-testing began in 2006, which. ScanEagle HFE has been deployed aboard the destroyers USS Mahan and USS Milius, and uses the same JP-5 kerosene-based diesel fuel commonly used in jet aircraft engines, as opposed to the more flammable and dangerous auto gas. Other advantages include simple starting and operation, a wider weather envelope, improved reliability and increased endurance.

Insitu developed the engine in partnership with combustion system experts Sonex Research, Inc. in Annapolis, MD.

July 9/09: #1,000. Insitu Inc. marks delivery of its 1,000th ScanEagle, and announces that it is expanding its UAS manufacturing capacity.

May 27/09: Canada. Boeing announces $25 million in contracts to Canadian industry, as part of its $30 million industrial offsets commitment following Canada UAV services order. See also April 6/09 entry.

Winners include: ING Engineering Inc. (field services), MKS (MKS Integrity software and consulting services for program life-cycle management), and NovAtel (ScanEagle GPS).

May 22/09: The SEALs must have really liked what the ScanEagle did for them during the Maersk Alabama incident, and been satisfied with past experiments involving launches from their MkV boats and trials on other Navy ships. Boeing announces a 5-year, $250 million contract from US Special Operations Command for:

“Intelligence, Surveillance and Reconnaissance (ISR) services… Boeing and its subsidiary Insitu Inc. will operate, maintain and support ScanEagle systems for the Special Operations Forces Mid Endurance Unmanned Aircraft System (MEUAS) program….”

Boeing VP of Boeing Defense & Government Services Greg Deiter says that Boeing’s past performance on ScanEagle battlefield surveillance contracts was a significant reason for their win. That kind of record will become a valuable competitive asset as new designs like the blended-wing KillerBee 4 begin competing in ScanEagle’s niche.

US SOCOM MEAUS

April 13/09: The Boeing Co. in St. Louis, MO received a $45.4 million ceiling-priced, unfinalized contract to provide persistent UAV services from land bases on the Afghan front.

Work will be performed in Bingen, WA (65%) and St. Louis, MO (35%), and is expected to be complete in December 2009. Contract funds in the amount of $22.7 million will expire at the end of the current fiscal year. This contract was not competitively procured, pursuant to FAR(Federal Acquisition Regulations) 6.302-2 (N00019-09-C-0050).

April 9/09: Maersk Alabama rescue. The US Navy releases some stills from videos of the Maersk Alabama’s 28-foot closed lifeboat, taken by ScanEagle UAVs. The hostage incident ended a couple of days later, when Cmdr. Frank X. Castellano of the USS Bainbridge [DDG-96] ordered Navy sharpshooters to kill the Somali pirates who were holding Capt. Richard Phillips hostage. Photo 1 | Photo 2 | Photo 3.

Maersk Alabama

April 6-12/09: During this week, ScanEagle UAVs flew their 150,000th hour in service with the U.S. Marine Expeditionary Forces, U.S. Navy, U.S. Special Operations Command, Australian Army and Canadian Forces. Boeing release.

April 6/09: Insitu receives an award to provide “small unmanned aerial vehicle (SUAV) services” to support the Canadian Forces in Afghanistan, and elsewhere. See also Nov 6/08 entry. The initial contract is worth US$ 30 million, with options for another US$ 31 million.

As part of the Request for Proposal, Insitu Inc. must provide 100% industrial and regional offset benefits. Its association with Boeing, which has substantial Canadian operations, should make that easy. Canadian government.

Canada

April 1/09: Boeing subsidiary Insitu, Inc. in Bingen, WA received a $20.9 million firm-fixed-price contract to supply ScanEagle hardware for 4 operational sites, 3 spare/operational float packages, and critical spares kits in support of the missions in Iraq and Afghanistan.

Work will be performed in Bingen, WA, and is expected to be complete in July 2009. This contract was not competitively procured, pursuant to FAR 6.302-2 (N00019-09-C-0005).

March 16/09: Australia – AWACS compatibility. Boeing’s two-fer. Australia’s Project JP129 failure has created an opening for Boeing’s ScanEagle UAV, but its flagship “Wedgetail” E-737 AWACS faces questions. Boeing responded by linking 2 birds with one datalink: a live demonstration in which a not-yet-delivered Wedgetail aircraft flying over Washington State, USA controlled and received sensor data from 3 ScanEagle UAVs.

The 3 ScanEagles were launched from Boeing’s Boardman Test Facility in eastern Oregon, approximately 120 miles/ 190 km away from the airborne Wedgetail. Using the company’s UAS battle-management software, airborne operators issued NATO-standard sensor and air-vehicle commands via a UHF satellite communication link and ground-station relay. Operators tasked the UAVs with area search, reconnaissance, point surveillance and targeting, while the UAVs sent back real-time video imagery of ground targets.

Boeing will conduct a follow-on demonstration for the Australian government in early May 2009 at RAAF Base Williamtown in New South Wales. A Wedgetail will take control of ScanEagles operated by Boeing Defence Australia personnel at Woomera Test Facility in South Australia, approximately 1,080 miles/ 1,730 km from Williamtown.

March 2/09: Singapore. Boeing announces that Singapore has been putting their ScanEagle UAV through ship-based trials, including flight from the helicopter decks of an LST amphibious support ship and a frigate. Boeing Defence Australia provided a complete maritime ScanEagle system for the successful trials, including a ground control station, communication links, launcher and SkyHook recovery system. They were complemented by a Boeing/ Insitu support team that was deployed to Singapore.

Jan 21/09: EnerLinks datalink. Viasat subsidiary Enerdyne Technologies Inc. signs an agreement with Insitu Inc. to supply its EnerLinksII DVA digital data link technology for use in the ScanEagle UAV. The EnerLinksII DVA is a small 3″ x 5″ x 1″ module that’s placed between the ScanEagle’s sensors and the RF transmitter, using less than 8 watts and weighing under 0.5 pounds.

The concept of a DVA (Digital Video over Analog) system involves simple conversion of older FM analog video links to encrypted digital links, without replacing any of the RF equipment in either the aircraft or the ground. EnerLinksII’s improved digital performance improves both UAV video link range and bandwidth use by a factor of 4, and can transmit 2 Mbps of IP data simultaneously with compressed FMV (Full Motion Video). Features include H.264 compression, IP multiplexing, AES encryption, FEC coding, and modulation waveshaping.

Jan 7/09: Boeing subsidiary Insitu announces that its ScanEagle unmanned aircraft system has just completed its 1,500th shipboard sortie in service with the U.S. Navy.

2008

US Navy win; US SOCOM, Canada place initial orders; Australian subsidiary; Shot locator, SWIR camera variants; NanoSAR.

ScanEagle returns
(click to view full)

Nov 26/08: Sensors – shot locator. The US Office of Naval Research and Naval Surface Warfare Center Dahlgren Division discuss a Navy Expeditionary Overwatch (NEO) program exercise, which involved US Navy Expeditionary Combat Command (NECC) sailors deploying a ScanEagle UAV, a manned Humvee with “Gunslinger” shot location and counterfire system, and an unmanned surface vehicle (USV) on a successful mission to detect and engage fictional insurgents over a 10 square mile radius.

The Gunslinger Humvee’s remote-control gun is operated by a gunner who sits at a control panel in the back seat. The Mk 45 weapons system is hooked up to video and infrared cameras connected to a set of sensors designed to detect gunfire, including a device that watches for muzzle flashes and listens for gunshots. It then points the remote-controlled weapons system on the Hummer’s roof at the source of fire.

At the Potomac River NEO demonstration, warfighters in the Humvee used the Gunslinger’s acoustic detection package and infrared sensors to determine the location of hostile fire and automatically move the weapon in the direction of the fire for friendly force response. The 36-foot-long semi-autonomous USV was also equipped with a Gunslinger payload and a range of sensors and communications systems. US Navy release | The Register re: Gunslinger..

Nov 12/08: Boeing receives a $65 million estimated value modification to a previously awarded indefinite delivery indefinite quantity “Interim UAS” contract, exercising an option for “persistent unmanned aerial system intelligence, surveillance, reconnaissance services in support of Global War on Terror, Operation Iraqi Freedom and Operation Enduring Freedom sea-based deployments and land-based detachments.” That’s milspeak for contractor operation and maintenance of ScanEagle UAVs in Iraq and Afghanistan.

Work will be performed in Bingen, WA (65%); and St. Louis, MO (35%), and is expected to be complete in November 2009. Contract funds in the amount of $6.8 million will expire at the end of the current fiscal year (N00019-08-D-0013).

Nov 6/08: Canada. Canada issues a MERX solicitation (W8486-09MGSL/A) for a leased small UAV service. Canada is already leasing ScanEagle UAVs that can fulfill the MERX requirements: 90% operational availability, 12 hours on station, ability to gather and transmit high quality imagery from a distance of 50km.

Aug 6/08: Sensors – SWIR. Boeing and Goodrich Corporation announce that they have successfully flight-tested a ScanEagle unmanned aircraft equipped for the first time with a short-wave infrared (SWIR) camera. A SWIR camera can see more effectively in fog, rain or when little or no heat is radiated, which makes it especially useful for maritime surveillance. Boeing release.

July 22/08: Merger. Boeing buys its partner Insitu, which will operate as a wholly owned subsidiary of Boeing’s Integrated Defense Systems’ Military Aircraft division. Subsequent reports place the price at around $400 million:

“Insitu’s key technologies and advanced capabilities in rapid prototyping and manufacturing are driving its revenue to an anticipated $150 million this year, 70 percent higher than in 2007, and have it well positioned for the future… Terms of the cash transaction were not disclosed. This transaction, anticipated to close by the end of September following regulatory approvals, does not affect Boeing’s financial guidance.”

Insitu, Inc. retained investment bankers Houlihan Lokey for the acquisition, and terms of the sale were not disclosed. Insitu’s investors are led by Battery Ventures, Second Avenue Partners, and Pteranodon Ventures. Boeing | Insitu | Wall Street Journal (subscription reqd).

Boeing buyout

June 2/08: Boeing received an estimated $65 million indefinite-delivery/ indefinite-quantity contract to “provide persistent Unmanned Aerial Vehicle Intelligence, Surveillance, Reconnaissance services supporting the Global War on Terror, Operation Iraqi Freedom and Operation Enduring Freedom sea-based deployments and land-based detachments.” The language above refers to their ScanEagle operation services, which are undertaken in cooperation with Insitu.

Work will be performed in Bingen, WA, (65%); and St. Louis, MO (35%) and is expected to be complete in May 2009. Contract funds in the amount of $7 million will expire at the end of the current fiscal year. This contract was competitively procured by electronic request for proposals, with 2 offers received (N00019-08-D-0013). Boeing release | Insitu copy.

Interim UAS win

May 28/08: NanoSAR. The NanoSAR test program continues, as Boeing, ImSAR and Insitu Inc. achieve real-time processing of Synthetic Aperture Radar (SAR) data aboard a ScanEagle UAV which is also equipped with a standard inertially stabilized electro-optical (EO) camera. The tests marked the first time SAR and EO capabilities have flown together on such a small, lightweight platform, and involved real-time SAR processing with streaming radar images displayed on the ground station. Creating real-time images onboard ScanEagle eliminates the requirement of either processing imagery on the ground after flight or using high-speed data links to a ground station. Insitu release.

May 26/08: Australia. Insitu, Inc.partners with the Queensland state government in Australia to announce the formation of its wholly owned subsidiary, Insitu Pacific Pty Ltd. The release adds that:

“Insitu, along with Boeing Australia, is proud to be part of the experienced team that has delivered more than 13,000 surveillance and reconnaissance flight hours to help protect Australian troops in Iraq and Afghanistan.”

Insitu Pacific

April 29/08: Insitu announces that the ScanEagle has now surpassed 50,000 combat flight hours with the U.S. Marine Expeditionary Forces (MEF) in Iraq and 1,000 shipboard recoveries with the U.S. Navy.

April 22/08: Testing. Insitu announces that it has flown Heavy Fuel Engine (HFE) equipped ScanEagles in Iraq, in cooperation with the US Navy. Heavy fuel refers to the kerosene-based fuel used in diesel and/or jet aircraft engines such as JP5, JP8, or Jet-A. ScanEagles flying in Iraq are using naval JP5 fuel, which is designed to be safer aboard ships.

The effort involved Insitu, Boeing, and Sonex Research Inc. in Annapolis, MD. The effort took 2 years of development and included over 2000 hours of testing, including a new ScanEagle flight endurance mark of 28 hours, 44 minutes using JP5. Insitu release.

April 18/08: Recall the Feb 7/08 launches from a Navy SEAL MkV boat, and demonstration by AFSOC at Hurlburt Field, FL.

Insitu Group, Inc., of Bingen, WA receives a firm-fixed price contract with a not-to-exceed value of $24 million for unmanned aircraft system information gathering, target surveillance, and reconnaissance services in support of U.S. Special Operations Command. The work will be performed in Bingen, WA and 3 other undisclosed locations using FY 2008 operations and maintenance funds (H92222-08-C-0022).

US SOCOM

March 25/08: Canada stands up an SUAV (Small Unmanned Aerial Vehicle) Troop. After live flight training in New Mexico, SUAV Troop deploys to Afghanistan to operate leased ScanEagles, which are referred to as “Interim SUAV”. Source: CASR.

Canada

Feb 7/08: US AFSOC. Air Force Special Operations Command, as the lead command for small unmanned aircraft systems, highlights the capabilities of the Scan Eagle during a demonstration at the Eglin Air Force Base test range. AFSOC has been training with the 820th Security Forces Group from Moody Air Force Base, GA since September 2007, to employ the system. AFSOC release.

Feb 7/08: USN SEALs. A Scan Eagle unmanned aerial vehicle is launched from a MK V naval special warfare boat off the coast of San Clemente Island. This is the first time a Scan Eagle, used for various applications such as intelligence gathering and battle damage assessment, has been launched from this kind of platform. Insitu photo links.

Jan 14/08: USN’s Interim UAS. Jane’s reports that:

“Industry rivals are waiting to hear if they have ousted the Boeing/Insitu ScanEagle unmanned aerial vehicle (UAV) from its role as provider of intelligence, surveillance and reconnaissance (ISR) support for US Navy ships at sea. A decision on the interim UAS contract, which will provide ISR imagery services to warships and to the US Marine Corps into the next decade, is expected in late January or early February 2008.”

Other competitors are thought to include AAI Corporation’s long-endurance Mk 4 Aerosonde, Aurora Flight Sciences’ vertical take-off and landing GoldenEye 80, BAE Systems’ Skylynx II, MTC Technologies’ Spyhawk T-16 and Raytheon/Swift Engineering’s Killer Bee. Insitu link.

UPDATE: the decision took until June 2008, and ScanEagle won.

NanoSAR on ScanEagle
(click to view full)

Jan 7/08: Sensors – NanoSAR. Boeing, Insitu, and ImSAR conduct a successful flight-test for the tiny NanoSAR Synthetic Aperture Radar aboard a ScanEagle UAV. The NanoSAR is a 2-pound system about the size of a shoebox, which is a couple orders of magnitude lighter than most SAR systems. As a sign of the times, “import to Google Earth” is an option for the system.

As a comparison, the I-Master SAR aboard Britain’s new Watchkeeper UAVs is considered small at 65 pounds. SAR radars aren’t an all-purpose replacement for ScanEagle’s existing electro-optical sensors, but they’re a very important complement because of their ability to see through fog, dust, et. al. The issue for NanoSAR will be providing acceptable resolution and coverage despite its tiny size.

Targets for the 1.5 hour test flight at the Boardman, OR test range included vehicles, structures and corner reflectors. Data collection worked as planned, and SAR imagery was later created on the ground. The next step in flight testing will be to create imagery aboard the UA in real time. Boeing release | ImSAR on NanoSAR | Insitu re: NanoSAR.

Additional Readings

• Insitu – ScanEagle System. ScanEagle is closely derived from the “Insight” base platform.

• Insitu – ScanEagle Imagers.

• Insitu – ScanEagle 2 The Limit.

News & Views

• Smithsonian Magazine, via WayBack (June 2011) – Drones are Ready for Takeoff.

• DoD Buzz, via WayBack (Oct 6/09) – FAA Acts or Drones Stop Flying. “Army drones will have to curtail training and operational flights by fiscal 2012 in the United States unless the FAA approves some form of UAS deconfliction, a top Army UAS official says.”

• IEEE Spectrum, via WayBack (January 2009) – Winner: Radio Eye in the Sky. Covers the concept of ultra-small SAR surface-looking radars.

• DID (June 12/07) – Boeing Operating ScanEagle UAVs for Australia. The rent-a-UAV concept gains another customer.

• Flight International, via WayBack (June 6/07) – Evergreen alliance with Insitu for civil UAV market. “Semi-civil” might be a better way of putting it. They will use Insitu’s Insight platform.

• DID (Jan 26/07) – ScanEagle + ShotSpotter = Sniper Spotter.

• Inc. Magazine, via WayBack (June 1/06) – How I Did It: Steven Sliwa, CEO and president, The Insitu Group

• DID (June 8/06) – ScanEagle to Detect Biological Agents. The program is called ScanEagle BCAS.

Barak-8 concept
(click to view full)

Over a development timeline measured in decades, India’s indigenous “Akash” and “Trishul” programs for surface to air missiles have failed to inspire full confidence. Trishul was eventually canceled entirely. Akash had a a long, difficult development period, but seems to have found customer acceptance and a solid niche in the rugged terrain of the northeast. India still needed longer-range advanced SAMs to equip its navy and army, however, and decided to try to duplicate the success of the partnership model that had fielded the excellent Indo-Russian PJ-10 BrahMos supersonic cruise missile.

In February 2006, therefore, Israel and India signed a joint development agreement to create a new Barak-NG medium shipborne air defense missile, as an evolution of the Barak-1 system in service with both navies. In July 2007 the counterpart MR-SAM project began moving forward, aiming to develop a medium range SAM for use with India’s land forces. Both missiles would now be called Barak-8. In between, “India to Buy Israeli “SPYDER” Mobile Air Defense System” covered India’s move to begin buying mobile, short-range surface-to-air missile (SAM) systems for its army, based on the Python and Derby air-to-air missiles in service with its air force and naval aircraft. These projects offer India a way forward to address its critical air defense weaknesses, and upgrade “protection of vital and strategic ground assets and area air defence.” This DID FOCUS article will cover the Barak-8 and closely related programs in India, Israel, and beyond.

The Barak, and Barak-8 Genesis: Barak-1

Barak Components
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Barak is a supersonic, vertically-launched short range air defense system, with an operational range of about 10 km/ 6 miles. That pushes it past the standard ranges of shoulder-launched options with naval counterparts, like the MBDA Mistral/SIMBAD or Saab Boofors’ RBS-70, but short of other small vertical launch options like the RIM-162 Evolved Sea Sparrow. Its closest western competitors on the international market are probably Raytheon’s horizontally-fired Amero-German RIM-116 Rolling Airframe Missile, and MBDA’s flexible Crotale VT-1/NG. Key attributes include a compact 8-cell vertical launching system that weighs just 1,700 kg, coupled with an equally compact 1,300 kg fire control system. This makes it easier to install in small ships, and to retrofit into older vessels.

Barak-1 reportedly in service with at Israel, Chile, India, Singapore, and Venezuela.

Barak launch
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India bought over $300 million worth of these missiles as a substitute for the indigenous but long-delayed Trishul (“Trident”) missile project, and Barak systems now equip India’s lone aircraft carrier INS Viraat, all 6 Project 16/16A Godavari/ Brahmaputra Class 3,850t frigates, 2 of 6 Rajput Class 4,974t destroyers, and the 3 new 6,200t Shivalik Class frigates. Current missile stocks aren’t adequate to cover that, and readiness requires regular training launches against live targets. Barak-1 missiles are also supposed to be part of upgrades to India’s 3 Delhi Class 6,200t destroyers, in order to remove the hole created by the Russian SA-N-7C ‘Gollum’ air defense missile system’s limited firing arc.

Barak-1 missiles are also supposed to be part of upgrades to India’s 3 Delhi Class 6,200t destroyers, in order to fix the SA-N-7C ‘Gollum’ air defense missile’s limited firing arc. The missile’s fast response time, effectiveness against missile threats, and compact size are considerable assets, but they are currently offset somewhat by its short range.

Next-Gen: Barak-8

Barak 8 display
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The Navy’s Barak-NG/ LR-SAM project aimed to give India’s naval defenses a much longer reach, with the intention of eventually making it India’s primary naval SAM. The project was later renamed Barak 8, and aims to deliver 60-70 km/ up to 42 mile range, thanks to a dual-pulse solid rocket motor whose second “pulse” fires as the missile approaches its target. This ensures that the missile isn’t just coasting in the final stages, giving it more than one chance at a fast, maneuvering target.

The missile’s most important feature may be its active seeker. Instead of forcing its ship or land-based radar to “paint”/illuminate its target at all times, the Barak 8 can be left alone once it is close to its target. This is an excellent approach for dealing with saturation attacks using older ship radars, which can track many targets but illuminate just a few. It’s also very useful for land-based systems, which will survive longer against enemy anti-radar missiles (ARMs) if they can turn themselves on and off to confuse enemy seekers, without worrying that they will lose all of their effectiveness.

That kind of performance vaults the Barak 8 past widespread options like the RIM-162 ESSM, or entries like VL-MICA on land. Though the Barak-8 may compete globally with those systems, a better comparison would be naval missiles like Raytheon’s SM-2 Block IIIA and MBDA’s Aster-15, or land-based options like the Patriot. The Barak 8’s active seeker would even give it a performance advantage over the SM-2, and corresponds more closely to the SM-6 currently in development.

The naval Barak-8 reportedly maintains its principle of using compact launchers and systems. Its ancillary capabilities will always depend on the radar and combat system aboard its ship.

One wild card is the Barak’s potential use in a point defense role against ballistic missiles, a role that can be played by some of its more advanced competitors on land or sea. This capability is implied in the land-based system’s name, but hasn’t been discussed publicly, or validated in publicly announced tests.

The land-based Barak 8 Air and Missile Defense (AMD) system includes several components:

• RAFAEL supplies the Barak-8 interceptor missile, which remains vertically launched.

• The battle management, command, control, communication and intelligence center (BMC4I) is produced by the MBT Division of IAI’s Missiles, Systems, and Space Group; it offers both stand alone operation for a single fire unit, and joint task force coordination (JTC).

• IAI ELTA Systems Ltd. supplies the Land-Based Multi-Function Surveillance, Track & Guidance Radar (LB-MF-STAR), a rotating S-band digital Active Electronic Steering Array (AESA) Radar System that can deliver an accurate, high quality arena situation picture, and extract low radar cross section targets like stealthy cruise missiles, even in the toughest environmental conditions. The naval MF-STAR is expected to be part of Israel’s next-generation missile frigates.

In Israel, the Barak-8 is slated to equip its next-generation frigates, and may find its way to other roles. India expects to field the missiles on land and sea.

Beyond those 2 countries, export prospects beckon for a missile that may offer a value-priced naval alternative to Raytheon’s Standard-2 and MBDA’s Aster-15. According to Defense News, the Barak-8 project features funding from American military aid dollars, as well as Indian cooperation and private/governmental funding in Israel. An Israeli source, on the other hand, has told DID that the USA has no claim on the Barak-8’s intellectual property. DID has been unable to verify he exact situation; but if the USA has no IP or significant American-made components in the Barak AMD system, it would have implications for both procurement funding sources and export policy.

India’s Barak Programs The Navy: LR-SAM

Engagement profile
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India has 2 different programs that could use the new longer-range Barak missile. The naval Barak-NG, or LR-SAM deal, was the first. Signed in 2006, it’s worth INR 26.06 billion (about $591 million at then-conversion) as of December 2009.

India’s Navy has decided as a matter of policy that it will only mount medium-long range surface-to-air missile systems on future warships, as opposed to depending on short range systems that might protect a ship, but don’t offer layered defense for the rest of the fleet. This was an early sign of its transition to a more of a “blue water” navy that can reach into high-threat areas, and a logical complement to India’s establishment of a serious carrier force beginning with INS Vikramaditya (ex Admiral Gorshkov).

Hence the 2006 Barak-NG naval agreement, which gives India an upgraded version of a familiar system, extends India’s technological capabilities, fosters economic ties and integration at sub-component levels, and helps the Israelis build a new system that meets some of their own emerging requirements. The new system would reportedly have a range of 50-60 km.

Making that happen required some loosening of bureaucratic constraints on India’s defense industry. Based on projections of need and the high cost of air defense systems, India’s Ministry of Defence began initiatives under which Indian state-owned agencies can forge joint co-development and co-production ventures with foreign companies. The rationale is that under these partnerships, much of the underlying technology will remain in India. Israel has risen to become one of India’s largest defense industry partners, and may be on its way to surpassing Russia as India’s largest partner.

That rise, India’s previous positive experiences with Barak, and the opportunity to help develop new technologies instead of buying them, all led India toward Israel for its next-generation naval SAM partnership.

Israel Aerospace Industries will be the key partner, and will contribute most of the applicable technology, just as Russia did for the BrahMos by offering its SS-N-26 Oniks missile as the base platform. 2011 Barak-8 materials show Indian firms contributing the dual-pulse rocket motor, associated motor arming/safing mechanisms, and the pneumatic actuation system. On the other hand, India Defence reports that IAI and its Israeli partners have agreed to transfer all relevant technologies and manufacturing capabilities to India.

The LR-SAM project is now slated for completion by December 2015, which would be about a decade from its 2005 project approval to fielding. Israel will be ahead of that schedule, as they began steps to field Barak-8 in their navy in mid-2013.

Land-Based: MR-SAM

SA-3
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The Barak-8’s follow-on project involves a land-based system, intended to replace old Russian systems. Most reports place MR-SAM’s desired capabilities at 70 km/ 42 mile range effective range, with 360 degree coverage, plus the ability to engage multiple targets simultaneously. As The Times of India put it, in 2007:

“The project is crucial because, as highlighted by TOI earlier, there are still “many gaping holes” in India’s radar network and the armed forces only have near-obsolete air defence units like Russian Pechora [DID: upgraded SA-3], OSA-AK [DID: SA-8B, scheduled for interim upgrades], and Igla [DID: SA-16 shoulder-fired] missile systems.

Sources peg the MR-SAM project as an extension of the ongoing DRDO-Israel Aerospace Industries (IAI) project, launched in January 2006 at a cost of $480 million, to develop a supersonic 60-km Barak-NG (new-generation) missile defence system for Navy.”

India Defence and the Israeli newspaper Ha’aretz also reported that MR-SAM would be an extension of work done on the Barak-NG deal, and this seems to be the general consensus.

SA-8
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The DRDO Defence Research and Development Organisation (DRDO) will be the ‘prime developer’ for the MR-SAM project, which will reportedly have a Rs 2,300 crore (INR 23 billion, about $445 million at signing in 2009) indigenous component within an estimated Rs 10,075 crore (INR 100.75 billion, about $1.95 billion at signing) total. The 4-5 year project aims to provide India’s military with 9 advanced air defense squadrons, each with 2 MR-SAM firing units. Each MR-SAM unit, in turn, would consist of a command and control center, an acquisition radar, a guidance radar, and 3 launchers with 8 missiles each.

MR-SAM’s total would therefore be 10 C2 centers, 18 acquisition radars, 18 guidance radars, and 54 launchers, armed with 432 ready-to-fire missiles. Some reports have placed total missile orders as high as 2,000, which would add a significant reserve stockpile to replenish missiles in any conflict.

Indian sources estimated a 4-year, $300 million System Design & Development phase to develop unique system elements, and produce an initial tranche of the land-based missiles. As of its approval by the Cabinet Committee on Security in July 2007, MR-SAM surpassed the BrahMos project in size, and may be the largest joint defense development project ever undertaken between India and any other country.

The MR-SAM project reportedly has a “probable date of completion” by August 2016, which would be around 7 years from its 2009 approval.

Contracts & Key Events 2014 – 2018

In service in Israel; DRDO challenges; Successful intercept test.

Empty
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July 4/18: New family member Israel Aerospace Industries (IAI) is adding a new missile to its Barak family. The Barak-MX is a modular and scalable networked air/missile defense system that links various sensors, launchers and Barak effectors in a single architecture that can be scoped and optimized to meet specific customer mission requirements. Barak MX is essentially a building block solution. It enables one to retain the central C2 capability but adds longer-range air defense sensors and Barak effectors to scale up the system. The Barak Battle Management Center (BMC), which creates and manages a unified multi-senor aerial picture, coordinates the force operation networks and manages the launch arrays. Barak BMC is available in mobile, transportable and stationary versions. The interceptors are vertically launched and support 360° coverage, quick reactions, short minimal ranges and active high-end RF seekers for targets with low radar cross sections and high maneuverability.

March 30/18: More missiles please Israel Aerospace Industries and Rafael Advanced Defense Systems have been contracted by the Indian Ministry of Defense to supply additional Barak-1 short-range surface-to-air missiles. The contract is valued at $70.5 million and includes 131 Barak-1 shipborne, point defense missiles to be delivered to the Indian Navy. The Barak-1 is a supersonic, vertically-launched short range air defense system, with an operational range of about 6 miles. That pushes it past the standard ranges of shoulder-launched options with naval counterparts, like the MBDA Mistral/SIMBAD or Saab Boofors’ RBS-70, but short of other small vertical launch options like the RIM-162 Evolved Sea Sparrow. Its closest western competitor on the international market is probably Raytheon’s horizontally-fired Amero-German RIM-116 Rolling Airframe Missile, and MBDA’s flexible Crotale VT-1/NG. Key attributes include a compact 8-cell vertical launching system that weighs just 1,700 kg, coupled with an equally compact 1,300 kg fire control system. This makes it easier to install in small ships, and to retrofit into older vessels.

May 22/17: Israel Aerospace Industries (IAI) has been awarded an additional contract by the Indian government to supply air and defense missile systems for four ships of the Indian navy. Valued at an estimated $630 million, the agreement will include local state-owned firm Bharat Electronics Ltd, who will serve as the main contractor on the project under New Delhi’s “Make in India” initiative. The deal follows a $2 billion one signed with IAI last month to supply India’s army and navy with missile defense systems. The Barak-8 system is a joint development effort between IAI, India’sDefence Research & Development Organisation (DRDO), Israel’s Administration for the Development of Weapons and Technological Infrastructure, Elta Systems, and Rafael, while Bharat produce the system’s missiles.

April 9/17: The Indian government has given the go ahead for the $1.8 billion purchase of the Medium Range Surface-to-Air Missile (MRSAM) from Israel Aerospace Industries (IAI). A land-based version of the Barak-8, the MRSAM was developed by IAI and India’s Defense Research and Development Organization (DRDO) in collaboration with Rafael and IAI/Elta, and worked with various Indian companies including BEL, L&T, BDL and other private vendors, and will be operated by the Indian Army. The company will also supply additional LRSAM air & missile defense systems for the first build in India Indian aircraft carrier.

March 2/17: Israel and India will co-develop and produce a medium-range surface-to-air missile for the Indian Army. Contracts for the deal are expected to be awarded later this month with the value of the project estimated at over $2.5 billion. Known as the MRSAM, development of the missile will be undertaken jointly by India’s DRDO, Israel Aerospace Industries (IAI), and will be produced by state-owned Bharat Dynamics Limited (BDL) in partnership with other state-owned and private defense companies. It does, however, remain unclear who will own the Intellectual Property Right (IPR) for the missile as well as the ownership of the data package for the technology.

July 5/16: India successfully tested the land version of its Barak-8 anti-air missile twice on Friday at India’s Integrated Test Range. Conducted by a team from India’s DRDO and Israel’s IAI, naval versions have already been fitted and tested aboard Indian Navy warships. The long-range rocket can identify and hit an air target within a range of 70 kilometers, or some 43.5 miles.

January 4/16: India has completed its first naval test of the Barak-8 long range surface to air missile (LRSAM). Developed jointly between the Indian Defence Research & Development Organization (DRDO) and IAI Israel, the recent test follows November’s successful testing on board an Israeli naval platform. The maiden firing consisted of the missile intercepting aerial targets at extended ranges up to 70km. Apart from the missile, the system includes a Multi Functional Surveillance and Threat Alert Radar (MF STAR) for detection, tracking and guidance of the missile. When completed, the missiles will be fitted on board all Kolkata class destroyers and major warships in the Indian Navy.

November 30/15: The Israeli Navy has announced the successful first test of the Barak-8 air defense system. The interceptor missile was launched from a Sa’ar-5 Corvette against a UAV target representing a threat against a ship at sea. The system has been jointly developed with India and aims to cater for the long range missile defence for both countries with India also planning to test the system before the end of the year. It is hoped that the system will have reached initial operational capability within the next two years.

November 16/15: India’s Barak-8 will be test-fired between now and the end of the year after it was announced that preparations are being made on board the INS Kolkata for the test which the Navy hope to have installed on all future warships and retrofitted on its current Kolkata class destroyers.

Mar 2/15: Indian interest renewed for MRSAM. Defense News reports that an Indian Defence Ministry official confirmed that the medium-range (MRSAM) variant is a go for joint development with Israel, with an initial expected order of $1.5 billion. Rafale and IAI would work with Indian firms Bharat Dynamics Tata Power SED and Larsen & Toubro.

Nov 10/14: Testing. A successful test of the Barak-8 “Air & Missile Defense System” acquires an incoming target drone using the system’s radar, fired the missile to an interception zone, and had the missile successfully acquire and kill the target using its own seeker. Indian officials were there, including DRDO chief Dr. Avinash Chander, and Israeli and Indian releases both pronounced their satisfaction with all aspects of test performance.

The Israelis already have the missile deployed, so they’re happy. What the releases didn’t say, is whether DRDO’s rocket booster was used in the test (Aug 14/14). It’s likely that they did, and the next step is warship trials for India. DRDO hopes to begin deliveries by the end of 2015. Sources: IAI, “IAI Successfully Tested the Barak-8 Air & Missile Defense System” | India MoD, “Successful Flight Testing of LR SAM Missile”.

Aug 14/14: INS Kolkata. Media reports indicate that India’s new 7,500t air defense destroyer INS Kolkata, which is set to be commissioned on Aug 16/14, will be armed with Barak-1 missiles until the Barak-8s arrive. The article doesn’t explain whether the vertical launchers are compatible, or whether the Barak-1 has been integrated yet with the IAI Elta MF-STAR active array radar that equips the new destroyer class. With respect to the Barak-8s:

“The missile is ready, but [DRDO’s] boosters to propel the missile [upon launch]… have failed.”

Hence the importance of the forthcoming tests, if DRDO can get its rocket boosters to Israel (q.v. Aug 11/14). Meanwhile, India is likely to have 3 Kolkata Class destroyers ready to go by the time they’re done testing the Indian LR-SAM. They’ll need to do something in the interim. Sources: oneindia News, “INS Kolkata, the Biggest Naval Destroyer, is the weakest link in Defence”.

Aug 11/14: Force majeure. India’s Business Standard explains how the recent battles in the Gaza Strip are affecting the LR-SAM program, which was already 2 years late:

“The DRDO confirms that the rockets, filled with highly combustible propellant, were despatched [sic] on a commercial airline, Korean Air, for trials in Israel. After the rocket motors reached Seoul – Korean Air’s global hub, from where they were to be routed onwards to Tel Aviv – the launch of Israeli airstrikes on Gaza on July 8 caused Korean Air to cancel all flights to Tel Aviv…. Consequently, a crucial and secret sub-system of the world’s most advanced anti-missile defence system has been languishing in a Korean Air warehouse in Seoul.”

Actually, the cancellation came on July 20/14, after Hamas rockets struck near the airport. Note that Iron Dome is programmed to ignore rockets that don’t threaten its priority areas, and many airlines have already reassessed the situation and resumed flights. Korean Air, on the other hand, won’t begin flights to Tel Aviv again until Aug 28/14. India’s DRDO is “monitoring the situation,” and could choose to request help from India’s Air Force, whose IL-76 heavy jet transports could pick up and deliver the missiles.

Once the Premier Explosives Ltd. rocket motors are delivered, they will be integrated with the IAI-built front section, and then undergo full homing trials at an Israeli range. After that, warship trials will begin, and DRDO hopes to begin deliveries by the end of 2015. By then, 3 new Project 15A Kolkata Class destroyers, and the aircraft carrier INS Vikramaditya, will all be waiting to receive their primary air defense weapons. Sources: India’s Business Standard, “Indian missiles languish in South Korea due to Gaza conflict” | Israel’s Globes, “Korean Air cancels all Israel flights until August 28”.

May 13/14: Israel. A Sa’ar 5 Eilat Class corvette has already been outfitted with IAI Elta’s MF-STAR S-Band AESA radar, and Barak-8 air defense missiles. The other 2 are set to follow.

The MF-STAR, or “Adir,” has been bought by India for its new Project 15A Kolkata Class destroyers. They are also expected to employ the Barak-8. Sources: The Jerusalem Post, “The Israel Navy is quietly enhancing its capabilities for precision, long-range missiles”.

2010 – 2013

Barak-8 development & testing continues; Azerbaijan sale?; Akash missile expands Indian footprint; Indian RFI for immediate MR-SAM option.

Barak-8 concept
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Dec 23/13: DAC OK. AK Antony and the Defence Acquisitions Council (DAC) clear the Indian Navy’s intent to buy 262 more Barak-1 missiles, in order to replenish their fast-dwindling stocks. The paper adds:

“The naval LR-SAM, approved in December 2005, is now slated for completion by December 2015. The MR-SAM project, sanctioned in February 2009, in turn, has a “probable date of completion” by August 2016.”

Read “Indian Naval Air Defenses: Another Avoidable Crisis” for full coverage.

Dec 17/13: Update. India’s Ministry of Defense provides updates regarding a number of DRDO projects, including LR-SAM. The development program’s original delivery target was May 2011, but the Probable Date of Completion is now December 2015: 4 1/2 years late, and well after it becomes fully operational in Israel. Sources: India MoD, “DRDO Projects”.

Nov 14/13: Stall. India’s LR-SAM and MR-SAM projects are stalled, even as Israel moves to deploy the Barak-8 at sea. The Barak-8 was supposed to be delivered for LR-SAM by 2012, and is supposed to go to the IAF as MR-SAM by 2017. Unfortunately, drawings for components aren’t enough to let Indian firms produce them properly, and:

“Frankly speaking, right now, not much is going on in the joint venture due to various issues between the two sides. Expecting Israel to share its technology with India is unfair. But such things should have been clarified before the joint venture was entered into,” said an official…. DRDO officials are also attributing the delay to a complicated and long procedure involving shuttling between India and Israel for various stages of development of a system etc… [DRDO] also reportedly found itself helpless on problems in propulsion system and other related issues while a significant number of parts or systems are yet to be tested following a delay in manufacturing.”

So, to sum up: contract terms that didn’t provide clear mechanisms to enable Indian production from the baseline they’re actually at, Indian DRDO bureaucracy sitting in the way of development and not delivering on key items, and manufacturing issues that have created Indian testing delays. While Israel fields the missile. DRDO Director General Avinash Chander wouldn’t comment on LR-SAM, which is already late, but he said MR-SAM remained on schedule for 2017. Sources: Times of India, “India-Israel joint venture to manufacture missiles fails to take off”.

July 31/13: Israeli installation. India may give the Barak-8 LR-SAM’s date of probable completion as 2015, but Israel intends to have the missile installed on its 3 Sa’ar 5 Eilat Class corvettes before the end of 2013.

The move is reportedly being made in response to Syria’s deployment of SS-N-26/ P-800 Yakhont supersonic anti-ship missiles, with a range of up to 180 miles. Some of the missiles reportedly survived a major Israeli strike, and Hezbollah’s leading role in the Syrian Civil War sharpens concerns about a transfer to Iran’s 21st-century Condor Legion. Incoming supersonic missiles will compress the Barak-8’s range, but its 60-70 km base range remains a large improvement over the Barak-1’s base 10-12 km. Arming the Eilat Class with the navy’s first wide-area air defense technology is a good backup move while Israel looks to determine the true state of Syria’s P-800 missiles, and if necessary, to target them for a final strike. Israel HaYom | UPI | China’s Xinhua.

Israel deploying Barak-8

March 18/13: An India MoD release offers a list of late DRDO projects, along with a voluminous list of excuses. Credit of some kind is due for not using “the dog ate our blueprints,” but every other issue one normally expects in projects of this nature can be found. LR-SAM is one of the listed projects, and its Probable Date of Completion has slipped from May 2011 to December 2015.

Dec 18/12: LR-SAM. India’s MoD offers quick year-end reviews for a number of key programs. With respect to LR-SAM, it says that:

“Control and Navigation Tests (CNT) for LRSAM, a joint development Programme between DRDO and Israel Aerospace Industry (IAI), to develop an Advanced Naval Air Defence System for Indian Navy) were conducted on 16th and 18th July 2012. All Planned mission objectives were fully met in both the tests. The missiles showed good navigation and control performance. DRDO is the Prime Development Agency and IAI the design authority for supply, installation and final acceptance.”

Development was pegged at 5 years under the original 2006 LR-SAM deal, so they’re late. MR-SAM isn’t mentioned, but LR-SAM missile tests are also effectively MR-SAM missile tests.

Dec 5/12: LR-SAM MoU. Israel Aerospace Industries and India’s state-owned Bharat Electronics Ltd. sign a memorandum of understanding (MoU), concerning their cooperation on future LR-SAM ship-defence system projects.

IAI already has a number of arrangements in place with Indian firms. Under this MoU, BEL will function as the Lead Integrator, ultimately taking over DRDO’s role once the missile is developed, and will produce major sub-systems. IAI will continue to act as the system’s Design Authority, and to produce sub-systems as a main sub-contractor of BEL. IAI.

Feb 26/12: Azerbaijan. Israel and Azerbaijan sign a government to government deal for a range of military equipment, including UAVs and “missile defense systems.”

The Caspian Sea’s gas and oil resources are increasing tensions in the region, and Russia’s recent hostility with Georgia has also roiled the waters. From 2008 to the present, SIRPI’s database confirms that Israel has become a significant supplier of military equipment to Azerbaijan, including artillery, UAVs, and anti-tank and anti-ship missiles. Russia and Ukraine are even more significant suppliers, transferring attack helicopters, artillery, missiles, armored vehicles – and long-range S-300 air defense missile systems.

Subsequent reports from SIRPI indicate that this $1.6 billion deal may contain up to 75 Barak-8 missiles, and an EL/M-2080 Green Pine long-range radar. That diversity of long-range systems would complicate planning for an attacker, and offers some insurance. Israel may even get more than just money from this. Depending on that Green Pine radar’s positioning, it should be able to see a long way into Iran’s airspace. Ha’aretz | News.Az.

Azeri deal?

SLAMRAAM test
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June 3/11: Industrial. Livefist shows an India DRDO presentation that helps break down technology responsibilities within the Barak-8. Indian firms will contribute the pneumatic actuator, dual-pulse rocket motor, and motor arming/safing technologies.

April 13/11: MR-SAM gap-filler RFI. IANS reports that India’s MoD has issued a request for information (RFI) from global and domestic missile manufacturers, asking them if they could supply the medium range air defense missile within a short time-frame to the Indian Air Force (IAF), for defense of vital installations. Submitted systems must be capable of all-weather, all-terrain, day/night operation with a 3.5 km altitude ceiling, and able to engage multiple targets that include a range of aerial enemies.

The RFI is ahead of a tender for the purchase of medium-range surface-to-air (MRSAM) missiles, and the emergency buy would reportedly be over and above the 18 MR-SAM units that India is buying from Israel in the 2009 deal. The near-term timeline would appear to disqualify the Barak-8, preventing tri-service acceptance. Obvious Air Force contenders would include India’s own Akash, and offerings from MBDA (VL-MICA), Kongsberg/Raytheon (SLAMRAAM/NASAMS, possibly Patriot PAC-3 as well), Russia (TOR-M2E, SA-20/S-300 PMU2 possible), and IAI/RAFAEL (Spyder MR-SAM variant, complementing the SR-SAM variant India has already ordered).

Akash SAM exhibit
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Aug 9/10: Defence Minister Shri AK Antony updates the status of various missile programs, in a Parliamentary reply to Shri SB Wankhede and Shri AP Shivaji. Trishul and Akash aren’t mentioned at all; the former presumably owing to its cancellation, the latter because it may no longer be a development program. LR-SAM’s ballistic flight trials was undertaken in May 2010. MR-SAM’s preliminary design has been carried out, along with “pre-tender briefing to all prospective vendors.”

Feb 2/10: Akash up, opportunity down. India increases its Akash SAM buy to 1,000, and will deploy them in the rugged terrain of the northeast as SA-3 replacements. The INR 42.79 billion (about $925 million) contract will buy 6 squadrons of Akash medium-range surface-to-air missiles (SAMs) from state-run Bharat Electronics Ltd (BEL). This 750 missile order follows an INR 12.21 billion (about $250 million) order for 2 initial squadrons with 250 missiles total, back in January 2009.

Delivery under this order is expected between 2012-2015, stabilizing Akash as a shorter-range complement to the MR-SAM and affirming the IAF’s confidence. That confidence doesn’t endanger the MR-SAM project, but it removes the expansion possibilities that would have been created by full cancellation, or a limited 2-squadron Akash program. The Hindu | Indian Express | Times of India | Times Now | Bloomberg | India’s Business Times.

2006 – 2009

LR-SAM and MR-SAM deals signed; Budgets; Competition by the back door?

VL-MICA test
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Dec 14/09: Confirmed. Defence Minister Shri AK Antony offers a program update, in a written Parliamentary reply to Shri Asaduddin Owaisi:

“Defence Research Development Organization (DRDO) has undertaken joint development of missiles, Long Range Surface-to-Air Missile (LRSAM) for Indian navy and Medium Range Surface to Air Missile (MRSAM) for Indian Air Force with M/s Israel Aircraft Industries (IAI), Israel. The cost of project for LRSAM is Rs. 2606.02 crore and cost of project for MRSAM is Rs. 10075 crore. Both the missiles being developed are comparable in performance and cost to missiles available in their class in the world market.”

Given conversion rates at contract time, that means $1.95 billion for MR-SAM, and $560.8 million for LR-SAM.

Indian deals & budgets

Nov 9/09: MR-SAM. Reports surface again that Israel and India have signed a deal for the Barak-8 missile system, which appears to be the Army’s MR-SAM project. Indian reports quote an Israel official, who says that India signed a $1.1 billion contract in April 2009, with delivery expected by 2017.

Islamabad’s The Daily Mail claim that the deal is $1.4 billion, and involves 2,000 Barak-8 missiles for land and naval forces. India has significant industrial offset laws, and The Daily Mail repo

E-6B TACAMO
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The USA’s E-6 Mercury (aka. TACAMO, as in TAke Charge And Move Out) “survivable airborne communication system” airplanes support their Navy’s SSBN ballistic missile submarine force and overall strategic forces. With the advent of the new “Tactical Trident” converted Ohio Class special operations subs, their unique capabilities become even more useful. The E-6B version also has a secondary role as a “Looking Glass” Airborne National Command Post, and in recent years they have seen use as communications relay stations over the front lines of combat.

Delivery of the first production E-6 aircraft took place in August 1989, with delivery of the 16th and final airplane coming in May 1992. This is DID’s FOCUS Article concerning the E-6 system, which includes details concerning the capabilities and associated contracts. The latest contracts involve important fleet upgrades, as the Navy tries to drag the jet’s systems into the 21st century.

E-6 Mercury: Messenger from On High

Crazy ’bout a Mercury…
(click to view cutaway)

The U.S. Navy has a total fleet of 16 E-6B aircraft deployed from Tinker AFB, OK. The 707-300 derivatives have a range of about 5,500 miles, and can easily carry 23 crew members. FAS reports that in the TACAMO role, the E-6 flies independent random operations from various deployed sites for approximately 15 day intervals. Each deployed crew is self-supporting except for fuel and perishables, and the mission requires a 24 hour commitment of resources (alert posture) in the Atlantic and Pacific regions.

The term “Looking Glass” referred to the aircraft’s ability to “mirror” the underground US STRATCOM command center, in the event that it’s destroyed or becomes disabled. The aircraft use their very-low-frequency (VLF) dual trailing wire antenna system to permit one-way, emergency communications to submerged submarines. That gives the Pentagon a vital link to the fleet from national command authorities, without forcing the subs to reveal their positions. In an emergency, the E-6 fleet will also provide an Airborne National Command Post (ABNCP) for United States Command in Chief for Strategic Forces and theater CINCs, including an Airborne Launch Control System capable of launching U.S. land-based intercontinental ballistic missiles.

In the ABNCP role, as directed by US STRATCOM, 2 aircraft would be flown to Offutt Air Force Base (AFB) to embark the battle staff and the airborne launch control system (ALCS) components, then placed in alert status.

The first E-6B aircraft was accepted in December 1997, and the E-6B assumed its dual operational mission in October 1998. The E-6 fleet was completely modified to the E-6B configuration in 2003, and maintenance of the systems is performed by the standard complement of squadron ground and in-flight technician personnel. The Block I upgrades provide the next big step forward for the fleet, and Full Operational Capability was declared in spring 2012.

E-6B Upgrade Efforts

MCS-10 system
(click to view cutaway)

E-6B Block I. This upgrade program began in 2004, as a collaborative effort between the Navy and industry. It adds open system architecture electronics via its new MCS-10 computers; a Voice over Internet Protocol (VoIP) Intercommunications System; and an on-aircraft, multi-level secure network for message processing. That electronic architecture also lays the groundwork for future upgrades, by making it much easier to insert new electronics. Rockwell Collins was the prime contractor, with ARINC as their sub-contracted installer. A related Internet Protocol and Bandwidth Expansion (IPBE) effort worked to improve the plane’s uplink/downlink speeds.

The MCS-10 is at the heart of all strategic data communication links aboard the E-6B, and makes it possible to receive and transmit Emergency Action Messages to deployed US Strategic (nuclear) Forces. It will also help the Airborne Command Post (ABNCP) mission by automating 2-way messages between the MCS-10 and battlestaff mission equipment, which frees crew members from unnecessary administrative duties of processing, verifying, and then re-typing complex data messages. This saves time and crew in critical situations, while removing the ever-present possibility of human error.

Full Operational Capability (FOC) was declared for the 15 modified E-6Bs and 3 training devices (including at least 1 737) in spring 2012. Since then, the program office has delivered 1 software update, all spares, updated the MCS-10 test bench, and submitted final Emergency Action Message (EAM) certification to the Joint Chiefs of Staff for approval.

E-6B Block II. The follow-on Block II program kicked off in earnest in June 2012. With this program, the E-6B begins to take full advantage of the Block I upgrades. Modifications like the dual line of sight/ satellite MR-TCDL datalink will let the TACAMO fleet connect to secure U.S. Department of Defense networks, at high data rates, while still in flight. That might seem like an elementary function for a national-level command aircraft, but the age of the planes made it a long slog to get there. For people on board, these Block II change will dramatically broaden the type and quality of information they can receive. Northrop Grumman is the prime contractor for Block II.

E-6B SLEP. In parallel with the communications refits, E-6Bs are also receiving Service Life enhancement Program modifications, designed to take the airframes from 27,000 safe flight hours to 45,000, and give them another 20 years of service life. The refit involves inspecting and replacing up to 15,000 fasteners on the aircraft’s wings, and widening and strengthening fastener holes. That means up to 28,000 man-hours per plane, as the Navy prefers a cold-working process to strengthen the fastening holes, which involves the physical removal and inspection of each fastener as well as rework of the holes.

While the Navy leads that SLEP process, most of the work is being performed by the USAF Oklahoma City Air Logistics Center’s 566th Aircraft Maintenance Squadron, who have a lot of experience with the USAF’s similar E-3 Sentry AWACS planes. The SLEP is estimated to cost over $3 million per aircraft, and the 16th and final E-6B is scheduled to roll out of the SLEP hangar in 2015.

E-6 Mercury: Contracts and Key Events FY 2013 – 2018

Block I FRP; TCDL datalink.

Bringing it in
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July 4/18: Repair work Performance Aircraft Services is being contracted for repair work on the Navy’s fleet of E-6B aircraft. The $57 million firm-fixed-price, indefinite-delivery/indefinite-quantity contract provides for the removal and replacement of sealant on fuel cells and aircraft surfaces, as well as on the internal surface of wing fuel tanks for up to 16 aircraft. The USA’s E-6 Mercury “survivable airborne communication system” airplanes support their Navy’s SSBN ballistic missile submarine force and overall strategic forces. The 707-300 derivatives have a range of about 5,500 miles and can easily carry 23 crew members. The E-6 flies independent random operations from various deployed sites for approximately 15-day intervals. Each deployed crew is self-supporting except for fuel and perishables, and the mission requires a 24-hour commitment of resources (alert posture) in the Atlantic and Pacific regions. Work will be performed in Waco, Texas and Oklahoma City, Oklahoma. It is expected to be completed in May 2023.

November 30/17: Maintenance & Support The US Navy has exercised a second year option with IAP Worldwide Services for logistics support services on E-6B Mercury aircraft. Worth over $58.9 million, the contract tasks IAP with maintaining and supporting the E-6B Take Charge and Move Out (TACAMO) and Airborne Command Post aircraft, support equipment, aircraft weapon system, associated support sites, and supporting organizations, up until November 2018. Work will take place at several US locations including: Oklahoma City, Oklahoma (70 percent); Patuxent River, Maryland (10 percent); Bellevue, Nebraska (10 percent); and Fairfield, California (10 percent). News of the contract comes as rising tensions over the possible threat of nuclear war with North Korea remain high, with Pyongyang testing yet another nuclear capable intercontinental ballistic missile on Wednesday. The Pentagon’s E-6 fleet, based out of Tinker Air Force Base, Oklahoma, is tasked with relaying instructions from the National Command Authority to its fleet of ballistic missile submarines in the event of nuclear war. E-6B model Mercury aircraft are also capable of remotely controlling Minutemen ICBMs.

November 22/17: Contracts-Upgrades Rockwell Collins has been awarded a $12.7 million contract modification to carry out upgrade work on the communication systems of US Navy E-6B Mercury aircraft. Under the award, the Navy will exercise an option for the installation of Block I/Internet Protocol Bandwidth Expansion Phase 3/Block IA Very Low Transmit Terminal/Nuclear Planning and Execution System kit on one E-6B aircraft. Field support engineering, training, and licenses are also included in the contract, which will be carried out at Oklahoma City, Oklahoma (85 percent) and Richardson, Texas (15 percent), with an estimated completion time scheduled for June 2019. The E-6 Mercury platform, which first went into service in 1989, has the ability for command and control authority to launch land and sea based nuclear ballistic missiles. 16 were built for the US Navy between 1988 and 1991.

October 06/17: Lockheed Martin and Rockwell Collins have both received USAF contracts ($81 and $76 million respectively) for the technology maturation and risk reduction phase of the Airborne Launch Control System Replacement (ALCS-R) program—the development of an airborne command-and-control system that makes it possible for the USAF to launch an intercontinental ballistic missile even if launch control centers on the ground are destroyed. The program will support intercontinental ballistic missile (ICBM) operations until 2075, meaning it will work with both the current Minuteman III system and its eventual replacement, the Ground Based Strategic Deterrent, which will come online in the late 2020s. During ALCS-R, the service intends to replace all of the airborne mission equipment onboard the 16 E-6B Mercury aircraft equipped with the current ALCS system, as well as ground-based radios in 450 launch-control centers, which haven’t been updated since the 1960s.

June 4/14: Training. Rockwell Collins, Inc. in Cedar Rapids, IA receives an $11.9 million firm-fixed-price contract modification to upgrade of the E-6B Mercury Weapon System Trainer, and keep it consistent with changes to the plane.

All funds are committed immediately, using Navy FY 2012-13 aircraft budgets. Work will be performed in Richardson, TX (60%) and Binghamton, NY (40%), and is expected to be complete in February 2017. US NAVAIR in Patuxent River, MD manages the contract (N00019-13-C-0004).

June 2/14: FAB-T contract. Raytheon in Marlborough, MA receives a $298 million firm-fixed-price and cost-plus-fixed-fee contract modification for 84 FAB-T Command Post Terminals (CPT), which will allow broadband-speed reception from the USAF’s hardened, secure new AEHF satellites. FAB-T CPTs will equip E-4B NAOC and E-6B Mercury Block II command post aircraft, as well as some ground and mobile locations. After FAB-T reaches Milestone C, Phase 2 production contract options for Low-Rate Initial Production and beyond will open up for Raytheon, expanding the contract considerably.

It’s a sharp blow to prior incumbent Boeing, but not entirely unexpected. Buying FAB-T terminals for USAF B-2 and B-52 bombers, RC-135 SIGINT/ELINT aircraft, or other planes, would require another procurement process.

Work will be performed in Marlborough, MA and Largo, FL, with the Florida location serving as the assembly point. USAF FY 2013 through 2019 budgets will fund FAB-T buys over time, with just $31,274 committed immediately. Two bids were solicited and two received. The USAF Life Cycle Management Center/HNSK at Hanscom AFB, MA, solicited 2 bids, and received 2 (FA8705-13-C-0005, PO 0002). Sources: Pentagon DefenseLINK | Raytheon, “Raytheon awarded $298 million for US Air Force FAB-T satellite terminal program” | Defense News, “Space Fence, FAB-T Awards Show an Emboldened DoD”.

Feb 25/14: New dome? The Aviationist passes along an interesting observation:

“On Feb. 14, Military Radio Comms Expert Allan Stern took a photograph of E-6B TACAMO 164407 landing at Patrick Air Force Base and several people noticed that there is a new dome on the aircraft, clearly visible before the tail.”

It’s about the same size as wifi antennas on commercial passenger jets, but that doesn’t tell us much. Until there’s an official explanation, the mystery continues. Sources & picture: The Aviationist, “E-6B Mercury “Doomsday plane” with brand new dome”.

Nov 27/13: Rockwell Collins Inc. in Richardson, TX receives a $10.8 million fixed-firm-price contract for E-6B sustaining engineering services, including the Mission Avionics System, the Long Trailing Wire Assembly (~5 miles, for VLF transmission), the Short Trailing Wire Assembly, the High Power Transmit Set and the Internet Protocol Bandwidth Expansion Phase 4 system.

$2 million in Navy FY 2014 operations and maintenance funds are committed immediately. Work will be performed in Richardson, TX (60%) and Tinker AFB in Oklahoma City, OK (40%) and is expected to be complete in November 2014. This contract was not competitively procured pursuant to FAR 6.302-1. US NAVAIR in Patuxent River, MD manages the contract (N00019-14-C-0027).

Nov 14/13: Block I. Rockwell Collins Inc. in Cedar Rapids, IA receives a $46.6 million firm-fixed-price contract modification, exercising an option to deliver and install 2 E-6B Block I modification aircraft kits, including Internet Protocol Bandwidth Expansion Phase III and very low frequency transmit terminals (VTT). They’ll also deliver and install 4 VTT retrofit modification kits, while providing field support, differences training for existing technicians, software licenses and agreements, and updates to an Operational Flight Trainer.

All funds are committed immediately. Work will be performed in Richardson, TX (56%); Oklahoma City, OK (43%); and San Antonio, TX (1%), and is expected to be complete in May 2015. US Naval Air Systems Command in Patuxent River, MD manages the contract (N00019-13-C-0004).

Nov 5/13: Support. DRS C3 & Aviation Co. in Gaithersburg, MD receives a $50.9 million firm-fixed-priced contract modification, exercising an option for E-6B support and spares, including the procurement and repair of operational, depot and Military Standard Requisitioning and Issue Procedures spares and associated shipping and data.

$13.3 million in FY 2014 O&M funds are committed immediately, and will expire on Sept 30/14. Work will be performed at Tinker Air Force Base (AFB), OK (70%); Offutt AFB, NB (10%); Travis AFB, CA (10%); and Patuxent River, MD (10%); and is expected to be complete in November 2014. US Naval Air Systems Command in Patuxent River, MD manages the contract (N00019-11-C-0011).

Nov 5/13: TCDL. Northrop Grumman Systems Corp. in Herndon, VA receives an $18.6 million firm-fixed-price contract modification, exercising an option to build, install and test E-6B related modifications to the Multi-Role TCDL’s [PDF, Tactical Common Data Link] Ku-band Line-of-Sight and Ka-band satellite communications systems. It also funds systems integration laboratory work, and aircraft development and operational test support.

$18.5 million in FY 2014 Navy aircraft procurement funds are committed immediately. Work will be performed in Greenville, TX (50%), Patuxent River, MD (35%), and San Diego, CA (15%), and is expected to be complete in November 2015. US Naval Air Systems Command in Patuxent River, MD manages the contract (N00019-12-C-0096).

July 1/13: FAB-T. Raytheon Network Centric Systems in Marlborough, MA receives a $34 million contract modification to continued development and testing of air (E-4, E-6) and ground fixed and transportable command post terminals with presidential and national voice conferencing. The systems are a parallel project award under the Family of Advanced Beyond line-of-sight Terminals (FAB-T) program, which leverages new AEHF secure, hardened broadband satellites.

Work will be performed at Marlborough, MA, and is expected to be complete by October 2013. Fiscal 2012 Research and Development funds are being obligated at time of award. Air Force Life Cycle Management Center/HNSK, Hanscom Air Force Base, MA manages the contract (FA8307-12-C-0013, PO 0013).

April 15/13: Block II: IPBE. US NAVAIR announces that the E-6B’s Internet Protocol Bandwidth Expansion (IPBE) upgrade was recently installed on its 4th aircraft (3 operational, 1 test), during a service life extension program (SLEP) overhaul. It was delivered back to the Navy’s VQ-4 Fleet Air Reconnaissance Squadron at Tinker AFB, OK on March 14/13. Twelve more E-6Bs are scheduled to get the IPBE upgrade, with the last installation scheduled for completion in mid-fiscal 2019.

The E-6 Airborne Strategic Command, Control and Communications Program Office (PMA-271) describes the IPBE upgrade as an ultra-high frequency line of sight digital data feed used while operating over the USA, and a commercial Inmarsat satellite feed for use when operating outside the USA. Besides offering much higher bandwidth, IPBE has the advantage of removing more than 5,000 pounds of backup equipment from the aircraft.

Nov 27/12: Block I FRP. Rockwell Collins Inc. in Cedar Rapids, IA receives a $53.8 million firm-fixed-price contract for 3 E-6B Block 1 modification aircraft kits, 3 E-6B Internet Protocol Bandwidth Expansion Phase III modification kits, and 4 very low frequency transmit terminal kits for the Block 1A engineering change proposal. Since VLF waves penetrate about 40 meters into salt water, they’re used for military communication with submarines. An accompanying trainer upgrade will keep the mission avionics systems trainer in sync. Rockwell Collins later reveals that there are also $241 unexercised options, which could upgrade up to 11 aircraft before all is said and done.

Work will be performed in Oklahoma City, OK (55%); Richardson, TX (35%); and Patuxent River, MD (10%), and is expected to be complete in February 2014. $51.4 million is committed on award. This contract was not competitively procured, pursuant to FAR 6.302-1. US Naval Air Systems Command in Patuxent River, MD manages the contract (N00019-13-C-0004). See also Rockwell-Collins.

Block I Full-rate production

Nov 19/12: Support. Finmeccanica subsidiary DRS C3 and Aviation Co. in Herndon, VA received a $50 million firm-fixed-price contract modification, exercising an option for logistics services in support of the E-6B Mercury, including common aircraft spares support for 2 CNATT E-6B Mission Avionics System trainers, an Integrated Avionics Trainer, 2 VQ-7 Operational Flight Trainers, an E-6B P2 Lab, and the E-6B System Integration Laboratory.

In addition, this option provides limited services for residual spares taken from retired 707 derivatives, including the VC-137 (command aircraft, incl. Air Force One) and C-18 (other specialty 707-320B derivatives).

Work will be performed at Tinker AFB, OK (70%); Naval Air Station Patuxent River, MD (10%); Travis AFB, CA (10%); and Offutt AFB, NB (10%), and is expected to be complete in November 2013. $15.1 million will be obligated on this award, and will expire at the end of the current fiscal year on Sept 30/12. US Naval Air Systems Command in Patuxent River, MD manages the contract (N00019-11-C-0011).

Nov 2/12: MR-TCDL. Northrop Grumman Information Systems’ Network Communication Systems subsidiary in San Diego, CA receives a $20.6 million firm-fixed-price contract modification, exercising an option to integrate the Multi-Role Tactical Common Data Link (MR-TCDL) into the E-6B aircraft. That’s going to require for ancillary equipment, hardware, and software changes to add the new data standards, flows, and interfaces. The MR-TCDL includes 2 Ku-band line-of-sight channels and 1 Ka-band satellite communications channel, with the accompanying power conditioning, cooling, electrical and network distribution, etc. that are part of the Block II B-kits.

Work will be performed in San Diego, CA (75%), Waco, TX (20%), and Patuxent River, MD (5%) and is expected to be complete in October 2014. US Naval Air Systems Command in Patuxent River, MD manages the contract (N00019-12-C-0096).

Oct 3/12: Replace? The Lexington Institute releases “Modernizing the Air Force’s Electronic Aircraft Fleet” [PDF]. It advocates replacing all current USAF 707 and C-135 derivatives with off-the-shelf or nearly OTS 737 military derivatives, restoring the fleet while saving on rising maintenance costs. KC-135 aerial tankers, which are being replaced with a Boeing “KC-46A” 767 variant, were excluded from their analysis, leaving just over 70 planes to replace. The Institute believes that the savings could amount to $3 billion per year once full replacement is accomplished, over an expected service life of 30 years. Unfortunately, they do not show their cost model.

It’s an unlikely outcome, but if the USAF did choose this option, the recently-modernized E-6 fleet would probably be the last aircraft phased out. These low-hours airframes that are fresh from an upgrade, and the USAF/USN would have to either design a new internal electronics architecture from the ground up, or convert and then fit the E-6B’s systems into a slightly shorter 737-800/900 ER jet. That would add expenses and time, and introduce technical risks. What it probably wouldn’t do, is significantly increase capabilities when compared to an E-6B Block II.

FY 2011 – 2012

Block I FOC, Block II development.

Gonna buy me a Mercury…
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Sept 10/12: Broadband SATCOM. The Raytheon Co. Network Centric Systems in Marlborough, MA, is being awarded a $70 million firm fixed price contract for development, testing and production of FAB-T engineering development models of air (E-4B NAOC, E-6B), ground fixed and transportable Command Post Terminals with Presidential and National Voice Conferencing (PNVC). FAB-T terminals are designed to work with the US military’s new AEHF hardened broadband satellites.

The location of the performance is Marlborough, MA. Work is to be complete by July 2013. The AFLCMC/HSNK at Hanscom AFB, MA manages the contract (FA8307-12-C-0013).

July 17/12: US NAVAIR discusses the new open architecture MCS-10 mission computer for the E-6B fleet, which was installed on 15 E-6B aircraft and 3 training devices, as a key part of the Block I upgrades.

June 26/12: Block II development. Northrop Grumman Corp. announces a $44.3 million contract from the Us Navy to begin the E-6’s Block II upgrades, which build on Block I’s enabling architecture. Northrop Grumman will design and produce networking and communications systems, first integrating them into the E-6B Systems Integration Laboratory and then onto a single E-6B aircraft. Under the US NAVAIR contract, Northrop Grumman will also provide testing, logistics and training to support operational fielding.

With the Block II Modification, the E-6B aircraft will be able to connect to secure U.S. Department of Defense networks at high data rates while still in flight. The upgrade will enable users on board the aircraft to access mission-essential, near-real-time information from worldwide sources, without impacting the operational performance of the aircraft. If all goes well, the Navy intends to field Block II capability to the entire E-6B fleet through a follow-on contract.

Block II SDD

Spring 2012: Block I FOC. Full Operational Capability (FOC) is declared for the 15 modified E-6Bs and 3 training devices. Source.

Block I done

Dec 1/11: Support. Finmeccanica’s DRS C3 & Aviation Co. in Herndon, VA receives a $48.5 million firm-fixed-price contract modification, exercising an option for management of government-owned inventory and material support of E-6B aircraft. This option provides for residual spares from past 707-derivative programs, including the VC-137 (former Air Force One) fleet, and the C-18 range of specialized monitoring and communications aircraft.

Work will be performed at Tinker Air Force Base, OK (70%); Naval Air Station Patuxent River, MD (10%); Travis Air Force Base, CA (10%); and Offutt AFB, NE (10%); and is expected to be complete by November 2012. $6.7 million will expire at the end of the current fiscal year, on Sept 30/11. US Naval Air Systems Command in Patuxent River, MD manages the contract (N00019-11-C-0011).

Dec 1/11: Block I production. Rockwell Collins, Inc. in Cedar Rapids, IA is being awarded a $45.4 million firm-fixed-price, cost-plus-fixed-fee contract modification to exercise an option to develop and produce A-kits and B-kits for the Block I modification of 3 low rate initial production E-6B aircraft, plus associated training and support to achieve Initial Operational Capability.

Work will be performed in Oklahoma City, OK (50%); Richardson, TX (40%); and Patuxent River, MD (10%). Work is expected to be completed by December 2013. Contract funds will not expire at the end of the current fiscal year. US Naval Air Systems Command in Patuxent River, MD manages the contract (N00019-10-C-0067).

June 23/11: Them’s the Brakes. General Atomics Systems Integration, LLC in Kaysville, UT wins a $25 million firm-fixed-price requirements contract to design, evaluate, test, install, and provide spares for lighter brakes, wheels, radial tires and a Brake Temperature Monitoring System for the E-6B fleet.

The E-6B fleet wouldn’t be the first military planes to find advantages in modern brake systems, which often use carbon fiber assemblies. Benefits include fewer parts, longer life, lower maintenance requirements, and lower weight that translates into fuel savings. The WBSI brake replacement program for the USAF’s KC-135 fleet, which uses a similar base airframe, was estimated to save a total of $583 million over the life of the program.

Work will be performed in Kaysville, UT (65%); Oklahoma City, OK (25%); and Patuxent River, MD (10%). Work is expected to be complete in September 2015. This contract was competitively procured via an electronic request for proposals, with 2 offers received by US Naval Air Systems Command in Patuxent River, MD (N00019-11-D-0005).

Feb 14/11: Block I. The Carlyle Group’s ARINC, Inc. in Annapolis, MD announces a sub-contract from Rockwell Collins to install their Block I upgrades in E-6B TACAMO and Airborne Command Post (ABNCP) aircraft (vid. Nov 22/10 entry).

ARINC will perform comprehensive removal, upgrading, and replacement of the receivers, transmitters, communications racks, and operator stations that support the aircraft’s Communications Central and Battle Staff suites. The same Block I modifications will be made to an existing Mission Avionics Systems Trainer currently used at Tinker AFB, OK.

Work will take place over 26 months at its Aircraft Modification and Operations Facility in Oklahoma City, OK, with personnel from NAVAIR PMA-271 and Rockwell Collins on hand to supervise and assist. ARINC recently began building a 2nd hangar at the facility, which will more than double available hangar space when it opens in June 2011. Induction of the first upgraded E-6B aircraft is scheduled for July 2011, with final delivery by September 2013.

Nov 23/10: JDME Award. NAVAIR announces that its E-6B Mercury Fleet Support Team has received the 2010 Joint Depot Maintenance Excellence Award (Team category) at the Department of Defense Maintenance Symposium in Tampa, FL. Capt. Bob Roof, the E-6B Airborne Strategic Command, Control and Communications (PMA-271) program manager:

“The E-6 aircraft is a national asset. With only 16 aircraft in the fleet, we could not send them through the normal time lined depot maintenance cycle and still maintain the aircraft readiness level necessary to meet its mission… our Tinker Air Force Base, Oklahoma, fleet support team solved this problem through collaboration with the Air Force using a process called Enhanced Phase Maintenance.”

Under EPM, the depot comes to the aircraft. Air Force artisans work side by side with Navy maintainers, in Navy hangars, to complete the required depot maintenance in as little as 6 weeks.

Nov 22/10: Block I production. Rockwell Collins, Inc. in Cedar Rapids, IA receives a not-to-exceed $60.5 million addition to a previously awarded but unfinalized $38.8 million contract (N00019-10-C-0067, vid. July 22/10). In exchange for this $99.3 million award, the firm will develop and produce A-kits and B-kits for 3 Low Rate Initial Production E-6B Block I modifications, along with “associated training and support systems to achieve initial operational capability.”

Work will be performed in Richardson, Texas (70%; Waco, TX (20%); and Oklahoma City, OK (10%). Work is expected to be complete in September 2013.

Nov 18/10: Support. Finmeccanica subsidiary DRS C3 & Aviation Co. in Herndon, VA wins a $43.5 million firm-fixed-price contract for logistics services in support of E-6B aircraft, to include management of government-owned inventory and material support.

Work will be performed at Tinker Air Force Base, OK (70%); Naval Air Station Patuxent River, MD (10%); Travis AFB, CA (10%); and Offutt AFB, NE (10%). Work is expected to be complete in November 2011, and $214,500 will expire at the end of the current fiscal year, on Sept 30/11. This contract was competitively procured via a request for proposal, with 2 offers solicited and 2 proposals received (N00019-11-C-0011).

November 2010: Testing. Month-long Fleet Introduction Team (FIT) checks at Tinker AFB, OK for operational evaluation of the final product with US STRATCOM. Source.

Oct 14/10: Rear. Adm. Donald Gaddis of the US Navy’s Program Executive Office for Tactical Aircraft approves the ACAT-II level E-6B Block I Modification Program’s move into Initial Operational Test and Evaluation (IOT&E).

The E-6B Mercury Block I Program entered into System Development and Demonstration (SDD) following Milestone B in March 2004. US NAVAIR.

Block I to IOT&E

FY 2009 – 2010

Block I Milestone C, production.

Routine maintenance
(click to view full)

September 2010: Testing. Final developmental testing completed by Air Test and Evaluation Squadron VX-20 personnel. Source.

July 22/10: Block I production. Rockwell Collins, Inc. in Cedar Rapids, IA receives an undefinitized, not-to-exceed $38.8 million contract. The firm will develop and produce an A-kit and B-kit for Block I modification on 1 low-rate initial production E-6 aircraft, as well as associated training and support systems to achieve initial operational capability.

Work will be performed in Richardson, TX (70%); Waco, TX (20%); and Oklahoma City, OK (10%). Work is expected to be complete in July 2011. This contract was not competitively procured, pursuant to FAR 6.302-2 (N00019-10-C-0067).

July 12/10: Block I. Rockwell Collins, Inc. in Cedar Rapids, IA receives a $43.7 million modification for prototype upgraded systems in the government’s E-6 systems integration laboratory, and on pre-production Block I modification aircraft. This order finalizes a previously awarded contract (N00019-09-C-0056) as a cost-plus-fixed-fee contract, and covers design, development, integration, installation, and test work.

Work will be performed in Richardson, TX (75%), and Patuxent River, MD (25%), and is expected to be complete in September 2013.

June 15/10: The E-6B Airborne Strategic Command, Control and Communications Program Office (PMA-271), teamed with the USAF Oklahoma City Air Logistics Center’s 566th Aircraft Maintenance Squadron (566 AMXS) at Tinker AFB, OK, and the In-Service Support Center in Jacksonville, FL, has completed their first Service Life Extension Program modification of an E-6B Mercury, extending its originally planned service life of 27,000 flight hours to 45,000 flight hours.

NAVAIR says that the first SLEP modification took 6 months to complete, which would mean that it started late (December vs. September 2009). Contractors included Boeing and Andromeda Systems, Inc., who helped narrow the original list of more than 100 critical rework locations to just the 14 locations reworked on the first SLEP aircraft. The SLEP crew at 566 AMXS replaced original fasteners with interference-fit fasteners and cold-worked 14,383 holes, while performing the 12 individual modification directives. Fatigue Technology, Inc., also provided critical engineering, tooling, and training for the actual cold-working process. Although the modification was similar to work typically done by the 566 AMXS, the cold-working process directed by the Navy to strengthen the fastening holes required additional work and inspections.

The 566 AMXS will perform the same modification on the remaining 15 Mercury aircraft at Tinker AFB with the last SLEP finishing in 2015, vs. the original estimate of 2013. See also Aug 28/09 entry. NAVAIR.

1st E-6B SLEP done.

June 8/10: Milestone C. The E-6B Airborne Strategic Command, Control and Communications Program Office (PMA-271) completes a Gate 6 / Milestone C review for the E-6B Modification program, and the E-6B Block I Program enters the Production and Deployment phase:

“The purpose of the Block I Program is to correct E-6B Airborne Command Post (ABNCP) Follow-on Test & Evaluation deficiencies and replace equipment that is obsolete or degrades mission performance by modifying aircraft, ground training systems, and the Systems Integration Laboratory (SIL)… The Prime Contractor for the Block IA Program is Rockwell Collins located in Richardson, Texas. Rockwell Collins, teamed with subcontract L-3 Communications, supports successful aircraft modifications in Waco, Texas.”

On NAVAIR’s side, the Block I IPT leads were Cmdr. Jaime Engdahl and Amy Houle Caruso. The E-6B Mercury Block I Program entered into System Development and Demonstration (SDD) following Milestone B (MS B) in March 2004. The SDD contract will be complete in Q1 2011 (Q2 FY11), but the Milestone C decision is expected to lead to an E-6B delivered for operational use in Q4 2011 (Q1 FY12), with the other 3 aircraft completed by Q4 2012 (Q1 FY13). NAVAIR.

Block I into production

Dec 17/09: Training. L-3 Link Simulation & Training announces a 1-year, $11.2 million contract option to continue to provide support for the U.S. Navy’s E-6B Aircrew Training System (ATS). Additional annual contract options could extend L-3 Link’s flight crew training support through 2015. L-3 Link has won 3 consecutive competitions since 1993, in order to remain prime contractor on the program.

The ATS contracts provide E-6B TACAMO pilots, navigators and flight engineers with instructor-led, computer-based and simulator training. Both academic and simulator aircrew instruction delivered by L-3 Link supports initial qualification, instructor upgrade, refresher, re-qualification, instrument ground school and crew resource management training. L-3 Link also operates and maintains all program training devices, including a new FAA Level D equivalent Operational Flight Trainer that enabled key training events to be moved from the aircraft to far less expensive simulators. The E-6B ATS schoolhouse is located at Tinker Air Force Base, Okla. and the FAA Level D equivalent E-6B Operational Flight Trainer is housed in an adjacent L-3 Link facility.

E-6B Mercury landing
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Aug 28/09: SLEP. Workers from the 566th Aircraft Maintenance Squadron at tinker AFB, OK are preparing to begin E-6B SLEP(Service Life Extension Program) work in September 2009. The refit will involve inspecting and replacing up to 15,000 fasteners on the aircraft’s wings, and widening and strengthening fastener holes. The SLEP is estimated to cost just more than $3 million per aircraft, and the 16th and final aircraft is scheduled to roll out of the hangar in the spring of 2013.

The 566th AMXS performs enhanced phase maintenance on the E-6 in addition to its main duties in refurbishing the similar USAF E-3. One difference is that the Navy prefers a cold-working process to strengthen the fastening holes, which involves the physical removal and inspection of each fastener as well as rework of the holes. That means an estimated 28,000 man hours of work for each aircraft, which is still slightly less than the 35,000 hours required to refurbish an E-3 during depot maintenance. USAF.

May 4/09: SLEP. Boeing in Wichita, KS received a $6 million cost plus fixed price delivery order against a previously issued Basic Ordering Agreement (N00019-05-G-0026) for the supplies and services necessary to plan, manage, and execute engineering support for the U.S. Navy’s E-6B aircraft Service Life Sustainment effort.

Work will be performed at Tinker Air Force Base, Oklahoma City, OK, and is expected to be complete in September 2011.

April 30/09: Avionics. Boeing in Wichita, KS received a $15.5 million modification to a previous a previously awarded firm-fixed-price contract, exercising an option for 15 Crash Survivable Flight Incident Recorders, 15 Flight Data Recorders, and associated technical data and spare and repair parts for E-6B Mercury aircraft.

Work will be performed at Tinker Air Force Base, OK, and is expected to be complete in September 2012 (N00019-09-C-0051).

April 14/09: Avionics. Boeing received a $20.7 million firm-fixed-price contract for one Crash Survivable Flight Incident Recorder and one Flight Data Recorder (CSFIR/FDR) for E-6B Mercury Aircraft. In addition, this contract provides for 2 modification kits for the Operational Flight Trainer (OFT); one modification kit for the OFT Replay Debrief Station Trainer, one for the Integrated Avionics Trainer; one for the Part Task Trainer, and one for the Forward Lower Lobe Device Trainer; and interim spare parts and technical data.

Work will be performed at Tinker Air Force Base, OK and is expected to be complete in April 2011. This contract was competitively procured under an electronic request for proposals, with 2 offers received by the Naval Air Systems Command in Patuxent River, MD (N00019-09-C-0051).

March 12/09: IPBE. Rockwell Collins Inc. in Richardson, TX received a $10.3 million “fixed firm price contract” for approximately 37,250 man-hours of engineering, installation, and testing in support of Phase 4 of the E-6B TACAMO’s Internet Protocol and Bandwidth Expansion (IPBE). In addition, a total of 3 options with a total value of $7.7 million are being exercised at time of award, for an additional 40,900 man-hours of non-recurring engineering, installation, and testing. This brings the totals to $18 million and 78,150 hours.

IPBE Phase 4 will install the Digital Northstar System on the E-6B aircraft, giving it the proper configuration to communicate and work with DNS ground sites in the US military’s global communications network.

Work will be performed in Richardson, TX (69%); Cedar Rapids, IA (18%); and Phoenix, AZ (13%), and is expected to be complete in March 2011. This contract was not competitively procured (N00019-09-C-0035).

Feb 25/09: NAVAIR’s Airborne Strategic Command, Control and Communications program office (PMA-271) accepts the first modified E-6B Mercury Block I from Rockwell Collins and L-3 Integrated Systems Group during a ceremony at the L-3 Integrated Systems facility in Waco, TX.

PMA-271 program manager Capt Bob Roof says that the E-6B Block I modification program addresses operator workload sharing, deal with electronics obsolescence issues, makes future upgrades easier, and corrects deficiencies identified during the E-6B Airborne Command Post modification operational test. US NAVAIR.

1st Block I delivered

Oct 30/08: Support. L-3 Communications Vertex Aerospace LLC in Madison, MS received a $28.7 million modification to a previously awarded indefinite-delivery/ indefinite-quantity contract (N00019-06-D-0011) to exercise an option for logistics services in support of the E-6B TACAMO aircraft fleet.

Work will be performed at Tinker Air Force Base (AFB), OK (70%); Naval Air Station, Patuxent River, MD (10%); Travis AFB, CA (10%); and Offutt AFB, NB (10%), and is expected to be complete in October 2009. Contract funds in the amount of $2.4 million will expire at the end of the current fiscal year.

Oct 30/08: Training. L-3 Communications Corp.in Arlington, TX received a $9.6 million modification to a previously awarded indefinite-delivery/ indefinite-quantity contract, exercising an option for training support and up to 2,000 flight instructor hours on a Boeing 737-NG aircraft to serve as an E-6B in-flight trainer.

Work will be performed at Tinker Air Force Base, Oklahoma City, OK; and is expected to be complete in October 2009. Contract funds in the amount of $9.5 million will expire at the end of the current fiscal year (N00019-05-D-0012).

FY 2007 – 2008

IPBE

E-6B Mercury
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June 23/08: IPBE. Boeing Aerospace Operations in Oklahoma City, OK received a $28.9 million cost-plus fixed-fee contract for non-recurring engineering, installation, and test of the Internet Protocol and Bandwidth Expansion (IPBE) Phase 1 on one (1) E-6B aircraft. The purpose of the IPBE Phase 1 is to install commercial satellite and line of sight radio equipment, allowing improved data capabilities and global Communications/Navigation, Surveillance and Air Traffic Management (CNS/ATM) on the E-6B aircraft.

Work will be performed in Wichita, KS (84%); Oklahoma City, OK (14%); and Seattle, WA (2%), and is expected to be complete in March 2010. This contract was not competitively procured (N00019-08-C-0053).

Aug 10/07: Gonna buy me a Mercury, and cruise it up and down Iraq. The USAF’s “Sailors help bridge gap for Soldiers in Baghdad” article describes the recent work of E-6 crews over Iraq:

“In the Middle East, the “Take Charge And Move Out” flies over Iraq to serve as the last means of communication between ground forces… The TACAMO has the capability of staying in the air for long periods of time, so the team flies over Iraq daily, for 12 to 14 hours providing communication.”

Combat

March 2008: Block I. Initial contractor and developmental testing of E-6B block I completed, creates list of “prioritized deficiencies”. NAVAIR also introduced new requirements to improve the airborne command post mission, and a 2nd round of tests took place in May 2009. Source.

April 13/07: Block I. Rockwell Collins, Inc. in Cedar Rapids, IA received a $45 million ceiling-priced modification to a previously awarded cost-plus-fixed-fee contract to provide additional funding for the E-6B Block I modification program, including the design, development, installation, and testing of a fully integrated airborne command and control communication system.

Work will be performed in Waco, TX (80%) and Richardson, TX (20%), and is expected to be complete in December 2009 (N00019-04-C-0101).

Oct 26/06: Support. L-3 Vertex Aerospace LLC in Madison, MS received a $28.5 million ceiling-priced modification to a previously awarded indefinite-delivery, indefinite-quantity contract (N00019-06-D-0011), exercising an option for logistics services in support of the E-6B fleet. Work will be performed at Tinker Air Force Base (AFB), OK (70%); Naval Air Station Patuxent River, MD (10%); Travis AFB, CA (10%); and Offutt AFB, NB (10%), and is expected to be complete in October 2007. Contract funds in the amount of $17.7 million will expire at the end of the current fiscal year.

Oct 26/06: Training. L-3 Communications Link Simulation & Training in Arlington, TX received a $13.7 million ceiling-priced modification to a previously awarded indefinite-delivery, indefinite-quantity contract (N00019-05-D-0012), exercising an option for up to 2,000 flight instructor hours on a Boeing 737 Next Generation Aircraft to serve as an E-6B In-Flight Trainer. Work will be performed at Tinker Air Force Base, Oklahoma City, OK; and is expected to be complete in October 2007. Contract funds in the amount of $13.6 million will expire at the end of the current fiscal year.

FY 1990 – 2006

2003 mods begin
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Jan 24/06: Support. L-3 Vertex Aerospace LLC in Madison, MS received a $27 million indefinite-delivery/ indefinite-quantity contract for logistics services in support of the E-6B Mercury fleet. With the exercise of 4 more 1-year options, the total value of the contract could reach $142.3 million.

Services will be provided to the Commander, Strategic Communications Wing ONE (CSCW-1), and three TACAMO squadrons at Tinker Air Force Base, OK (70%). Support for operations will be given at Travis AFB, CA (10%); Naval Air Station (NAS) Patuxent River, MD, including the Systems Integration Lab (10%); and Offutt AFB, NB (10%), and are expected to be complete in October 2006. This contract was competitively procured via an electronic request for proposals; one offer was received by the Naval Air Systems Command in Patuxent River, MD (N00019-06-D-0011). Sources: DefenseLINK,

A1075813200000*B1138933632000*DgroupByDate*J2*M704*N1001302&newsLang=en&beanID=1963892417&viewID=news_view">L-3 corporate release.

Oct 18/05: Support. Boeing Aerospace Operations in Oklahoma City, OK received an estimated value $8.5 million modification to a previously awarded firm-fixed-priced, time and materials, cost-reimbursement contract (N00019-01-C-0066) for the repair services and procurement of spare parts for the E-6 platform. The aim is to reduce the existing repair backlog and replenish of wartime spare kits to proper wartime sparing levels. Work will be performed at Tinker Air Force Base in Oklahoma City, OK and is expected to be complete in December 2005.

Oct 18/05: Training. L-3 Communications Link Simulation & Training in Arlington, TX received a $13.4 million ceiling-priced modification to a previously awarded indefinite-delivery, indefinite-quantity contract (N00019-05-D-0012). The modification exercises an option for up to 2,000 Flight Instructor hours on a Boeing 737 Next Generation Aircraft, to serve as an E-6B In-Flight Trainer. Work will be performed at Tinker Air Force Base in Oklahoma City, OK and is expected to be complete in October 2006.

March 30/04:Block I. The Rockwell Collins Government Systems in Cedar Rapids, IA receives a $79.5 million cost-plus-award-fee contract for the system development and demonstration of the E-6B’s Block I modification. Block I aims to:

“…correct follow-on operational test and evaluation, deficiencies, readiness degraders, and obsolescence issues. This effort includes design, development, installation, and testing of the fully integrated system modifications in a systems integration laboratory and a production representative aircraft.”

Work will be performed in Waco, TX (37%); Richardson, TX (36%); Manassas, VA (11%); San Antonio, TX (9%); Cedar Rapids, IA (4%); and Sacramento, CA (3%), and is expected to be complete in September 2008. This contract was competitively procured through a Request for Proposals; 2 firms were solicited and 2 proposals were received by US Naval Air Systems Command in Patuxent River, MD (N00019-04-C-0101).

Block I SDD

Dec 1/03: Avionics. Boeing’s Wichita Modification and Developmental Center in Wichita, KS received a $20 million modification to a previously awarded firm-fixed-price contract (N00019-99-C-1228), exercising an option for the purchase of 7 Multifunction Display System (MDS) kits, and installation of 6 MDS kits, for the cockpit of the E-6 aircraft. MDS kits will increase the mean time between failures, reduce spares, and provide substantial life cycle savings over 20 years in operations and support. Work will be performed in Cecil Field, FL (90%), and Wichita, KS (10%), and is expected to be complete in November 2004.

Oct 1/1998: The USAF retires the EC-135, but its Looking Glass role remains with the Navy’s E-6 fleet. USAF.

Looking Glass shifts

July 24/1990: USAF “Looking Glass” aircraft cease continuous airborne alert, but remain on ground or airborne alert 24 hours a day. USAF Strategic Air Command initiated the Looking Glass airborne command post on Feb 3/1961 using the EC-135, whereupon flying shifts kept a Looking Glass aircraft in the air at all times 24 hours a day, 365 days a year for more than 29 years, accumulating over 281,000 accident-free flying hours.

The name “Looking Glass” referred to the aircraft’s ability to “mirror” the underground SAC (now U.S. Strategic Command) command center in the event it was destroyed or became disabled. USAF.

Additional Readings

• US STRATCOM – E-6B Airborne Command Post (ABNCP)

• US NAVAIR – E-6B Mercury

Other National Command Jets

• DID – Nightwatch: The USA’s E-4B NAOC “Doomsday” Fleet

• DID – Boeing Contracted to Support Air Force One VC-25s

IEDs: The Aftermath
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The US military is working on the next-generation of jammers to defeat improvised explosive devices (IEDs) that pose such a grave threat to US forces deployed overseas. The jammers are called Joint Counter Radio-Controlled Improvised Explosive Device (RCIED) Electronic Warfare (JCREW) devices. They are high-power, modular, programmable, multiband radio frequency jammers designed to deny enemy use of selected portions of the radio frequency spectrum. They come in 3 varieties – fixed, mounted, and dismounted.

The first generations of JCREW devices were developed and deployed quickly to meet an urgent need in the field. The next generation of JCREW devices, known as 3.x, are being developed to increase capabilities and tap into the power of the network to enhance their effectiveness. The JCREW 3.1 version is a dismounted device, the 3.2 version is a mounted device, and the 3.3 version is being developed to work in mounted, dismounted, and fixed-installation roles, using a common open architecture of electronics.

Contracts and Key Events

Mounted JCREW System

So far, most awards are dismounted JCREW 3.1 orders. ITT and NGC’s JCREW 3.2 was never fielded, and a January 2013 query received a response of: “The program office is currently considering its next steps forward on the effort.” ITT/Exelis initially won the JCREW 3.3 development program, but that didn’t work out, and it’s now being conducted by Northrop Grumman instead. Technically, JCREW 3.3 has been replaced by the JCREW I1B1 development program, but the terms are synonymous. We’ll continue to use “JCREW 3.3” for visual clarity.

Unless otherwise noted, the Naval Sea Systems Command in Washington, DC awards JCREW 3.x contracts. The Navy manages the Joint CREW program for Office of the Secretary of Defense’s Joint Improvised Explosive Device Defeat Organization.

FY 2011 – 2018

JCREW 3.3.

July 4/18: More contracts Northrop Grumman is being tapped for work in support of the Navy’s PMS 408. The firm-fixed-price, cost-plus-fixed-fee modification is valued at $96,5 million and provides for the production for the Joint Counter Radio-Controlled Improvised Explosive Device Electronic Warfare Increment One Block One systems. PMS 408 is the Navy program management office for explosive ordnance disposal (EOD), counter radio controlled improvised explosive device electronic warfare (CREW), and anti-terrorism afloat (ATA) systems. The modification is for Counter Radio-Controlled Improvised Explosive Device Electronic Warfare (CREW) systems that provide combat troops protection against radio-controlled improvised explosive devices (RCIEDs). They are high-power, modular, programmable, multiband radio frequency jammers designed to deny enemy use of selected portions of the radio frequency spectrum. They come in 3 varieties – fixed, mounted, and dismounted. CREW systems are designed to provide protection for foot soldiers, vehicles and permanent structures. The Joint CREW Increment One Block One system is the first-generation system that develops a common open architecture across all three capabilities and provides protection for worldwide military operations. Work will be performed in San Diego, California and Sierra Vista, Arizona, and is expected to be completed by April 2020.

September 21/17: Sierra Nevada Corp has been awarded a $205 million US Special Operations Command contract to supply support services for Special Operation Command’s Dismounted Counter Radio-Controlled Improvised Explosive Device Electronic Warfare systems. Work will run through Sept. 12, 2022, and performed in Sparks, Nev., and Folsom, Calif. The Dismounted Counter Radio-Controlled Improvised Explosive Device Electronic Warfare system is part of the wider Joint Counter Radio-Controlled Improvised Explosive Device Electronic Warfare (JCREW) series of IED jammers. The JCREW is designed to jam enemy radio-frequencies used to detonate improvised explosive devices. It comes in three different models, including a man-portable version for foot patrols, vehicle-mounted variants, and a static model for protecting key points at installations.

September 15/17: Northrop Grumman will enter its software-programmable jammers, known as JCREW, into full-rate production, after receiving a $57.7 million US Navy contract. If all options are exercised, the total contract value could rise to $505 million, with contract completion scheduled for August 2022. JCREW systems are software-programmable jammers for use against device-triggered IEDs. Northrop Grumman have developed dismounted, mounted and fixed-site variants of the system.

Jan 11/13: JCREW 3.3 switch? Northrop Grumman Network Communication Systems in San Diego, CA receives a $14.1 million contract modification, exercising a firm-fixed-price contract option to support JCREW 3.3’s system development and demonstration phase through Preliminary Design Review. All funds are committed immediately.

We’re given to understand that this is not a firm-fixed price contract, but await a correction. It would seem that EDO/ITT’s task has been given to Northrop Grumman, but DID awaits official confirmation.

Work will be performed in San Diego, CA (95%) and Sierra Vista, AZ (5%), and is expected to be complete by January 2014 (N00024-09-C-6317).

Dec 15/11: JCREW 3.1. Sierra Nevada Corp. in Sparks, NV receives a $20.5 million contract modification for dismounted JCREW systems and associated ancillary equipment to support the Marine Corps. Work will be performed in Sparks, NV (90%), and Rancho Cordova, CA (10%), and is expected to be complete by July 2012 (N00024-09-C-6306).

June 22/11: JCREW 3.1. Sierra Nevada Corp. in Sparks, NV receives a $12 million contract modification to provide spares and “consumables” for JCREW 3.1 systems. Work will be performed in Sparks, NV (90%), and Rancho Cordova, CA (10%), and is expected to be complete by December 2011 (N00024-09-C-6306).

June 14/11: Over at WIRED Danger Room, Noah Shachtman pens “The Secret History of Iraq’s Invisible War,” which looks at ITT’s JCREW efforts and evolution.

May 13/11: JCREW 3.1. Sierra Nevada Corp. in Sparks, NV receives a $38.6 million firm-fixed-price contract modification for 360 dismounted JCREW systems, to be used by forces in each of the military services of the Central Command area of responsibility. Discussions with Sierra Nevada confirm that these are JCREW 3.1s.

Work will be performed in Sparks, NV (90%) and Rancho Cordova, CA (10%), and is expected to be complete by December 2011 (N00024-09-C-6306).

Dec 20/10: JCREW 3.3. Mercury Computer Systems Inc. in Chelmsford, MA announces an ITT subcontract for the JCREW (Joint Counter-Radio Controlled Improvised Explosive Device) 3.3 program.

Mercury notes that the JCREW 3.3 specification requires open architecture-based software-enabled implementations, and cites the firm’s experience working on industry-wide OpenVPX specifications. Mercury offers 3U and 6U OpenVPX embedded computing platforms specifically designed and optimized for the active electronic warfare requirements of high-density processing, high memory bandwidth, and fast input/output.

Oct 5/10: JCREW 3.3. EDO (now ITT) in Thousand Oaks, CA receives a $29.1 million modification to a combination cost-plus-incentive-fee, cost-plus-award-fee, cost only, and firm-fixed-price contract, exercising options for all material and services to support the JCREW 3.3’s System Development and Demonstration phase through to engineering design models for all 3 capabilities (dismounted, mounted and fixed site).

Work will be performed in Clifton, NJ (67%), and Thousand Oaks, CA (33%), and is expected to be complete by March 2012 (N0024-09-C-6316). ITT release

FY 2009 – 2010

JCREW 3.1 production, 3.2 contract, 3.3 development.

Sept 17/10: JCREW 3.1. Sierra Nevada Corp. in Sparks, NV receives a $49.8 million contract modification for 587 dismounted JCREW 3.1 systems, to be used by forces in each of the military services within the CENTCOM area of responsibility.

Under the original contract awarded June 11/09, Sierra Nevada is to provide up to 2,500 JCREW 3.1 dismounted systems, support equipment and services, and additional long-lead time material, for a total contract value of $248.3 million. Work on this order will be performed in Sparks, NV (90%), and Rancho Cordova, CA (10%), and is expected to be complete by July 2011 (N00024-09-C-6306). SNC release.

Aug 19/10: ITT Advanced Engineering & Sciences in Annapolis Junction, MD receives a $455 million firm-fixed-price, cost-plus-fixed-fee, cost-only indefinite-delivery/ indefinite quantity contract for up to 5,000 JCREW 3.2 mounted systems and associated support, to be used by all US military services on CENTCOM’s front lines in Iraq and Afghanistan.

Work will be performed in Thousand Oaks, CA (95.35%); Annapolis Junction, MD (3%); Charleston, SC (1.09%); and Clifton, NJ (0.56%). Work is expected to be complete by September 2014. This contract was competitively procured via the Federal Business Opportunities website, with 2 offers received (N00024-10-D-6300).

JCREW 3.2 contract

April 13/10: JCREW 3.1. Sierra Nevada Corp. in Sparks, NV receives an $8.8 million contract modification for depot repair parts and material to repair 1,300 dismounted JCREW systems – vid. previous production contracts.

Work will be performed in Sparks, NV (90%), and Rancho Cordova, CA (10%), and is expected to be complete by December 2010 (N00024-09-C-6306).

April 7/10: JCREW 3.3. Northrop Grumman Space and Mission Systems’ Network Communication Systems group in San Diego, CA receives a $28.4 million cost-plus-incentive-fee, cost-plus-award-fee, cost only, and firm-fixed-price modification to previously awarded contract (N00024-09-C-6317). These options cover all material and services to support the JCREW 3.3 system development and demonstration phase, through to critical design review, for the dismounted, mounted, and fixed site variants.

Work will be performed at various Northrop Grumman Space and Mission Systems locations, as follows: San Diego, CA (84%), Sierra Vista, AZ (14%), and Killeen, TX (2%), and is expected to be complete by October 2010.

April 5/10: JCREW 3.3. ITT subsidiary EDO Communications and Countermeasures Systems, Inc. in Thousand Oaks, CA receives a $31.3 million cost-plus-incentive-fee, cost-plus award fee, cost-only, firm-fixed-price modification to previously awarded contract (N0024-09-C-6316). These options cover all material and services to support the JCREW 3.3 system development and demonstration phase, through to critical design review, for the dismounted, mounted, and fixed site variants.

Work will be performed at Clifton, NJ (41%), Annapolis Junction, MD (30%), and Thousand Oaks, CA (2%), and is expected to be complete by June 2010. $8.5 million in contract funds will expire at the end of the current fiscal year, on Sept 30/10.

Dec 4/09: JCREW 3.1. Sierra Nevada Corp. in Sparks, NV received a $7.4 million modification to a previously awarded contract to exercise an option for spares and consumables for 1,300 production systems, 4 field service representatives, and 350 training surrogates for 1,300 dismounted JCREW 3.1 devices.

This contract is for the procurement and support of JCREW systems to be used by forces in each of the US military services of the Central Command area of responsibility. Work will be performed in Sparks, NV (90%) and Rancho Cordova, CA (10%), and is expected to be complete by December 2010 (N00024-09-C-6306).

Oct 1/09: Northrop Grumman’s Space and Mission Systems in San Diego, CA won a $24.3 million firm-fixed-price contract for all material and services to support system development and demonstration phase through preliminary design review for the 3 capabilities (dismounted, mounted, and fixed site) of the JCREW 3.3 system. Northrop Grumman will perform the work in San Diego, CA (84%); Sierra Vista, AZ (14%); and Kileen, TX (2%), and expects to complete it by March 2010. This contract was competitively procured via the FedBizOpps website, with 3 offers received (N00024-09-C-6317).

Oct 1/09: ITT Force Protection Systems in Thousand Oaks, CA won a $16.0 millon firm-fixed-price contract for all material and services to support system development and demonstration phase through preliminary design review for the 3 capabilities (dismounted, mounted, and fixed site) of the JCREW 3.3 system. ITT will perform the work in Clifton, NJ (41%); Annapolis Junction, MD (30%); and Thousand Oaks, CA (29%), and expects to complete it by March 2010. This contract was competitively procured via the FedBizOpps website, with 3 offers received (N00024-09-C-6316).

JCREW 3.3 development

Sept 24/09: JCREW 3.1. Sierra Nevada Corp. in Sparks, NV received an $80.6 million modification to a previously awarded contract (N00024-09-C-6306) to exercise Option CLIN (contract line item number) 0003 for production systems, including shipping containers and ancillary equipment and cables, for 1,300 dismounted JCREW 3.1 systems. This contract is for the procurement and support of JCREW systems, to be used by forces in each of the US military services of the Central Command area of responsibility. Work will be performed in Sparks, NV (90%); Rancho Cordova, CA (10%), and is expected to be completed by December 2010.

Aug 10/09: JCREW 3.1. Sierra Nevada Corp. in Sparks, NV received a $26.3 million modification to a previously awarded contract (N00024-09-C-6306) to exercise an option for long lead material for 1,300 dismounted JCREW 3.1 systems. This contract is for the procurement and support of JCREW systems to be used by forces in each of the US military services of the Central Command Area of Responsibility. Work will be performed in Sparks, NV (90%) and Rancho Cordova, CA (10%), and is expected to be completed by December 2010.

June 11/09: Sierra Nevada Corp. in Sparks, NV won a $36.5 million firm-fixed-price, cost-plus-fixed-fee, cost-only contract for production of Joint Counter Radio-Controlled Improvised Explosive Device Electronic Warfare (JCREW) 3.1 dismounted systems to meet the requirements of US troops in Iraq and Afghanistan. Dismounted JCREW systems are electronic jammers designed to prevent the initiation of radio-controlled improvised explosive devices (RCIED).

This contract includes options which, if exercised, would result in a cumulative contract value of $248.3 million. Sierra Nevada will perform the work in Sparks, NV (90%) and Rancho Cordova, CA (10%), and expects to complete it by December 2010. This contract was competitively procured via the FedBizOpps website, with 3 proposals solicited and 3 offers received (N00024-09-C-6306). See also Sierra Nevada release.

JCREW 3.1 production

Additional Readings

• USMC SYSCOM – USMC Counter Radio-Controlled Improvised Explosive Device (RCIED) Electronic Warfare (CREW), 3.3 THOR III SYSTEM. It’s actually the JCREW 3.1 offering, also known as AN/PLQ-9.

• WIRED Danger Room (June 14/11) – The Secret History of Iraq’s Invisible War. “…I received an unusual offer from ITT… Company executives were ready to discuss the jammer – its evolution, and its capabilities. They were finally able to retell the largely-hidden battles for the electromagnetic spectrum that raged, invisibly, as the insurgencies carried on. They were prepared to bring me into the R&D facility where company technicians were developing what could amount to the ultimate weapon of this electromagnetic war…”

• Soldier Modernisation (Vol. 2, January 2009) – Dismounted Counter-IED: Size, Weight & Power Limits

Americas

• Bell Boeing is being awarded a contract conversion in support of the V-22 aircraft. The conversion into a fixed-price-incentive-fee multiyear contract is valued at $4.1 billion and provides for the manufacturer and delivery of 78 V-22s. Under the contract the Navy will receive 39 CMV-22Bs, 34 MV-22Bs are marked for the Marine Corps, the US Air Force will receive 1 CV-22B and the government of Japan will take delivery of 4 MV-22Bs. V-22 Initial Operational Capability didn’t begin until 2007, about 24 years after the initial design contract. A long series of design issues and mass-fatality crashes almost got the program canceled, but Congressional industrial lobbying preserved it. This modification combines purchases for the Navy ($2,8 billion); Marine Corps ($1,03 billion); Air Force ($75,7 million); and the government of Japan ($230,2 million), under the Foreign Military Sales program. Work will be performed at various locations inside and outside the continental US. Locations include Fort Worth, Texas; East Aurora, New York; Rockford, Illinois. It is expected to be completed by November 2024.

• The Air Force is contracting Boeing in support of its F-15 fleet. The firm-fixed-price contract provides for the production of F-15 vertical stabilizers and is valued at $23.6 million. The F-15A reached initial operational capability for the US Air Force in September 1975, and approximately 670 F-15s remain in the USAF’s inventory. Vertical stabilizers serve two basic purposes: flight stability and aircraft attitude alteration in yaw direction (i.e. yawing the aircraft left or right). In addition, they provide perfect mounting place for RWR and ECM antennae (located on the top of each stabilizers). Location of performance is at the company’s location in Missouri and is scheduled for completion by May 31, 2022.

• The US Special Operations Command is boosting its missile power. Raytheon is set to produce an un-specified number of Griffin missiles under an indefinite-delivery/indefinite-quantity contract that is valued at $315 million. The contract also provides for related support for product improvements, operations and sustainment. Raytheon’s Griffin is a precision guided “mini-missile” and glide weapon that comes in three variants. The Griffin-A is currently in use as part of American roll-on armed kits for its C-130 Hercules transports. The Griffin-B is a powered missile can be a forward-firing weapon, and can be launched from land, naval, or aerial platforms. And the Griffin C attempts to compete against Lockheed’s Hellfire and MBDA’s Brimstone 2 by adding dual-mode laser/IIR guidance for a fire-and-forget missile that uses thrust-vectoring control for vertical launch compatibility, a datalink for retargeting in flight, and waypoint flight to maneuver around obstacles. Work will be performed at contractor facilities in Tucson. No completions date has been given at this point.

• General Electric is set to provide further work on the Air Force’s Adaptive Engine Transition Program (AETP) program. The contract is valued $437 million and provides for designing, fabricating, integrating, testing and completing the flight-weight adaptive engines. The F-35 JSF will be required to not only fly farther than today’s aircraft but will also need more speed and power when engaging the enemy. But from a propulsion perspective, up until now these objectives have been mutually exclusive. Longer range and subsonic loiter require lower fuel burn and good cruise efficiency, while higher thrust for supersonic dash demands larger cores and much higher operating temperatures, neither of which is good for fuel burn or stealth. The Adaptive Engine Transition Program (AETP) is aiming to solve this conundrum and is the successor to the Adaptive Engine Technology Development (AETD) program. The contract modification is for the execution of next generation adaptive propulsion risk reduction for air superiority applications. Work will be performed in Cincinnati, Ohio, and is expected to be completed by March 30, 2022. Total cumulative face value of the contract is $1,4 billion.

Middle East & Africa

• The Kingdom of Morocco is currently negotiating the possible purchase of Apache AH-64 attack helicopters. This announcement comes after reports pointed towards the likely acquisition of Turkish T-129 attack helicopters. The AH-64A/D Apache has become a dominant attack helicopter around the globe. The new AH-64E Apache Guardian version incorporates 26 new technologies designed to enhance the aircraft’s capabilities, including a better flight performance, sensor performance and UAV integration. If Morocco buys the Apache it would join countries like Egypt, Greece, Israel, and the United Arab Emirates. The North-African nation is currently involved in a regional arms race with Algeria.

• Israel Aerospace Industries is reportedly preparing a tender for Vietnam’s planned acquisition of three advanced reconnaissance unmanned aerial vehicles. The contract has a potential face value of $160 million. Currently, IAI Group has not specified the type of UAV they will over to Vietnam, however considering the value of the deal it seems likely that the Heron TP platform will be the main contender. The Heron-TP variant is larger than the Heron 1, with a bigger 1,200 hp Pratt & Whitney Canada PT6A turboprop to power it. Typical mission payload rises to 2204 lb., which can be carried to around 45,000 feet, and the UAV has a maximum flight time of over 36 hours in favorable conditions. As a large MALE (Medium Altitude, Long Endurance) UAV, it’s built to carry multiple payloads at a time for a variety of missions.

Europe

• Jane’s reports that the UK Royal Navy is currently upgrading its fleet of Type 45 destroyers. The HMS Defender is the first vessel to receive a datalink software upgrade for its CMS-1 combat management system (CMS). The UK Royal Navy’s Type 45 destroyers have replaced the Type 42 destroyers, which were in service since 1978. BAE Systems Integrated System Technologies (Insyte) supplied the combat management system (CMS) and fast ethernet data transfer system for the destroyers. The Type 45 CMS integrates the PAAMS missile system and control all sensors and weapons. The new CMS-1 software (version 3.0.0.2) brings an improved version of the Cayman software application that interfaces with Defender’s Link 11 and Link 16 tactical data exchange networks and the ship’s satellite tactical data link (STDL) system. Cayman correlates information, including contacts, from these various systems. The ship’s communications bandwidth capacity was also increased, with the installation of the latest SCOT5 Full Maritime Terminal (FMT) to support the ship’s satellite communications capability.

Asia-Pacific

• Singapore will soon announce its plans for replacing its ageing fleet of F-16 fighter jets. Singapore’s fleet of around 60 F-16 jets are at the tail end of their service. So far, the country is investigating different replacement options, including the Eurofighter Typhoon and F-35s. Singapore’s F-16s first entered service in 1998. The country has typically used US-made aircraft in the past, making the F35s – a variant of which appeared at the city-state’s airshow back in February – a likely successor. The head of Lockheed’s international business said that initial talks with Singapore were centered on the F-35B short take-off and landing variant, which he described as “a nice fit for a smaller land-constrained environment”.

Today’s Video

• The Royal Australian Navy presents its future Global Combat Ship

F-15C over DC
(click to view full)

“Array of Aging American Aircraft Attracting Attention” discusses the issues that accompany an air force whose fighters have an average age of over 23.5 years – vs. an average of 8.5 years in 1967. One of the most obvious consequences is the potential for fleet groundings due to unforseen structural issues caused by time and fatigue. That very fear is responsible for the #1 priority placed on bringing new KC-X aerial tankers into the fleet to complement the USA’s 1960s-era KC-135 Stratotankers.

It can also affect the fighter fleet more directly.

Following the crash of a Missouri Air National Guard F-15C aircraft Nov 2/07 (see crash simulation), the US Air Force suspended non-mission critical F-15 flight operations on Nov 3/07. While the cause of that accident is still under investigation, preliminary findings indicate that a structural failure during flight may have been responsible. In response, Japan suspended its own F-15 flights, which left them in a bit of a bind – even as Israel’s F-15s joined them on the tarmac. As the effects continue to spread and the USAF and others continue to comment on this situation, DID continues to expand its coverage of this bellwether event. A conditional restoration of the American F-15A-D fleet to flight status was soon overturned by the re-grounding of that fleet as a result of the report’s conclusions – a status that remains only been partially lifted. Meanwhile, the accident report has been released (compete with video dramatization) and the status of the remaining aircraft will have significant implications for the USAF’s future F-15 fleet size. Not to mention its other procurement programs.

Then, too, this is America. Now there’s a lawsuit.

F-15E, Afghanistan
(click to view full)

The F-15A reached initial operational capability for the US Air Force in September 1975, and approximately 670 F-15s remain in the USAF’s inventory. Current F-15 flying locations include bases in the continental United States, Alaska, England, Hawaii, Japan and the Middle East, and the aircraft are active on the Iraqi and Afghan fronts. The Missouri Air National Guard F-15C that crashed was built in 1980.

Lt. Gen. Gary L. North, US CENTCOM Combined Forces Air Component commander, is maintaining the newer F-15E Strike Eagles on ground alert, to be used if required. Otherwise, he says he will accomplish all assigned missions using a variety of fighter, attack and bomber aircraft, and unmanned aerial vehicles. Lt. Gen. North added that:

“I worry about the health of our aging fleet and how sometimes it is not well understood by those our Airmen protect… The investigation will get to the cause of the accident.”

USAF Chief of Staff Michael Moseley was even more specific in an Oct 30/07 interview with GovExec.com:

“The F-15s and F-16s were designed and built in the late ’60s and ’70s. Some of them were produced up until the early ’80s. But they’ve led a pretty hard life of 17 years of combat. So you have to replace them with something, because we were continuing to restrict the airplanes. In the F-15 case, we’ve got the airplane restricted to 1.5 Mach. It was designed to be a 2.5 Mach airplane. We’ve got it limited on maneuvering restrictions because we’ve had tail cracks, fuselage cracks, cracks in the wings. The problem with that is – and Mike Wynne uses this analogy – it’s almost like going to the Indy 500 race practicing all the way up until Memorial Day at 60 miles an hour, and then on game day, accelerating the car out to 200 miles an hour. It’s not the time to be doing that on game day.

So in our training models and in our scenarios, we’re limiting these airplanes because they’re restricted and getting old. So there’s two parts to the recapitalization of the fighter inventory. The first part is the existing stuff is old and it’s getting broke, and it’s getting harder to get it out of depot on time. And our availability rates and our in-commission rates are going down. The ability to generate the sorties on those old airplanes is in the wrong direction.”

And Flight International:

“A USAF F-15 crashed in the Gulf of Mexico in 2002 when it broke up after the leading edge of its left vertical stabiliser detached in a high-speed dive to Mach 1.97. The pilot was killed.

The USAF says it began replacing the leading edge and upper aft portion of the vertical stabilisers during depot overhaul and has so far completed 463 of its 664 aircraft. The F-15 involved in the Missouri accident had its vertical stabilisers repaired in August 2003, the service says.”

Further investigation focused on the plane’s longerons, which connect the aircraft’s metal ‘skin’ to the frame, and run along the length and side of the aircraft. Both the Accident Investigation Board and Boeing simulations have indicated them as a possible source of catastrophic failure; indeed, DID had wondered why structural failure was suspected immediately, and it with that revelation it began to make sense. As DID explained at the time, if one or more of those longerons had failed, the stresses on the airframe could have folded or broken the plane in half – a very unusual form of accident. Eventually, the publication of the formal report confirmed that hypothesis:

“The one longeron, already not up to design specifications, cracked apart under the stress of a 7G turn, the colonel said. This led to the other longerons failing as well, which then caused the cockpit to separate from the rest of the fuselage. The pilot was able to eject, but suffered a broken arm when the canopy snapped off.”

F-4EJ “Kai(zen)”
(click to view full)

Nor is this problem confined to the USA – or even to the here and now.

The Chinese government’s Xinhua agency reports that Japan has also grounded its F-15 fleet. Japan’s F-15Js were built locally under license, on a more recent production schedule, but their oldest planes do date back to 1980. This is a precautionary measure until more is known.

Since Japan’s F-16-derived F-2 fighters are also grounded in the wake of a recent crash at Nagoya, this leaves 1960s era F-4EJ ‘Kai’ Phantom IIs as Japan’s interceptor and fighter patrol fleet for the time being.

Israel confirmed to Flight International that it had also grounded its 70 F-15A-D air superiority aircraft, which are undergoing multi-role conversions, and its F-15I Strike Eagles. The Strike Eagles were later removed from the USA’s concern list, but its F-15 A-D fleet is an important component of Israeli air defenses alongside its larger F-16 fleet.

Gen. John D.W. Corley, the commander of US Air Combat Command, was not encouraged by the results of the report, and of the in-depth fleet inspections that led to 40% of the Eagle fleet remaining on the ground over 3 months after the investigation:

“The difficulty is that issues have been found with F-15s built between 1978 and 1985, across A through D models at several bases, so no one source of the problem can be isolated… This isn’t just about one pilot in one aircraft with one bad part… I have a fleet that is 100 percent fatigued, and 40 percent of that has bad parts. The long-term future of the F-15 is in question… We don’t have a full and healthy fleet, so we’ve gotten behind on training missions, instructor certifications, classes and exercises…

We’re going over each and every aircraft to make a determination. We will take some F-15s out of the inventory. It just doesn’t make sense to spend the time and money if it won’t be worth it for some aircraft.”

Updates

F-15E, P-51, F-22A
(click to view full)

July 3/18: Vertical stabilizers The Air Force is contracting Boeing in support of its F-15 fleet. The firm-fixed-price contract provides for the production of F-15 vertical stabilizers and is valued at $23.6 million. The F-15A reached initial operational capability for the US Air Force in September 1975, and approximately 670 F-15s remain in the USAF’s inventory. Vertical stabilizers serve two basic purposes: flight stability and aircraft attitude alteration in yaw direction (i.e. yawing the aircraft left or right). In addition, they provide perfect mounting place for RWR and ECM antennae (located on the top of each stabilizers). Location of performance is at the company’s location in Missouri and is scheduled for completion by May 31, 2022.

April 03/18: AESA orders for USAF Boeing has been awarded a modification to a previously awarded contract for the US Air Force’s F-15 Fighter Modernization Program (RMP) radar upgrades. The contract is valued at over $187 million. It provides for work on 29 Group A and Group B kits, spares, fuel tanks and other equipment and services. The F-15A reached initial operational capability for the US Air Force in September 1975, and approximately 670 F-15s remain in the USAF’s inventory. Current F-15 flying locations include bases in the continental United States, Alaska, England, Hawaii, Japan and the Middle East. The RMP development and testing began in January 2011. The RMP replaces the F-15 legacy APG-70 mechanically scanned radar with an AESA system designated APG-82(V) and is designed to retain functionality of the legacy radar system while providing expanded mission employment capabilities including longer air-to-air target selection and enhanced task capabilities and enhanced air-to-ground and air-to-air combat identification capabilities. Work will be performed in St. Louis, Missouri, and is scheduled for completion in April 2022.

February 26/18: New wing for Qatar’s FMS F-15QA fighter aircraft being produced for Qatar will come with a newly designed wing, as manufacturer Boeing prepares to offer the design option for any future structural upgrades ordered for the US Air Force’s F-15Cs. Speaking to Flight Global, Steve Parker, Boeing’s vice-president of F-15 programs said the QA variant introduces a number of previously-announced features, including an advanced cockpit system with a large format display, and that the redesigned wing will strengthen the internal structure of the fighter without changing its aerodynamics. If the USAF decide to keep its F-15Cs flying for another two decades, the new features will be offered as part of any service life extension work ordered, and could also be offered to any other operators of F-15 aircraft, such as Japan.

June 16/17: Despite a spat with its Arab neighbors amid claims they were funding terrorism, Qatar has completed negotiations with Boeing to move ahead with a purchase of 36 F-15QA fighter aircraft. Qatari Defense Minister Khalid Al-Attiyah was in Washington to sign the $12 billion Foreign Military Sale agreement with his counterpart Jim Mattis, and could be extended to cover a total of 72 planes at a cost of approximately $21 billion. The move may confuse Washington’s allies in the region, after President Trump has initially sent a series of tweets that appeared to take credit for and praise the decision when Saudi Arabia and several Arab countries cut off ties with Qatar. “The nation of Qatar, unfortunately, has historically been a funder of terrorism at a very high level,” Trump said in a speech at the White House last week. “We ask Qatar, and other nations in the region to do more and do it faster.

March 19/17: The Israeli Air Force is considering a procurement of advanced F-15 jets from Boeing instead of purchasing additional F-35s. Tel Aviv will evaluate and consider this advanced version, capable of carrying more missiles and potentially in line with Boeing’s suggested 2040 configuration, and could order as many as 20-25 aircraft to augment its F-35 fleet. At present, the IAF has plans for a 50-strong F-35I fleet.

December 12/16: Engineers from Boeing have been working on USAF F-15Es, replacing old APG-70 radars with the state-of-the-art APG-82 AESA radar. The work has been underway since September on planes located at Seymour Johnson Air Force Base, North Carolina. Dubbed as the RMP Eagle modernization program, more than 90 jets will receive the overhaul which is expected to be completed within the next seven to nine years.

November 7/16: Boeing landed a $479 million USAF contract for engineering, manufacturing, and development of the Eagle Passive/Active Warning and Survivability System for the F-15 Eagle fighter jet. The system will provide advanced aircraft protection, significantly improved situational awareness and support for future F-15 mission requirements, replacing the jet’s Tactical Electronic Warfare Suite and keeping the aging aircraft in scheduled service through 2040. As 413 F-15Cs and F-15Es will be upgraded under the program, the expected costs may run to $7.6 billion.

October 12/16: The USAF has tasked Boeing with selecting a supplier for a $198 million upgrade of the F-15C/D which will allow the fighter to detect at long range the heat generated by an aircraft engine. After selecting the infrared search and track (IRST) sensor supplier, Boeing will be tasked with integrating the pod with the F-15’s other systems, including the Raytheon-supplied active electronically scanned array (AESA) radar. By delegating such work, the USAF avoids giving losing bidders a chance to protest Boeing’s decision to the US Government Accountability Office (GAO).

September 19/16: A recently released White House fact sheet on US military aid has revealed that Israel is to get ten F-15Ds under the excess defense articles program. Eight F-15s have been delivered so far, and are primarily used as a training aircraft but can also take part in air-to-air combat. Other excess articles given by the Obama administration to Israel include several Lockheed Martin C-130 cargo aircraft, AGM-114 Hellfire missiles and joint direct attack munitions.

May 2/16: USAF’s fleet of more than 500 F-15s are to get a wheel and brake upgrade after successful flight testing. Once completed, F-15C/D/E fighters will be capable of undertaking 1,400 landings before having to swap out their brakes. The USAF stands to save over $194 million in F-15 maintenance costs once all of the aircraft are fitted with the upgrade, and this will be the first brake testing to be carried out on the jet since the 1980s.

May 26/09: Aviation Week reports that the USAF is looking into the possibility of a Service Life Extension Program for its F-15A-D fleet, designed to increase their service lives from 8,000 flight hours to 12,000.

The move is driven, in part, by the impending collapse of Air National Guard wings that can be used in domestic air sovereignty patrols, as older fighters retire and are not replaced. The USAF is accelerating the retirement of 250 F-16 and F-15 fighters in FY 2010, and current plans calls for 2 ANG air sovereignty mission units to get F-22s, 4 to get receive upgraded F-15A-Ds, and the remaining 12 are yet to be determined.

March 22/08: Maj. Stephen Stilwell, a pilot for Southwest Airlines whose Missouri Air National Guard F-15C’s mid-air crackup began the fleet groundings, has filed suit in U.S. District Court against claiming Boeing Corp. His injuries left him with a 10-inch metal plate in the injured arm and shoulder, and he reports that he has suffered from chronic pain since the accident.

Stilwell’s suit, filed by attorney Morry S. Cole, says that Boeing knew or should have know that the F-15 as manufactured allowed and permitted for catastrophic flight break-up, and adds that Boeing failed to notify the Air Force and Missouri Air National Guard of “the likelihood of excess stress concentrations, fatigue cracking, structural failure and in-flight aircraft break up as a result of the structural deficiencies.” St. Louis Post-Dispatch.

February 2008: The largest effects of the F-15 fleet’s grounding may yet play out on the procurement front. If many of the USAF’s F-15s, which were supposed to serve until 2025 or so, must be retired, how should they be replaced? Read “Aging F-15s: Ripples Hitting the F-22, F-35 Programs.”

Jan 21/08: This week’s edition of the “Today’s Air Force” show highlights how the Air Force carried on its mission while more than 700 of its F-15 Eagles were grounded. See “The Eagle flies once again!” on the Pentagon Channel, American Forces Radio and Television Service stations around the world, and video podcast [30 minutes].

Jan 14/08: Officials begin flight operations again as 39 of the 18th Wing F-15C/Ds at Kadena Air Base, Japan are cleared to fly again after remaining on the ground for more than 2 months as a result of a fleet-wide stand-down. See USAF story.

Jan 10/08: According to the Air Combat Command Accident Investigation Board report released on this day. Their conclusion? The plane was simply too old:

“…a technical analysis of the recovered F-15C wreckage determined that the longeron didn’t meet blueprint specifications. This defect led to a series of fatigue cracks in the right upper longeron. These cracks expanded under life cycle stress, causing the longeron to fail, which initiated a catastrophic failure of the remaining support structures and led to the aircraft breaking apart in flight… the pilot’s actions during the mishap sequence were focused, precise and appropriate. The pilot’s actions did not contribute to the mishap, said Colonel Wignall. In addition, a thorough review of local maintenance procedures revealed no problems or adverse trends which could have contributed to the accident.”

Col. William Wignall, the head of the accident investigation added that:

“We’ve had great involvement from Boeing during the investigation. In fact, they’re the ones who determined the longeron was the problem. This was then confirmed by the Air Force Research Laboratory.”

See the USAF’s “F-15 Eagle accident report released,” and the accompanying video dramatization, as well as “Air Force leaders discuss F-15 accident, future.”

Jan 9/08: Air Combat Command officials clear 60% of the F-15A-D fleet for flying status, and recommends a limited return to flight for those planes that have cleared all inspections. The decision follows detailed information briefed on Jan 4/08 to Air Combat Command from the Air Force’s F-15 systems program manager, senior engineers from Boeing and the Warner Robins Air Logistics Center; as well as a briefing received on Jan 9/08 from the Accident Investigation Board president.

The USAF report describes inspections as “more than 90% complete,” with remaining inspections focusing primarily on the forward longerons. Thus far, 9 other F-15s have been found with longeron fatigue-cracks, and almost 40% of inspected aircraft have at least 1 longeron that is thinner than blueprint specifications. ACC believes each affected F-15 will have to be analyzed to determine if there is sufficient strength in the non-specification longeron, and this analysis will take place at the Warner-Robbins Air Logistics Center over the next 4 weeks. A number of F-15s are scheduled to be retired in 2009, and calculating the cost of fixes and airframe life of fixed aircraft could have a substantial bearing on the size of the USAF’s future F-15 fleet.

Meanwhile, the 2-month grounding, which has been the longest of any USAF jet fighter, is a gift that keeps on giving. Fully 75% of US Air Force and Air National Guard F-15A-D pilots have lost their currency status for solo flight, and another week would have made it 100%. Instructor pilots have retained their currency and will begin flying F-15B/Ds with the other pilots, so the pilots can land the plane and regain their status. This will be followed by further pilot training, which is required to regain operational proficiency status. USAF report | Flight International.

F-15C CAP(Combat Air Patrol)
(click to view full)

Dec 27/07: The Associated Press details some of the ripple effects created by the F-15 A-D grounding. With the F-15s in Massachusetts out of commission, the Vermont Air National Guard (ANG) is covering the whole Northeast. The Oregon ANG’s fighters are grounded, so the California Air National Guard is standing watch for the entire West Coast plus slices of Arizona and Nevada. To meet that need, the Fresno, CA based 144th Fighter Wing has had to borrow F-16s from bases in Indiana and Arizona and trim back training.

The Minnesota ANG is manning sites in Hawaii, while the Illinois ANG covers Louisiana. In Alaska, the new F-22 Raptors are stepping in – and so are Canadian CF-18s, which have intercepted several Russian bombers near Alaska in recent weeks.

Dec 10/07: The F-15 A-Ds remain grounded. A USAF update informs us that throughout the Air Force, maintainers have found cracks in the upper longerons of 8 F-15s so far: 4 from Air National Guard 173rd Fighter Wing, Kingsley Field, OR; 2 from USAF 18th Wing, Kadena Air Base, Japan; 1 from 325th Fighter Wing, Tyndall AFB, FL; and 1 from ANG 131st Fighter Wing, St. Louis, MO.

Inspections are underway using previous methods, until the Warner Robins ALC develops new ones for the fleet. After the area’s paint is stripped and bare metal is exposed, Airmen apply chemicals that reveal cracks under a black light. “Other inspections in hard-to-see areas are done with a boar scope [sic… maybe they mean “borescope”?] – a tool that uses a tiny camera and fits in tight areas.” Inspection time per aircraft is 12.5 to over 20 hours, and the 2-seat B and D models are more time consuming because the rear seat must be removed to access the upper longerons. USAF story.

UPDATE from USAF: “Yes, other readers pointed that out as well (although yours was the funniest). The story was corrected…”

Dec 3/07: It’s now official. Gen. John D.W. Corley, the commander of Air Combat Command orders the stand-down of all ACC F-15 A-Ds until further notice, and recommends the same for all other branches of the USAF. The stand-down does not affect the F-15E Strike Eagle and its variants abroad.

Technical experts with the Warner Robins Air Logistics Center at Robins Air Force Base, GA are developing a specific inspection technique for the suspect area, based on the recent findings. However, unlike previous inspections, the inspected aircraft will not be returned to flight until the F-15 A-D model findings and data have been analyzed, required inspections have been accomplished, and the necessary repair or mitigation actions have been completed. To date, longeron cracks have been discovered in an additional 4 aircraft. USAF release.

F-15E: Mission executed.
(click to view full)

Nov 28/07: The accident investigation board (AIB) report leads to the recommended re-grounding of the USAF F-15 A-D fleet, and almost certainly those of other countries as well. The new AIB findings have drawn attention to the F-15’s upper longerons near the canopy of the aircraft, which appear to have cracked and failed. Longerons connect the aircraft’s metal ‘skin’ to the frame, and run along the length and side of the aircraft. In addition to the AIB’s conclusions, manufacturer simulations have indicated that a catastrophic failure could result from such cracks, which were also discovered along the same longeron area during 2 recent inspections of F-15C aircraft.

The commander of Air Combat Command has recommended the stand-down of all F-15 A-D model aircraft across the US military, and ordered a renewed fleet-wide inspection of all ACC F-15 A-D model aircraft using a very specific inspection technique for the suspect area. The multi-role 2-seat F-15E Strike Eagles, which were manufactured later and had several design changes made, remain exempt from these cautions and exceptions. USAF article.

Nov 21/07: All USAF’s F-15s are being returned to flight status, despite acknowledgment that the service is accepting a degree of risk in doing so. Gen. John D.W. Corley, commander, Air Combat Command:

“The cause of the mishap remains under investigation… At the same time, structural engineers have conducted in-depth technical reviews of data from multiple sources… First, we focused on the F-15Es. They are… structurally different than the A-D models. Problems identified during years of A-D model usage were designed “out” of the E-model… Next, we concentrated on the remainder of the grounded fleet. The AIB(Accident Investigation Board) is now focused on the area just aft of the cockpit and slightly forward of the inlets. Warner Robins ALC mandated a thorough inspection and repair of all structural components in this area. I have directed each F-15 aircraft be inspected and cleared before returning to operational status. Today, ACC issued (a flight crew information file) and Warner Robins ALC issued an Operational Supplemental Tech Order to further direct and guide your pre-flight and post-flight actions.”

There are 666 F-15s in the Air Force inventory. As of this day, 219 of the 224 E-models and 294 of the 442 A-D models in the USAF’s inventory have been inspected and re-cleared for flight.

Nov 19/07: Shortly after becoming the first deployed F-15E unit in the Air Force to return to full operational capability following the Air Force’s fleet-wide grounding of the aircraft, the 455th Expeditionary Maintenance Squadron at Bagram AFB, Afghanistan, began the move from 5-7 day phase inspections every 200 flight hours, to a phase inspection every 400 flight hours. This change isn’t slated for implementation until 2008, but it’s being implemented early at Bagram AFB to keep more F-15Es in the air and meet mission demands.

The USAF says that its engineers at the Warner-Robins Air Force Base Air Logistics Center, GA looked carefully at all the data after years of F-15E analysis and testing, before approving the change. USAF release.

Nov 15/07: A USAF release says that an order issued by Air Combat Command’s Commander Gen. John Corley on Nov 11/07 mandates a 13-hour Time-Compliance Technical Order (TCTO) on location for each of the USAF’s F-15E Strike Eagles, to inspect hydraulic system lines, the fuselage structure, and structure-related panels. Aircraft that pass this inspection may return to flight status, and similar procedures are likely to be underway for Israel’s F-15Is. ACC Combat Aircraft Division chief Col. Frederick Jones said that this was possible because:

“We were able to determine, based on initial reports from an engineering analysis, that the F-15E is not susceptible to the same potential cause of the Missouri mishap.”

The TCTO inspection is designed to confirm the engineering analysis, and aircraft deployed the CENTCOM has apparently completed inspections and returned to flying status. This still leaves 2/3 of the USAF’s F-15 fleet grounded, however, as the F-15A-D models remain under suspicion. The F-15Es are about 15 years old on average, but the F-15A-D models were introduced earlier. Maj. Gen. David Gillett, ACC director of Logistics said that:

“What we’ve got here is an example in the C model of what happens when you have an airplane that’s about 25 years old… What you find is that it becomes more and more expensive to modify [the F-15 airframe] over time… Our costs have gone up 87 percent in the last five years and continue to rise rapidly. Even when you invest in an old airframe – you still have an old airframe.”

Additional Readings & Sources

• Gannett’s Military Times – F-15’s midair breakup. Hosts the Pentagon’s Crash Simulation.

• DID Spotlight article – Aging Array of American Aircraft Attracting Attention. The problem is not at all unique to America.

• Reuters (Oct 15/08) – US Air Force eyes fighter cuts to boost modernization. The force cuts would reduce the reserve fleets by about 137 F-15s, but it would also cut 177 F-16 fighters and 9 A-10s. The goal is to save $3.4 billion, to be applied to F-35 purchases.

• Investors Business Daily (Dec 7/07) – The Eagles are Grounded. Quotes ACC chief Maj. Gen. Ronald Keys re: the slippage of fighter fleet average age from 1967 to the present.

• Flight International (Nov 6/07) – VIDEO: Israel and Japan join US in grounding F-15s

• USAF (Nov 6/07) – Mission continues during grounding of F-15s.

• US DoD DefenseLINK (Nov 6/07) – Air Force Grounds F-15 Fleet Following Crash

• Xinhua, via Military.com – Now Japan Grounds F-15 Fighters

• USAF (Nov 4/07) – Air Force suspends some F-15 operations

Naval launch
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As UAVs proliferate, and the demands of counter-insurgency fights force militaries to look at arming new kinds of aircraft, a number of manufacturers and governments are looking to develop precision-guided “mini-missiles” and glide weapons. Raytheon’s 33+ pound, 42 inch long Griffin is a member of that class, and comes in 3 versions.

Griffin was privately developed, and Raytheon took pains to re-use components from existing weapons like the AIM-9X Sidewinder air-air missile and the Javelin anti-tank missile. The resulting weapon carved out a niche in the growing market for small and relatively inexpensive guided weapons, but Raytheon thinks it has more potential, and has been investing in new capabilities…

The AGM-176 Griffin Family

KC-130J, Afghanistan

AGM-176A. Griffin-A is currently in use as part of American roll-on armed kits for its C-130 Hercules transports. It’s dropped out of “gunslinger” tubes and “derringer doors,” providing precision weapon drops from the rear ramp and side door. It packs a 13 pound blast-fragmentation warhead, and uses a combination of GPS/INS and a semi-active laser seeker for guidance.

AGM-176B/ MK-60. Griffin-B is a powered missile can be a forward-firing weapon, and can be launched from land, naval, or aerial platforms. The missile’s estimated range is similar to the larger AGM-114 Hellfire: about 3.5 miles if surface-launched without a booster motor, rising to 12.5 miles or more if fired from an aerial platform at altitude. That’s fine for aerial platforms, as Griffin A/B offers them the ability to carry more Griffins than Hellfires, while achieving similar reach and precision. The tradeoff is a smaller warhead.

There are still targets like tanks that will demand a larger AGM-114 Hellfire warhead, and targets like buildings may demand a full-size AGM-65 Maverick missile or LJDAM bomb. In many cases, however, the Griffin offers a “just enough, for less” solution that has the added benefit of minimizing collateral damage.

The AGM-176B Block III adds an improved semi-active laser seeker, enhanced electronics and signal processing, and a new Multi-Effects Warhead System that works against a number of different target types.

Confirmed Platforms: AT-6C turboprop, KC-130J Harvest Hawk, AC-130J Ghost Rider, MC-130W Combat Spear, MQ-1 Predator UAV, MQ-8B Fire Scout VTUAV, MQ-9 Reaper UAV, Cyclone Class patrol boat. Has also been tested using ground launch system, and on the OH-58D Kiowa Warrior scout helicopter.

AGM-176C. The Griffin C attempts to compete against Lockheed’s Hellfire and MBDA’s Brimstone 2 by adding dual-mode laser/IIR guidance for a fire-and-forget missile that uses thrust-vectoring control for vertical launch compatibility, a datalink for retargeting in flight, and waypoint flight to maneuver around obstacles.

The AGM-176C-ER keeps these improvements, and its rocket motor extends surface-launched range to 10 miles or more – about 3x the range of previous Griffins, or their larger Hellfire/ Brimstone competitors.

Looking Beyond

Griffin on HMMWV
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The Army has tested the 45-pound, powered Griffin-B missile as an option for forward outposts. Its de facto competition here is Raytheon’s own Javelin missile, which is already widely deployed, and offers similar range and firepower. Javelin is a rather expensive missile, and takes some time to activate and reload, but comes with advanced sensors that troops use independently.

In order to find a viable niche and achieve acceptance, Griffin will have to compete on cost and response time/volume. Griffin C’s added range will help, but this missile family’s ability to receive geo-coordinate cues from UAVs and other sensors, without the need for an operator to find the same target himself, may be their biggest edge.

On the naval front, the picture isn’t as rosy. Griffin-B reportedly costs about half as much as the Raytheon NLOS-LS PAM, but its surface-launched range is less than 1/6th of NLOS-LS PAM’s 21 nautical miles. This severe cut in reach, coupled with the warhead’s small size, sharply limits its versatility. Griffins could engage enemy speedboats, but guidance modes for the A & B models force one-at-a-time engagements. Nor can Griffin do much damage to full-size enemy vessels – most of which will pack large anti-ship missiles with a 50 – 200 mile reach.

This didn’t stop the Navy from designating the Griffin as an interim solution, and it has been a very useful addition to their Cyclone Class patrol boats. On the other hand, Griffin’s limitations, and the availability of fire-and-forget Hellfire missile stocks, led the US Navy to equip their Littoral Combat Ship with AGM-114L Hellfire Longbow radar-guided missiles instead.

Griffin C’s combination of range and guidance modes may give it a chance on other vessels that are thinking of mounting Brimstone-class weapons, but it’s never going to compete with anti-ship missiles. Nor does it have the range to deliver naval fire support for ground forces, outside of a CONOPS involving small speedboat/ USV swarms. That leaves close-in fire as Griffin’s sweet spot, with a potential boost from its ability to also equip tactical-size shipboard UAVs.

Contracts & Key Events

KC-130J’s “gunslinger”
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Unless otherwise noted, the USAF’s Air Armament Center Contracting, Advanced Programs Division at Eglin Air Force Base, FL manages these contracts, though U.S. Army Contracting Command at Redstone Arsenal, AL also seems to have its share. The contractor is Raytheon Missiles Systems Co. in Tucson, AZ.

FY 2016-2018

 

AT-6C & Griffins
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July 3/18: USSOCOM The US Special Operations Command is boosting its missile power. Raytheon is set to produce an un-specified number of Griffin missiles under an indefinite-delivery/indefinite-quantity contract that is valued at $315 million. The contract also provides for related support for product improvements, operations and sustainment. Raytheon’s Griffin is a precision guided “mini-missile” and glide weapon that comes in three variants. The Griffin-A is currently in use as part of American roll-on armed kits for its C-130 Hercules transports. The Griffin-B is a powered missile can be a forward-firing weapon, and can be launched from land, naval, or aerial platforms. And the Griffin C attempts to compete against Lockheed’s Hellfire and MBDA’s Brimstone 2 by adding dual-mode laser/IIR guidance for a fire-and-forget missile that uses thrust-vectoring control for vertical launch compatibility, a datalink for retargeting in flight, and waypoint flight to maneuver around obstacles. Work will be performed at contractor facilities in Tucson. No completions date has been given at this point.

February 5/18: Production Orders The US Air Force (USAF) granted Raytheon a $105.2 million contract modification on Wednesday, January 31, for the provision of an undefined number of AGM-176 Griffin missiles. The contract award also includes options for all variants of Griffin standoff precision guided munitions and corresponding production, test and engineering support. Work will be performed in Tucson, Arizona, and is expected to be complete by Dec. 31, 2020. Capable of being launched from a variety of platforms and used by multiple services in the US military, the Griffin A is an aft-eject missile which can be fired from a common launch tube or from a C-130 aircraft, while the B-variant is forward-firing and can be fired from a composite launch tube integrated on both rotary and fixed-wing aircraft, ground platforms, and Navy Cyclone-class Patrol Coastal ships. A C-variant is currently in production and will feature dual-mode guidance and Griffin C-ER aims to extend the range of the missile. The modification brings the total cumulative face value of the contract to $210,080,601.

August 21/17: Raytheon has been granted a $103 million contract to supply its AGM-176 Griffin precision guided missile and associated support to the US Air Force. Work will be conducted in Tuscon, Ariz., and is expected to be finished by Dec. 31, 2018. Originally designed for MC-130 special operations gunships, the light attack missile comes in eitheraft-launch or forward firing variants for aircraft and can also be deployed from ground and naval units.

January 18/16: Raytheon has been given an $85 million contract to supply Griffin A & B Block II/III missiles to the USAF. Delivery of the missiles is expected to be January 31, 2017. The missiles are the two variants of the AGM-176 Griffin mini-missile. The Griffin A is an unpowered precision munition that can be dropped from a rear cargo door, or a door-mounted launcher of an aircraft, while the rocket-powered Griffin B can be employed as an air-to-surface or surface-to-surface missile. Both are currently being used on a variety of weapons platforms including LCS vessels, C-130 aircraft and UAVs.

FY 2012 – 2015

AGM-176C Griffin triples range, adds retargeting and dual-mode guidance; Griffin elbowed aside for LCS by Army AGM-114L Hellfires; Army, Naval tests; Griffin fired from RAM missile launcher.

May 29/15: Orders.The Air Force signed a contract with Raytheon to procure Griffin missiles, with the deal worth $12 million. The Griffin is a precision miniature munition that utilizes parts from other Raytheon-manufactured missiles – such as the Javelin ATGM and the AIM-9X AAM – to keep costs down. The missile is currently used as part of roll-on armed kits for US C-130 transport aircraft.

Nov 3/14: Orders. A maximum $85.5 million indefinite-delivery/ indefinite-quantity contract for Griffin AGM-176A Block II and AGM-176B Block III (q.v. Feb 20/14) missiles and test/ support equipment, along with engineering support under a cost-plus-fixed-fee CLIN. $32.6 million is committed immediately as an initial order, using FY 2013 – 2015 USAF budgets.

DID asked Raytheon’s Griffin Programs Director Steve Dickman about this order. He told us that this isn’t a major shift for Griffin, just a way for the government to continue buying missiles as it needs them. Based on past figures, the initial order is very solid.

Work will be performed at Tucson, AZ, and the government will be able to continue buying missiles and services under its terms until Oct 30/17. This award is the result of a sole-source acquisition. The USAF Life Cycle Management Center at Eglin AFB, FL manages the contract (FA8656-15-D-0241).

Multi-year contract

Oct 28/14: Testing. Raytheon announces that its SeaGriffin has had a name change to Griffin C, and successfully completed flight tests at Yuma Proving Ground, AZ. The missile extends range to around 10 km, adds in-flight retargeting, and features IIR and laser seekers for fire and forget mode. Sources: Raytheon, “Raytheon Griffin C flight tests demonstrate in-flight retargeting capability”.

July 17/14: LCS closed. Navy Recognition interviews a US Navy representative re: the Surface to Surface Mission Module aboard LCS, which will sit above the helicopter hangar on the Freedom Class, and behind the 57mm gun on the Independence Class. Key excerpts:

“Longbow Hellfire is the selected missile to help meet the LCS Surface Warfare Mission Package’s (SUW MP) engagement requirement per the LCS Capabilities Description Document (Flight 0+). Currently, no new requirement exists to warrant acquisition of a new engagement capability…. An LCS variant can only receive one SUW mission package. This will have one Surface-to-surface Missile Module (SSMM), which will utilize one launcher structure that holds 24 Longbow Hellfire missiles…. There currently is no requirement for at-sea reloads.Therefore, the current SSMM design does not support at-sea reloads… It utilizes an existing Army M299 launcher mounted within a gas containment system.”

Looks like Raytheon’s SeaGriffin has lost its shot, despite tripling its previously-comparable range and adding comparable fire-and-forget capability in its latest iteration. Sources: Navy Recognition, “Q & A with the US Navy on Lockheed Martin Hellfire missiles for Littoral Combat Ships”.

July 14/14: SeaGriffin. Raytheon hasn’t given up on its “SeaGriffin missile” for the Littoral Combat ship just yet. A recent test was used to demonstrate a dual-mode laser and imaging infrared guidance system, whose fire-and-forget capability would allow the same kind of salvo launches against swarming targets that the AGM-114L Hellfire’s MMW radar seeker offers. They also tout “an extended range motor that will nearly triple [SeaGriffin’s] range,” giving it a notable advantage over Lockheed Martin’s AGM-114L Hellfire or MBDA’s Dual-Mode Brimstone 2.

Other SeaGriffin enhancements beyond the Griffin-B Block II include a datalink for in-flight target updates, waypoint navigation, and vertical launch capability with vectoring thrust control. The firm says that they’re conducting a series of SeaGriffin guided flight tests to demonstrate the missile’s readiness as an option for the LCS Surface Warfare module. Sources: Raytheon, “Raytheon SeaGriffin completes guided flight test with new dual-mode seeker”.

SeaGriffin (Griffon C/ C-ER) introduced

LCS: Hellfire
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April 9/14: LCS. The US Navy confirms that they have picked the AGM-114L Hellfire Longbow radar-guided missile as the LCS Surface Warfare Package’s initial missile. Its fire and forget guidance, salvo capability, and ability to use the ship’s radar tipped the balance against Griffin. Lockheed Martin says that the missile has had 3 successful test firings in vertical launch mode, and there are plans to test-fire the missile from LCS itself in 2014, using a new vertical launcher.

Hellfire wouldn’t have any more range than Griffin’s 3.5 nmi, but the millimeter-wave radar seeker allows the ship’s radar to perform targeting, while allowing salvos of multiple fire-and-forget missiles against incoming swarms. In contrast, the Griffin’s laser designation must target one boat at a time, from a position that’s almost certain to have a more restricted field of view than the main radar. Navy AGM-114L missiles would be drawn from existing US Army stocks, which will have shelf life expiry issues anyway. That’s one reason the Army intends to begin buying JAGM laser/radar guided Hellfire derivatives around FY 2017.

Griffin’s existing aerial platforms won’t be affected by this decision, except to the extent that costs will be slightly higher with fewer missiles ordered. LCS deployment probably won’t affect Griffin use on the PC-1 Cyclone Class patrol boats, either, as they don’t have radar targeting capabilities. Sources: DoD Buzz, “Navy Adds Hellfire Missiles to LCS” | USNI News, “Navy Axes Griffin Missile In Favor of Longbow Hellfire for LCS”.

Griffin out of LCS

March 25/14: MK-60 IOC. The MK-60 Patrol Coastal Griffin Missile System has formally achieved initial operational capability with the US Navy on its Cyclone Class vessels. they’ve actually been carrying Griffin for a while; testing began in March 2012.

The MK-60 system includes the AGM-176B Griffin missile, a laser targeting system, a US Navy-designed launcher, and a battle management system on a laptop for use by the missile’s operator. Sources: Navy Recognition, “DIMDEX 2014 Show Daily: US Navy achieves IOC on Patrol Coastal Griffin Missile System” | Shephard, “US Navy declares IOC for MK-60 Griffin missile system”.

Naval IOC

Feb 20/14: Griffin Block III. After a range of testing including a number of live test shots against fixed and moving targets, Raytheon says that the new Griffin Block III is on the production line as the missile’s new iteration.

Block III introduces an improved semi-active laser seeker, enhanced electronics and signal processing, and a new Multi-Effects Warhead System that works against a number of different target types. We’re starting to see a lot of general convergence between blast, fragmentation, and armor-piercing effects, and the trend seems to be headed toward sharp reductions in the number of weapon variants determined by warhead type. Sources: Raytheon, “Raytheon demonstrates Griffin Block III missile”.

Feb 5/14: #2,000. Raytheon announces delivery of its 2,000th Griffin Missile since production began in 2008, an AGM-176B Block III variant. The production milestone also highlights 70 consecutive months of on-time or early Griffin deliveries to the warfighter. Sources: Raytheon, “Raytheon marks delivery of 2000th Griffin missile”.

Delivery #2,000

July 22/13: GAO Report. The US GAO releases GAO-13-530, “Significant Investments in the Littoral Combat Ship Continue Amid Substantial Unknowns about Capabilities, Use, and Cost”. The entire report is a long chronicle of the Littoral Combat Ship program’s history of falling short and unresolved issues, including a number of issues with the mission modules. While Griffin missiles have been deployed on Cyclone Class patrol boats, GAO says they may never be deployed aboard LCS:

“The Navy assessed over 50 potential missile replacements for LCS, and in January 2011 selected the Griffin IIB missile as an interim solution based, in part, on it costing half of [NLOS-LS per missile]. The program now intends to purchase one unit with a total of eight Griffin IIB missiles, to be fielded in 2015, which leave other SUW module equipped ships with a limited ability to counter surface threats. However, Navy officials told us that they may reconsider this plan because of funding cuts related to sequestration. According to OPNAV, funding for Griffin development and testing has been suspended for the remainder of fiscal year 2013. OPNAV and the LCS program office, with LCS Council oversight, plan to investigate using a more cost-effective, government-owned, surface-to-surface missile system that would provide increased capability, including increased range. According to Navy program officials, the deployment of the Increment IV [Griffin successor] missile could also be delayed by over a year [i.e. to 2020] because funding reductions have delayed early engineering work and proposal development for the missile contract.”

June 12/12: Testing. Raytheon reveals a winter 2012 test in which 3 Griffin missiles were fired from a sea-based launcher at 3 separate speeding-boat targets more than 2 km / 1.2 miles away. The weapons were guided by laser, and scored direct hits on the targets.

The test demonstrates that the Griffin can defend a warship against speedboats that venture inside mutual torpedo range. On the one hand, that’s a good thing. Those with a grasp of naval history might recall British Royal Navy Captain Augustus Willington Shelton Agar, VC, DSO. As a Lieutenant, he sank the Russian heavy cruiser Oleg and a submarine depot ship, and badly damaged 2 battleships in 1919, using torpedo-armed speedboats launched from the Terijoki Yacht Club in Finland. The bad news is that Agar’s successors use larger Fast Attack Craft, armed with anti-ship missiles that vastly outrange the Griffin. The AGM-176B can still be very useful on patrol boats and smaller craft, but it’s a secondary defense at best for warships.

May 29/12: Orders. An $8.2 million firm-fixed-price contract modification buys “Griffin stand-off precision guided munitions” and engineering services support. Work will be performed in Tucson, AZ, with an estimated completion date of Dec 31/12. One bid was solicited, with one bid received. The U.S. Army Contracting Command at Redstone Arsenal, AL manages this contract. (W31P4Q-10-C-0239).

This order pushes announced contracts to date over $166 million.

Order

May 18/12: Orders. An $85.5 million firm-fixed-price, cost-plus-fixed-fee contract to buy Griffin missiles. Based on past records (q.v. Nov 2/11), the total contract would correspond to a maximum of over 800 missiles.

It isn’t all committed at once, and the initial order buys just 22 Griffin all-up-rounds, and 43 telemetry rounds for testing. Work will be performed in Tucson, AZ, and will run until July 31/13 (FA8677-12-D-0037).

Major order

April 18/12: RAM shot. Raytheon announces that sometime in winter 2011, the USN fired a Griffin B missile from a land-based Rolling Airframe Missile (RAM) launcher. The shot was taken at a static target about 2 miles away, and the GPS/laser guidance produced a direct hit.

OK, successful demonstration. On the other hand, the RAM system already has the ability to hit surface craft from longer range than Griffin, albeit with less surety than Griffin’s laser guidance. Since RIM-116 missiles can also kill incoming anti-ship missiles, it isn’t clear why a ship would mount Griffins by sacrificing several RIM-116 slots on a 21-slot MK-49 or 11-shot SeaRAM launcher. Sources: Raytheon, “US Navy Fires Raytheon Griffin Missile From RAM Launcher”.

Feb 14/12: Army testing Griffin. Raytheon announces that the US Army is testing its powered Griffin B as a potential system to provide 360 degree quick-reaction firepower to smaller outposts. Raytheon’s Javelin missile can already do this within the Griffin’s firing range, so the Griffin will have to compete on cost, responsiveness, and fire volume:

“During the test, warfigthers fired a Griffin missile from a launcher at a static target more than 4 kilometers (2.5 miles) away. Using GPS coordinates generated by a tethered aerostat, the missile directly impacted the target, achieving all test objectives.”

FY 2008 – 2011

Griffin ordered for C-130 aircraft, UAVs, and Cyclone Class patrol boats; Picked for LCS.

Griffin testing

Nov 7/11: LCS. Inside the Navy reports [subscription] that the Griffin missile will be part of LCS’ initial surface warfare module, but a competition will begin in 2012, and:

“The program executive office for the Littoral Combat Ship has already identified capabilities that could replace the Griffin missile…”

The new missile would be due for fielding after FY 2016. One possibility that’s already on the market is IAI’s Jumper.

LCS SuW pick

Nov 7/11: KC-130J-HH. Inside the Navy reports [subscription] on Griffin usage in Afghanistan:

“Less than a year after first introducing it to the fleet, the Marine Corps has already used the Harvest Hawk… to fire 74 Hellfire and 13 Griffin missiles… while also providing intelligence, surveillance and reconnaissance, a Marine aviation official said here recently.”

Nov 2/11: Orders. A $9.3 million firm-fixed-price contract modification to buy 70 Griffin Block IIA all up rounds, and 21 Griffin Block II A telemetry rounds that replace the warhead with testing electronics. The primary location of performance is Tucson, AZ, and the purchase supports U.S. Special Operations Command (FA8677-11-C-0115, PO 0008).

Order

Aug 19/11: UAVs. Aviation Week reports on 2 key milestones for the MQ-8 Fire Scout helicopter UAV program. One is the addition of the larger MQ-8C/ Fire-X. The other is weapons approval for the MQ-8B, beginning with the APKWS-II laser-guided 70mm rocket that’s already cleared for use from Navy ships.

Raytheon’s laser-guided short-range Griffin mini-missile is slated for a demonstration before the end of August 2011, and will be the platform’s next weapon, as opposed to Northrop Grumman’s own GBU-44 Viper Strike.

Aug 15/11: Orders. An $11.5 million firm-fixed-price cost-plus-fixed-fee contract for an unspecified number of Griffin missiles, and associated engineering services support. Work location will be determined by task order, with an estimated completion date of Sept 30/12. One bid was solicited, with one bid received by the U.S. Army Contracting Command at Redstone Arsenal, AL (W31P4Q-10-C-0239).

Order

July 14/11: Orders. A $9.1 million contract modification to buy 4 Griffin Block II A telemetry rounds for testing (part number 2292000-25), and 74 Griffin Block IIA all up rounds (Part Number 2292000-26) to include shipping, engineering services, and proposal development costs.

Griffin is currently used on UAVs and armed C-130s, as well as a potential future aboard the LCS (FA9200-11-C-0180, PZ0003).

Order

May 12/11: LCS. Inside the Navy reports:

“The Navy may not have settled on the Griffin missile to replace the canceled Non-Line-Of-Sight missile on the Littoral Combat Ship, despite the service’s announcement in January that it planned to use the missile for both a short-term and long-term solution to the capability gap, officials told Inside the Navy last week…”

Jan 11/11: LCS. Media report that the U.S. Navy is moving towards selecting Raytheon’s Griffin missile as the replacement for the cancelled NLOS-LS, instead of taking over that program’s development now that the Army has pulled out. USN surface warfare division director Rear Adm. Frank Pandolfe told a Surface Navy Association convention audience in Arlington, VA that a 6-month review had settled on this Raytheon product, as something that can hit targets at “acceptable” ranges and cost.

That recommendation must be endorsed by the Navy before anything comes of this; if they do, the service would field the existing very short range Griffin by 2015, and try to develop a longer range version later. DoD Buzz | Arizona Daily Star.

Sept 8/10: UAVs. Flight International reports that the Griffin is being integrated onto MQ-1 Predator and MQ-9 Reaper UAVs. They are not specific, but these are probably US Special Operations Command’s modified MALET drones.

Griffin-B launch
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June 9/09: Orders. A $14.5 million firm-fixed-price with cost-plus-fixed-fee line items contract for Griffin A & B munitions and engineering services. Even the air-launched versions have ranges of just 9+ miles, however, and at this point, Griffin is not on the radar screen for use on LCS.

Work is to be performed in Tucson, AZ, with an estimated completion date of May 31/10. One bid was solicited, with one bid received by the US Army Aviation and Missile Contracting Center at Redstone Arsenal, AL (W31P4Q-09-C-0517).

Order

Dec 24/08: Orders. A firm-fixed-price with cost-plus-fixed-fee line items contract for Griffin munitions and engineering services – but the amount is not mentioned. Work will be performed in Tucson, AZ, with an estimated completion date of Aug 31/09. One bid was solicited and one bid received by the U.S. Army Aviation and Missile Contracting Center at Redstone Arsenal, AL (W31P4Q-08-C-0252).

Order

Aug 13/08: Orders. A $6.1 million firm-fixed price with cost-plus fixed fee line items contract for Griffin munitions and engineering services. Work will be performed in Tucson, AZ, and is expected to be complete by Aug 31/09. One bid was solicited on Feb 5/08 by the U.S. Army Aviation and Missile Command in Redstone Arsenal, AL (W31P4Q-08-C-0252).

At this point, NLOS-LS is still a program in good standing, and Griffin is seen as a UAV and helicopter weapon. The prospect of equipping an MQ-1A/B Predator with 6 Griffins instead of 2 Hellfires is seen as especially attractive. See also Aviation Week, “Small Raytheon Missile Deployed On Predator” [dead link].

Order

May 23/08: Order. A $10.25 million firm-fixed price contract for Griffin munitions. Work will be performed in Tucson, AZ, and is expected to be complete by March 31/09. One bid was solicited on Feb 5/08 by the U.S. Army Aviation and Missile Command in Redstone Arsenal, AL (W31P4Q-08-C-0252).

Order

May 7/08: Order. A $9.4 million firm-fixed price contract with cost-plus-fixed fee items for Griffin munitions, and associated engineering services. Work will be performed in Tucson, AZ, and is expected to be completed by Dec 31/08. One bid was solicited on Feb 5/08 by the U.S. Army Aviation and Missile Command in Redstone Arsenal, AL (W31P4Q-08-C-0252).

Order

Additional Readings

• Raytheon – Griffin.

• Defense Update – Griffin [and] Small Tactical Munition (STM); Griffin B

• DID- The Right to Bear Arms: Gunship Kits for America’s C-130s.

• DID – The USA’s New Littoral Combat Ships (LCS). Griffin-B was slated to replace the canceled NLOS-LS PAM missile, but was displaced by the radar-guided AGM-114L Hellfire Longbow.

• DID – Arming RQ-7 UAVs: The Shadow Knows…. Even Griffin may be too heavy for the RQ-7, though…

• DID – GBU-44 Viper Strike: Death From Above. A Griffin competitor from Northrop Grumman.

• Flight International (Sept 8/10) – Raytheon’s Griffin missile makes quiet gains with US military .

Americas

• Huntington Ingalls is being tapped to further support the Navy’s shipbuilding efforts. The un-definitized fixed-price, incentive firm target modification is valued at $200 million and provides for the purchase of additional long lead time material in support of USS Enterprise (CVN 80). The USS Enterprise will be the third Gerald F. Ford class carrier and will replace the USS Dwight D. Eisenhower (CVN 69). The air wing of this new carrier will be capable of supporting more than 75 aircraft of varied kinds, including fixed-wing and rotary-wing systems. Moreover, an Electromagnetic Aircraft Launch System (EMALS) will be incorporated in the ship to replace the steam catapults of the older versions. Work will be performed in Newport News, Virginia, is expected to be completed by February 2027.

• Lockheed Martin Corp. will continue its research on hypersonic technology. The $11.8 million contract awarded by Strategic Systems Programs provides for Hypersonic Booster technology development seeking to demonstrate technologies related to intermediate range capability through booster design, fabrication and validation testing. Strategic Systems Programs is a mainstay in the Navy’s development and procurement of sea-based deterrent missile systems. Hypersonic missiles are defined as those traveling at speeds between Mach 5 and Mach 10. That is, between 3,106 and 15,534 miles per hour, or one to five miles per second. China, Russia and the United States are all currently investing heavily in hypersonic systems, while a few other countries are also exploring the technology to a much lesser degree. Work will be performed at various locations, including Sunnyvale, California; Magna, Utah and Elma, New York. It is scheduled for completion by June 2019.

• The Air Force is contracting Raytheon in support of weapons integration on its fleet of F/A-18E/F fighter aircraft. The indefinite-delivery/indefinite-quantity contract is valued at $93 million and provides for the integration of the Small Diameter Bomb II (SDB II) onto the fighter jet. Raytheon’s GBU-53/B SDB-II is 7? in diameter around the tri-mode (laser, IIR, radar) seeker, with a clamshell protective door that comes off when the bomb is dropped. Range is expected to be up to 40 nautical miles when launched at altitude, thanks to a high lift-to-drag ratio in the design. Since SDB-II is an unpowered glide bomb, its actual range will always depend on launching altitude and circumstances. This contract provides for the testing, analysis, support and sustainment of SDB II weapon onto the F/A-18E/F platform with developmental and operational testing. Work will be performed in Tucson, Arizona, and is expected to be completed by July 1, 2023.

Middle East & Africa

• The government of Azerbaijan is adding a new stand-off-missile (SOM) to its inventory. The cruise missile is being manufactured by Turkish defense manufacturer Roketsan. The SOM is highly effective against moving land / surface targets, high-value stationary targets, strategic assets, shelters, exposed aircraft, aircraft hangars, and command and control centers, as well as sea surface threats. It has resistance against countermeasures as well as clutter effects. The missile is capable of performing in-flight re-targeting as well as in-flight mission selection among pre-planned missions. Its rear section is fitted with control fins for providing lifting and improved maneuverability. This is the first known export of the SOM, which has a range of more than 250 km with a high explosive/blast fragmentation warhead weighing approximately 226 kg. The most likely launch platforms for Azerbaijan’s SOMs are its MiG-29 multirole fighters, although the Su-24 strike aircraft may also be an option.

• Jane’s reports that a UK Royal Air Force C-130J was seriously damaged in a heavy landing during an apparent special forces mission. he previously undisclosed incident took place last August during the height of coalition operations against the so-called Islamic State (IS) in northern Syria around Raqqa. The UK ordered 15 C-130J-30s in 1994, with the first delivery in August 1998. The Hercules is the RAF’s primary tactical transport aircraft and in its current C.Mk 4 and C.Mk 5 versions of the C-130J-30 and C-130J, respectively, has been the backbone of UK operational tactical mobility tasks since it was brought into service. It is frequently employed to operate into countries or regions where there is a threat to aircraft; its performance, tactics and defensive systems make it the ideal platform for such tasks. This is the first UK air loss during Operation ‘Shader’, the codename for its participation in the war against the IS.

Europe

• The German defense manufacturer RAM-System is being tapped by the US Navy for work on its Rolling Airframe Missile (RAM) system. The firm-fixed-price un-definitized contract is valued at $68 million provides for work on the RAMs MK 49 Guided Missile Launching System as well as associated shipboard hardware and spares. The Rolling Airframe Missile Guided Missile Weapon System is co-developed and co-produced under an International Cooperative program between the US and Federal Republic of Germany’s governments. The RAM system is a supersonic, lightweight, quick-reaction, fire-and-forget weapon, designed to attack enemy helicopters, aircraft, and surface craft. It uses passive RF and infrared guidance for engaging several threats simultaneously. The MK 44 guided missile round pack and the MK 49 guided missile launching system together hold 21 missiles. Existing shipboard sensors can provide the system with target and pointing information. Work will be performed at various locations in Germany and the US, including Louisville, Kentucky; Ulm, Germany and Schrobenhausen, Germany. Work is scheduled for completion by September 2022.

• Hungary is the second confirmed customer for the Airbus Helicopters’ HForce common weapons platform, with an order for 20 H-145M helicopters. The helicopter acquisition is part of Budapest’s military modernization program Zrinyi 2026. Together with the helicopters, Airbus will provide an extensive training and support package. With a maximum take-off weight of 3.7 tons, the H145M can be used for a wide range of tasks, including troop transport, utility, surveillance, air rescue, armed reconnaissance and medical evacuation. The Hungarian fleet will be equipped with a fast roping system, high-performance camera, fire support equipment, ballistic protection as well as an electronic countermeasures system to support the most demanding operational requirements. The HForce system, developed by Airbus Helicopters, will allow Hungary to equip and operate their aircraft with a large set of ballistic or guided air-to-ground and air-to-air weapons. No details on the contract value or delivery timelines have been disclosed. The Hungarian armed forces currently operate a fleet of ageing Russian-built Mil Mi-17 transport helicopters.

Asia-Pacific

• The Australian government is contracting BAE Systems for the production of the country’s next-generation, anti-submarine warfare (ASW) frigates. The $25.9 billion contract is Australia’s largest peace-time warship building program. The British designed Type 26 Global Combat Ship was selected in a lengthy comparative evaluation process over the ASW variant of the FREMM multi-mission frigate offered by Italy’s Fincantieri, and an ASW evolution of the F-100 Alvaro de Bazan-class design. Key Type 26 design criteria include multi-role versatility, flexibility in adapting to future needs, affordability in both construction and through-life support costs, and exportability. Intended to begin replacing the eight workhorse Anzac-class frigates of the Royal Australian Navy (RAN) in 2027–28, the new Hunter class will be constructed by ASC Shipbuilding at Osborne on the outskirts of Adelaide.

Today’s Video

• Russia’s SLBM enters operational service

USA’s Nimitz Class &
UK’s Invincible Class
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Some nations have aircraft carriers. The USA has super-carriers. The French Charles De Gaulle Class nuclear carriers displace about 43,000t. India’s new Vikramaditya/ Admiral Gorshkov Class will have a similar displacement. The future British CVF Queen Elizabeth Class and related French PA2 Project are expected to displace about 65,000t, while the British Invincible Class carriers that participated in the Falklands War weigh in at just 22,000t. Invincible actually compares well to Italy’s excellent new Cavour Class (27,000t), and Spain’s Principe de Asturias Class (17,000t). The USA’s Nimitz Class and CVN-21 Gerald R. Ford Class, in contrast, fall in the 90,000+ tonne range. Hence their unofficial designation: “super-carriers”. Just one of these ships packs a more potent air force than many nations.

Nimitz Class cutaway
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As the successor to the 102,000 ton Nimitz Class super-carriers, the CVN-21 program aimed to increase aircraft sortie generation rates by 20%, increase survivability to better handle future threats, require fewer sailors, and have depot maintenance requirements that could support an increase of up to 25% in operational availability. The combination of a new design nuclear propulsion plant and an improved electric plant are expected to provide 2-3 times the electrical generation capacity of previous carriers, which in turn enables systems like an Electromagnetic Aircraft Launching System (EMALS, replacing steam-driven catapults), Advanced Arresting Gear, and integrated combat electronics that will leverage advances in open systems architecture. Other CVN-21 features include an enhanced flight deck, improved weapons handling and aircraft servicing efficiency, and a flexible island arrangement allowing for future technology insertion. This graphic points out many of the key improvements.

DID’s CVN-21 FOCUS Article offers a detailed look at a number of the program’s key innovations, as well as a list of relevant contract awards and events.

The New Gerald R. Ford Class

CVN-21: Improvements and Innovations

CV 1: USS Langley
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The Nimitz Class was designed in the 1950s and 1960s, and despite a number of equipment changes since then, the basic design remains. Rear Adm. Dennis M. Dwyer, the Navy’s program executive officer for aircraft carriers, put it this way in a May 2003 National Defense Magazine article: “If you take the time period between Nimitz and CVN-21 [design], it’s the same time period between [the USS] Langley (CV 1) – the first carrier – and Nimitz.” The Langley was commissioned in 1922.

The technological jump is much shorter. Aircraft carriers are a mature technology, and CVN-21’s refinements are more about marginal improvements to effectiveness, cost-efficiency, and future upgradeability than any revolution in carrier design.

Even so, creating a new ship class isn’t cheap. According to NAVSEA, the cost of the initial design work to create the CVN-21 ship class and develop its new technologies is projected at $5.6 billion. By 2005, as advance construction began, the estimate for building the CVN 78 Gerald R Ford was $8.1 billion, plus about $5.4 billion in ancillary work related to the class as a whole. Newport News worked to test the design-build strategy before overall construction kick-off in 2007.

DID investigated the CVN-21’s exact build cost, and the future operating cost savings expected as a result of its design innovations. Essentially, CVN-21 carriers are expected to generate savings in 2 major ways.

One is through an array of design and automation changes to various areas of the ship that reduce the required number of sailors aboard.

The other is through reduction in the number of major maintenance overhauls required. NAVSEA expects these changes to save $5 billion per ship over the ships’ projected 50-year lifetime.

Meanwhile, measures are being taken aimed at improving the carriers’ effectiveness and survivability.

Ford Class: New Technologies

CVN-21 Enhancements
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An electromagnetic aircraft launching system (EMALS) will replace the steam-powered system used on current ships. The current steam catapults are large, heavy, and operate without feedback control. They impart large loads to the airframe via sudden shock, and are difficult and time consuming to maintain. Additionally, the trend towards heavier, faster aircraft will soon result in energy requirements that exceed the capacity of steam catapults.

EMALS Components
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EMALS offers a 30% increase in launch energy potential, as well as substantial improvements via reduced weight, smaller volume, and more flexibility; plus increased control, availability, reliability, and efficiency. Self-diagnostics can be embedded in it, simplifying maintenance. The other thing that simplifies maintenance is the removal of the 614 kg of steam required for each aircraft launch, plus hydraulics and oils, water for braking, and associated pumps, motors, and control systems. A corresponding Advanced Arresting Gear (AAG) system will replace existing Mk7 hydraulic motors with a system based on electric motors, in order to handle the arresting wires used to catch aircraft tailhooks on landing.

The EMALS-based system will take up far less space, providing design flexibility. EMALS launchers can be moved far more easily, downsized and incorporated into a ramp to provide additional launchers for short take-off aircraft, etc. Finally, its steadier acceleration is expected to reduce launch strains on naval aircraft, which helps extend their airframe life. That isn’t calculated as part of cost savings for the ship, but it definitely adds up over time.

The bad news? EMALS is such a big change from existing steam-driven catapult systems that it’s a critical technology for the CVN-21 Class. Its progress and performance will have a substantial effect on the ships’ on-time delivery, and on their ability to fulfill their cost promises.

Advanced arresting gear. The Naval Air Systems Command, headquartered at Patuxent River Naval Air Station, is working on an improved system for trapping aircraft as they land and hook the arresting cables. This electrical-hydraulic combination will be designed to be able to handle emerging platforms, such as the F/A-18E/F Super Hornet and F-35C Joint Strike Fighter, which are heavier and able to return to the ship with more unexpended munitions than their predecessors.

A redesigned nuclear reactor is expected to supply 25% more power for propulsion, but require only 50% the maintenance costs and a 50% reduction in sailors required to operate it. Removing the steam catapults in favor of EMALS is synergistic, reducing work on the maintenance-heavy steam conduits and allowing the steam from the nuclear reactor to do other things – like make electricity. The CVN-21 Class is expected to have 3 times the electricity generating capacity of the Nimitz Class. If our personal experiences with power hungry electronics over the last 20 years are anything to go by, they may need it.

NAVSEA says that the Ford Class is planned to have a long-lived reactor, but an expensive mid-life refueling and complex overhaul (RCOH) is still planned after about 25 years of operation.

Rear Adm. Dwyer has estimated that these and other technical changes involving increased automation will enable the size of the CVN-21 ships’ crews to be reduced from about 3,000 – 2,500, and possibly as low as 2,100. Note that some 2,500 personnel are also carried in the air wing, and will not be subject to reductions from any of the methods described here.

DBR on CVN-21
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Dual-Band Radar. This was pioneered on the Zumwalt class DDG-1000 destroyers. Most warships carry 2 radars with very different functions. The volume search radar performs wide area scans over a large footprint, while the targeting and fire control radar guides missiles and other weapons fired by the ship. They are integrated at the combat system level, but each is a separate sub-system, operating in different bands with different detection strengths. The DBR approach integrates both a SPY-3 active-array X-band radar for excellent fire control against saturation attacks, and an active array S-band radar for wide area search and performance in clutter, in order to provide a single combat picture with fewer coverage gaps and better response. All in less space than existing systems, allowing designers to shrink the “island” tower on deck.

The use of active-array, digital beamforming radar technology will help DBR-equipped ships survive saturation attacks, since they can allocate emitters to track and guide against tens of incoming missiles simultaneously. Active array radars also feature better reliability than mechanically-scanned radars, and recent experiments suggest that they could have uses as very high-power electronic jammers, and/or high-bandwidth secure communications relays. Read “The US Navy’s Dual Band Radars” for full coverage.

Ford Class: Design Improvements

CVN 79 Concept, 2009
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Electronic upgradeability. CVN 21 will also employ an integrated warfare system that allows its electronics to slot into a single, open-architecture, scalable weapons system, based on commercial, off-the-shelf technologies. Dwyer noted that the US Navy would like everything to “plug and play.” While technology never works quite that way, the process can be made easier – and doing so would improve long-term performance. As Rear Adm. Dwyer pointed out:

“Right now, the way we build aircraft carriers is to buy all the electronic equipment up front, then take seven years to build a ship and deliver it with obsolete electronics. It’s kind of crazy now that you think about it. We don’t want to do that any more… What we’d like to do is put the electronic equipment in separately from the actual shipbuilding process.”

Along similar lines, CVN-21 will feature a so-called smart deck, equipped with redundant and flexible fiber-optic cable that is easier to move and repair than hard copper wiring. It can be blown through the ship for installation – and more easily reeled out for replacement. Its capacity is also easier to upgrade, by clipping on terminating devices that allow for richer exploitation of different electromagnetic bandwidths of light.

A NASCAR flight deck philosophy. The “island” tower on the flight deck is being redesigned, reduced, and moved. As Rear Adm. Dwyer noted: “The people who actually handle aircraft said, ‘The island’s in the wrong place. It makes the aircraft all jam up. Why don’t you move it?'” So the island has shifted 100 feet aft, and the carrier’s elevators, deck et. al. are being shifted to a racetrack-like pattern of operations, complete with “pit stop” parking et. al.

It is this system that accounts for the expected 33% improvements in operational flights per day – a key measure of the carrier’s ability to both project power and defend itself. The US Navy’s goal is 160 sorties per day for the Ford Class, vs. the Nimitz Class’ 120 in a 12-hour fly day. Surge goal is 270 sorties on 24-hour fly days, vs. 240 sorties for the previous Nimitz Class.

Survivability also received attention. While the bridge and flight deck operations will remain on the island, the carrier’s command and decision centers are being moved from the island, to a “smart deck” down lower in the ship. This places them somewhere that’s both safer, and less in the way of aircraft operations. Meanwhile, the fuel tanks and bomb/ missile/ ammunition magazines are getting more armor, and the hull is being reinforced.

Transitional Carrier: CV 77, USS George H.W. Bush

CVN 77: Men at work
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The improvements described above are large leaps. To help with this transition, the USS George H.W. Bush was designed as a transitional ship between the Nimitz Class and the Ford Class. As such, CVN 77 has been a candidate for development, evaluation, and incorporation of a range of advanced technologies and acquisition reform initiatives. The hope is that these initiatives would result in lower life cycle costs, and also set the standard by which further improvements in the CVN-21 Class will be measured.

Technology innovations fielded in CVN 77 are targeted to achieve a 15% reduction in Operation and Support Costs, and they will also be backfit as feasible in the other nine ships of the Nimitz Class through the Carrier Improvement Plan. The carriers’ mid-life refueling overhauls and refit are the most likely time, given the scale of effort required. Some cost-saving transitional features and improvements designated for this last ship of the Nimitz Class included:

• A new automated JP-5 jet fuel system with programmable consoles and an improved filtration system (for significant reduction in operational/maintenance workload)

• A new vacuum collection sewage system that utilizes fresh water instead of sea water for flushing. This creates fewer long term corrosion problems, and reduces the quantity of sewage from water closets and urinals by ratio of 10 to 1.

• Enhanced radio center automation, which involves integrating communications apertures and C4I systems within the radio room to enable an automated full service integrated network that operates at greater effectiveness and efficiency.

• A composite mast made from a lighter, composite material instead of steel that reduces topside weight (up to 20 tons) and reduces electromagnetic blockage. It also includes accelerated introduction of new antenna technology: mast clamp current probe antennas will eliminate numerous HF antennas.

• Some propulsion plant changes to reduce manpower and maintenance requirements, though this will not represent a full conversion to the new CVN-21 nuclear power plant.

The George H.W. Bush was originally scheduled to be finish construction in April 2008, but delays pushed the timeline back to about March 2009, and increased costs from $5.9 billion to $6.2 billion in appropriation-year dollars. The Newport News Daily Press reports that CVN 77 was commissioned on Jan 10/09 at NAS Norfolk, despite being approximately 3-4 months away from the point at which it would normally be considered ready. The ship was towed into place for the ceremony, whose date was set in order to commission the ship while its namesake’s son was still President. In practice, however, this meant that the Navy accepted the ship even though it had never tested its major operating systems or nuclear reactors at sea.

The carrier is now in service. She was officially delivered to the US Navy on May 11/09, and departed on her first mission on May 11/11.

The CVN-21 Carrier Replacement Program

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The USA’s carrier replacement project has been underway at some level for many years now. Activity can easily trace back to 1994, and really kicked off in 1997 when the Naval Research Advisory Committee (NRAC) was asked to study technology opportunities that might be useful in “CVX.” From that moniker, the effort evolved to become the “CVN-21 Carrier Replacement Program.” As the ships are built and fielded, however, more and more references will be made to the CVN-78 Gerald R. Ford Class instead.

Long-lead appropriations for the Gerald R. Ford [CVN-78] began in 2001, and long-lead appropriations for the unnamed CVN 79 are already underway. Beyond that, construction of additional carriers becomes less certain. Current Pentagon plans call for a “drumbeat” of one new carrier every 5 years, which slows planned construction, raises per-ship costs by adding more fixed costs, and also imposes additional costs by requiring more re-designs for new electronics etc. with each new ship. The USA’s rapidly-deteriorating fiscal situation are throwing even that plan into difficulty, however, even as advances in ship-killing missiles are calling the large aircraft carrier’s pre-eminence into question.

Purchases of something as expensive as a super-carrier take time, and are spread over many annual budgets. First, finished items like engines, which must be present at early stages of construction, are bought as “long-lead” materials, along with some advance sub-assembly work. Then full construction funding is appropriated over several years. Recent budgets include:

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3-D Pump Room model
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The target date for CVN 78 commissioning was 2014, but current plans say it won’t be delivered before September 2015. Initial Operational Capability isn’t expected until FY 2017, with Full Operational Capability in FY 2018. When it does enter service, it will replace America’s first nuclear-powered aircraft carrier – the 50+ year old USS Enterprise (CVN 65), which retired in 2012. CVN 78 is also expected to serve for 50 years, from 2014-2064.

Newport News is designing the new ships using a 3-D product model tool called CATIA (Computer-Aided Three-Dimensional Interactive Application), a widespread standard for advanced design in the shipbuilding industry that is also in widespread use by the global auto industry. They’re also using CAVE, (Computer-Aided Virtual Environment), a 3D immersive environment tool used for viewing certain areas of the CATIA product model, and refining the construction strategy.

CVN-21 Class: Contract Awards & Key Events

Unless otherwise specified, the US Naval Sea Systems Command (NAVSEA) in Washington Navy Yard, DC manages the contracts. Huntington Ingalls Industries, Inc., formerly Northrop-Grumman’s Newport News Shipbuilding and Drydock Co. in Newport News, VA, is the project lead and contract recipient.

FY 2013 – FY 2018

CVN 78 structural erection done. Cost inflation.

CVN-21 Concept
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July 2/18: New Contract: Huntington Ingalls is being tapped to further support the Navy’s shipbuilding efforts. The un-definitized fixed-price, incentive firm target modification is valued at $200 million and provides for the purchase of additional long lead time material in support of USS Enterprise (CVN 80). The USS Enterprise will be the third Gerald F. Ford class carrier and will replace the USS Dwight D. Eisenhower (CVN 69). The air wing of this new carrier will be capable of supporting more than 75 aircraft of varied kinds, including fixed-wing and rotary-wing systems. Moreover, an Electromagnetic Aircraft Launch System (EMALS) will be incorporated in the ship to replace the steam catapults of the older versions. Work will be performed in Newport News, Virginia, is expected to be completed by February 2027.

April 18/18: CVN 80-Design & Fabrication Huntington Ingalls received Friday, April 13, a $64.9 million contract modification from the US Navy for the continued design and fabrication on the future USS Enterprise (CVN 80). Under the terms of the agreement, Huntington will provide long lead time material in support of the vessel, which is the third out of five new Gerald R. Ford-class aircraft carriers currently announced by the Navy. Work on the contract is expected to be complete in August 2022. Advance construction work on the future Enterprise startedlast August with the ceremonial cutting of a 35-ton steel plate, which was signed by US Olympic gold medalists Simone Biles and Katie Ledecky as part of the ceremony. The Enterprise is expected to be built and operating by 2027.

April 5/18: Materials & Services contracts Huntington Ingalls received Monday, April 2, a $179 million cost-plus-incentive-fee modification for for services related to production of the new USS Enterprise, the Navy’s third Ford-class aircraft carrier. The contract covers the procurement of the long-lead-time material for the USS Enterprise, which is currently within the fabrication phase of production. Work will be performed in Newport News, Virginia, and is expected to be completed by February 2027. The agreement follows a $55.8 million award announced by the Pentagon the previous Friday, which tasked Huntington with providing services to support the USS Gerald R. Ford, the class’ flagship vessel that is expected to leave on its first deployment in 2021. Work on this contract will occur in Hampton Roads, Va., and is expected to be complete in June 2019. Washington so far plans to build ten Ford-class carriers with three currently in various stages of construction.

March 21/18: Two-ship buy, if the price is right Shipbuilder Huntington Ingalls has been asked by the US Navy for a detailed pricing on the cost of two new Ford-class aircraft carriers as the service looks to see what possible saving could be made on a multi-vessel buy. Over the last several months the Navy said it has been working to estimate the total savings associated with procuring CVN 80, the USS Enterprise, and CVN 81, still unnamed, as a two-ship buy. Construction of the USS Enterprise began May 2016. The service said it would spend $43 billion in total to build the first three ships in the class, including the USS John F. Kennedy and the USS Enterprise. Speaking on the possibility of multi-ship buys, Huntington CEO Mike Peters said that “the most effective way to reduce cost of aircraft carriers is to take a multi-ship purchase approach and build them every three to four years.” However, James Geurts, assistant secretary of the Navy for research development and acquisitions, warned that the two-ship contract was “dependent on significant savings that the shipbuilding industry and government must demonstrate.”

December 22/17: CVN 81 Two Ford-class aircraft carriers may be block-bought by the US Navy, according to Vice Adm. Tom Moore, commander of Naval Sea Systems Command. Speaking to USNI News, Moore said such a dual-purchase would allow the service “to get (CVN) 81 [The future USS Enterprise] quicker” as materials can be ordered for both ships at the same time, while also cutting costs. The procurement program is one of six selected—the others being the MDA’s Standard Missile program, the USAF’s C-130-J retrofit kits, the Japanese Global Hawk FMS program, and two classified programs—under a new DoD pilot program aimed at slashing acquisition timelines to help improve lethality and readiness in the military. Each program will look to have a contract signed within 210 days of the request for proposal being issued, with an ultimate goal of getting major programs on contract within 180 days of the RFP’s release.

August 28/17: Advanced construction has commenced on the US Navy’s third Gerald R. Ford-class aircraft carrier by Huntington Ingalls. The firm’s Newport News Shipbuilding division started the process last Thursday with a ceremonial cutting of a 35-ton steel plate of the Enterprise (CVN 80) under an advance-fabrication contract awarded earlier in the year. The Navy expects to make an award for the ship’s detail design and construction next year.

July 24/17: US President Donald Trump turned out on Saturday to attend the commissioning of the Navy’s first Ford-class aircraft carrier, the USS Gerald R. Ford. Hailing the vessel as a “100,000 ton message to the world,” adding that America’s enemies will “shake with fear” when they see the Ford cutting across the horizon. After the speech, he put the Ford into commission and asked God to “bless and guide this warship and all who shall sail in her.” He was followed by Susan Ford Bales, the ship’s sponsor and daughter of the 38th president, from whom the ship, and class, takes its name. $43 billion has been spent on producing three Ford-class carriers, the others being the USS Enterprise and USS John F. Kennedy.

July 20/17: Additional long lead time construction materials have been ordered by the US Navy for the construction of the Ford-class CVN 80 Enterprise. Work will be carried out in Newport News, Va., and is expected to be completed by January 2024. Navy 2017 shipbuilding funds of $148.7 million will be obligated to the project. Long lead parts involve the lengthy planning, development and work of certain components and subsystems needed for the vessel. These include examples like shipboard nuclear power plants to the thousands of tons of steel needed to construct an aircraft carrier hull. The Enterprise is powered by A1B nuclear reactors and can generate two-and-a-half times the electrical power of its Nimitz-class predecessor, giving it the capacity to mount future weapons and electronics like laser weapons. It also has an electro-magnetic aircraft launch system rather than standard steam-powered catapults.

June 6/17: The US Navy has received delivery of the air carrier USS Gerald R. Ford from Huntington Ingalls Industries after completing acceptance trials on May 26. It is the first aircraft carrier to join the fleet since USS George H. W. Bush in 2009, and features a larger flight deck, the ability to host more aircraft, additional weapons and aviation fuel storage, and the Electromagnetic Aircraft Launch System and Advanced Arresting Gear, giving the Navy increased sortie rates by one-third when compared to Nimitz-class vessels. The Ford will be commissioned later this summer and will be declared operational in 2020.

May 22/17: General Atomics has received a $195.2 million contract modification for the advanced arresting gear of the CVN-80 Enterprise aircraft carrier currently under construction. Built as the the third in the Gerald R. Ford-class line of aircraft carriers, the contract includes manufacturing, assembly, and testing, while technical data and drawing changes are also part of the program. Work will be completed in primarily in San Diego, Calif., with portions conducted in Tupelo, Miss., Boston, Mass., and other locations across the country. Completion is scheduled for September 2027.

April 16/17: Just days into its first sea trials, the PCU Gerald R. Ford (CVN 78) responded to an emergency on the USS Oak Hill, where a sailor onboard needed urgent medical attention. The mission involved a MH-60S from HSC-22 which took off from the ship and rendezvoused with Oak Hill on Apr. 11 to take the patient to Navy Medical Center Portsmouth. Following the successful transportation, Capt. Richard McCormack, Ford’s commanding officer, addressed the crew and expressed his pride in Ford sailors and the embarked squadron for their flexibility, mission readiness, and eagerness to help a Shipmate in need. The sailor is in a stable condition.

April 9/17: Aircraft carrier Gerald R. Ford is to commence its first sea trials this week, paving the way for the US Naval Systems Command to take possession of the vessel by early April. The $12.9 billion warship has experienced several delays over its development, much of it due to growing pains with new technology including issues with its electromagnetic catapults and aircraft arresting gear that uses water-twister technology. Next week’s testing will involve putting the ship’s basic systems through rigorous checks prior to further acceptance trials after a period of downtime.

May 25/16: Huntington Ingalls has been awarded a $152 million US Navy contact for advance planning for the construction of the aircraft carrier Enterprise (CVN 80). The third aircraft carrier in the Gerald R. Ford class was named in honor of the Navy’s first nuclear-powered aircraft carrier, USS Enterprise (CVN 65). Work to be carried out includes engineering, design, planning, and procurement of long-lead-time material, and will be performed at the company’s Newport News Shipbuilding division through March 2018. Construction is to commence in 2018 and be delivered to the Navy in 2027.

September 24/15: Delivery of the first Ford-class carrier to the Navy will be delayed owing to the need for additional testing before sea trials can begin. The Gerald R. Ford (CVN-78) will now be delivered in May 2016, six to eight weeks after the scheduled March 2016 delivery date. With the carrier currently 93% complete, the cost of the test will be absorbed below the $12.9 billion cost cap mandated by Congress. The ship’s schedule took a hit in August when Pentagon procurement chief Frank Kendall ordered the Navy to conduct full-scale shock tests on the Ford, rather than the second carrier in class, the Kennedy. That decision will likely push back the carrier’s Initial Operating Capability by several months.

August 20/15: Newport News Shipyard will lay down the hull of the future USS John F. Kennedy (CVN-79) on Saturday, following the awarding of $4.3 billion in contracts in June to accelerate construction of the second Ford-class carrier. The ceremony will mark the official start of the ship’s construction, with first work on the hull having begun in 2011.

August 13/15: The Navy’s new Gerald R. Ford (CVN-78) carrier will undergo shock testing, despite this likely causing schedule delays of up to six months. Previously, Navy officials planned to carry out the tests – designed to replicate extreme combat stress – on the second carrier in class, the John F. Kennedy, due to enter service in the early 2020s, in order to accelerate the Gerald R. Ford’s entry into service. Pentagon procurement chief Frank Kendall reportedly ordered the Navy to conduct the tests, despite the inevitable delay such testing would produce.

June 8/15: Huntington Ingalls was awarded $4.3 billion through two contracts on Friday, with the shipyard handed a $3.35 billion detail design and construction contract for CVN-79, a member of the Navy’s new class of super-carriers. The subsidiary of Newport News Shipyard also received a $941.2 million modification to a previously awarded contract in support of CVN-79, also known as the USS John F. Kennedy. The new class of carriers was recently criticized for being too expensive, with Huntington Ingalls the sole manufacturer of nuclear-powered aircraft carriers. The John F. Kennedy is the second ship in the class, under construction with a cost-cap of $11.5 billion.

Mar 11/15: McCain complains about Ford-class costs.Former carrier pilot Sen. John McCain told Navy officials that the new Ford class of carriers is too expensive, coming in between $11 and $13 billion per copy. The first is being tested now before being delivered to the Navy. The second (JFK) and third (Enterprise) are in various states of construction. The Enterprise will be the ninth ship to take on the name. The eighth, CVN-65, was a carrier McCain served on in the 1960s, flying A-1 Skyraiders in a ground support role.

Mar 2/15: CVN-79 work moved up, but schedule stays put. The Navy tells Congress that it will move up work on the JFK, but not to launch the ship any sooner. To do so would create an impractical overlap of an extra carrier for a couple year prior to the retirement of CVN-68. Instead, they will delay the completion of the ship, waiting until the last minute to purchase and install the electronics, which presumably will be somewhat improved by the period just before launch in the summer of 2022.

Mar 2/15: CVN-73 will get its Refueling and Complex Overhaul in 2017, with preparation work moved up. The USS George Washington will come back to port in July 2017 for its RCOH. Work has been awarded to Newport News Shipbuilding for planning, design and procurement – a 30-month project leading up to the actual work.

May 8/13: Hearings. The US Senate Armed Forces Seapower subcommittee hears testimony from US Navy officials covering US Navy shipbuilding programs. The prepared statement says that a 2012 affordability review has led to noticeable changes in CVN 79, and lessons learned will lead to higher ship completion percentages at each build stage. An excerpt:

“Inarguably, this new class of aircraft carrier brings forward tremendous capability and life-cycle cost advantages compared to the NIMITZ-class it will replace. However, the design, development and construction efforts required to overcome the technical challenges…. have significantly impacted cost performance on the lead ship. [The detailed review and revised build plan for CVN 78]… will not recover costs to original targets… but should improve performance on the lead ship while fully benefitting CVN 79 and following ships of the class.”

See April 10/13 entry for expected costs per ship, which do decline in real terms for CVN 79-80. The question is whether practice will meet predictions. SASC prepared statement.

May 7/13: CVN 78. HII Newport News hoists the last of 162 primary structure “superlifts” onto CVN 78 Gerald R. Ford (CVN 78), a 75 foot long, 66 ton ship catapult forward section.

The lift ends 3 years of structural erection work, and 3 1/2 years since construction began in November 2009. There’s still a lot of work left before the ship is even floated out to begin finishing: hull painting, shafting work, completion of electrical systems, mooring equipment, and installation of radar arrays. HII.

May 6/13: CVN 79. A $60.8 million long lead-time material contract for CVN 79, which began attracting funding in 2009. HII has been working with their suppliers, and HII VP for CVN 79 Mike Shawcross says that this award will help them implement some of those buying initiatives for air conditioning systems, controllers and pumps, etc. Announced CVN 79 construction preparation contracts now stand at $1.865 billion, with the main construction contract expected later in 2013.

Work will be performed in Newport News, VA, and is expected to be complete by October 2015 (N00024-09-C-2116). See also HII.

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 program remains steady, with $1.68 billion requested to fund the 2nd year of construction for CVN 79 John F. Kennedy, and completion costs for CVN 78 Gerald R. Ford.

The FY 2014 budget submission places the $FY13 cost of CVN 78 at $12.829 billion, and the expected cost of CVN 79 at $11.338 billion. CVN 80 is pegged at $13.874 billion (+22.4% vs. CVN 79), but that’s in 2018. Math reminder: just 4.2% inflation, compounded over 2014-2018, is 22.8%.

Per ship costs

April 1/13: CVN 78. HII in Newport News, VA receives an $18.2 million contract modification for for CVN 78 special tooling, special test equipment, and supplier related vendor support services.

Work will be performed in Newport News, VA, and is expected to be complete in September 2015. All funds are committed immediately, using the FY 2011 Shipbuilding and Conversion budget (N00024-08-C-2110).

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. As of August 2012, CVN 78 was 51% complete, but its build costs have grown by 17% since the 2008 construction contract was issued. There’s enough blame to go around. A build contract awarded when the 3D model was incomplete and only 5/13 critical technologies were mature. Government-furnished equipment arriving late. Construction problems like warping and flexing of new steel decking, a shortage of new valves, and welding complications. The DBR radar decision that forced the CVN-21 program to take on a new immature technology, instead of receiving a mature technology from the DDG 1000 program.

The 3D model is complete now, and either 6 or 12 of the 13 critical technologies are mature, depending on whether you ask GAO (6) or OSD (12). Now the challenge is to have all of the required sub-components arrive in configurations that fit the design, and don’t reveal a need for constraint-breaking changes during testing. CVN 79 John F. Kennedy and CVN 80 Enterprise will change in response to all of the construction and testing issues found in CVN 78 Gerald R. Ford, which is normal. The hope is that required changes won’t be too difficult to fit into CVN 79. Meanwhile, retrofits of CVN 78 could be costly, driving its build price higher.

The US Navy plans to award the CVN 79 main contract in September 2013, take delivery of the USS Gerald R. Ford in September 2015, have the Ford ready for deployment by March 2017, and award CVN 80’s main build contract by the end of 2017.

March 21/13: CVN 79. A $407.4 million contract modification can be drawn on in order to extend construction preparation efforts, and provide the ability to procure additional long-lead material and advance construction activities for CVN 79 if required. If the funds aren’t needed, fine. If budget issues or political gridlock create a problem, this funding can help preserve the construction schedule.

This may be an expansion of the March 7/13 contract. Either way, DID’s records show that the total for all announced contracts involving CVN 79 is around $1.8 billion so far. Work will be performed in Newport News, VA and is expected to complete by October 2015 (N00024-09-C-2116).

March 11/13: CNAS – Carrier eclipse? The center-left CNAS think-tank publishes a new example of their “disruptive defense papers,” with USN Capt. Henry J. Hendrix’s “At What Cost a Carrier?” [PDF] He proposes slowly divesting from aircraft carriers, while canceling the F-35C and building a transition bridge of UCAVs to lengthen carrier strike range and lower operating costs. Precision strike would also shift toward undersea platforms. On the surface, fewer carrier battlegroups would enable investment in more “influence squadrons” of amphibious ships, patrol corvettes, riverines squadrons, etc., in order to make up the “presence deficit” complained of by the Navy. The core of his argument is summed up in these excerpts:

“Nimitz-class carriers can generate approximately 120 sorties a day. Ford-class carriers, with the new… EMALS… launch around 160 sorties per day, a 33 percent increase in launch capacity. This seems very impressive until one realizes that the USS George H.W. Bush, the last Nimitz carrier, cost $7 billion and the USS Gerald R. Ford is coming in at $13.5 billion. In the end, the nation is paying nearly 94 percent more for a carrier that can only do 33 percent more work. 13 Even factoring in projected savings from reduced manning and lower maintenance costs, this investment is still not a good use of U.S. taxpayer money…. The inefficiency of manned aviation, with its massive fiscal overhead of training, pilot currency and maintenance, is rapidly outpacing its utility. The idea that the United States needs a large sortie capability inexorably drives decisionmakers to large carriers. These maritime juggernauts are expensive and hence need to be defended by an ever-larger ring of exquisite technologies in order to launch a historically shrinking number of very expensive aircraft from ever-increasing distances that may or may not drop their bombs. This raises the question of who is shaping whom within the current strategic environment.

To continue to invest in aircraft carriers at this stage, to believe that the USS Ford, with a service life of 50 years, can see the carrier through to a 150-year life unchallenged upon the high seas smells of hubris. Advancements in surveillance, reconnaissance, global positioning, missiles and precision strike all signal a sea change in not only naval warfare, but all forms of warfare.”

See also Information Dissemination, which responds that the carrier isn’t becoming obsolete – its air wing is.

March 7/13: CVN 79. A $65 million contract will provide the ability to order additional long lead material and advance construction activities if required. Work will be performed in Newport News, VA, and is expected to be complete by October 2015. Additional funding is not being committed yet (N00024-09-C-2116).

Dec 1/12: CVN 80. Nearly 12,000 past and current crew members, family and friends attend the formal inactivation of the first nuclear-powered aircraft carrier, USS Enterprise, at Naval Station Norfolk, VA. It’s the last public ceremony, but there’s still a lot of work to do, and significant contracts to issue, before the ship is deactivated and safe.

US Secretary of the Navy Ray Mabus doesn’t attend, but he plays a video message to announce that the 3rd Ford Class carrier, CVN-80, will become the next USS Enterprise when and if she is built. US Navy | USN CVN 65 site.

From one USS Enterprise to the Next

Jan 26/13: CVN 78. HII lowers the 555t “island” onto Gerald R. Ford’s deck. The island hosts the bridge, air traffic command center, etc. It’s the 452nd of about 500 modular “lifts” involved in assembling the carrier, which is almost 90% structurally complete right now. HII.

Jan 17/13: DOT&E Report. The Pentagon releases the FY 2012 Annual Report from its Office of the Director, Operational Test & Evaluation (DOT&E). The Gerald R. Ford is included, as the Navy plans for its service entry as the 1st ship of its class.

An operational assessment actually began in September 2012, trying to assess build progress and future test readiness. OT&E’s biggest concern is that the current Test and Evaluation Master Plan (TEMP) will test components, but doesn’t have enough testing involving all of the pieces working together. Their concern is that “platform-level” problems will start cropping up during Initial Operational Test & Evaluation, which can be hard to fix, and could delay either delivery or IOC.

The battle over Total Ship Survivability Trials (TSST) and the Full Ship Shock Trial (FSST) is still on. The Navy and OT&E are closer to agreement on TSST, but the budget isn’t there. They’re still at odds over moving FSST to CVN 79. The Navy wants to reduce the gap in available carriers. OT&E believes the 4-6 month delay is outweighed by having test data to affect the design of future carriers.

Other issues noted by the report involve various key technologies that will have a big say in whether the ship is ready on time, from the DBR radar (combat system integration an issue), to the EMALS (new armature, making progress), Advanced Arresting Gear (significant redesign of multiple components) and CANES onboard networking (testing in Q4 FY 2014). The Virtual Carrier model is a minor technology needed to test Sortie Generation Rate, which is supposed to represent a major improvement. It needs more refinement before it’s useful.

A final concern involves the F-35’s big engine, whose 10,000 “power module” is too heavy for current underway replenishment systems (the line and pulley system used with supply ships). The Ford Class carriers will have a system rated to 12,000 pounds, but plans to install that new system on the supply ships have slipped by 8 years.

Oct 4/12: Industrial. A 1,024-metric ton unit of CVN 78 is lifted into the drydock at the Huntington Ingalls Newport by the shipyard’s 1,050-metric ton crane. This superlift is their biggest to date, and contributed to assembling the gallery deck (i.e. O-3 level). HII | NAVSEA.

FY 2012

More work on CVN 78, 79.

CVN 78: May 2012
(click for alternate view)

Sept 27/12: CVN 79. A $296.1 million contract modification for more CVN 79 John F. Kennedy long-lead-time materials, and continuation of construction preparation efforts in FY 2013. This will include necessary research studies; engineering; design; related development efforts; advanced planning; advanced procurement for detail design and procurement of long lead material; advance construction; life cycle support; logistics data and other data.

Work will be performed in Newport News, VA, and is expected to be complete by October 2015 (N00024-09-C-2116).

Aug 30/12: CVN 78. A $9.7 million modification to the Gerald R. Ford’s cost-plus-incentive-fee detail, design and construction contract, covering one-time engineering efforts to configure the Gerald R. Ford’s decision centers. Work will be performed in Newport News, VA, and is expected to complete by September 2015. The USN Supervisor of Shipbuilding Conversion and Repair in Newport News, VA manages this contract (N00024-08-C-2110).

Including the main build contract in FY 2008, the total for announced contracts that are specific to CVN 78 is around $6.63 billion so far. Billions of dollars in contracts aimed at “CVN-21” also contributed to the ship’s design, and to early manufacturing experiments and efforts, but their benefits will be shared among all ships of class.

Aug 9/12: Testing tiff. The DOT&E disagrees with the Navy’s position that computer modeling is enough to evaluate the new carrier’s survivability, without using explosive underwater shock tests. In fact, they’ve revoked approval of the Navy’s test plan. BusinessWeek:

“The U.S. Navy is inappropriately delaying or scaling back $70 million in needed combat testing of the USS Gerald R. Ford, an aircraft carrier that may cost $14.2 billion, in the name of cutting costs, according to the Pentagon’s top weapons tester.

A test that would “rigorously evaluate the ship’s ability to withstand shock and survive in combat” would be postponed until a second carrier in the new Ford class is built and may not be completed for seven years, Michael Gilmore, the Defense Department’s director of operational test and evaluation, told Navy Secretary Ray Mabus in a July 12 memo obtained by Bloomberg News.”

July 18/12: CVN 79. A $43.4 million contract modification for more CVN 79 “long lead time material.” That category actually includes research studies, engineering, design, life cycle support, and advance planning; as well as long lead items and advance construction.

To date, announced long-lead contracts for CVN 79 have reached $1.0478 billion. Work will be performed in Newport News, VA, and is expected to be complete by October 2015 (N00024-09-C-2116).

July 16/12: CVN 78. A $7.6 million contract modification to buy previously planned materials to build CVN 78 Gerald R. Ford. This modification increases the effort under the existing cost-plus-fixed-fee provisioned items order. Work will be performed in Newport News, VA, and is expected to complete by September 2015. The Supervisor of Shipbuilding Conversion and Repair in Newport News, VA manages this contract (N00024-08-C-2110).

Dec 21/11: CVN 79. Huntington Ingalls, Inc. in Newport News, VA receives an $113.2 million contract modification, exercising options to continue construction preparation for CVN 79 John F. Kennedy, including engineering, detail design, and lead yard services. Work will be performed in Newport News, VA, and is expected to be complete by October 2012 (N00024-09-C-2116). See also HII release.

Oct 26/11: CVN 79. A $16.9 million contract modification exercising priced CVN 79 research, development, test and evaluation options. HII will provide all services and material in preparation for final detail design and construction of the John F. Kennedy, including research studies; engineering; design; related development efforts; advanced planning; advanced procurement for detailed design and procurement of long lead material; advance construction; life cycle support; logistics data; etc.

Work will be performed in Newport News, VA. All contract funds will expire at the end of the current fiscal year, on Sept 30/12 (N00024-09-C-2116).

FY 2011

Work on CVN 78, 79.

CVN 78: Aug. 2011
(click to view full)

Sept 12/11: Industrial. HII’s Newport News Shipbuilding division places an 825-ton superlift section, completing the Gerald R. Ford’s stern. The final superlift of the ship’s aft end included the steering gear rooms, electrical power distribution room, store rooms and tanks. At 90 feet long, 120 feet wide and 30 feet deep, the superlift was among the largest of the 162 that comprise CVN 78, the future USS Gerald R. Ford. HII.

Sept 8/11: Future carrier options. James Hasik looks at future options for the American super-carrier fleet, and delivers a preliminary cost analysis for various scenarios – including a scenario that involves halting the new CVN-21s after the John F. Kennedy, mothballing 2 existing Nimitz Class boats, and dropping to 8 operational carriers.

July 29/11: CVN 78. A $504.1 million contract modification to complete one-time platform engineering support related to the CVN 78, the Gerald R. Ford. Work will be conducted in Newport News, VA, and ship delivery is expected to take place in September 2015. (N00024-08-C-2110).

July 14/11: Rumors are flying that the Navy is looking to delay further carrier build contracts, in order to save money. A WTKR Virginia report adds fuel:

“U.S. Rep. Randy Forbes asked two top-ranking Navy admirals about a rumor he’d heard: that the Navy was considering deferring the purchase of the Newport News-built John F. Kennedy aircraft carrier by two years. The answer he received in a subcommittee hearing Tuesday – a beat of silence followed by a deflection – left him and other members of Virginia’s congressional delegation unsettled.”

Some proposals would even cancel the Kennedy, and use the money to buy LHA/LHD amphibious ships instead. American LHA/LHDs can carry fighters, and the LHA-6 America Class is an escort carrier in all but name. See Aviation Week | The Hill | WTKR.

May 29/11: The US Navy announces that CVN 79, the 2nd ship of class, will be named the USS John F. Kennedy. It will continue the namesake legacy of the non-nuclear powered CV 67, which was retired in 2007.

CVN 79 named

May 21/11: Industrial. HII moves a 945-ton pre-assembled “superlift” section into place near the stern of the ship, using the shipyard’s 1050-metric ton crane. This is one of the heaviest of 162 superlift modules making up the Ford, and was itself assembled over 18 months from 18 smaller structural units. It contains a diesel generator room, a pump room, an oily water waste pump room, 16 complete tanks and 18 partial tanks that will be completed when the superlift is welded to the rest of the ship.

The Gerald R. Ford’s keel was laid Nov 14/09, and christening is planned for 2013, with delivery to the U.S. Navy in 2015.

Feb 25/11: Steel is cut to begin building CVN 79, the 2nd carrier in this class. If only budgets and funding could be as certain. The carrier isn’t due for delivery until 2020, and the yard has received almost $1 billion for the carrier, but more than $900 million is tied up in Congress, as it wrestles with the FY 2011 and FY 2012 budgets.

Funding for the CVN-79 and a planning contract for the mid-life nuclear refueling and overhaul of the Abraham Lincoln carrier are both in flux at the moment. Both are “long fuse, big bang” projects, where the ability to order materials and ramp up staffing in a timely manner are critical. If funding issues create schedule stoppages, they’ll make the program late, and raise overall costs. Northrop Grumman | Newport Daily Press

CVN 79 “steel cut”

Jan 21/11: CVN 78. Northrop Grumman Shipbuilding Inc. in Newport News, VA received an $11 million contract modification to previously awarded contract in support of the USS Gerald R. Ford’s [CVN 78] engineering detailed design work.

Work will be performed in Newport News, VA, and is expected to be complete in September 2015. The US Navy Supervisor of Shipbuilding Conversion and Repair in Newport News, VA (N00024-08-C-2110).

Dec 8/10: CVN 79. A $323.6 million contract modification to continue construction preparation efforts for CVN 79, the as-yet unnamed 2nd aircraft carrier of the Gerald R. Ford class. Work will include necessary research studies; engineering; design; related development efforts; advanced planning; advanced procurement for detailed design and procurement of long lead material; advance construction; life cycle support; logistics data, and other data to support the anticipated FY 2013 ship detail design and construction.

Work will be performed in Newport News, VA, and is expected to be complete by October 2012 (N00024-09-C-2116). This contract raises CVN 79’s specific announced advance contracts to $874.3 million over the last 4 years. See also Northrop Grumman release.

Nov 10/10: CVN 78. A $189.2 million contract modification is just part of the planned funding for detailed design engineering work supporting construction of the Gerald R. Ford [CVN 78].

Work includes engineering; integration; related development efforts including drawing and work package development; advanced planning; design weight estimate; lifecycle support products and related logistics data; production planning; test and evaluation; further definition of initiatives to reduce CVN 78 class total ownership costs; and other data necessary to support construction of CVN 78. Northrop Grumman’s Mike Shawcross, VP of Gerald R. Ford-class engineering adds that: “Now that the design is in the three-dimensional product model, our engineering and planning effort is focused on the production of instructions for the shops and ship assembly.”

Work will be conducted in Newport News, VA, and is expected to complete by September 2015. This contract was not competitively procured; there wouldn’t be any point (N00024-08-C-2110). See also Northrop Grumman.

Nov 5/10: CVN 79. A $55.1 million contract for additional materials and assemblies, as the shipyard gets ready for an expected CVN 79 ship detail design and construction contract in FY 2013.

Work includes necessary research studies; engineering; design; related development efforts; advanced planning; advanced procurement for detailed design and procurement of long lead material; logistics data; and other data. It will be performed in Sunnyvale, CA, and is expected to be complete by Aug 25/14 (N00024-09-C-2116).

FY 2010

Cost increases.

CVN 78: July 2010
(click to view full)

Sept 30/10: CVN 79. A $37.8 million contract modification for additional long lead time materials as the shipyard prepares to start building CVN 79, the 2nd Ford class carrier. Work will be performed in Newport News, VA, and is expected to be complete by October 2016 (N00024-09-C-2116).

Sept 7/10: CVN 79. A $12 million cost-plus-fixed-fee contract modification for procurement of additional long-lead-time materials in support of CVN 79 construction, the 2nd carrier of this class. Work may include research studies, engineering, design, related development efforts, advance planning, advance procurement, logistics data, and other data to support an expected FY 2013 ship detail design and construction date for CVN 79.

While aircraft carriers of the same class are broadly the same, the multi-year gap in construction generally means that each is fielded with slightly different technologies. Lessons from earlier ships also lead to minor design changes, which must be planned out and accounted for.

Work will be performed in Newport News, VA, and is expected to be complete by October 2011. This contract was not competitively procured, as the ship’s contractor is already determined (N00024-09-C-2116).

July 28/10: CVN 78. Northrop Grumman Corporation lifts 2 diesel generators weighing over 195,000 pounds each into the aft section of the Gerald R. Ford [CVN 78], at the company’s Shipbuilding sector in Newport News, VA. The ship is now about 11% complete.

When underway, the carrier will generate its electricity through its nuclear power plant. the diesel generators serve as emergency backups. Northrop Grumman.

May 12/10: CVN 78. Northrop Grumman Shipbuilding, Inc. in Newport News, VA receives an $186.6 million contract modification, as part of the planned increments of detailed design engineering work supporting Gerald R. Ford [CVN 78] construction. Northrop Grumman Shipbuilding will complete the detail design and construction of CVN 78 including engineering; integration; related development efforts including drawing and work package development; advanced planning; design weight estimate; lifecycle support products and related logistics data; production planning; test and evaluation; further definition of initiatives to reduce CVN 78 class total ownership costs; and other data necessary to support construction.

These design efforts will continue to be performed in Newport News, VA, and is expected to be complete by September 2015 (N00024-08-C-2110).

May 3/10: Gates’ speech. US Secretary of Defense Robert M. Gates delivers a speech at the Navy League’s annual Sea-Air-Space Convention, in National Harbor, MD. It’s widely seen as casting doubt on the future of the USA’s Ford Class carriers. Excerpts:

“The U.S. operates 11 large carriers, all nuclear powered.  In terms of size and striking power, no other country has even one comparable ship… At the higher end of the access-denial spectrum, the virtual monopoly the U.S. has enjoyed with precision guided weapons is eroding – especially with long-range, accurate anti-ship cruise and ballistic missiles that can potentially strike from over the horizon.  This is a particular concern with aircraft carriers and other large, multi-billion-dollar blue-water surface combatants, where, for example, a Ford-class carrier plus its full complement of the latest aircraft would represent potentially a $15 to $20 billion set of hardware at risk. The U.S. will also face increasingly sophisticated underwater combat systems – including numbers of stealthy subs – all of which could end the operational sanctuary our Navy has enjoyed in the Western Pacific for the better part of six decades… Our current plan is to have eleven carrier strike groups through 2040 and it’s in the budget. And to be sure, the need to project power across the oceans will never go away. But, consider the massive over-match the U.S. already enjoys. Consider, too, the growing anti-ship capabilities of adversaries.  Do we really need eleven carrier strike groups for another 30 years when no other country has more than one?  Any future plans must address these realities.

And that bring me to the third and final issue:  the budget… Just a few years ago, the Congressional Budget Office projected that meeting the Navy’s shipbuilding plan would cost more than $20 billion a year – double the shipbuilding budget of recent years, and a projection that was underfunded by some 30 percent… I do not foresee any significant increases in top-line of the shipbuilding budget beyond current assumptions. At the end of the day, we have to ask whether the nation can really afford a Navy that relies on $3 to 6 billion destroyers, $7 billion submarines, and $11 billion carriers.”

April 20/10: CVN 79. Northrop Grumman Shipbuilding, Inc. in Newport News, VA received a $16.8 million modification to buy more long lead time materials, as part of construction preparation for CVN 79, the 2nd carrier of this class. Work will include necessary research studies; engineering; design; related development efforts; advanced planning; advanced procurement for detailed design and procurement of long lead material; logistics data; and other data to support the anticipated FY 2013 ship detail design and construction contract.

Work will be performed in Newport News, VA, and is expected to be complete by March 2012 (N00024-09-C-2116).

April 1/10: SAR – Congress costs us. The Pentagon releases its April 2010 Selected Acquisitions Report, covering major program changes up to December 2009. The new carriers experience large cost increases, but most of them are self-inflicted by Pentagon program scheduling. The exception is the EMALS catapult system:

“Program costs increased $5,426.4 million (+15.5%) from $35,119.1 million to $40,545.5 million, due primarily to the shift from a four-year to five-year build cycle (+$4,131.2 million), which placed the program on a more fiscally sustainable path while continuing to support a minimum of 11 aircraft carriers through fiscal 2040. Additional increases resulted from revised cost estimates for the Electromagnetic Aircraft Launch System (EMALS) (+$1,292.6 million), platform non-recurring engineering (+$350.0 million), and labor and material projections (+$311.7 million), a stretch-out of the procurement buy profile (+$520.6 million), and the application of revised escalation indices (+$301.8 million). These increases were partially offset by decreases resulting from inflation and other miscellaneous adjustments (-$933.1 million) and a shipbuilding reduction across the program (-$627.0 million).”

SAR increase

March 30/10: The US GAO audit office delivers its 8th annual “Defense Acquisitions: Assessments of Selected Weapon Programs report. With respect to the “CVN 21 Program,” it says:

“The CVN 21 program has consistently demonstrated the maturity of its critical technologies later than recommended by best practices… Three of these technologies – EMALS, advanced arresting gear, and dual band radar-present the greatest risk to the ship’s cost and schedule… Construction of approximately 50 percent of the ship’s units are complete. According to program officials, these units are low on the ship and only account for 9 percent of the ship’s production hours… the fiscal year 2010 President’s Budget recommends moving the carrier to a 5-year build cycle. If adopted, the fabrication start date for CVN 80 will be delayed by 2 years, which will increase the amount of shipyard overhead costs paid under the CVN 79 contract.”

Most of the GAO’s commentary concerns critical carrier sub-systems, however, and those comments are covered in that section, below.

Dec 23/09: CVN 79. A $31.8 million modification to a previously awarded contract, to buy more long lead time materials as the Navy prepares to begin construction on CVN 79. Work will be performed in Newport News, VA, and is expected to be complete by April 2013 (N00024-09-C-2116).

Nov 14/09: CVN 78. A 23-story, 1,050 metric ton capacity gantry crane lifts an 81-foot by 96-foot building block into place in Dry Dock 12, during a keel-laying ceremony for the Gerald R. Ford [CVN 78]. Under partial block construction, each module is pre-outfitted with pipes and fixtures that will make final assembly quicker and more efficient. This ship’s blocks are larger than past carriers, which forced a $40 million upgrade of the gantry crane. Local media report that yard workers have assembled about 540 of 1,200 blocks that will be welded together in dry dock from 2009-2012, to form the Ford’s skeleton. A new $37 million stadium-sized manufacturing facility with a retractable roof will allow work to continue in any weather, and the firm hopes this will help the Ford avoid some of the delays that have plagued other carriers.

NGC’s Newport News shipyard has been assembling the units since 2006, with about 1,500 waterfront workers and about 2,000 engineers and planners involved in the program at the end of 2009. When construction peaks in 2013, the number of construction workers is expected to hit 4,000. US Navy | Northrop Grumman | Newport News, VA Daily Press | Reuters.

CVN 78 “keel laying”

Oct 28/09: FY 2010 budget. President Obama signs the FY 2010 defense budget into law. The Pentagon’s FY 2010 budget request of $1,397.3 million included 1,223.7 million as the 3rd year of incremental funding for CVN 78, plus 173.6 million in RDT&E. The reconciled budget tables that came out of House-Senate conferences list $739.3 million for the program, but the release characterizes it as full funding of the Pentagon’s request. White House | House-
Senate Conference Report summary [PDF] & tables [PDF] | Pentagon AFPS article.

Oct 9/09: CVN 78. Northrop Grumman uses the foundry at its Newport News, VA shipyard to melt 35 tons of steel, in order to cast the strut arms needed to support the Gerald R. Ford’s propeller shafts. Their release quotes aircraft carrier construction program VP Mike Shawcross, who says that about 5% of the construction contact is complete at this point. The Nov 14/09 keel-laying is the next major milestone.

FY 2009

EMALS dependency.

CVN 78, March 2009
(click for alternate view)

April 3/09: Tech crunch. Naval site Information Dissemination runs an article assessing EMALS’ current state, and the Navy’s contention that the system poses no schedule risks. The title: “Wal-Mart Called, They Want Their Yellow Smiley Face Back.”

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

March 30/09: GAO report. The US government’s GAO audit office issues GAO-09-326SP: “Defense Acquisitions: Assessments of Selected Weapon Programs.” With respect to EMALS and the CVN-21 program, it says that 10/14 technologies are either fully mature, including the nuclear propulsion and electrical plant, or approaching maturity. Of the remaining 4 immature technologies

“…the development and design of the electromagnetic aircraft launch system (EMALS), the advanced arresting gear, and the dual band radar (composed of the volume search and multifunction radars) present the greatest risk to the ship’s cost and schedule.”

Ominously, it adds:

“A February 2008 program assessment recommended a number of changes to the EMALS program to improve performance. The Navy re-planned the test program and changed the management approach. The CVN 21 program office is now responsible for overseeing EMALS production and ship integration, rather than the Naval Air Systems Command. In addition, EMALS will no longer be provided as government-purchased equipment. Instead, the shipbuilder will purchase EMALS, giving it a more direct role in managing the integration on CVN 78. The cost impact of this change has not been finalized.”

There are also schedule concerns:

“Problems during EMALS development have already resulted in cost growth and schedule delays. In order to meet CVN 78’s delivery date, the Navy adopted a strategy that will test, produce, and ultimately install EMALS with a high degree of concurrency. In September 2008, the contractor completed the first round of high- cycle testing, gaining confidence in the performance of the generator–a source of past problems. Contractor-led integrated land-based system testing will not be complete until the end of fiscal year 2011–2-years later than estimated in December 2007. Assuming no further delays, EMALS will not demonstrate full performance of a shipboard ready system until at least 7 months after installation on CVN 78 has begun…”

Jan 15/09: CVN 79. A $373.5 million cost plus fixed-fee contract covering construction preparations for CVN 79, the 2nd aircraft carrier of the Gerald R. Ford Class. Efforts will include engineering, detail design, test and evaluation, research and development with some suppliers, and purchases of long lead time items. Special performance incentives are also included under the contract.

Work will be performed in Newport News, VA, and is expected to be complete by October 2010. This contract was not competitively procured (N00024-09-C-2116). The full scale construction contract for CVN 79 is expected to begin in 2012. Northrop Grumman release.

FY 2008

Main CVN 78 contract.

CVN 78 sub-assembly
(click to enlarge)

Sept 10/08: A $5.115 billion cost-plus-incentive-fee, cost-plus-fixed-fee, cost-plus-award-fee contract for the detail design and construction of USS Gerald R. Ford [CVN 78]. This contract includes a $30 million option which would bring the total contract value to $5.145 billion, if exercised.

The May 21/04 contract covered up to $2.7 billion in advance construction or purchase of sections and items that were not dependent on the detail design; Northrop Grumman says that about 1/3 of the ship’s 1,200 structural units are already under construction. This contract takes the next step, and begins full ship construction based on the detail design. The contract will include engineering; integration; related development efforts including drawing and work package development; advanced planning; design weight estimate; lifecycle support products and related logistics data; production planning; test and evaluation; further definition of initiatives to reduce CVN 78 class total ownership costs; and other data necessary to support construction of CVN 78.

Work will be performed in Newport News, VA. The ship’s keel will be laid in the fall of 2009 (Nov 14/09), and delivery to the Navy is scheduled for September 2015. This contract was not competitively procured (N00024-08-C-2110). See also NGC release.

Main CVN 78 contract

March 14/08: During US House Armed Services Seapower and Expeditionary Forces Subcommittee hearings about the proposed the FY 2009 budget, chairman Gene Taylor [D-MS] discusses on the state of the program:

“Another very risky program is the new aircraft carrier. Not that the Navy and Newport News Shipyard don’t know how to build aircraft carriers, they do. However, one of the major new technologies, the electro-magnetic launch system, or EMALS, has not even been tested in a shipboard configuration and the ship is already under construction. Just this last week the Navy requested an additional $40 million dollars for continued development of EMALS because, and I quote, ‘the contractor underestimated design and production cost.’ The cynic in me would say the contractor purposefully low-balled the bid to get the contract knowing full well the Navy would be forced to pay whatever the true costs of the system turned out to be. Perhaps we should have built another Nimitz class carrier until the research and design for EMALS was complete.”

Read “US Navy’s 313-Ship Plan Under Fire in Congress” for more.

Jan 31/08: CVN 79. A $16.3 million modification to previously awarded contract (N00024-07-C-2116), exercising an option to develop and refine the second-of-class CVN 79 design. The integrated product and process development contract funds research and development that aims to reduce the price, reduce lifetime ownership costs, and maintain weight/center of gravity service life allowance thresholds. All of which ties in to the ongoing systems development, engineering services, technology options studies, and feasibility studies underway for the as-yet unnamed CVN 79. Work will be performed in Newport News, VA and is expected to be complete by October 2008.

Jan 11/08: CVN 78. A $595.9 million modification to previously awarded contract (N00024-04-C-2118) to continue CVN 78 class design effort, long lead time material procurement; and non-nuclear advance construction for the lead ship of the class, Gerald R. Ford [CVN 78]. Work will be performed in Newport News, VA (92%) and Groton, CT (8%), and is expected to be complete by July 2008. See May 21/04 entry for more details.

Northrop Grumman Newport News “will provide all services and material in preparation for construction of CVN 78 including necessary research studies; engineering; design; related development efforts, including required engineering development models and prototypes for engineered components; advanced planning; advanced procurement for detailed design and procurement/fabrication of long lead material; advanced construction; system specifications; design weight estimate; logistics data; lists of government-furnished equipment; production planning; further definition of initiatives to reduce CVN 78 class total ownership costs; and other data to support an integrated product data environment for the CVN 21 program.”

FY 2007

Gerald R. Ford class.

Sept 24/07: Rep. Roscoe Bartlett [R-MD], the ranking minority member in the US House Armed Services subcommittee on Seapower & Expeditionary Forces, releases a statement re: the GAO’s August 2007 report, which he requested:

“At my request, the Congressional Research Service, the Congressional Budget Office previously and now the GAO have told Congress the Navy’s current shipbuilding program is unrealistic based upon the Navy’s past performance. The development of three critical technologies has been delayed to such an extent that this first-of-class ship must experience 100% success in order to come in on budget and on schedule eight years from now. The GAO report also reminds us that both the shipbuilder’s initial cost estimate and the DOD independent estimate were higher than the Navy’s budget. As far as comparisons to LCS go, what is most disturbing is that the cost for CVN 78 is orders of magnitude higher than LCS. If CVN 78 should experience just 10% cost growth – far less than LCS – in the eight years until its scheduled delivery, the Navy will request another billion dollars. In this budget environment, that’s going to be a difficult sell. It reminds me that VADM Cebrowski’s alternative fleet study suggested a larger number of smaller carriers might provide more value than the Navy’s strategy of a few Super Carrier platforms.”

Aug 23/07: GAO report expresses doubts re: project costs:

“While the Navy has mitigated the impact of some technologies, such as the nuclear propulsion and electric plant, three systems–the electromagnetic aircraft launch system (EMALS), the dual band radar, and the advanced arresting gear–have faced problems during development that may affect the ship’s construction costs… A structured design approach and a lengthy construction preparation contract have enabled the program to perform more work prior to construction than on previous carriers… Costs for CVN 78 will likely exceed the budget for several reasons. First, the Navy’s cost estimate, which underpins the budget, is optimistic… Second, the Navy’s target cost for ship construction may not be achievable… Third, the Navy’s ability to manage issues that affect cost suffers from insufficient cost surveillance. Without effective cost surveillance, the Navy will not be able to identify early signs of cost growth and take necessary corrective action.”

July 24/07: In a statement before the US House Armed Services Subcommittee on Seapower and Expeditionary Forces, Congressional Budget Office representatives testify that [PDF]:

“CBO believes that the Navy’s cost estimate for the first ship of the class, the Gerald R. Ford (CVN-78), is optimistic. In its budget submission to the Congress, the Navy estimates that the CVN-78 will cost about $10 billion in 2008 dollars, including about $2.2 billion for nonrecurring engineering and design.16 The Navy argues that actual construction time and cost for the CVN-78 will be less than for its predecessor ship, the George H.W. Bush (CVN-77). CBO, by contrast, estimates that the CVN-78 will cost about $11 billion, allowing for the cost growth that has affected past shipbuilding programs at the CVN-78’s stage of construction. If the CVN-78 experiences [cost growth] similar to that of other lead ships the Navy has purchased in the past 10 years, costs could be higher still.17 Moreover, Navy officials have told CBO that the confidence level associated with their estimate is below a 50 percent probability of meeting the cost target, which also suggests that costs could increase. In addition, a number of critical technologies for the CVN-78 are still under development, and difficulties could still arise in integrating the various new technologies associated with that class.”

Jan 19/07: Gerald R. Ford Class: It’s official. Secretary of the Navy Donald C. Winter announced that USS Gerald R. Ford would be the name of the first CVN-21 aircraft carrier, which would henceforth be designated the Gerald R. Ford Class. This selection honors the 38th President of the United States, and pays tribute to his lifetime of service in the Navy and the U.S. government. See official NAVSEA release.

“Gerald R. Ford” Class

Nov 30/06: CVN-21. A $754 million modification (cost type) to previously awarded contract #N00024-04-C-2118 for continuation of CVN-21 design effort; long lead time material and non-nuclear advance construction; and system development, engineering services, and feasibility studies for the Future Aircraft Carrier Program. Work will be performed in Newport News, VA (90%) and Groton, CT (10%), and is expected to be complete by December 2007. The contract includes an additional $106.7 million in options which would make this an $860.7 million award, and bring the total value of Northrop Grumman’s CVN-21 advance construction contracts so far to $2.1 billion.

See May 21/04 entry for more details. Under this contract modification, Newport News will provide all CVN-21 services and material in preparation for ship construction planned to commence in FY 2008, “including the necessary research studies; engineering; design; related development efforts including required Engineering Development Models and prototypes for engineered components; advanced planning; advanced procurement for detailed design and procurement/fabrication of long lead material; advanced construction, system specifications; design weight estimate; logistics data; lists of government-furnished equipment; production planning; further definition of initiatives to reduce CVN-21 total ownership costs; and other data to support an integrated product data environment for CVN-21.”

Mike Shawcross, vice president of the CVN 21 program for Northrop Grumman Newport News, said that they are “more than 50% complete with the overall design.” See also Northrop Grumman press release.

FY 2006 and earlier

Specs complete.

CVN 79 early concept
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Nov 15/06: CVN 79. DefenseLINK announces a $7.4 million cost-plus-fixed-fee, level of effort contract for systems development, engineering services, and feasibility studies for CVN 79, the second ship of the class. Northrop Grumman, on the other hand, announces it as a $24.6 million total planning and design contract, including planning, feasibility studies, system development, engineering services and other design efforts. Work will be performed in Newport News, VA and is expected to be completed by October 2007. The contract was not competitively procured (N00024-07-C-2116).

“This is our first contract for the CVN 79 and an important step forward for the CVN 78 program,” said Mike Shawcross, the vice president responsible for CVN 79 at Northrop Grumman’s Newport News sector. “We’re focused on using the work we’ve accomplished on the first ship of the class, CVN 78, as the basis for a successful integration into the planning and design for CVN 79.” Construction on CVN 79 is slated to begin in 2012, with delivery to the US Navy in 2019.

Oct 17/06: Gerald Ford? President George W. Bush signs the John Warner National Defense Authorization Act for FY 2007. Section 1012 of the act declares that “[it] is the sense of Congress that the nuclear-powered aircraft carrier of the Navy designated as CVN-78 should be named the U.S.S. Gerald R. Ford.”

Sept 5/06: The Naval Sea Systems Command (NAVSEA) and the Program Executive Officer (PEO) Aircraft Carriers held a signature and awards ceremony at the Washington Navy Yard to commemorate the certification of the ship specifications for the CVN 78 aircraft carrier, after 12 months of specification writing and 3 months of intense reading sessions. NAVSEA’s Ship Design, Integration and Engineering Directorate (SEA 05) and lead design shipyard Northrop Grumman Newport News led these efforts.

This certification marks a major milestone in the future aircraft carrier design process, and forms the basis of the technical data package used to prepare a ship construction contract. The CVN 78 Ship Specifications were signed by Rear Adm. David Architzel, PEO Aircraft Carriers, and Rear Adm. Kevin M. McCoy, NAVSEA’s deputy commander for SEA 05. NAVSEA release | PEO Carriers release.

Specifications done.

July 29/06: Leadership. Rear Adm. Dennis M. Dwyer is honored at the end of his tenure as PEO Carriers. He receives the Navy Distinguished Service medal for his “exceptionally meritorious service,” for his efforts in “Aircraft Carrier design and build, government and industry business modeling, and workforce restructuring methodologies… Dwyer’s ultimate contribution – the design and build of the U.S. Navy’s Next Generation Aircraft Carrier – CVN 21 – will decisively affect the Nation’s strategies, policies, and defensive posture for the next 50 years…” See NAVSEA release.

Nov 15/05: CVN-21. A $558.7 million cost-type modification exercises an option under previously awarded contract N00024-04-C-2118 for continuation of CVN-21 design effort; long lead time material procurement and non-nuclear advance construction; system development, engineering services, and feasibility studies for the future aircraft carrier program. See Oct 29/04 for further details.

Work will be performed at Newport News, VA (92%) and Groton, CT (8%), and is expected to be complete by December 2006, though it would be followed by other contracts in this vein in 2006 and 2007. This contract was not competitively procured. See also Northrop Grumman’s press release.

June 7/05: CVN-21. A $9.2 million cost-type modification for CVN-21 construction preparation, non-propulsion plant long lead-time material and advance construction. Work will be performed at Newport News, VA and is expected to be complete in December 2006. This contract was not competitively procured (N00024-04-C-2118).

April 1/05: CVN-21. A $50.6 million cost-type modification for continuation of CVN-21 engineering services and feasibility studies for the future aircraft carrier program. Work will be performed at Newport News, VA (85%) and Groton, CT (15%), and is expected to be complete by December 2006. This contract was not competitively procured (N00024-04-C-2118).

Oct 29/04: CVN-21. A $492.1 million cost-plus-fixed-fee and cost-plus-award-fee modification exercises an option for continuation of CVN-21 design effort; long lead time material and non-nuclear advance construction and system development, engineering services, and feasibility studies for future aircraft carrier programs. See May 21/04 entry for further details.

Newport News Shipbuilding will provide all CVN-21 services and material in preparation for ship construction planned to commence in FY 2007, including research studies; engineering; design; related development efforts including required engineering development models (EDMs) and prototypes for engineered components; advanced planning; advanced procurement for detailed design and procurement/ fabrication of long lead material; system specifications; design weight estimate; logistics data; lists of government-furnished equipment; production planning; further definition of initiatives to reduce CVN-21 total ownership costs; and other data to support an integrated product data environment for CVN-21.

As we have seen with programs like the LPD-17 San Antonio Class, changes at the design stage are far cheaper to execute than changes at the engineering stage. Work will be performed at Newport News, VA (87%) and Groton, CT (13%), and is expected to be complete by October 2005. This contract was not competitively procured (N00024-04-C-2118).

May 21/04: CVN-21. A $182.5 million cost-plus-fixed-fee contract with performance incentives for CVN-21 design effort; long lead time material and non-nuclear advance construction; and system development, engineering services, and feasibility studies for the Future Aircraft Carrier Program. Newport News Shipbuilding will provide all CVN-21 services and material in preparation for ship construction. Work will be performed at Newport News, VA (87%) and Groton, CT (13%), and is expected to be complete by December 2006. This contract was not competitively procured (N00024-04-C-2118).

Northrop Grumman would later describe this contract as having a potential total value of $2.7 billion, adding that this contract to build and buy key sub-assemblies and sectional pieces:

“…allowed shipbuilders to test the design-build strategy, exercise new processes, prototype new features used on this ship before the overall construction contract was awarded, and to build a sufficient backlog of ship units to support production, undocking and delivery.”

CVN-21: Other Related Contracts and Events

Coverage under this section includes 2 key technologies that are also broken out as independent, free-to-view articles: EMALS electro-magnetic aircraft catapults, and the accompanying AAG arrester gear system; and the carrier’s new AN/SPY-3 & AN/SPY-4 dual-band radar. Listings for those 2 programs will feature only major milestones.

FY 2012 – 2013

1st F-35C launch
(click for video)

May 29/13: JPALS. Raytheon in Fullerton, CA receives a $14.6 million cost-plus-incentive-fee contract modification for the Joint Precision Approach and Landing System (JPALS), maintenance Design Phase II. They want to change the design to allow for increased organizational level maintenance (i.e. on board ship) of JPALS Increment 1A ship systems.

Work will be performed in Fullerton, CA (60%); Cedar Rapids, IA (28%); and Indianapolis, IN (12%); and is expected to be complete in December 2013. $13.9 million is committed immediately, using FY 2012 – 2013 funds, and $5.3 million of those will expire at the end of the current fiscal year, on Sept 30/13. US Naval Air Systems Command in Patuxent River, MD manages the contract (N00019-08-C-0034).

JPALS
click for video

May 24/13: JPALS. The Pentagon finally releases its Dec 31/12 Selected Acquisitions Report [PDF]. For JPALS, which began development in 2008:

“Joint Precision Approach and Landing System (JPALS) Increment 1A – Program costs increased $106.8 million (+10.7%) from $996.0 million to $1,102.8 million, due primarily to additional engineering effort for algorithm refinement and development of an alternate configuration for the JPALS Inc 1A ship system variant, resulting in a smaller footprint for air capable ships (small combatants) (+$84.5 million). Additional increases were attributable to an extension of the procurement and installation profile from FY 2018 to FY 2020 (+$15.3 million) and a related increase in support costs (+$2.3 million), and a quantity increase of 1 system from 26 to 27 systems (+$7.5 million) and associated estimating allocation (-$1.4 million). These increases were offset by a decrease in initial spares requirements (-$1.5 million).”

The GPS-centric JPALS will be installed well beyond the Ford Class – indeed, beyond the US Navy. This technology may become a separate article, but for now we’re adding it here as a key CVN-21 technology, which will play a critical role in handling F-35 fighters and UAVs. A JPALS 1A Milestone C production decision is expected in Fall 2013.

JPALS landing system – cost increases

Nov 18/11: F-35C launches. The land-based EMALS at Lakehurst, NJ launches an F-35C Lightning II fighter for the 1st time. The EMALS launch of test aircraft CF-3 follows more than 50 steam catapult launches.

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

FY 2010 – 2011

May 9/11: EMALS Delivery. General Atomics delivers the 1st set of EMALS production components to US NAVAIR, for installation in the Gerald R. Ford. NAVAIR will convey the items on to Huntington Ingalls Industries, Inc., in Newport News, VA. General Atomics.

March 31/11: CVN 78 CEC. An $8.1 million contract modification for AN/USG-2B systems delivery and test aboard the Nimitz Class aircraft carrier USS Abraham Lincoln [CVN 72, headed into deep refit] and the Gerald R. Ford. It’s a key component of the Navy’s Cooperative Engagement Capability, which allows equipped ships to share a common picture of threats around them, even if those threats are out of their own sensor range.

Work will be performed in Largo, FL (47%); St. Petersburg, FL (20%); Dallas, TX (18%); and McKinney, TX (15%), and is expected to be completed by May 2013 (N00024-08-C-5203).

1st EMALS launch: F/A-18E
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Dec 18/10: Launch! The EMALS test catapult at Naval Air Systems Command in Lakehurst, NJ successfully performs the 1st electro-magnetic aircraft catapult launch in history.

The F/A-18E Super Hornet from Air Test and Evaluation Squadron 23 (VX-23) was piloted by Lt. Daniel Radocaj. Chief Petty Officer Brandon Barr of NAWCAD’s Test Department was the “shooter,” assisted by Petty Officers 1st Class Hunsaker and Robinson, and Petty Officers 2nd Class Williams, Wong, and Simmons.

Engineers will continue system functional demonstration testing at NAVAIR Lakehurst, with test launches set to expand to C-2 Greyhound cargo aircraft and T-45 Goshawk trainers in 2011. The ALRE program manager at this time is Capt. James Donnelly, and Cmdr. Russ McCormack of PMA-251 is deputy program manager for future systems. US NAVAIR | USN Photo release | Gannett’s Navy Times.

1st EMALS Launch

Oct 12/10: AWE. Exlar Corporation announces an award from Federal Equipment Company in Cincinnati, OH to provide its GM30 linear actuators for the Gerald R. Ford’s Advanced Weapon Elevators. The AWEs can carry up to 24,000 pounds at speeds up to 150 feet per minute, a big improvement over previous designs.

Exlar’s GSM30 linear actuators are used to fire locking pins to keep the elevators in position at each deck level. They combine a brushless servo motor, an inverted roller screw and an encoder/resolver feedback source into a single compact assembly. The brushless servo design allows them to be used in state-of-the art closed loop servo systems, where electronic control of positioning and velocity is required.

Aug 11/10: SDTS tests. Raytheon Integrated Defense Systems in Tewksbury, MaA receives a $36.1 million contract modification (N00024-05-C-5346) for mission systems equipment (MSE) that will be used on the US Navy’s Self Defense Test Ship, in support of the Anti-Air Warfare Self Defense Enterprise Test and Evaluation Master Plan. The equipment will support the DDG 1000 and CVN 78 classes of ships, in addition to follow-on operation test and evaluation efforts for the Evolved Sea Sparrow Missile (RIM-162 ESSM) and Surface Electronic Warfare Improvement Program (SEWIP).

Work will be performed in Andover, MA (58.7%); Portsmouth, RI (32%); Sudbury, MA (5.4%); Tewksbury, MA (2.7%); and San Diego, CA (1.2%). Work is expected to be completed by March 2013. US Naval Sea Systems Command in Washington, DC manages this contract.

March 31/10: Power & cooling. Raytheon Integrated Defense Systems in Tewksbury, MA received a $9.8 million modification to previously awarded contract (N00024-05-C-5346) for CVN 78 dual-band radar common array power system and common array cooling system long-lead time materials and associated efforts. These materials, and associated engineering and management efforts, must be bought now, to ensure that critical production schedules are maintained for the CVN 78 program.

Work will be performed in Andover, MA (87.8%); Sudbury, MA (10.4%); Tewksbury, MA (0.9%); and Portsmouth, RI (0.9%), and is expected to be complete by September 2010. The Naval Sea Systems Command in Washington, DC manages these contracts.

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 key CVN-21 sub-systems, DID has divided the comments by system:

“While CVN 21 program officials stated that the EMALS program is on schedule to deliver material to the shipyard when it is needed for construction, concurrent EMALS testing and ship construction continue to present cost and schedule risks to the program… As a result of the [2009 EMALS] tests, the program identified design changes that are necessary to improve the performance of EMALS, but add cost and schedule risk to the program… The Navy plans to test EMALS with actual aircraft in summer 2010. The Navy awarded a not-to-exceed fixed-price production contract to General Atomics for EMALS and the advanced arresting gear in 2009. At the time of award, the contract price had not been finalized. The Navy expects to finalize the price of this contract in March 2010.”

“…The advanced arresting gear includes seven major subsystems. Programs officials expect that six of the subsystems will be mature after analyzing data from a recent reliability test. The remaining subsystem – control system software – will remain immature until integrated land-based testing with actual aircraft occurs in fiscal year 2012. This testing will overlap with the first arresting gear deliveries to the shipyard.”

“…Testing of carrier specific dual band radar functionality is scheduled to conclude in fiscal year 2012. Dual band radar equipment will be delivered incrementally from fiscal years 2012 through 2014… Given the recent decision to truncate the DDG 1000 program, CVN 21 program officials stated that the dual band radar production line may be idle for up to 4 years before production begins for CVN 79 [and so adding] costs associated with restarting the production line.”

March 12/10: Fiber optic cabling. As fiber optic cable replaces conventional cabling in large naval vessels, driving down component manufacturing and repair costs becomes especially appealing. The US Naval Surface Warfare Center Dahlgren Division in Dahlgren, VA issues the Kitco/kSARIA LLC limited partnership small business in Norfolk, VA a $9.8 million contract for the automated fiber optic manufacturing initiative (AFOMI). AFOMI seeks to drive lifetime fiber optic component manufacturing and repair costs down by miniaturizing and automating as many processes as possible. If the effort suceeds, it will have obvious benefts beyond CVN 78, or even the military sphere.

Kitco/kSARIA LLC is a limited partnership of KITCO Fiber Optics in Virginia Beach, VA (contract administration, 10%), and kSARIA Corp. in Lawrence, MA (technology development & manufacturing, 90%). kSARIA has worked with the US Navy for some time, and touts itself as “the only fiber cable manufacturer in the world with an end-to-end automated assembly process.” Work is expected to be complete in March 2015, but $1.5 million in contract funds will expire at the end of the current fiscal year. This contract was competitively procured via the Naval Electronics Commerce Online and Federal Business Opportunities Web sites, with 2 offers received (N00178-10-D-2003). See also Military & Aerospace Electronics magazine | Video overview.

Nov 9/09: AAG. General Atomics in San Diego, CA receives a $102.2 million modification to the unfinalized EMALS Ship-set contract (N68335-09-C-0573) to provide for the production of 1 counterpart advanced arresting gear system ship-set for CVN-78. While EMALS will serve as the Ford’s launch technology, the Advanced Arresting Gear will offer related improvements around carrier landings, using a system based on electric motors rather than the Mk7 hydraulic system used with current arrester wires. Unlike EMALS, AAG is also slated for refits to existing Nimitz class carriers.

Work will be performed in San Diego, CA (35%); Mt. Pleasant, PA (28%); Tupelo, MS (15%); Waltham, MA (12%); and Aston, PA (10%), and is expected to be complete in September 2015. The Naval Air Warfare Center Aircraft Division in Lakehurst, NJ manages the contract.

AAG CVN 78

FY 2007 – 2009

EMALS motor, HCT-1
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June 30/09: EMALS. General Atomics in San Diego, CA received an unfinalized $573 million ceiling-priced contract to build the EMALS shipset for the Gerald R. Ford [CVN 78]. This is added to a $43 million long-lead contract (q.v. March 27/09), creating a total of $613 million.

Work will be performed in San Diego, CA (49%); Tupelo, MS (19%); Mankato, MN (12%); Waltham, MA (4%); and various locations across the United States (16%), and is expected to be complete in September 2015. This contract was not competitively procured, pursuant to FAR 602-1. The Naval Air Warfare Center Aircraft Division in Lakehurst, NJ manages this contract (N68335-09-C-0573).

CVN 78 EMALS

April 23/09: DBR. Raytheon Integrated Defense Systems in Tewksbury, MA received a $217 million cost plus fixed fee modification to a previously awarded contract (N00024-05-C-5346) for 2 Volume Search Radars (VSR). Lockheed Martin makes the antennas for these radars, but Raytheon is the lead contractor, and also makes the radars’ common back-end electronics and software.

These S-band naval radars will be mounted on one of the new DDG-1000 Zumwalt Class destroyers, and on the inaugural CVN-21 carrier USS Gerald R. Ford [CVN 78]. Work will be performed in Moorestown, NJ (95%) and Sudbury, MA (5%), and is to be complete by March 2013. The Naval Sea Systems Command in Washington, D.C. manages this contract.

DBR radar for CVN 78

April 15/09: Review. Reuters reports that the U.S. Navy has completed a major review of EMALS that weighed possible technical, costs, and schedule risks. The Navy has decided to proceed, on the grounds that EMALS is the best option for keeping the program on schedule, vs. redesigning and building the ship for steam. The system’s potential cost savings are also listed as a factor by US Navy spokesman Lt. Cdr. Victor Chen.

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

EMALS survives

April 7/09: DBR. Raytheon announces a successful initial “lightoff” test of the Dual Band Radar, which includes the X-band AN/SPY-3 Multi-Function Radar and S-band Volume Search Radar. Both radiated radiated at high power during lightoff at the Navy’s Engineering Test Center in Wallops Island, VA. Following this successful lightoff test, the radar suite will begin an extended period of operational performance testing.

March 31/09: EMALS. The Daily Press of Virginia reports:

“We’re still conducting a review to assess and mitigate risks in the program cost, schedule and performance of EMALS,” said Lt. Cmdr. Victor Chen, a Navy spokesman. “At this point, EMALS is still the launching system of record for (the Ford).

…If EMALS is scrapped for the Ford, the shipyard would have to re-engineer the carrier to support the old steam-driven catapults used on previous ships. That process, which includes running thousands of feet of new pipe to and from the Ford’s propulsion system, could extend the construction schedule by up to a year and is expected to cost several hundred million dollars.”

“At this point…” is perhaps not the ringing endorsement one had hoped for.

March 27/09: CVN 78. Northrop Grumman Shipbuilding, Inc. in Newport News, VA received $43 million, unfinalized modification to a previously awarded contract (N00024-08-C-2110). The contract covers long lead-time materials that must be ordered early, in order to ensure timely production of Gerald R. Ford’s [CVN 78] EMALS catapults. Materials bought will include Energy Storage Subsystem (ESS) Induction Motor Stator Assemblies, ESS Induction Motor Rotor Assemblies, ESS Exciter Stator Assemblies, ESS Exciter Rotor Assembly, ESS Rectifier Assemblies, ESS Main Rotor Assemblies and Power Conversion Subsystem Rectifier material components.

Work will be performed in North Mankato, MN (74%); Mt. Pleasant, PA (17%); and San Diego, CA (9%), and is expected to be complete by November 2012. The US The Naval Sea Systems Command in Washington Navy Yard, D.C. manages this contract.

EMALS CVN 78

Nov 3/08: Nuke plant. Curtiss-Wright Corporation announces a contract from Bechtel Plant Machinery, Inc. (BPMI), to provide critical valves for the nuclear propulsion systems in the U.S. Navy’s next 4 Virginia-Class submarines, and the 2nd Ford-Class Aircraft Carrier [CVN 79]. The contract contains options for up to 4 more sets: a submarine ship-set and an aircraft carrier ship-set funded in 2008, and 2 additional submarine ship-sets to be funded in 2009.

The value is over $83 million if all options are exercised, and the initial award is for an initial ship-set of submarine valves and long lead materials valued at approximately $15 million. Curtiss-Wright’s Flow Control segment will perform the work at its facility in East Farmingdale, NY. Delivery is scheduled to commence in 2009 and continue through 2017.

Variants of Curtiss-Wright’s Smart, Leakless Valves are already used in the commercial nuclear power industry. These fully automated, sealed solenoid valves can control the flow of liquids, gas, and steam, withstanding up to 2500 psi pressure and 670F temperatures while requiring little to no maintenance over long periods. The firm is now using the valve beyond nuclear power applications, and has a $62 million contract to retrofit all of the JP-5 jet fuel pumping station valves on the U.S. Navy’s Nimitz class aircraft carriers.

Oct 20/08: DBR. Raytheon announces a $23.5 million U.S. Navy contract to adapt the Dual Band Radar (DBR) it’s developing for the DDG-1000 Zumwalt Class destroyer, for installation on the future U.S.S. Gerald R. Ford [CVN 78]. Raytheon will deliver DBR supporting equipment hardware and software designs to meet the installation and integration requirements of the CVN 78 class of ships.

Sept 30/08: SSDS. An $8.3 million cost-plus fixed-fee letter contract to act as the SSDS Platform System Engineering Agent. The contractor will be responsible for the integration of complex war-fighting improvements into the modular SSDS, including components associated with the new Gerald R. Ford Class carrier’s Dual Band Radar (DBR), and with the popular Rolling Airframe Missile (RAM) Block 2.

Work will be performed in San Diego, CA (90%); Tewksbury, MA (2.5%); Portsmouth, RI (2.5%); St. Petersburg, FL (2.5%); and Tucson, AZ (2.5%), and is expected to be completed by April 2009. This contract was not competitively procured (N00024-08-C-5122).

Nov 28/07: General Atomics’ Electromagnetic Aircraft Launch System (EMALS) catapult recently passed its final critical design review (CDR), led by Mr. Dave Cohen of NAVAIR’s Systems Engineering competency. The team spent a week thoroughly reviewing the entire EMALS program, and determined that the design is technically compliant with requirements and properly documented, although “a few open action items remain.” As noted above, EMALS is one of the new technologies that will be critical to the CVN-21 Class’ ability to fulfil its cost-saving promises and enter service on time.

Capt. Stephen Rorke, Aircraft Launch & Recovery Equipment program manager thanked the team for open and honest dialog during the months leading up to the CDR as evidenced by the fact “the team knew about all open issues prior to the review and that no issues of major significance surfaced during the CDR.”

The next step in the process is to begin installing the full size, ship representative EMALS equipment in the recently completed EMALS test facilities at Naval Engineering Station Lakehurst, NJ. The EMALS equipment installation is scheduled to begin in mid 2008, with actual testing to begin in early 2009 and continue throughout 2009. The first components of the EMALS equipment is scheduled to be delivered to Northrop-Grumman Newport News Shipbuilding in Norfolk, VA for installation in the Gerald R. Ford [CVN-78] in 2011. The USS Gerald R. Ford is scheduled to be delivered to the US Navy in 2015. NAVAIR release.

EMALS CDR

FY 2004 – 2006

new weapons elevator
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Dec 13/05: Electronics. Raytheon Company passed the systems requirements review (SRR) for the CVN-21 Class’ electronics. They’re the industry lead for integration of all government furnished combat systems, C4ISR (command, control, communications, computers, intelligence, surveillance and reconnaissance) and aviation support systems.

Raytheon is working to leverage the open architecture and technology advancements achieved as the mission systems integrator on the DD (X) destroyer and LPD-17 San Antonio Class ship programs. The idea is to create common technologies and processes across multiple platforms in the U.S. Navy fleet. Raytheon.

Oct 20/05: AWE. Northrop-Grumman selects Federal Equipment Company and their technology partner, MagneMotion to design and build the advanced weapons elevator for CVN-21.

Newport News sector awarded the approximately $50 million contract following a year-long design competition, during which vendors refined their designs and built and tested a full-scale, one-quarter load elevator drive. The preliminary design competition concluded in early 2005, and a full-scale prototype elevator for land-based testing is the next step. Prototype testing will be completed by late 2007, after which Federal Equipment will begin to manufacture the production units. These units are scheduled for shipboard installation on CVN 78 in mid-2010.

AWE SDD

Oct 20/05: Nuke plant. The Naval Sea Systems Command in Washington, DC awards Bechtel Bettis Inc. at Bettis Atomic Power Laboratory in West Mifflin, PA a $480.7 million cost-plus-fixed-fee modification to previously awarded contract (N00024-98-C-4064) for naval nuclear propulsion work at the Bettis Atomic Power Laboratory. As DID notes in its coverage: “Bettis [Atomic Power Laboratory] is engaged solely in the design and development of naval nuclear propulsion plants. …A major new initiative for the Laboratory is design of the nuclear propulsion plants and electrical power systems for the next class of US Navy aircraft carriers.”

See “The US Navy’s Nuclear Propulsion Contracts” for coverage of all American naval nuclear propulsion work.

Aug 11/05: Infrastructure. On Aug. 11 Northrop Grumman Newport News hosted a ceremonial steel cut and grand opening ceremony for one of several new facilities that will support CVN-21 construction. The ceremony was held in the shipyard’s new Heavy Plate Bay.

April 18/05: SSDS. Raytheon Technical Services Company LLC will lead a group of companies working under the Navy’s direction to design, install and test a new version of their SSDS combat system, which will integrate all onboard weapons systems and electronics on the Navy’s first CVN-21 class aircraft carrier (CVN-78). These systems will protect CVN-78 from attack by cruise missiles and other weapons, and integration will be centered on Raytheon’s proven Total Ship System Engineering approach to a common enterprise computing environment. DID covers the contract, which could be worth up to $95 million over 12 years.

Feb 23/05: AAG pick. Reports indicate that the US Navy has selected a team led by General Atomics to perform the System Development and Demonstration (SDD) phase of the Advanced Arresting Gear (AAG) Program. The Naval Air Systems Command (NAVAIR) down-selected from the 2 contractors performing the Component and Technology Development phase. Other team members are Curtiss-Wright Electro-Mechanical Corporation, Engineered Arresting Systems Corporation, Foster-Miller, Inc. (now QinetiQ North America), John J. McMullen Associates, Inc., and EDO Corporation.

In the 5-year, $95.8-million SDD phase, the GA-led Team will design, develop, manufacture, install, and demonstrate a production-representative AAG unit. System installation and demonstration will be at a NAVAIR test facility at Lakehurst, NJ. Defense West News.

AAG SDD

April 2/04: General Atomics is awarded a System Development and Demonstration (SDD) $145 million contract to design, build, integrate test and support a full scale, full length, shipboard representative Electromagnetic Aircraft Launch System (EMALS) for NAVAIR Lakehurst, at the Naval Air Engineering Station Lakehurst, NJ. The contract is the final step in a multi-phase research and development acquisition program to replace the current steam catapults used on aircraft carriers. According to the Navy release, “General Atomics, based in San Diego, will have its equipment installed at Lakehurst by 2006 and conduct testing in 2007-2008.”

The EMALS land based support facility is to be built by Hensel Phelps Construction Co., of Aurora, CO under a $20.5 million contract, and is expected to be complete by December 2005 [DID: the ribbon cutting would actually take place in November 2007, and construction will last to late 2008]. It will include building the infrastructure, supporting buildings and related utilities for the EMALS program. US Navy | General Atomics.

EMALS base SDD

July 30/03: Infrastructure. The US Navy opens its new CVN-21 Government Design Site in the Washington Navy Yard. The design site will have 60 workstations and allow more than 100 engineers to participate on an as-needed basis in the CVN-21 design effort. This will include engineers from NAVSEA, Naval Air Systems Command, Space and Naval Warfare Systems Command, Office of Naval Research, Northrop Grumman Newport News, as well as Naval Surface Warfare Center Dahlgren and Carderock Divisions. Although the CVN-21 design site is not the first at the Washington Navy Yard, it is the largest. Co-locating government engineering and technical expertise close to the aircraft carrier program office is designed to ensure critical and timely support throughout the design effort – a vital factor to the continued success of the program.

CVN-21 Class: Additional Readings and Sources

• Northrop-Grumman Newport News – CVN-21 team site

• US Department of the Navy Research, Development & Acquisition – CVN 21 Aircraft Carrier. Pretty bare-bones, but an authoritative source for the most basic specifications.

• Global Security.org – CVN-21 (formerly CVX)

• USNI Proceedings (September 2012) – A Leap Ahead for the 21st Century Navy. Describes the core characteristics and advantages of the class.

• DID (Dec 19/05) – Costing the CVN-21: A DID Primer. Sets the record straight on the CVN-21 Class’ cost per ship, and also goes into detail re: the lifetime operating cost savings expected as a result of design and technology innovations.

• Gannett’s Navy Times (Feb 22/12) – Navy looks to rein in carrier program costs

• GlobalSecurity.org – CVN-77 – George H.W. Bush

• Northrop-Grumman Newport News – George H.W. Bush (CVN 77) Home Page

• GlobalSecurity.org – CVN-68 Nimitz Class. See also accompanying links for more in-depth background, including their Ships List with its linked Strike Group information for each ship.

• Naval Technology – Nimitz Class Nuclear Powered Aircraft Carriers, USA

Official Reports

• US Government Accountability Office (GAO-07-866, Aug 23/07) – Navy Faces Challenges Constructing the Aircraft Carrier Gerald R. Ford within Budget. “The Navy requested authorization of CVN 78 in its fiscal year 2008 budget. GAO was asked to assess the Navy’s ability to meet its goals for developing the new carrier. Specifically, this report assesses (1) the extent to which technology development could affect the capability and construction of CVN 78, (2) the status of efforts to achieve design stability, and (3) the challenges to building CVN 78 within budget. To accomplish this, our work includes analysis of test reports, development schedules, and ship progress reviews; interviews with Navy and other officials; and examinations of cost estimates and our own past work.”

• US House Armed Services Subcommittee on Seapower and Expeditionary Forces (July 24/07) – Congressional Budget Office, Statement of J. Michael Gilmore, Assistant Director for National Security and Eric J. Labs, Senior Analyst: The Navy’s 2008 Shipbuilding Plan and Key Ship Programs [PDF format]

• Congressional Research Service Report for Congress (May 25/05) – Navy CVN-21 Aircraft Carrier Program: Background and Issues for Congress. The figures won’t match DID’s figures above. This DID article explains the differences.

• US DoD Office of Force Transformation – Alternative Fleet Architecture Design study [PDF format]. This is the study led by Vice-Adm. Cebrowski. See also this June 2005 Congressional Research Service Report that includes this study and 2 others [Google HTML cache | PDF Format].

• RAND Corporation (2002) – Refueling and Complex Overhaul of the USS Nimitz (CVN 68): Lessons for the Future

Ancillary Systems

• DID Spotlight – EMALS: Electro-Magnetic Launch for Carriers

• American Heritage (Spring 2006) – Shot Into the Air. Good look at the use of naval catapults from their earliest days to the forthcoming EMALS. Fine conceptual schematic of the modern steam catapult included.

• GlobalSecurity.org – Electromagnetic Aircraft Launch System – EMALS

• General Atomics – Electromagnetic Aircraft Launch System (EMALS)

• Smithsonian Air & Space Magazine (Dec 2007 – Jan 2008) – How Things Work: Electro-Magnetic Catapults

• Aviation Week (Jule 13/07) – Risk Areas In CVN 21 Cost, Development

• Defense Tech (April 5-7/07) – EMALS: Next-Generation Catapult and Building a New Ford. Latter includes some interesting background re: EMALS integration challenges and solutions.

• Electronics Design News (April 11/02) – Electronics poised to replace steam-powered aircraft launch. I like the references and linked diagrams.

• DID Spotlight – The US Navy’s Dual Band Radars

• Curtiss-Wright – Advanced Aircraft Arresting Gear. “The Advanced Arresting Gear (AAG) system incorporates turbo-electric power to capture tailhook-equipped aircraft landing on the deck of an aircraft carrier. This advanced technology will replace the current hydraulic arresting system…”

• Seapower Magazine (June 2003) – New Carrier Island Is At Heart Of Higher Sortie Rates For CVN 21

• National Defense Magazine (May 2003) – Navy Starts Work on Next Class of Carriers. Good overview of why many of the design changes were made, and how maladaptive some of the old approaches were – like putting new carriers to sea with obsolete electronics on day 1. Remember, however, that costs must be normalized to FY 2008 dollars.

• Seapower Magazine (June 2001) – Today’s Carrier Force — And Tomorrow’s: Being Transformed by “Leap-Ahead” Technology

The Carrier’s Future

• CNAS (October 2015) – Retreat from Range: The Rise and Fall of Carrier Aviation By Dr. Jerry Hendrix, USN (Ret’d)

• CNAS (March 2013) – At What Cost a Carrier? By Capt. Henry J. Hendrix, USN (Ph.D.)

• US DoD (May 3/10) – Navy League Sea-Air-Space Exposition: Remarks as Delivered by Secretary of Defense Robert M. Gates, Gaylord Convention Center, National Harbor, Maryland

• Information Dissemination (Aug 31/09) – Dropping the Carrier Requirement to 10, 9, and Potentially 8

• US Naval Institute Proceedings Magazine (April 2009) – Buy Fords not Ferraris

• Singapore MINDEF, Pointer Journal (V25, N1; March 1999) – Is the Super Carrier Going to be Obsolete? An interesting third-party look at the super-carrier and its alternatives. Singapore does not currently own a carrier of any description, and has no plans to do so.

• Popular Mechanics (October 1998) – 21st Century Carrier Force. Some of the ideas at first were a bit more radical. As it turned out, the Nimitz class would not mark the end of large carriers – nor would CVN-21 be a stealth ship, or non-nuclear.

GBU-53/B, aka. SDB-II
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The 250 pound GBU-39 Small Diameter Bomb gives American fighters the ability to carry more high-precision GPS-guided glide bombs, without sacrificing punching power against fortified targets. The initial award to Boeing was controversial, and the Darlene Druyun corruption scandal ultimately forced a re-compete of the Increment II development program. Whereas the initial GBU-39 SDB-I offered GPS-guided accuracy in a small and streamlined package, the goal of the GBU-53 SDB-II competition was a bomb that could hit moving targets in any weather, using a combination of guidance modes.

For the SDB-II competition, Boeing found itself allied with Lockheed Martin, its key opponent for the initial SDB-I contract. Its main competitor this time was Raytheon, whose SDB-II bid team found itself sharing its tri-mode seeker technology with a separate Boeing team, as they compete together for the tri-service JAGM missile award against… Lockheed Martin. So, is Raytheon’s win of the SDB-II competition also good news for its main competitor? It’s certainly good news for Raytheon, who wins a program that could be worth over $5 billion.

Raytheon’s GBU-53 Small Diameter Bomb

SDB-II: cutaway
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Raytheon’s GBU-53/B SDB-II is 7″ in diameter around the tri-mode (laser, IIR, radar) seeker, with a clamshell protective door that comes off when the bomb is dropped. A GPS receiver adds a 4th targeting mode. The bomb tapers to about 6″ diameter beyond the pop-out wings, and is about 69.5″ long. The wings remain swept back when deployed, and are about 66″ across with a 5 degree anhedral slope. The bomb weighs about 200 pounds, and all of these dimensions are important when trying to ensure that the US Marines’ F-35B, with its cut-down internal weapon bays, can still carry 4 of them per bay.

The US Navy is developing a Joint Miniature Munitions BRU to address internal F-35 carriage, and SDB-II also fits on BRU-61 external bomb racks. No word yet on whether the JMM BRU will also fit in the USAF’s F-22A, which is also slated to deploy this weapon.

Range is expected to be up to 40 nautical miles when launched at altitude, thanks to a high lift-to-drag ratio in the design. Since SDB-II is an unpowered glide bomb, its actual range will always depend on launching altitude and circumstances. An F-22A would be able to extend that range significantly by launching at supercruise speeds of Mach 1.5, for instance, as long as the bomb proves safe and stable at those launch speeds.

SDB-II’s Attack Modes: Seekers & Sequences

SDB-Is on F-15E
(click to view larger)

Once a target is picked by the pilot, initial communication and GPS coordinates are transmitted between the aircraft and the SDB-II bomb using the Universal Armament Interface (UAI) messaging protocol, which was designed to make integration of new weapons easier. The post-launch datalink will be Rockwell Collins’ TacNet, a 2-way, dual band link that enters the network quickly using encrypted UHF radio frequencies from the ground or secure Link-16 from the launching aircraft, and provides both weapon and target status to the shooter. TacNet’s datalink software is programmable if other frequencies/waveforms need to added in future, and Raytheon cites a message speed of 38 messages per minute as further evidence of the system’s ability to keep pace with future needs. Link-16 makes the weapon part of a much larger system, and gives SDB-II the ability to be dropped by one platform and then targeted or re-targeted by another. The bomb can also be sent an abort command, if necessary. If the link is lost, the bomb will continue with its mission, using its own on-board seekers.

Raytheon’s SDB-II contender uses a close precursor of the tri-mode seeker technology featured in the joint Raytheon/Boeing bid for the JAGM missile, which adds some refinements. The SDB-II uses jam-resistant GPS/INS targeting like Boeing’s GBU-39 SDB-I, but its added seeker features 3 modes of operation: semi-active laser, millimeter-wave radar, and uncooled imaging infrared. By combining these 3 modes, the GBU-53 can have excellent performance against a variety of target types, under any weather conditions, while making it much more difficult to use countermeasures or decoys successfully:

GBU-53 uses IIR/MMW
click for video

Semi-active laser guidance. This is standard for a wide range of missiles and rockets, and offers the best on-target accuracy and assurance, especially in urban environments. Its flip side is problematic performance through heavy fog, sandstorms, etc. That’s where GPS/INS guidance to a specified coordinate, and the next 2 fire-and-forget modes, come in.

Millimeter wave radar will operate through any weather. It’s especially good at distinguishing metal targets and noting movement, and is used in weapons like AGM-114 Hellfire Longbow missiles to give them “fire and forget” capability. These days, most people probably hear the term and think of airport scanners.

Imaging infrared (IIR) This was adapted from the much larger AGM-154 JSOW glide bomb, and uses high-resolution thermal scans to create a target picture. It also helps with target identification, and offers better performance against some kinds of targets like humans. By using an uncooled IIR seeker, the bomb lowers both its cost and its maintenance requirements. The uncooled seeker also allows snap-attacks against targets that present themselves quickly, since the it doesn’t need any time to cool down before it begins to work.

GBU-53 uses laser
click for video

Once launched, the SDB-II relies on a sophisticated package of internal computing and algorithms that are designed to get the most out of its tri-mode sensors, and make the process of launch and targeting as simple and flexible as possible for the pilot. The GPS/INS system or datalink messages guide the bomb toward the target during the initial search phase, while the tri-mode seeker gathers initial data. A revisit phase combines information from all of its sensor modes to classify targets. That’s especially useful because the SDB-II can be told to prioritize certain types of targets, for example by distinguishing between tracked and wheeled vehicles, or by giving laser “painted” targets priority.

SDB-II warhead test
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Different targets require different warhead types, which is why the GBU-53 contains a warhead from General Dynamics Ordnance & Tactical Systems that delivers shaped charge, blast and fragmentation effects all at once. A scored blast and fragmentation warhead makes it deadly against buildings and people as well.

This warhead was actually redesigned mid-way through the development phase, as the USAF added a requirement to destroy main battle tanks. That initial hardship became a positive experience, as the redesign actually ended up shrinking Team Raytheon’s bomb’s size, and improving its manufacturing costs.

SDB-II: The Program

As of 2013, the Boeing SDB-I/ GBU-39 Small Diameter Bob program was finished production at 12,300 weapons, and 2,000 BRU-61 bomb racks. Another 350 specialized Focused Lethality Munitions use carbon fiber bodies to deliver more near-field blast and less collateral damage; their last order was in FY 2012. Going forward, SDB-II is expected to be the default buy.

The overall program target for SDB-II is about 17,000 weapons over about 11 years: 12,000 bombs for the USAF, and 5,000 for the US Navy. Initial fielding will take place on USAF F-15E Strike Eagles, and F/A-18 E/F Super Hornets, even though the USMC and US Navy’s F-35B/C Block 4s are technically the program’s 2nd “threshold aircraft. Software development issues are likely to push F-35 fielding to 2022 or later in practice. Planned candidates for future fielding include F-16, F-22A, and F-35A multi-role fighters; B-52, B-1B, and stealth B-2A bombers; and MQ-9 Reaper drones.

Special Operations Command is even considering it for their AC-130 gunships, though they aren’t an official “objective” platform just yet. SDB-II was also supposed to equip the USAF’s A-10C close support planes, but the Pentagon is battling Congress to cancel the program.

The GBU-53 may also feature integration with other fighters, if the bombs are sold abroad. Raytheon isn’t in discussions with any foreign buyers yet, and doesn’t foresee the US government releasing the weapon for export discussions and sales before Low-Rate Initial Production begins in late 2014.

SDB-II schedule, 2010
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The SDB II Program is currently a $450.8 million Fixed Price Incentive Firm-type Engineering and Manufacturing Development contract. F-15E integration is being accomplished by Boeing in St. Louis, MO through the F-15 Development Systems Program Office using Air Force SDB II funding. The F-35B and F-35C aircraft integration contract will be awarded to Lockheed Martin in Fort Worth, TX by the F-35 Joint Strike Fighter JPO using Department of the Navy SDB II funding.

Elements of the SDB-II design have been tested, but putting the entire weapon together with its carrying aircraft and declaring the combination ready for fielding is still a development effort. Although many military development efforts are “cost-plus” (contractor’s costs plus an agreed percentage), the US military issued the SDB-II EMD Phase development contract as a fixed-price contract with incentives. The targeted flyaway cost per unit during Full Rate Production was $FY05 62-81k, but that doesn’t include amortized development costs; just the bomb, container, and shipping. Current Pentagon documents indicate that $FY19 100-125k per unit is likely.

Right now, the key challenge is making it through the development process successfully. The program is progressing well, but in FY 2011 it hit a funding shortfall from Congress that has crimped its progress. Past and projected budgets include:

Raytheon’s Industrial Approach

Before it won the SDB-II development contract in 2010, Raytheon had secured firm-fixed price quotes in for 90% of required materials from its suppliers, and conducted detailed planning for whole program that includes reservations for setbacks and project margins. These are necessary steps for any fixed-price development program, but this is a good illustration of the fact that it’s often the work done before contracts are signed that determines a program’s fate.

In terms of the industrial team, Raytheon Missile Systems in Tucson, AZ will be the final assembly center, with key items and assemblies coming in from several supply-chain partners:

• General Dynamics OTS: Fuze and dual-mode shaped charge blast/fragmentation warhead.
  
• Klune Industries: Overbody.
  
• Rockwell Collins: TacNet dual-band (Link-16, UHF), 2-way datalink.
  
• Raytheon Dene at NAPI, NM: Aft section.
  
• Raytheon Missile Systems in Tucson, AZ: Tri-mode seeker.
  
• The program also uses Goodrich and Cobham to make the bomb’s deployment mechanisms, and Celestica will be manufacturing circuit cards.

Raytheon executives said that they took a somewhat different supply-chain approach to the SDB-II, picking suppliers early and then working directly with them to improve productivity at every step. While Raytheon prototyped their final assembly line, and began using lean production techniques to reduce the amount of “touch labor” and improve productivity, they brought in suppliers to do the same thing. For instance, Celestica engineers were embedded with the team, in order to run their own producibility tools on circuit card designs and refine them to improve yield and costs. Rockwell Collins, who makes the datalink, did the same thing. This is not uncommon in general manufacturing, but defense manufacturing has traditionally been more stovepiped.

Within Raytheon itself, another key industrial choice involved the uncooled infrared seeker. As noted above, uncooled infrared has lower performance than cooled infrared designs, in exchange for snap-attack capability, better reliability, and lower production and maintenance costs. If Raytheon wanted to use this aproach, they would have to begin early, and take a risk. Their engineers worked to adapt the IIR seeker in their 2,000 pound AGM-154 JSOW as a starting point, and they did eventually produce a version that fit SDB-II, was cheaper to manufacture, and more than met government requirements.

Raytheon’s initial team during development will be about 300, but this is expected to drop below 50 for production phase – in part because Raytheon has already used lean techniques, and focused from the beginning on creating a design that was simpler to manufacture.

Minimum Sustaining Rate for production is just 30 weapons/ month, with normal production at 117 and maximum surge production rising to 250/ month. Projected American buys through FY 2019 never top 140/month, which should leave plenty of room for export orders.

Contracts and Key Events FY 2017-2018

Cheaper than expected – but F-35 lateness could endanger that; F-35 is biggest risk; Phase 1 testing done; GAO Report.

The biggest risk
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July 2/18: F/18 integration The Air Force is contracting Raytheon in support of weapons integration on its fleet of F/A-18E/F fighter aircraft. The indefinite-delivery/indefinite-quantity contract is valued at $93 million and provides for the integration of the Small Diameter Bomb II (SDB II) onto the fighter jet. Raytheon’s GBU-53/B SDB-II is 7? in diameter around the tri-mode (laser, IIR, radar) seeker, with a clamshell protective door that comes off when the bomb is dropped. Range is expected to be up to 40 nautical miles when launched at altitude, thanks to a high lift-to-drag ratio in the design. Since SDB-II is an unpowered glide bomb, its actual range will always depend on launching altitude and circumstances. This contract provides for the testing, analysis, support and sustainment of SDB II weapon onto the F/A-18E/F platform with developmental and operational testing. Work will be performed in Tucson, Arizona, and is expected to be completed by July 1, 2023.

March 1/18: Lot 4 Productions Raytheon will produce additional Small Diameter Bomb (SBD) IIs for the US Air Force, under a $77.3 million contract option exercised by the service on Tuesday, February 27. Under the terms of the deal, the firm will provide low rate initial production for 570 SDB II Lot 4 munitions, 398 SDB II Lot 4 single weapon containers, 126 SDB II Lot 4 dual weapon containers, 20 Production Reliability Incentive Demonstration Effort captive vehicles, 24 SDB II Lot 3 weapon load crew trainers /conventional munitions maintenance trainers, and other data. Work will be performed in Tucson, Arizona, and is expected to be complete by July 31, 2020.

December 15/17: Milestone Lot 1 production of the Small Diameter Bomb-II, an update to Boeing’s SDB-I, has been completed by Raytheon. The firm said it is producing SDB-II bombs at its facilities in Tucson, Ariz., and that the program is nearing completion of developmental testing. The US Air Force has also contracted Raytheon to produce Lots 2 and 3, and the munition is scheduled to be integrated on the F-35 and F/A-18E/F by the USAF and Navy, and Raytheon is expected to have it prepared for integration with the F-15E by the end of the year.

October 04/17: Australia has been cleared by the US State Department for the possible purchase of GBU-53/B Small Diameter Bomb Increment II weapons. Valued at an estimated $815 million, the foreign military sale will see 3,900 GBU-53/B Small Diameter Bombs and related equipment and services delivered to Canberra by manufacturer Raytheon. Extras include weapon load crew trainers, practical explosive ordinance disposal trainers, bomb containers, support, and ground crew test equipment. Transportation, warranties, repair and return, maintenance, publications, and technical documentation round out the package. The awarding agency, the US Defense Security Cooperation Agency (DSCA), said the sale will compliment the ongoing sale of F-35A Joint Strike Fighter aircraft to the Royal Australian Air Force.

October 02/17: Raytheon received a $450 million US Air Force contract for engineering changes and development of the Small Diameter Bomb II. Under the terms of the deal, the firm will conduct design, development, integration, test and production engineering for changes to the SDB. The munition is currently being integrated for use on the F-35 and F/A-18E/F by the USAF and Navy, and Raytheon is expected to have it prepared for integration with the F-15E by the end of the year. Work will be performed in Tucson, Ariz., with an expected completion time set for Aug. 31, 2024.

July 26/17: The United States Air Force has awarded a $75 million contract to Raytheon to conduct technical work on the GBU-53 Small Diameter Bomb (SBD) II guided air-dropped weapon system. Work will be conducted at Tuscon, Ariz., and covers engineering, manufacturing development and production work for the SDB II. Completion time is expected by July 25, 2024. The all-weather munition is carried on USAF-operated F-15E, F/A-18E/F, and F-35B/C aircraft.

February 1/17: Raytheon has been contracted to deliver Small Diameter Bombs (SDB) to the USAF. While the exact value of the contract modification was undisclosed, the company received $62 million at the time of the award. The contract calls for the delivery of low-rate initial production for 312 SDB II Lot 3 munitions for the branch, and also includes 413 SBD Lot 3 single weapon containers, 20 weapon conversions for guided test vehicles, 20 production reliability incentive demonstration effort captive vehicles and training and maintenance services. SBDs are being integrated on a number of USAF and US Navy aircraft, and provide warfighters with the ability to engage their targets when faced with poor weather and other adverse conditions.

FY 2012 – 2014

Cheaper than expected – but F-35 lateness could endanger that; F-35 is biggest risk; Phase 1 testing done; GAO Report.

Oct 28/14: JMM. Raytheon Technical Services LLC in Indianapolis, IN a sole-source $35 million indefinite-delivery/ indefinite-quantity contract for F-35 integration of the Joint Miniature Munitions Bomb Rack Unit (JMM BRU), including integration and life cycle technical support throughout the technology development and engineering, manufacturing and development (EMD); and EMD F-15 flight test and production phases.

Work will be performed at Indianapolis, IN and is expected to be complete by Aug 31/21. USAF Life Cycle Management Center at Eglin AFB, FL manages the contract (FA8672-15-D-0054).

June 26/14: Testing. Raytheon and the USAF have concluded a series of SDB-II GTV flight tests using the IIR/MMW seeker, culminating in direct hits on stationary land targets. Those can be harder to hit than moving targets, which naturally stand out more against fixed object ground clutter.

The GTVs are full GBU-53 rounds, but with telemetery in place of the warhead. Raytheon says that there have been other Guided Test Vehicle shots between October 2013 and this announcement, including moving target shots, as part of the testing program. Live-fire shots with full warheads are expected in August or September 2014. Sources: Raytheon, “Small Diameter Bomb II nears end of development phase”.

April 16/14: Exports. The Pentagon releases is next set of Selected Acquisition Reports, which includes a reference to exports:

“SDB II is a Defense Exportability Features (DEF) pilot program and meetings were held on January 15, 2014 with the DEF Program Office, the Office of the Under Secretary of Defense (Acquisition, Technology, and Logistics), Office of the Director, International Cooperation and Raytheon Missile Systems (RMS). The Program Office is working with RMS to incorporate a Phase II approach for implementing design changes to support exportability requirements. The Program Office briefed the Tri-Service Committee on January 16, 2014 and a favorable decision memorandum was received on February 4, 2014.”

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. Our program dashboard has been updated accordingly. SDB-II still has good looking cost figures and a stable design, with 11/12 sub-system (all but the seeker) passing qualification testing. Bad news? There are a couple of flaws that need to be fixed, and its schedule is out of margin.

The System Verification Review has slipped 7 months to August 2014, due in part to 2 test failures (cover stuck on seeker, navigation error). They’ve also found a leak in the warhead case, and seeker encoders that died under vibration testing. The seeker encoders have a fix ready by the time the GAO report closed, but not the case leak. Meanwhile, the program resumed testing again in October 2013, and the 3 tests since went well. They need 11 total successful flight tests to pass Milestone C into low-rate production, including 2 live fire events. It amounts to 7 successful flight tests remaining over 5 months.

March 4-11/14: FY15 Budget/ R&D. The US military slowly files its budget documents, detailing planned spending from FY 2014 – 2019. The “flyaway” cost per SDB-II is expected to hover around $242,000 in FY 2014, but costs are expected to drop to around $125,000 by FY 2018. Totals are reflected in the chart above. The reports also call attention to the development of an new internal bomb rack for the Navy, which is considered to be part of the program’s overall R&D:

“The Joint Miniature Munitions Bomb Rack Unit (JMM BRU) is an Air Force (AF) led ACAT III program. It is required for the Department of the Navy’s (DoN) carriage of the SDB II weapon in the internal bay of the F-35B and F-35C…. The BRU-61/A, currently in production in the AF, does not meet the needs to operate with SDB II within the F-35 internal bay in the DoN environment. The JMM BRU, designated BRU-61A/A, fills the capability gap….”

No US Navy buy totals are given in the detailed budget justifications, but the Budget Briefing contains the expected figures for FY 2017 – 2019; which indicates that the USN will be buying SDB-II at the USAF’s flyaway cost. This USAF budget justification excerpt is also relevant:

“As a result of the Joint Strike Fighter (JSF) (F-35) programs restructure, SDB II integration was moved from the JSF Operational Flight Plan (OFP) Block 3 to Block 4. IOC is FY2020.”

The program office hasn’t officially changed the date, in other words. F-35 OFP Block 3F operating software might be ready by 2020, but the Norwegians have been told to plan for 2022 – 2024 as the window for actual fielding of F-35s with operational Block 4 software, and hence Kongsberg’s new JSM anti-ship missile.

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 SDB-II is included in passing:

“This project addresses the inaccuracies in engineering models to predict sympathetic detonation of solid rocket propellant when subjected to non?reactive fragments and shaped charge threats. The Air Force 780th Test Squadron tested the ability of the small diameter bomb [DID: SDB-II in the labeled picture] warhead to detonate 122 mm rocket motors. The test results were compared with predictions from Sandia National Laboratories’ Combined Hydro and Radiation Transport Diffusion Hydrocode by Applied Research Associates. Analysis is ongoing, and is expected to enable further development of concepts and methodologies for enhanced vulnerability, lethality, and survivability in the area of insensitive munitions and non-reactive materials.”

Oct 29/13: Testing resumes. Raytheon announces that the USAF has concluded its series of test flights with the SDB-II GTV, using the bomb’s Imaging Infrared and Milimeter-Wave Radar guidance and culminating in “direct hits on targets moving at operationally representative speeds.” Next? System Verification Review and a Milestone C decision, which is behind schedule.

This is actually the 1st set of tests following a 6-month testing moratorium, which was prompted by seeker cover and navigation failures in previous tests. The firm says that the USAF has invested over $700 million in the program so far. Sources: Raytheon, Oct 29/13 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. Overall, SDB-II is a stable design with maturing technologies. It successfully completed a test in its most difficult Immediate Attack sub-mode, but another test failed when the front sensor’s protective dome cover refused to come off.

They’re working on that urgently, as more delays to the Milestone C/ LRIP (Low-Rate Initial Production) decision risk re-negotiation of the Pentagon’s LRIP-1 through LRIP-5 production contract years. If so, it would raise costs that had come in substantially under budget. Meanwhile, Raytheon will build 50 GTV bombs for testing and live fire before beginning Low-Rate Initial Production, which is expected to involve a whopping 40% of planned GBU-53 lifetime orders (math says about 6,800 bombs).

Unfortunately, SDB-II/ GBU-53 has been affected by the F-35’s lateness, which has forced postponement of SDB-II’s Full Rate Production decision by another 2 years, to 2020. The GPS-only SDB-I will now integrated with the F-35 2 years ahead of the SDB-II, and so will other weapons with more sensitive thermal and vibration requirements. That will help the Pentagon discover whether the F-35s conform to their design documents, or whether weapon changes will be required in several weapon types including the GBU-53. Meanwhile, SDB-II will deploy aboard the F-15E.

Jan 22/13: Testing. Raytheon touts a successful fit check of the GBU-53/B Small Diameter Bomb II in the F-35A, with 4 GBU-53s loaded alongside an AIM-120 AMRAAM missile. Essentially, the 4 SDB-IIs replace one 2,000 pound JDAM.

The weapons seemed to have adequate space, though flight testing will be needed to be sure. The F-35B will be a more challenging test, because its internal bay is smaller.

July 17/12: Testing. An F-15E Strike Eagle flying over White Sands Missile Range, NM launches a GBU-53/B, which successfully engages and hits a moving target using its tri-mode seeker’s IIR and radar sensors. Raytheon.

March 30/12: GAO Report. The US GAO tables its “Assessments of Selected Weapon Programs” for 2012, which include the GBU-53. Overall, the GAO sees good progress, with 97% of design drawings releasable by the 2011 Critical Design Review, and serious efforts to achieve manufacturing maturity before production. As with any early stage EMD program, however, risks remain. The biggest may be Congressional management of weapons procurement:

“A postdesign review identified several risks related to weapon effectiveness verification, target classification, seeker reliability, and JSF [F-35B/C Block 4] integration. The program office is working to address each of these risks… However, the program’s biggest risk – integration with the JSF – will not be resolved until after [low-rate initial] production begins… The SDB II program office is managing a $53 million funding shortfall in fiscal year 2011, which could have programmatic and contractual implications. The SDB II contract is an incrementally funded, fixed-price incentive contract, and program officials stated that the funding shortfall could mean that the next part of the work will have to be deferred or the contract will need to be renegotiated or terminated.”

March 30/12: SAR shows success. The Pentagon’s Selected Acquisitions Report ending Dec 31/11 includes the SDB-II, and validates many of Raytheon’s releases:

“Small Diameter Bomb Increment II (SDB II) – Program costs decreased $994.1 million (-19.1%) from $5,206.6 million to $4,212.5 million, due primarily to a decrease in the estimate to reflect actual contract pricing (-$994.3 million).”

That’s 23.6% less than the baseline estimate, a very impressive achievement for any weapons program.

Good contract

Nov 16/11: Testing. Raytheon says that things are going very well for the SDB-II’s warhead, and the entire program is on cost and ahead of schedule:

“After building the test warheads on the production line, engineers put the warheads through an accelerated conditioning regime equivalent to 500 flight hours and 20 years of aging in a bunker, followed by live detonation testing… [It] performed at twice what was required…”

Nov 8/11: Industrial. Raytheon announces that its engineers have used design changes and other improvement approaches to cut the time for building SDB-II uncooled tri-mode seekers almost in half, from more than 75 hours to 40 hours. This is part of Raytheon’s efforts to meet their promised prices.

FY 2010 – 2011

Raytheon wins; Program baseline set; Early industrial work & tests.

SDB-II test pod
(click to view larger)

Aug 16/11: Industrial. Raytheon announces that they’ve built their 5th GBU-53 tri-mode seeker in its new automated factory, which is dedicated to tri-mode seekers. That specialization may be helpful to other programs as well. Tom White, Raytheon’s SDB II program director, says that:

“Building integrated tri-mode seekers is much more complicated than just putting together three unrelated sensors, and our fifth build proves Raytheon is the only company with the technical expertise to manufacture [them]… We’re meeting predicted component build times, and as we continue to mature the program, we will find other efficiencies and cost savings we will pass on to the customer.”

Aug 8/11: Testing. Raytheon says that a series of laboratory tests on the SDB-II’s tri-mode seeker “demonstrated that it exceeds anticipated performance parameters.” Good job.

July 28/11: Support. Raytheon Missile Systems in Tucson, AZ receives a maximum $70 million firm-fixed-price contract to provide Small Diameter Bomb II technical support. The AAC/EBMK at Eglin Air Force Base, FL manages the contracts (FA8672-11-D-0107).

April 4/11: CDR. Raytheon announces that the SDB II program completed a USAF critical design review (CDR), clearing the way for the weapon to begin captive flight testing later in 2011.

CDR

Nov 15/10: SAR Baseline. The Pentagon releases its Selected Acquisition Report for the September 2010 reporting period. With respect to SDB-II, the total expected program cost is listed as $5.21 billion, if it continues through planned production:

“This was the initial SAR following Milestone B approval authorizing the program to enter the engineering manufacturing and development (EMD) phase in August 2010. The EMD phase contract was awarded to Raytheon Missile Systems for $450.8 million. [The gating decision for] Low Rate Initial Production (Milestone C) is planned for August 2013.”

Program baseline

Nov 2/10: Sub-contractors. Rockwell Collins announces what Raytheon had already confirmed: its TacNet datalink will be part of the GBU-53.

Rockwell Collins’ TacNet data link system is a small form factor, dual-channel, 2 waveform terminal that enables in-flight target updates, retargeting, weapon handover coordination, bomb hit assessments and better cooperation with other networked platforms.

Aug 9/10: Contract. Raytheon Missile Systems in Tucson, AZ receives a $450.8 million contract to cover the GBU-53/B Small Diameter Bomb Increment II program’s engineering and manufacturing development phase. Delivery is expected to begin in 2013, with a required availability date in late 2014.

At first, the SDB-II will be integrated on the USAF’s F-15E Strike Eagles, the US Marines’ F-35B, and the US Navy’s F-35C aircraft. The F-35Bs should just be entering service by 2013, but the F-35Cs aren’t expected to enter service until after SDB-II deliveries begin. Raytheon Missile Systems president says that their design “fully meets the load-out requirements for all versions of the fifth generation F-35 Joint Strike Fighter’s internal weapon bays.” SDB-II integration is also expected to extend to other USAF and US Navy aircraft and UAVs over time. At this time, $23.5 million has been committed by the Miniature Munitions AAC/EBMK at Eglin AFB, FL (FA8672-10-C-0002).

During the fly-off’s technical demonstration program, Raytheon had to prove that its compact tri-mode seeker could seamlessly transition between guidance modes, and demonstrate claimed performance and reliability. Raytheon says that their GBU/53-B seeker flew 26 missions in 21 days, without a single hardware failure. Raytheon.

Raytheon wins EMD Phase

FY 2009 and Earlier

Protest derails; New early-phase awards; Big design changes.

SDB-I: separated.
(click to view full)

2008: Design shifts. Mid way through the 38-month risk reduction program, Team Raytheon is faced with challenges on 2 fronts. One challenge was the need to carry 8 SDB-II bombs in the cut-down internal bomb bay of the F-35B STOVL (Short Take-Off, Vertical Landing) fighter. That meant the weapon had to become shorter, always a challenge when space is at a premium. The second challenge came from the USAF, which wanted a weapon that could disable main battle tanks. That meant the blast & fragmentation warhead the team had begun with wasn’t going to work.

In response, GD OTS started work on an innovative ‘multi-effects’ warhead. It would use a shaped charge plasma jet to kill tanks, and a scored case design improved fragmentation effects to the point that USAF engineers reportedly dubbed it “the shredder.” Meanwhile, seeker electronics had to be repackaged in a way that provided a clear path for the plasma jet. As it happens, the warhead and seeker changes allowed the bomb to become shorter, and the seeker changes made it easier and cheaper to manufacture. Raytheon would go on to win the competition. Aviation Week.

April 17/06: Contracts. The Headquarters Air-To-Ground Munitions Systems Wing at Eglin Air Force Base, FL awards 2 cost-plus fixed-fee R&D contracts under the Small Diameter Bomb (SDB) Increment II, 42-month Risk Reduction Phase. The purpose of the Risk Reduction phase is to define and validate a system concept that meets the performance requirements outlined in the SDB II System Performance Specification. Successful tests with modified JDAM recently, and weapons like Israel’s Spice GPS/INS/EO “scene-matching” bombs, strongly indicate that success is possible. Solicitations began December 2005, negotiations were complete in March 2006, and work will be complete in October 2009. The 2 winners will be competing for selection in 42 months as the prime contractor for the SDB II program, which has a potential value of $1.3-1.7 billion.

Boeing subsidiary McDonnell Douglas in St. Louis, MO receives a $145.8 million contract (FA8681-06-C-0151). This is actually a Boeing/Lockheed venture as of October 2005; prime contractor Boeing will supply the weapon and data link system, while principal supplier Lockheed Martin provides the multi-mode seeker that lets it hit moving targets. That leaves Boeing’s original Small Diameter Bomb partner, Northrop-Grumman, out in the cold.

Raytheon Co. in Tucson, AZ received its own $145.8 million contract (FA8681-06-C-0152), and is competing on its own.

Risk Reduction Phase

Feb 18/05: GAO protest. The Congressional Government Accountability Office (GAO) sustains Lockheed Martin’s protest. It finds that Darlene Druyun had played a role in the bid process that led to changes in the bomb’s technical requirements, and the deletion of related evaluation criteria. The GAO recommends a re-opened competitive procurement for the program’s $1.7 billion second phase, which had previously been awarded to Boeing and Northrop-Grumman along with SDB-I.

In September 2005, the USAF decided to re-open the Small Diameter Bomb Increment II competition. Increment II was originally awarded to Boeing and Northrop-Grumman as part of the overall SDB award.

Protest sustained

Additional Readings

DID thanks Raytheon Missile Systems, including SDB-II Deputy Program Director Murali Krishnan and Jeff White of Air Warfare Systems, for their assistance. Any errors are our own damn fault.

• Raytheon – Raytheon GBU-53/B Small Diameter Bomb II (SDB II). Mini-site, including CONOPS videos.

• Stars and Stripes, via WayBack (Dec 6/11) – Some weapons too important to lose in DOD cuts.

• Raytheon (Aug 24/10) – Raytheon presentation and press conference [dead link, see event release]. Contained extensive discussion of their SDB-II design.

• Aviation Week, via WayBack (Aug 24/10) – Winning SDB II: Innovation in Action. By Raytheon’s Harry Schulte.

Mk-44 firing RAM
(click to view full)

The Rolling Airframe Missile (RAM) MK-31 guided missile weapon system is co-developed and co-produced under a NATO cooperative program between the United States and German governments to provide a small, all-weather, low-cost self-defense system against aircraft and cruise missiles. The RIM-116 was later called RAM (Rolling Airframe Missile), because it spins during flight. To save costs, Designation Systems notes that the RAM was designed to use several existing components, including the rocket motor of the MIM-72 Chaparral, the warhead of the AIM-9 Sidewinder, and the Infrared seeker of the FIM-92 Stinger. Cueing is provided by the ship’s radar, or by its ESM signal tracing suite.

RAM is currently installed, or planned for installation, on 78 U.S. Navy and 30 German Navy ships, including American LSD, LHD, LPD and CVN ship types. This number will grow as vessels of the LPD-17 San Antonio Class and Littoral Combat Ships enter the US Navy, and the LCS will sport an upgraded SeaRAM system that will include its own integrated radar and IR sensors. Abroad, the South Korean Navy has adopted RAM for its KDX-II and KDX-III destroyers, and its LPX Dokdo Class amphibious assault ships; other navies using or buying RAM include Egypt, Greece, Japan, South Korea, Turkey, and the UAE/Dubai.

RAM Systems: Fast, Flat & Flexible

From USS Kitty Hawk
(click to view full)

GlobalSecurity.orrg notes that The MK-31 RAM Guided Missile Weapon System (GMWS) is defined as the MK-49 Guided Missile Launching System (GMLS) and the MK-44 Guided Missile Round Pack (GMRP). The launching system and missiles comprise the weapon system. The RAM weapon system consists of a 21-round missile launcher, below-deck electronics, and a guided missile round pack. The round pack consists of a 5-inch supersonic missile and a launching canister, which slides into the launcher and provides the interface with the carried missile. The term “All-Up-Round (AUR)” is often used, as the canister is also used for storage/transport.

Raytheon’s partner is the German firm RAMSYS, a joint company of Diehl/BGT and EADS GmbH. These firms extended their agreement for another 10 years in June 2004.

System improvements continue. New MK-44 Guided Missile Round Packs and ORDALT kits are designed to upgrade current systems to RAM Block 1 missile configuration (RIM-116B) or above. Block 1 systems feature an image scanning infrared seeker that allows the missile to more easily counter helicopters and advanced anti-ship threats that do not employ active radar guidance. Another new feature is called IRDM (IR Dual Mode Enable). In that mode, the RAM missile is launched with IR guidance enabled, but can switch to passive radar homing when the target’s radiation becomes adequate to guide on. It also incorporates HAS (Helicopter, Aircraft, Surface) software that lets it prosecute a wider array of targets out to about 9 km/ 4.9 nm, including targets like speedboats that move at slower speeds in radar/IR clutter.

RAM Block 1. This system is installed or planned for installation on many U.S. Navy surface ships, including CV/CVN aircraft carriers, DD-963 Spruance Class destroyers, Oliver Hazard Perry Class FFG guided missile frigates, Littoral Combat Ships, the LHA Tarawa Class and LHD Wasp Class amphibious assault ships, the future LHA-R amphibious assault ships, and LSD and LPD-17 amphibious assault ships. The US Navy expects to buy around 2,000 Block 1 missiles in total.

SeaRAM
(click to view full)

Follow-on modifications include an upgraded missile, and the SeaRAM system.

RAM Block 2. A new version that is beginning production, with deliveries beginning in August 2014. The RIM-116 missile’s effective range gets a boost via a larger dual-thrust rocket motor, while an independent 4-canard control actuator system improves maneuverability. Other enhancements include an upgraded passive radio frequency seeker, a digital autopilot, and engineering changes in selected infrared seeker components. The Block 2 system demonstration and development (SDD) program was scheduled to reach initial operating capability in 2011, but it’s 2013 and the missile is still in testing. IOC will wait until 2014.

While most of the RAM Block 2 work is Raytheon’s, the effort is a partnership. Operating under a cooperative Memorandum of Understanding for the Block 2 SDD program, German industry partner RAM-System GmbH also received funds. They’re working to develop an evolved missile radio frequency sensor with better sensitivity and discrimination, in order to kill targets that are using more advanced guidance radars.

SeaRAM. RIM-116 Block 2 missiles, and Block 1 upgrades to the MK31 system, will both be incorporated into the new SeaRAM variant, also known as the “MK 15 MOD 31 PHALANX SeaRAM Close-In Weapon System.” Once it’s bolted on and installed, SeaRAM becomes a complete, self-cueing system that can work with existing systems, or operate on its own. It packages the RAM Block 1 upgrade’s infrared sensors and IR dual-mode with the radar dome mounted on top of the Mk15 Phalanx 20mm CIWS. The penalty for its bolt-on versatility is that it cuts the 21-round missile launcher down to an 11-missile load, in order to remain within the same space “footprint” as the Phalanx 1B. It will equip the USA’s new Littoral Combat Ships, among others.

Program and Budgets

While the number of RAM missiles procured by the USA has been relatively stable each year, Pentagon budget documents show US program spending fluctuating. That’s because some annual budgets also include funds for system upgrades (generally from Block 0 to Block 1) and things like Block 2 development work:

These budgets do not include international orders.

Contracts & Key Events

Unless otherwise stated, all contracts are awarded by the Naval Sea Systems Command in Washington, DC to Raytheon Company in Tucson, AZ. It should be noted, however, that the RAM Guided Missile Weapon System is co-developed and co-produced under a NATO Cooperative Program between the United States’ and Federal Republic of Germany’s governments.

FY 2016 – 2018

 

RAM reload
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July 2/18: German contract The German defense manufacturer RAM-System is being tapped by the US Navy for work on its Rolling Airframe Missile (RAM) system. The firm-fixed-price un-definitized contract is valued at $68 million provides for work on the RAMs MK 49 Guided Missile Launching System as well as associated shipboard hardware and spares. The Rolling Airframe Missile Guided Missile Weapon System is co-developed and co-produced under an International Cooperative program between the US and Federal Republic of Germany’s governments. The RAM system is a supersonic, lightweight, quick-reaction, fire-and-forget weapon, designed to attack enemy helicopters, aircraft, and surface craft. It uses passive RF and infrared guidance for engaging several threats simultaneously. The MK 44 guided missile round pack and the MK 49 guided missile launching system together hold 21 missiles. Existing shipboard sensors can provide the system with target and pointing information. Work will be performed at various locations in Germany and the US, including Louisville, Kentucky; Ulm, Germany and Schrobenhausen, Germany. Work is scheduled for completion by September 2022.

May 14/18: RAM heads towards the Middle East Raytheon Missile Systems will deliver Rolling Airframe Missiles (RAM) to Qatar as part of US foreign military sales. The contract is valued at over $242 million and provides for the delivery of RAM Block 2 guided missile round pack, missile ordnance alterations, and spares. RAM is a missile system designed to provide anti-ship missile defense for multiple ship platforms. The RAM MK-31 guided missile weapon system is co-developed and co-produced under a NATO cooperative program between the United States and Germany. It provides a small, all-weather, low-cost self-defense system against aircraft and cruise missiles. The launching system and missiles comprise the weapon system. The round pack consists of a 5-inch supersonic missile and a launching canister, which slides into the launcher and provides the interface with the carried missile. This contract includes options which, if exercised, would bring the cumulative value of this contract to $529 million. This contract combines purchases for the Navy and the governments of Qatar, Egypt, and Turkey. Work will be performed at multiple locations, including Ottobrunn, Germany and Tucson, Arizona, and is expected to be completed by September 2023.

December 18/17: Contracts-Engineering Support Raytheon won Thursday, a $22.5 million US Navy modified contract for support services on the Rolling Airframe Missile Mark-31 Guided Missile Weapon System. The agreement covers design agent and engineering support services for the Rolling Airframe Missile (RAM) upgraded MK-31 Guided Missile Weapon System Improvement program—a joint effort conducted by both Washington and Germany. Work will take place mostly in Tucson, Arizona, with some work taking place in Louisville, Kentucky. The contract is expected to be completed by September 2019.

August 21/17: Upgrades planned for the RIM-116C Rolling Airframe Missile (RAM) Block 2B will include improved seeker and missile-to-missile link (MML) capability. Known as the RAM Block 2B Raid Engineering Change Proposal (ECP), the enhancements will increase the missile’s ability to deal with complex multi-missile raids—in effect allowing missiles to talk to each other. Raytheon’s Block 2B upgrades have aimed to increase the use of kinematic and sensor upgrades, designed to expand the missile’s engagement envelope, so as to defeat more manoeuvrable and higher-speed anti-ship cruise missiles.

June 28/17: RAMSYS GmbH has being awarded a $92.3 million contract for design and development work on the Rolling Airframe Missile Block 2B (RAM) in a deal fully funded by the German government. Work will be conducted mainly at Ueberlingen, Germany, and several other sites across the country with a completion date scheduled for June 2021. The program is a joint effort between the the German and US navies, with other allies including South Korea, Japan, Egypt, Greece deploying the system on board vessels that include aircraft carriers, amphibious assault ships and littoral combat ships.

May 19/17: Raytheon has received a $26.8 million contract for the engineering and support of the MK-31 Rolling Airframe Missile (RAM). The US Navy contract was awarded as part of a joint cooperative development and production program between the United States and Germany under a memorandum of understanding. The program is meant to test reliability, along with maintenance, logistics, and software issues, and work is expected to be completed by September 2018. The RAM is designed for point-defense against anti-ship missiles and can be deployed on ships of any size. . It uses passive radio frequency and infrared guidance systems to track and destroy targets.

February 21/17: The UAE will become the first Middle East operator of Raytheon’s RIM-116 Rolling Airframe Missile (RAM) Block 2 close-in weapon system. While the number of systems ordered remains unknown, the systems will be installed on the Emirate’s Baynunah-class corvettes, of which six vessels will be manufactured. Improvements made on the system’s predecessor include kinematic and sensor upgrades to expand the missile’s engagement envelope in order to defeat more maneuverable and higher speed anti-ship cruise missiles. Furthermore, the Block 2 upgrade significantly expands the missile’s effective engagement envelope by introducing a larger dual-thrust rocket motor and independent four-canard control actuator system to increase effective range by about 50% and deliver a three-fold improvement in maneuverability.

May 19/16: Raytheon’s SeaRam anti-ship defense system has undergone its most rigorous testing in recent US Navy testing. Targets successfully engaged involved two supersonic missiles flying in complex, evasive maneuvers which the system successfully took down with the Rolling Airframe Missile (RAM) Block 2 missiles. The SeaRAM is an upgrade of Phalanx Block 1B and it swaps out the gatling gun with an 11-round Rolling Airframe Missile guide.

January 13/16: The US Navy successfully tested a Rolling Airframe Missile (RAM) Block II from the SeaRAM anti-ship missile defense system for the first time. SeaRAM, used on the Independence class of Littoral Combat Ships, successfully detected, tracked and engaged an inbound threat, and fired a RAM Block II that successfully intercepted the target. The SeaRam system utilized Raytheon’s Phalanx Close-In Weapon System for the test which is a rapid-fire, computer-controlled radar and 20mm gun system that acquires, tracks and destroys enemy threats that have penetrated all other ship defense systems. The two systems combined can also be found on the Navy’s destroyers.

January 7/16: The DoD has awarded Raytheon $66.5 million to provide Navy Rolling Airframe Missile (RAM) Block 2 guided missile round pack requirements. The RAM defense system uses an infrared homing surface-to-air missile to provide anti-ship missile defense from multiple vessels, and is developed jointly by the US and Germany. The contract will see the manufacture and assembly of RAM Block 2 MK 44 Mod 4 guided missile round packs for the US Navy, with options that could include a foreign military sale to Japan. A sale to Japan would see the value of the contract rise to $142 million.

FY 2014-2015

 

September 21/15: The Navy has test fired a Rolling Airframe Missile Block 1A from an Independence-class Littoral Combat Ship, the USS Coronado (LCS-4). The trimaran’s SeaRAM air defense system fired the missile as part of a risk-reduction and certification trial. The SeaRAM system incorporates the Rolling Airframe Missile and the Block 1B Phalanx Close-In Weapon System (CIWS) as a more flexible air defense system, trading bolt-on versatility for a reduced missile load compared with the RAM system on its own.

May 18/15: The Navy announced Friday that it has achieved Initial Operating Capability with the Block II Rolling Airframe Missile aboard the USS Arlington (LPD 24). The joint program with Germany was recently included as part of a $1.6 billion overhaul package by the US Navy intended to provide improved protection to carriers and amphibious ships.

May 11/15: The Navy is planning to spend $1.6 billion on carrier and amphibious ship defenses in order to protect the Service’s fleet of F-35s. The new defenses will focus on supersonic threats, with a series of overhauled technologies including new missiles and radars set to be integrated into Ship Self Defense Systems (SSDS). Key components of these future systems include the Rolling Airframe Missile and the Evolved Sea Sparrow Missile.

Aug 27/14: Block 2. Raytheon delivers the 1st RAM Block 2 missile to the US Navy, as part of the company’s 2012 Low Rate Initial Production contract. Sources: Raytheon, “Raytheon delivers first Block 2 Rolling Airframe Missiles to US Navy”.

1st Block 2 delivery

July 30/14: GAO Report. The US GAO releases Report #GAO-14-749, “Littoral Combat Ship: Additional Testing and Improved Weight Management Needed Prior to Further Investments.” It looks at weight issues within the 2 Littoral Combat Ship classes. Though Freedom Class LCS 5 and beyond will make enough changes to meet their required design margin:

“Another proposed change would increase commonality and combat capability by replacing the Freedom variant’s rolling airframe missile system with the heavier [SeaRAM] missile system found on the Independence variant. While the specifics of this potential change have not yet been determined or approved, Navy technical experts told us that such a modification would subsequently increase the Freedom variant’s weight and could also result in center of gravity changes.”

June 24/14: FY 2014. A $73.4 million firm-fixed-price contract for FY 2014 rolling airframe missile (RAM) guided-missile round pack requirements for the U.S. and allied navies, including 23% of the contract’s value for Japan, spares for the Federal Republic of Germany, and testing equipment upgrade and replacement requirements. All funds are committed immediately.

This contract involves foreign military sales to Japan (23%). Work will be performed in Tucson, AZ (49.7%); Ottobrunn, Germany (42.7%); Rocket Center, West Virginia (4.5%), and Andover, Massachusetts (3.1%); it is expected to be complete by November 2016. This contract was not competitively procured (N00024-14-C-5417).

FY 2014: USA, Japan

Jan 3/14: Raytheon in Tucson, AZ receives a $52.1 million Design Agent Engineering and Technical Support Services modification for maintainence of, and improvements to, the Mk15 Phalanx, Land-based Phalanx, and SeaRAM weapon systems.

Work will be performed in Tucson, AZ, and is expected to be complete by January 2015. $12.5 million is committed immediately from a wide array of USN FY 2014 and FY 2013 R&D, weapons, and shipbuilding budget lines, plus a US Army budget. Of that, $4 million will expire on Sept 30/13 (N00024-12-C-5405).

Dec 9/13: Support. Raytheon in Tucson, AZ receives a $35 million contract modification, exercising an option for MK-31 RAM’s FY 2014 design agent engineering services. This will include improvement program support, guided-missile round pack support, and guided-missile launching system support.

$8.2 million in USN FY 2014 R&D, operations, and Deutsche Marine funding is committed immediately. Work will be performed in Tucson, AZ, and is expected to be complete by September 2014 (N00024-10-C-5432).

FY 2013

German multi-year order; Block 2 goes from tests to fleet firing; SeaRAM may now equip both LCS types.

USN LPD 23 & 24
(click to view full)

Sept 10/13: SeaRAM. A $136.2 million contract to overhaul and upgrade 19 MK 15 Phalanx systems, and produce 4 new SeaRAM systems. This contract provides purchases for the U.S. Navy (80%), Japan (15%), the US Army (4%) and Pakistan (1%) under the foreign military sales (FMS) program; and all funds are committed immediately. $55 million will expire at the end of the current fiscal year, on Sept 30/13.

Another $94.8 million in options exist for a FY 2014 buy of 12 more Phalanx upgrades, and another 4 SeaRAM systems, to bring the total contract to $231 million.

Work will be performed in Louisville, KY (26%); Anaheim, CA (16%); Melbourne, FL (11%); Dayton, OH (11%); Syracuse, NY (10%); McKinney, TX (5%); Andover, MA (5%); Bloomington, MN (5%); Radford, VA (5%); Salt Lake City, UT (3%); and Tucson, AZ (3%), and is expected to be complete by September 2017. This contract was not competitively procured in accordance with FAR 6.302-1(a)(2)(iii) “one responsible supplier” provisions (N00024-13-C-5406). Sources: Pentagon | Raytheon Sept 11/13 release.

Aug 6/13: Block 2. The US Navy has completed the first RAM Block 2 fleet firing with a pair of tests from USS Arlington [LPD 24] and the Navy’s Self Defense Test Ship. The missiles went 4/4 against sub-sonic and supersonic maneuvering targets. The USN intends to achieve Initial Operational Capability in 2014. Raytheon, Aug 6/13 release.

July 25/13: LCS standardization? During House Armed Service Committee hearings on the Littoral Combat Ship, Assistant Secretary of the Navy Sean J. Stackley says that the Navy is strongly considering standardizing both ship classes on the SeaRAM configuration. The Freedom Class currently uses the full RAM installation, while the Independence Class trimaran uses the SeaRAM system with an integrated radar but fewer missiles. HASC video.

F219 w. RAM
(click to view full)

March 28/13: Germany. The German government places a $343.6 million contract with Raytheon’s partner RAMSYS GmbH in Ottobrunn, Germany for 445 RIM-116 Block 2 All-Up-Round missiles between now and January 2019, to insert into their MK-44 Mod 4 RAM Guided Missile Round Packs. As one might expect, the Germans use RAM missiles on several of their ship classes. $1.3 million is committed immediately.

Work will be performed in Tucson, AZ (49.7%); Ottobrunn, Germany (42.7%); Rocket Center, WVA (4.5%); and Andover, MA (3.1%). This contract was not competitively procured (N00024-13-C-5459). See also Raytheon.

German multi-year order

Dec 20/12: USA FY 2013. A $45.6 million firm-fixed-price FY 2013 option for 61 Rolling Airframe Missile Block 2 (MK-44 Mod 4) guided-missile round pack all-up-round missiles. All contract funds are committed immediately.

Work will be performed in Tucson, ArZ (49.7%), Ottobrunn, Germany (42.7%), Rocket Center, WVA (4.5%), and Andover, MA (3.1%), and is expected to be complete by February 2015 (N00024-12-C-5450).

Dec 14/12: Ship sets. Raytheon in Tucson, AZ receives a $12.3 million firm-fixed-price contract modification for 4 refurbished and upgraded Rolling Airframe Missile MK 49 Mod 3 guided-missile launch systems and associated hardware. These 21-missile launch packs will equip the San Antonio Class LPD 27 John P. Murtha (2 systems), and the Freedom Class ships LCS 9 and LCS 11 (1 each). All funds are committed on award, and there are options for 4 additional launch systems.

At the time of award, a $5.5 million option is also exercised for 2 remanufactured MK 49 launch packs, with Mod 3 updates and associated hardware. They’ll equip the Freedom Class ships LCS 13 and LCS 15.

Work will be performed in Tucson, AZ, and is expected to be complete by December 2015. This contract was not competitively procured pursuant to 10 U.S.C. 2304c1 (N00024-11-C-5448).

Nov 27/12: Support. Raytheon in Tucson, AZ receives a $12 million cost-plus-fixed-fee contract modification to exercise an option for FY 2013 Design Agent Engineering Services for MK-31 RAM support services, providing maintenance and resolving issues through design, software maintenance, and engineering.

Work will be performed in Tucson, AZ, and will run until September 2013. $44,800 will be obligated at the time of award (N00024-10-C-5432).

Nov 9/12: Support. An $11.3 million contract modification exercises the FY 2013 option for MK-31 design agent engineering services. Work will be performed in Tucson, AZ and is expected to be complete by September 2013 (N00024-10-C-5432).

Oct 22/12: Test. Raytheon announces that its RAM Block 2 has successfully completed its 3rd guided test vehicle flight, using production-representative hardware, in a 2 missile salvo. The engagement resulted in a direct hit on the target.

“Raytheon was awarded a low-rate production contract this year calling for 51 RAM Block 2 missiles. The company is scheduled to deliver 25 [RIM-116] Block 2 missiles during the integrated testing phase of this program.”

FY 2012

Business as usual.

RIM-116 Block 2
(click to view full)

July 30/12: FY 2012. A $51.7 million firm-fixed-price contract for 51 MK-44 Mod 4 Rolling Airframe Missile (RAM) Block 2 guided missile round pack all-up-rounds. In other words, the missiles and storage/interface tubes that fit into the launchers.

Work will be performed in Tucson, AZ (49.7%); Ottobrunn, Germany (42.7%); Rocket City, WVA (4.5%); and Andover, MA (3.1%), and is expected to be complete by September 2014. This contract includes options which could bring the cumulative value of this contract to $105.8 million, and presumably about 105 missiles.

This contract was not competitively procured (N00024-12-C-5450).

May 17/12: Ship sets. Raytheon in Tucson, AZ receives a $57.9 million contract modification, covering FY 2012 requirements for MK 15 Phalanx Close-In Weapon Systems (CIWS). It includes MK 15 Mod 31 CIWS SeaRAM missile upgrade kits and conversions in support of Austal’s forthcoming LCS 10 and 12; as well as Phalanx Block 1B BL2 upgrade kits and conversions, 2 Phalanx Block 1Bs for the forthcoming DDG 116 destroyer, MK 15 CIWS hardware product improvements and ancillary equipment, Block 1B Ordalt (Ordnance Alternation) kits; and MK 15 CIWS Block 1B Class A overhauls.

Work will be performed in Louisville, KY (39%); Germany (12%); Palm Bay, FL (12%); Tucson, AZ (9%); Pittsburgh, PA (8%); Burlington, VT (6%); Andover, MA (4%); Syracuse, NY (4%); Long Beach, CA (1%); Radford, VA (1%); Bloomington, MN (1%); Salt Lake City, UT (1%); Norcross, GA (1%); and New Albany, IN (1%); and is expected to be complete by September 2015. $24.2 million will expire at the end of the current fiscal year, on Sept 30/12 (N00024-10-C-5427).

Jan 19/12: Support. A $30 million cost-plus-fixed-fee contract modification for the MK-31 RAM system’s FY 2012 design agent engineering services. they’ll work to maintain current system capability, as well as resolve issues through design, systems, software maintenance, reliability, maintainability, quality assurance and logistics engineering.

Work will be performed in Tucson, AZ, and is expected to be complete by September 2012. $342,272 will expire at the end of the current fiscal year (N00024-10-C-5432).

Dec 6/11: FY 2012. A $22.2 million contract modification for the production of 50 Block 1 MK-44 Mod 2 Rolling Airframe Missile (RAM) guided missile round pack all-up-rounds.

Work will be performed in Tucson, AZ (49.7%); Ottobrunn, Germany (42.7%); Rocket City, WVA (4.5%); and Andover, MA (3.1%), and is expected to be complete by February 2014 (N00024-08-C-5401).

FY 2010 – 2011

US orders; Major UAE order; Block 2 initial integration & tests.

UAE’s Baynunah Class
(click to view full)

Sept 15/11: Block 2 tests. Raytheon and Germany’s RAMSYS announce that they have finished RAM Block 2 missile upgrade and integration testing in the 5 control test vehicle flights, meeting all upgrade requirements. They’re not done yet, however. The program will begin guided flight tests at the end of 2011, and is expected to enter low rate production in late 2012.

Aug 25/11: Ship sets. A not-to-exceed $161 million contract modification to previously awarded contract for MK15 Mod 31 SeaRAM systems in support of Independence Class ships LCS 6 Jackson and LCS 8 Montgomery, and Japan’s “DDH 2405 helicopter destroyer.” It will also buy Phalanx CIWS Block 1B class “A” overhauls, and land-based Phalanx Weapon System class “A” overhauls.

Japan’s “DDH-2405” may be the first ship of Japan’s new “22DH” project to field 800 foot, 30,000t vessels that are larger than its existing 18,000t Hyuga Class. The Hyuga Class are properly characterized as LPH helicopter carriers, and 22DHs could be classed as escort carriers, but Japan’s constitution forbids them from owning aircraft carriers. The SH-60 Seahawk helicopters on board JMSDF Hyuga and JMSDF Ise certainly proved themselves in the wake of the 2011 tsunami, which should mute any domestic criticism.

Work will be performed in Louisville, KY (30%); Andover, MA (19%); Tucson, AZ (9%); Germany (7%); Syracuse, NY (7%); Long Beach, CA (6%); Radford, VA (6%); Burlington, VT (6%); Palm Bay, FL (2%); Pittsburgh, PA (2%); Bloomington, MN (2%); Salt Lake City, UT (2%); Norcross, GA (1%); and New Albany, IN (1%). Work is expected to be complete by September 2015, but $90.7 million will expire at the end of the current fiscal year, on Sept 30/11 (N00024-10-C-5427).

Aug 1/11: Ship sets. A $7.4 million contract modification for 3 refurbished and upgraded RAM MK 49 Mod 3 Guided Missile Launch Systems with associated hardware, for use on LHA 7 (unnamed, America Class escort carrier, 2) and LCS 5 (Detroit, Freedom Class Littoral Combat Ship, 1).

Work will be performed in Tucson, AZ, and is expected to be complete by March 2013. Contract funds will not expire at the end of the current fiscal year (N00024-11-C-5448).

June 30/11: FY 2011. A $57.9 million contract modification for 90 Block 1 MK-44 Mod 2 RAM guided-missile round pack all-up-rounds, and 40 ordnance alteration kits. This contract modification includes options, which, if exercised, would bring the cumulative value of this modification to $113 million.

Work will be performed in Tucson, AZ (49.7%); Ottobrunn, Germany (42.7%); Rocket City, WVA (4.5%); and Andover, MA (3.1%); and is expected to be complete by December 2013 (N00024-08-C-5401).

Feb 23/11: UAE. At IDEX 2011, the UAE announces an AED 800.5 million ($218 million) order for Raytheon’s RAM missile systems. The missiles equip the UAE’s new Baynunah-class corvettes, built in country by Abu Dhabi Ship Building (ADSB).

The initial ship of class UAENS Al Hesen was a significant exhibit at the show. Jane’s.

UAE order

Nov 23/10: Block 2 test. Raytheon announces that its RAM Block 2 missile has completed the 4th and final controlled test vehicle flight. This test measured kinematic performance and stability, with attention to the missile’s rocket motor, airframe, control section, and autopilot software. Raytheon will build 25 Block 2 missiles during the design and development test period, and expects a low rate initial production contract to follow.

Oct 29/10: Ship sets. A $17.7 million fixed-price contract for 2 refurbished and upgraded rolling airframe missile (RAM) MK 49 Mod 3 guided missile launch systems (GMLS) with associated hardware. They’ll be mounted on the USA’s LPD 26, a San Antonio Class large amphibious ship. The contract also involves 1 new MK 49 Mod 3 system, which will be mounted on Egypt’s new Ambassador III Class fast missile craft. Note that the MK 49 needs to add the MK 44 guided missile round pack to become a fully effective MK 31 RAM missile system.

This contract combines purchases for the U.S. Navy (37.1%) and the government of Egypt (62.9%) under the Foreign Military Sales program. It includes options which could bring the cumulative value of this contract to $32.8 million. Work will be performed in Tucson, AZ, and is expected to be complete by January 2013. This contract was not competitively procured (N00024-11-C-2404).

July 8/10: Sub-contractors. LaBarge, Inc. announces a $1.2 million contract from Raytheon to provide printed circuit card assemblies for the RAM missile system.

LaBarge already produces a variety of complex wiring harnesses for the system, and will perform this new work at its Tulsa, OK facility. Production is expected to begin in July 2010 and continue through June 2011.

July 2/10: Support. A $44.5 million cost-plus-fixed-fee contract for the MK-31 rolling airframe missile (RAM) guided missile weapon system’s FY 2010 design agent engineering services. The support covers maintenance, and adds design, systems, software maintenance, reliability, maintainability, quality assurance, and logistics engineering services as necessary. The contract includes options which would bring the cumulative value of this contract to $167.3 million, if exercised.

Work will be performed in Tucson, AZ, and is expected to be complete by September 2010. $2.25 million will expire at the end of the current fiscal year, on Sept 30/10. This contract was not competitively procured (N00024-10-C-5432).

May 24/10: LCS. Raytheon announces that its SeaRAM system successfully completed 2 blast test missile launches aboard the USS Independence [LCS 2], designed to test the structural integrity of both the weapon system and the ship. The launches clear the way for SeaRAM’s live-fire testing on that Littoral Combat Ship class later in 2010.

SeaRAM cuts the number of available missile pack rounds from 21 to 11, but marries the RAM launcher to the 20mm Mk15 Phalanx’s base structure and engagement radar, in order to create a truly bolt-on air defense option for ships. In the Independence Class, the system is also integrated into the ship’s wider combat system.

May 21/10: Block 2. A $10.8 million contract modification to increase the ceiling amount to previously awarded contract, for the “rebaselining of the system design and development” of the RAM Block 2 upgrade. Work will be performed in Tucson, AZ, and is expected to be complete by December 2011.

According to Raytheon representatives, what’s really happening is an extension of the program’s schedule, as well as about a year’s worth of added work from Navy requests. The net effect is to more or less restore the requirements that the program began with 4 years ago, with some changes in light of subsequent tests. Raytheon has now run 3 control test vehicle launches, with 1 to go. Guided test launches will be next, with Navy testing expected to begin with about 25 Design-Test/ Operational-Test missiles in Q1 2012 (N00024-07-C-5454).

RAM Block 2 rebaselined

March 23/10: Testing. A Germany Navy video shows an exercise held off the Cape of Good Hope, whose stormy seas keep the area clear enough to allow live missile tests. The video shows AS.34 Kormoran anti-ship missiles being intercepted by older RIM-7 SeaSparrow missiles… but the RAM system on F215 Brandenburg misses the target drone.

Missed

Oct 16/09: Block 2. A $7.7 million modification to previously awarded contract to increase the ceiling amount for System Design and Development of the RAM Block 2 upgrade. The funds will cover additional guidance section design verification testing, to ensure that the software interfaces properly with the missile’s hardware guidance section. Work will be performed in Tucson, AZ and is expected to be complete by August 2011 (N00024-07-C-5454).

FY 2008 – 2009

Orders: USA, Egypt.

SeaRAM firing
(click to view full)

July 20/09: SeaRAM. A $16.8 million modification to a previously awarded contract for 2 more MK 15 Mod 31 CIWS SeaRAM weapon systems, ancillary equipment, spares, and support. Unlike the Mk 44 launchers, SeaRAM systems have only 11 missiles in the launcher, in order to fit within the self-contained Mk 15 Phalanx mounting.

Work will be performed in Louisville, KY (33%); Tucson, AZ (8%); Andover, MA (6%); Pittsburgh, PA (4%); Mechanicsville, MD (3%); Fort Defiance, AZ (3%); Bloomington, MN (2%); Santa Clara, CA (2%); Munich, Germany (37%); and Athens, Greece (2%), and is expected to be complete by September 2011. Contract funds in the amount of $9.2 million will expire at the end of the current fiscal year (N00024-07-C-5444).

June 8/09: FY 2009. A $56.4 million modification to previously awarded contract for the production of 90 Block 1 MK-44 Mod 2 rolling airframe missile (RAM) guided missile round pack (GMRP) all-up-rounds (AURs), and 40 ordnance alteration kits. This contract modification includes options which would bring the cumulative value of this modification to $118 million, if exercised.

GMRPs are the 21-round missile launchers used by the RAM system, and 90 GMRP AURs is the standard annual American order. The total FY 2009 RAM missile budget is $70.8 million.

Work will be performed in Tucson, AZ (49.7%); Ottobrunn, Germany (42.7%); Rocket City, WVA (4.5%); and Andover, MA (3.1%), and is expected to be complete by December 2011 (N00024-08-C-5401).

Jan 16/09: Ship sets. Raytheon in Tucson, AZ receives an $18.8 million contract modification buy 4 of their Mk 49 MOD 3 Guided Missile Launcher Systems (GMLS), which hold the full 21-missile Mk 44 packs. The Mk 49 systems will be installed on the amphibious assault ship LPD 25 Arlington, and the first-of-class CVN 78 Gerald R. Ford aircraft carrier. Another 10 ORDALT (ORDnance ALTeration) Mod 1 to Mod 3 GMLS Ordalt Kits will also be provided as part of this order, and will be used to upgrade a number of Mk49 systems around the fleet.

Work will be performed in Ottobrunn, Germany (50%), Louisville, KY (45%) and Tucson, AZ (5%) and is expected to be complete by February 2012 (N00024-06-C-5402).

Oct 15/08: Sub-contractors. BAE Systems spinoff Atlantic Inertial Systems (AIS) announces a production order from Diehl BGT Defence GmbH worth about $3 million for the second batch of its SiARS Micro-Electro Mechanical Systems (MEMS) Inertial Measurement Unit (IMU). The order follows AIS’ successful completion of design, qualification and initial production deliveries.

IMU systems offer a way to precisely measure distance and vector from a known launch point, without requiring GPS or external aids that may not be available. MEMS technology helps this IMU perform that job reliably in a violently spinning missile like RAM.

AIS has been involved in the RAM program for a number of years, and their release says they anticipate receiving annual production orders into the next decade. The firm has facilities in Cheshire CT, USA, and in Plymouth, UK, employing over 800 personnel worldwide.

June 11/08: FY 2008. A $59.5 million contract for the production of 90 Block 1 MK-44 Mod 2 Rolling Airframe Missile (RAM) Guided Missile Round Pack All-Up-Rounds, and 60 ORDALT(ORDnance ALTeration, usually means upgrades) Kits.

Work will be performed in Tucson, AZ (49.7%), Ottobrunn, Germany (42.7%), Rocket City, WVA (4.5%), and Andover, MA (3.1%) and is expected to be complete by May 2011. (N00024-08-C-5401).

Dec 31/07: Egypt. Egypt’s order comes in – see Sept 28/07, as Raytheon receives $72.5 million modification to previously awarded contract for 139 Block 1 MK-44, Mod 2 Rolling Airframe Missile (RAM) Guided Missile Round Pack (GMRP) All-Up-Rounds.

Work will be performed in Ottobrunn, Germany (49%), Tucson, AZ (44%), Rocket City, WVA (6%), and Andover, MA (1%), and is expected to be complete by January 2011. This modification supports the Republic of Egypt (100%) under the Foreign Military Sales Program (N00024-04-C-5456).

Egypt

FY 2006 – 2007

Orders: USA, UAE, South Korea; Export requests: Egypt; RIM-116 Block 2 development contract; Shingo Prize for the factory; SeaRAM picked for LCS-2 trimarans.

RIM-116 RAM Launch

Sept 28/07: The US DSCA announces [PDF format] Egypt’s formal request for up to 139 RIM-116B Block 1A Rolling Airframe Missiles (RAM) with MK-44 Guided Missile Round Packs, containers, support equipment, spare and repair parts, publications and technical data, maintenance, personnel training and training equipment, U.S. Government, contractor engineering and logistics technical support services, and other related elements of logistics support. The systems will be installed on Egypt’s new Ambassador MK III Fast Missile Craft [PDF format] boats for air defense, along with the 20mm Mk 15 Phalanx CIWS. See also Feb 10/06 entry.

The total value, if all options are exercised, could be as high as $125 million. The prime contractor will be Raytheon Systems Corporation in Tucson, AZ. There are no offset agreements associated with this potential sale, and implementation will not require the assignment of any additional U. S. Government or contractor personnel in country.

DSCA request: Egypt (139)

Aug 15/07: LCS. A $5.8 million firm-fixed-price modification under previously awarded contract for the fabrication, test, and delivery of one (1) MK 15 MOD 31 PHALANX SeaRAM Close-In weapon System (CIWS). As noted above, the SeaRAM uses the Phalanx system’s integrated radar, and will equip the USA’s Littoral Combat Ships. Work will be performed in Louisville, KY, and is expected to be complete by September 2009 (N00024-04-C-5460).

June 5/07: Raytheon announces a contract for 7 RAM Block 1A systems with Abu Dhabi Ship Building of the United Arab Emirates. The direct commercial sale, valued at $76.5 million, calls for the systems to be delivered starting in December 2007, and installed on 6
of the UAE’s new 70m Baynunah Class corvettes. The agreement also provides for an on-shore Rolling Airframe Missile test and training system, spares support and other services. Raytheon release.

The RAM system was not originally slated to equip the UAE’s new corvettes, but in 2006 the UAE decided that escalating regional tensions and anti-ship missile proliferation required improved inner layer defenses. The system will be mounted near the ship’s rear, atop the helicopter hangar. Outer defense will be handled by Raytheon’s RIM-162 Evolved Sea Sparrow Missiles fired from Mk56 vertical launchers, while last-ditch defense will rely on the corvette’s Oto Melara 76mm naval gun and 30mm secondary guns.

RAM backfit for UAE

May 24/07: Support. Raytheon Co. in Tucson, AZ received an $11.6 million cost-plus-fixed-fee contract for 70,590 engineering man-hour design agent engineering services for the MK-31 Rolling Airframe Missile (RAM) guided missile weapon system, and associated efforts. Work will be performed in Tucson, AZ and is expected to be complete by September 2007.

Support procured under this contract is required to maintain current weapon system capability, as well as resolve issues through design, systems, software maintenance, reliability, maintainability, quality assurance and logistics engineering services. The contract was not competitively procured by The Naval Sea Systems Command in Washington, DC (N00024-07-C-5443).

May 8/07: Block 2. Raytheon Missile Systems in Tucson, AZ received a $105.5 million cost-plus scheduled event-based incentive-fee contract for system design and development of the Block 2 upgrade to the RAM MK31 Guided Missile Weapon System, in support of the Program Executive Office-Integrated Weapon Systems. “The Block 2 upgrade will enable the RAM missile to more effectively counter the emerging threat of more maneuverable anti-ship missiles.” Details regarding the Block 2 upgrade are given in the RAM System section.

Work will be performed in Tucson, AZ and is expected to be complete by December 2010. The contract was not competitively procured by the Naval Sea Systems Command in Washington, DC (N00024-07-C-5454).

See also Raytheon’s June 27/07 release, which announces the contract as “$145.4 million… for production and enhancement of its Rolling Airframe Missile program. Nearly $105.5 million will go to the development of Rolling Airframe Missile Block 2…”

RAM Block 2 development

March 6/07: FY 2007. Raytheon Company in Tucson, AZ received a $39.9 million firm-fixed-price modification to previously awarded contract (N00024-04-C-5456) for production of 90 Block 1 MK 44 Mod 2 Rolling Airframe Missile (RAM) Guided Missile Round Packs, and 90 MK 20 Mod 2 RAM Active Optical Target Detectors. This represents the full FY 2007 request.

Work will be performed in Tucson, AZ (50%) and Ottobrunn, Germany (50%), and is expected to be complete by March 2009. The Naval Sea System Command in Washington, DC issued the contract.

Feb 8/07: Shingo Prize. Raytheon Missile Systems’ (RMS) Louisville, KY facility has captured a prestigious Shingo Prize for Excellence in Manufacturing, marking the 4th consecutive year that various Raytheon facilities have won. The Louisville facility manufactures the Phalanx CIWS and RAM/SeaRAM systems. See full DID coverage.

April 11/06: South Korea. Raytheon announces a $17.4 million contract for production 30 RAM Block 1/HAS (helicopter, aircraft, surface) tactical guided missile round packs and test equipment design maintenance for the South Korean RAM program.

RAM Block 1/HAS is the ship self-defense weapon of choice for the country’s KDX II, or Chungmugong Yi Sunshin Class destroyers. Note that the KDX-IIs will also use longer range Standard SM-2 Block IIA missiles as part of their surface-air missile armament.

Raytheon reports that they also have contracts to supply launchers for South Korea’s future KDX III AEGIS destroyers and LPX Dodoko Class amphibious assault ships.

South Korea

April 4/06: RAM on LCS. Raytheon Company has announces that it will install the SeaRAM anti-ship missile defense weapon system on General Dynamics’ trimaran design for the Littoral Combat Ship (LCS). SeaRAM combines upgraded MK 15 Phalanx Block 1B close in weapon system’s radar & infrared sensors and Rolling Airframe Missile (RAM) Block 1A Helicopter, Aircraft, and Surface (HAS) guided missiles. Raytheon will work with General Dynamics to integrate SeaRAM with the LCS combat management system.

RAM for LCS-2 Class

April 3/06: FY 2006. Raytheon Co. in Tucson, AZ received a $77 million firm-fixed-price modification to previously awarded contract for production of 90 Rolling Airframe Missile (RAM) Block 1/HAS MK-44, Mod 3 all-up-round tactical guided missile round packs (GMRP). This is the USA’s full procurement amount for FY 2006, similar to the 86 GMRP requested in FY 2005 and the 90 missiles in the FY 2007 budget request. This contract also covers 120 RAM Block 1/HAS MK-44, Mod 3 ordnance alteration (ORDALT) kits.

Work will be performed in Tucson, AZ (50%) and Ottobrunn, Germany (50%), and is expected to be complete by March 2009 (N00024-04-C-5456).

Feb 10/06: Egypt. Raytheon announces that the Egyptian navy will outfit its new Ambassador III Class Fast Missile Craft with Rolling Airframe Missile (RAM) launching systems. Raytheon’s Mk49 RAM launchers and associated RAM Block 1A missiles will provide the primary ship self-defense capability for the Fast Missile Craft, built by VT Halter Marine in Gulfport, MS.

Approximately 50% of the production work will be performed at Raytheon Missile System facilities in Louisville, KY and Tucson, AZ with the remaining half to be completed by RAM-System GmbH of Ottobrunn, Germany.

Egypt picks RAM for FACs

Additional Readings

• Raytheon – Rolling Airframe Missile (RAM) Guided Missile System.

• Raytheon – SeaRAM Anti-Ship Missile Defense System.

Type 26 concept
(click to view full)

In the late 2000s Britain slated to replace its existing fleet of Type 22 Broadsword Class and Type 23 Duke Class frigates with 2 new ship classes under a program known then as “Future Surface Combatant” (FSC). By the 2010 Strategic Defence and Security Review (SDSR), the FSC’s C1 (T26) and C2 (type 27) tentative variants were merged into a single Type 26 Global Combat Ship (GCS) class.

Outside attention often focuses on big-ticket ships like aircraft carriers, submarines, and advanced destroyers – but the frigate is the real backbone of most modern navies.

Lord Nelson loved his HMS Victory and her fellow first-rate ships of the line, but he asked the admiralty for more cruisers because he knew their versatile value as the “eyes of the fleet.” Modern multi-role frigates that can engage threats on the water, under water, and in the air fill that same role today, protecting other navy ships or undertaking independent action away from their task group.

The Type 26 GCS will have to fill that niche – but first, its requirements and design must be defined.

Britain’s Future Surface Combatants

Type 23 frigate:
HMS Northumberland

Of Britain’s 30 frigates built – 14 Type 22s and 16 Type 23s – 17 (4 Type 22s, 13 Type 23s) still serve in the Royal Navy, and some of the Type 23s have received modern refits to keep them going a bit longer. All remain outclassed by more modern designs. Another 10 frigates of these types have been sold abroad to Brazil, Chile, and Romania, and 3 Type 22s have been deliberately scrapped or sunk. The 2010 SDSR decided that the rest of the Type 22s will join their fellows abroad, or in the scrapyard, leaving just the Type 23 Duke Class. Fortunately, the Type 23s have been doing a lot of sailing in less strenuous environments than the treacherous North Atlantic seas they were designed for. That has helped them to last longer, but no ship lasts forever, and replacements are needed.

Type 26, 2013
click for video

Key Type 26 design criteria include multi-role versatility, flexibility in adapting to future needs, affordability in both construction and through-life support costs, and exportability. In reality, these requirements represent a set of key trade-offs. Some can be complementary, such as cost and exportability. Other pairings usually come at each other’s expense, such as the desire for high-end multi-role capability within a small ship footprint, versus the desire to keep initial purchase costs low.

The current Assessment Phase was designed to make many of these trade-offs, and the program was timed so it can take the 2010 Strategic Defence Review into account. Initial reports indicate an imagined cost of about GBP 400 million per ship, but the Royal Navy is no better than the American Navy at shipbuilding cost estimates.

The first ships of the Type 26 class are due to enter service in the early 2020s, and Britain envisions at least 12-13 of them. The current Type 26 plan involves 5 basic frigates, and another 8 ships with additional anti-submarine warfare equipment.

By the 2030s, around half of front line Royal Navy personnel are expected to operate on Type 26 frigates.

Type 26: Design

T26 concept, 2012
(click to view full)

At present, there is no full detail design, and hence no defined equipment set for the Type 26. BAE’s original working baseline reportedly involved a 141m, 6,850t ship, but reductions in target cost led them to publish figures of 148m but just 5,400t. The crew would be just 118, with room for 72 embarked troops.

The ship will use a CODOG (Combined Diesel Electric or Gas Turbine) propulsion system, with a 36MW MT30 turbine from design partner Rolls-Royce, unspecified MTU diesel generator sets, and a gear box via David Brown Gear Systems Ltd. GE will be the overall integrator for the diesel-electric system. Current plans state a top ship speed of 28+ knots, with 60 days endurance and a range of 7,000 miles/ 11,000 km) at normal steaming speed of 15 knots/ 28 kmh.

MK45 Mod 4

Armament will include a 127mm gun, where according to Jane’s BAE’s Mk 45 Mod 4 has an edge over Oto Melara for the Maritime Indirect Fire System requirement. The new MBDA/Thales CAMM (Common Anti-air Modular Missile) will replace the current Seawolf system for short range air defense. CAMM/FLAADS-M benefits from carrying an active radar seeker, reducing the need to rely on a ship’s own radar illumination for targeting during saturation attacks. The Ministry of Defence has also reiterated that the ship would have a mission bay for “unmanned air, surface and underwater vehicles, or additional boats.”

Little is certain beyond that. The big outstanding questions involve radars, the combat system, and secondary weapons.

T26 mission bay, 2012
(click to view full)

Radars. Based on the drawings of the May 2012 design, the long-range volume search radar atop the integrated mast would be a Type 997 Artisan system, which is also slated to equip Britain’s future carriers and upgraded Type 23 frigates. The drawings also show the compact antenna faceplates of an active array radar mounted around the integrated ship’s mast, however, similar to Australia’s CEAFAR/ CEAMOUNT solution. At the very top end, a dedicated air defense variant of the ship could use the SMART-L derived S1850M radar that equips British Type 45 destroyers.

VLS. The May 2012 design’s 48 illustrated vertical launch missile silos combine 24 larger Mk.41 or Sylver cells and 24 shorter cells. The VLS systems do come in different lengths, and the smaller cells would probably be slated for the short-range CAMM air defense missile. By October 2014 it appeared Mk.41 was the UK’s choice.

Combat system. The use of CAMM means that at least some aspects of the PAAMS combat system will find their way onto the ship, but that area is still very unclear. What is clear, is that the ships will lack America’s Cooperative Engagement Capability, which allows participating ships to see, track, and even fire on targets illuminated by any other CEC-equipped ship or plane. CEC makes a big difference to roles like wide-area air defense, and to ship’s potential for use in anti-ballistic missile networks. Its presence would have pushed the Type 26 toward a positioning as a high end frigate, especially in conjunction with a very long-range radar like the S1850M. Instead, the Type 26 looks set to become a versatile mid-budget “value play” within the global export market.

Secondary Weapons. The displayed layout shows a last-ditch CIWS gatling gun, and its positioning would allow Thales’ through-deck 30mm Goalkeeper. On the other hand, Britain has now used Raytheon’s smaller, bolt-on 20mm Phalanx system on its Type 45 destroyers, so either choice would just expand existing buys. The Goalkeeper has more stopping power, but the Admiralty could decide that Phalanx’s expandability makes it the more desirable option. The ability to convert a MK15 Phalanx mount into an 11-missile “MK15, MOD31” SeaRAM launcher, or some kind of future “laser Phalanx,” is something Goalkeeper doesn’t have.

Helicopters. Merlin helos will provide maritime force protection and anti-submarine warfare capabilities, while AW159 Lynx Wildcats HMAs (Helicopter Maritime Attack) will play a variety of attack and utility roles. The Wildcats will share Stingray torpedoes and Mk11 depth charges with the Merlins, and they will also sport Martlet (light) and Sea Venom (heavy) missiles.

Industrial Team

BAE Systems has made 10 selections so far, and expects another 19-20 agreements in 2014, before the production contract is signed. Official selections so far include:

Targeting Exports

F124 fires SM-2
(click to view full)

Britain intends to develop its frigates with an eye to export orders, in hopes of to spreading development costs over more vessels, getting more benefit from the manufacturing learning curve, reducing costs per ship thanks to volume orders, and sustaining the UK’s naval shipbuilding industry.

Rumored design options for export customers include a choice of gas turbine engines for maximum speed, or a slower but more efficient all-diesel design; as well as optional ship equipment fit-outs focused on either anti-submarine warfare (ASW) or air defense.

So far, countries that have been reported as expressing some level of interest have included Australia, Brazil, Canada, India, Malaysia, New Zealand, and Turkey.

DSEi report

Talks do not a deal make, however, and Britain will have a formidable set of established competitors to contend with.

While the Americans have more or less abandoned this field, the Franco-Italian FREMM program offers a fully modern design, using the same MBDA PAAMS air defense missiles and DCNS SYLVER vertical launch systems as Britain’s Type 45 air-defense destroyers. Meanwhile, variants of France’s Lafayette Class stealth frigate design remain popular around the world.

The German-Dutch F124 air defense frigates offer stealth and advanced air defense via active array radars, while using the ubiquitous American Mk.41 vertical launch system for their missiles. Lower down the scale, ThyssenKrupp Marine’s globally popular MEKO Class family of ships provides a budget alternative. So does Damen Schelde’s modular Sigma Class, which can be built as anything from an Offshore Patrol Vessel to a full-size frigate.

Beyond the standard competitors, and countries like Russia with their own separate set of naval clients, China has recently begun exporting frigates in Asia. They will soon be joined by South Korea’s very capable naval shipbuilding industry, which has demonstrated success in fielding modern domestic warships, and has a very strong commercial shipbuilding base to draw from.

Contracts & Key Events 2015 – 2018

Long-lead production contracts; first ship timetabled late 2016.

July 2/18: Next customer The Australian government is contracting BAE Systems for the production of the country’s next-generation, anti-submarine warfare (ASW) frigates. The $25.9 billion contract is Australia’s largest peace-time warship building program. The British designed Type 26 Global Combat Ship was selected in a lengthy comparative evaluation process over the ASW variant of the FREMM multi-mission frigate offered by Italy’s Fincantieri, and an ASW evolution of the F-100 Alvaro de Bazan-class design. Key Type 26 design criteria include multi-role versatility, flexibility in adapting to future needs, affordability in both construction and through-life support costs, and exportability. Intended to begin replacing the eight workhorse Anzac-class frigates of the Royal Australian Navy (RAN) in 2027–28, the new Hunter class will be constructed by ASC Shipbuilding at Osborne on the outskirts of Adelaide.

March 5/18: VLS Ordered BAE Systems has tapped Lockheed Martin to supply its Mk 41 Vertical Launching System (VLS) for the three City-class Type 26 anti-submarine warfare (ASW) frigates on order for the British Royal Navy. The VLS is the only one available that is capable of launching anti-air, anti-submarine, surface-to-surface and strike-length missiles, and initial orders from London calls for the delivery of nine MK 41 VLS modules—enough for the first three ships—the already under construction Glasgow, and the ordered Cardiff and Belfast.

December 1/17: Foreign Military Sale Canada’s government has received a proposal from a team led by Lockheed Martin to build vessels for the Canadian Surface Combatant (CSC) program. Partnered with BAE Systems, CAE, L3 Technologies, MDA and Ultra Electronics, the effort is offering the Type 26 Global Combat Ship (GCS), and will utilise high-tech platform innovations from prominent Canadian companies, including a Canadian-developed combat management system, CMS 330. No other details on the proposal were given. Designed by BAE Systems, eight Type 26 frigates are already planned for the British Royal Navy.

September 28/17: The British Ministry of Defence has announced that the next of its new Type 26 frigates for the Royal Navy will be named the HMS Belfast. The announcement was made by defense minister Sir Michael Fallon during a visit to the shipbuilder Harland and Wolff in the city, where the Navy’s last HMS Belfast—a light cruiser that is now a museum ship moored in London—was built before World War Two. Eight Type 26 frigates have been slated for production, with the first beginning combat operations in the mid-2020s, and will be used to protect the UK’s nuclear submarines and aircraft carriers.

September 06/17: MBDA and the British Royal Navy have completed the first love-firing of the Sea Ceptor air defense missile system from the Type 23 frigate HMS Argyll. Utilising MBDA’s next-generation Common Anti-air Modular Missile (CAMM), the system is being fitted to replace the Sea Wolf weapon system on the Type 23 frigates as part of their life-extension program. The Argyll will conduct further firing trials of the Sea Ceptor system before returning to frontline service.

August 15/17: BAE Systems has entered a bid to build Australia’s next fleet of anti-submarine warfare frigates. Nine vessels will be built under the contract and the company is offering a variant of the Type 26 Global Combat Ship frigate being constructed for the British Royal Navy. The frigates for the country’s SEA 5000 Future Frigate program are part of a company effort to partner with the government to develop a long-term ship building strategy.

July 24/17: Construction of the first (of three) Type 26 frigate has begun in earnest at a BAE Systems shipyard in Scotland. A ceremony last Thursday which launched the vessel’s production was attended by British Secretary of State for Defense Michael Fallon, who said the warship “will maintain our naval power with a truly global reach. Designed for a service life of at least 25 years, the Type 26 frigates will form the backbone of the future Royal Navy surface fleet into the 2060s.” Due to be named the Glasgow, the ship will be 492 long, 68 feet in the beam and have a speed of more than 26 knots. Its operational range will be more than 7,000 nautical miles.

July 5/17: The UK MoD has ordered its first batch of three Type 26 frigates for the Royal Navy. Valued at $4.81 million, steel for the first vessel will be cut in lead-contractor BAE System’ shipyard in Glasgow, Scotland in the coming weeks. London’s Type 26 Global Combat Ship program calls for the delivery of eight vessels for use as an anti-submarine warfare ship and will replace the current fleet of Type 23 frigates. The Type 26 will be the most advanced ship in its class around the world and we are exploring potential export opportunities where there is strong interest from international customers.

November 7/16: MBDA has been awarded a $125 million Demonstration and Manufacture contract by the British MoD for the Sea Ceptor air defense system for the Type 26 (T26) Global Combat Ship (GCS). The company said the deal will last for 10 years and involves support to the T26 design as well as the manufacture of the electronics equipment required for the class of eight ships. News of the deal comes following the announcement by BAE Systems that the first steel for the frigate will be cut in Glasgow next summer.

March 23/16: BAE Systems and the UK government have signed a contract extending the company’s development of a new class of Type 26 anti-submarine frigate. The $670 million deal will run from this April for 15 months, and follows a previous 12 month extension of demonstration phase which comes to an end next month. Work will now be carried out to further maturing the frigates design, and manufacturing of equipment for the first three of eight ships scheduled to be built by BAE. However, neither BAE or the MoD commented on whether a full scale production will follow the end of the latest contract.

March 9/16: BAE Systems and the UK MoD are currently in discussions to agree on to the next tranche of work, and establish a revised production schedule that could delay the start of building a fleet of new anti-submarine warfare/general purpose frigates. An initial contract under the Type 26 program was to build 13 of the vessels, however this was cut to eight last November by the Conservative government. To fill the capability gap, the Type 31 program looks to build five cheaper, smaller general purpose frigates. The current discussions aim to decide on how these programs will go forward with a revised schedule expected for the early fall.

August 7/15: The Royal Navy’s future frigate program, the Type 26 Global Combat Ship has received a boost with the announcement of a number of long-lead production contracts totaling $265 million. The subcontracts were placed with principal suppliers for the delivery of key system components. Prime contractor BAE Systems is executing a $1.3 billion, one-year demonstration contract awarded in February, with negotiations on the production and delivery schedule of the thirteen Type 26 ships planned still underway. Manufacture of the first ship is provisionally timetabled to begin in late 2016, with the first ships in class thought to be scheduled to enter Royal Navy service in the early 2020s. Other states have reportedly taken an interest in the Type 26, including Australia, Canada and Germany.

2013 – 2014

Design changes; Export prospects; Sub-contractors picked; CAMM-M Sea Ceptor missile confirmed.

Dec 1/14: Industrial. In the run-up to the September referendum on Scottish independence, then defence secretary Philip Hammond had made clear that UK naval ships were made in the Union, meaning that an independent Scotland couldn’t build future ships such as T26 frigates. Now that the Scots have voted to remain within the UK, Michael Fallon defence secretary confirms that Type 26 frigates will be built on the Clyde.

Fallon hopes to announce long lead contracts in early 2015. That would assuage for good Scottish voters who were distressed by statements made last month by the head of the Royal Navy who implied that a foreign procurement may be in the cards. BAE is improving infrastructure at the Scotstoun yard as well as recruiting more than 200 people there and at Govan. An OPV contract awarded in August was a first step to secure future work for these yards.

Sources: E&T: Frigates to be built on Clyde, Fallon confirms | The Herald: Boost for Clyde yards as BAE to take on 165 apprentices | The Telegraph: MoD announces new £348m shipbuilding contract for Clyde [OPVs].

Nov 9-13/14: Negotiations. A Defense News interview with First Sea Lord Adm. George Zambellas creates a bit of a firestorm, and underscores the difficult state of negotiations for the planned 13-ship contract. Which means approval could be delayed until at least mid-2015, making it hard to begin cutting steel in 2016. Adm. Zambellas stirred up a lot of passion in Scotland when he seemed to say that Britain may turn away from the Type 26 altogether, right after a referendum that dangled the shipbuilding contract as a major reason for a “no” vote on independence:

“The acquisition process looks for a solution …. to be able to give us what we need. The affordability question that comes from that depends on the best that industry can deliver. You’ll notice, I haven’t necessarily said that that’s the British industry, because the decision has not been made as to exactly what that solution to the requirement will be, and we wait to see what comes of it… But the Navy knows what it wants. It wants a credible platform with global reach and the sort of quality, particularly in anti-submarine warfare to keep us right up there.”

Key problems seem to revolve around the Type 26’s cost, and are made more difficult by reports that Type 26 ship size is creeping up to 6,500t / 8,000t full displacement. If true, that’s destroyer size, which would makes a per-ship cost target under GBP 400 million (about $650 million) almost impossible to achieve. Meanwhile, McKinsey’s consultants have been brought in to undertake a GBP 1.9 million program cost review.

The 6,000t Franco-Italian FREMM is mentioned by outside observers as the most obvious alternative, given its combat system and VLS compatibility with the Type 45s. On the other hand, even if Britain moved past its policy of only building warships in the UK, the French Senate’s 2013 report pegged per-ship program cost at EUR 605 / GBP 480 million. GBP 6.24 billion for 13 is far beyond Britain’s budget, and even paying less than the French paid for development is unlikely to bridge a gap near GBP 2.25 billion. Sources: Defense News, “Britain Struggles With Costs for New Frigates” | The Scotsman, “MoD considers pulling [GBP] 4bn Clyde frigate contract”.

Oct 27/14: Sub-contractors. The Type 26 will use CODOG hybrid propulsion of an MT30 gas turbine for sprinting, and diesel-electric systems for patrolling and cruising at lower speeds. General Electric is responsible for the diesel-electric propulsion system (q.v. June 3/14), and they have deployed a team of noise and vibration specialists using 3-D software to model its acoustic dynamics.

The goal for any sub-hunting frigate is to create a system that is somehow shock-proof, compact, and extremely quiet. It isn’t easy, but it’s one of those underrated characteristics that makes as much difference to the ship’s long-term performance as any carried weapon. Sources: Manufacturing.NET, “A Warship So Quiet, It Sneaks Up On Submarines”.

Oct 9/14: components. Defence Secretary Michael Fallon writes in answer to a question from the House of Commons that T26 GCS will use Mk41 as its vertical launch system, which has the benefit of accommodating a large number of missiles. Another tidbit is that the light LMM to be used by the Royal Navy on Wildcat helicopters will be dubbed Martlet. Source: MoD/House of Commons [PDF].

Aug 18/14: The Royal Navy is looking to acquire 13 Type 26 frigates in all, at an estimated cost of about GBP 4 billion (US $6.6 billion). The initial order is expected to involve 8 ships as a “phased commitment,” but one must wonder if a cash-strapped government will really be able to order the rest.

The main investment decision is supposed take place around the end of 2014, and BAE is very focused on getting a contract in place before the May 2015 elections. Meanwhile, a potential “yes” vote in the September 2014 referendum on Scottish independence threatens to derail the contract entirely. Sources: Defense News, “New UK Frigate Proposals Coming Together”.

June 24/14: Sub-contractors. Imtech Marine announces that a contract from BAE Systems will supply the frigates’ complete low-voltage electrical distribution systems, and a climate control system that includes protection against chemical, biological, radioactive and nuclear threats (CBRN).

Imtech Marine’s HVAC specialised division Schiffbau-/Dockbautechnik will design, manufacture, install and test the HVAC system. For naval applications Imtech Marine has developed a standard switchboard IMAS design, which is capable of adaptation with respect to voltages of 440V/690V, current ratings up to 4000A/5000A, head height restrictions, maintenance access, internal partitioning/separation, tolerance to flooding, arc flash detection, tolerance to shock and vibration, EMI & EMC tolerance and emissions, CO2 injection ports and top and bottom cable entry. Britain’s Bay Class LSDs use it, and so will the new Queen Elizabeth Class aircraft carriers. Sources: Imtech Marine, “Imtech Marine selected by BAE Systems to provide key systems for the Type 26 Global Combat Ship Programme”.

CAMM-M launch
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June 6/14: Australia. Australia’s new Liberal government announces funding for initial studies around their 8-ship SEA 5000 future frigate program. The initial commitment is A$ 78.2 million, for design & engineering studies around installation of the CEAFAR/ CEAMOUNT radar faces and associated electrical & cooling systems, Saab’s 9LV combat system, and the RIM-162 Evolved Sea Sparrow [ESSM] – to be mounted on the same Navantia 7,000t hull used for the Hobart Class air defense destroyer.

That’s a very big ASW frigate, and that size introduces extra costs. If that remains the chosen approach, the Type 26 will be out of the running, but Australia has to be able to afford these choices. On which point, the Liberal Party government is also making serious threats about buying their ASW frigates abroad if ASC can’t improve its productivity, which the Minister says stands at 150 man-hours per tonne instead of the global benchmark of 60.

That leaves an opening, but the decisions here also introduce technical complications to a Type 26 bid. The CEAFAR/ CEAMOUNT active-array radar faces are very different from the rotating Type 997 Artisan that’s currently planned for the Type 26, and would require significant changes to the existing mast and superstructure. The 9LV is a very popular global combat system, and that might make it a good choice if Britain wants to export Type 26s, but it would add extra costs to integrate Britain’s chosen CAMM-M Sea Ceptor air defense missile. Likewise, Australia’s insistence on the RIM-162 ESSM requires the American Mk.41 vertical launch system, not the French SYLVER A50 on board the Type 45s. Adopting those would also be good for export prospects, but now the Type 26s can’t share the Type 45’s Aster-15 missile as a long-range air defense option. Each of these incompatibilities creates extra costs for someone. Read “Australia’s Future ASW Frigates: Warfare Down Under” for full coverage.

June 3/14: Sub-contractors. BAE Systems announces a 2nd set of sub-contractor awards for the Type 26 program (q.v. Sept 11/13 for the 1st set). The new members include:

• Babcock for the ship’s Air Weapons Handling System. they also do this for submarines.
  
• DCNS for work on the vessel’s propulsion shaftlines
  
• GE Energy Power Conversion for the Electric Propulsion Motor and Drive System
  
• Imtech for the Heating, Ventilation and Air Conditioning System, and the Low Voltage Electrical equipment
  
• Raytheon to develop the Integrated Navigation and Bridge Systems
  
• Tyco Fire & Integrated Solutions for the ship’s Fixed Firefighting Systems

BAE is expecting a manufacturing contract by the end of 2014, so they expect to sign on about 25 suppliers this year. Sources: BAE, “Type 26 Programme Welcomes New Suppliers On Board”.

Feb 7/14: Industrial. BAE’s preferred plan for the Type 26 project involves closing the Govan shipyard on the Clyde river once carrier and OPV construction ends in 2018, and investing about GBP 200 million to upgrade the Scotstoun yard in Glasgow as the sole GCS build facility. After comparing processes with 34 leading shipyards around the world, they’ve come to the conclusion that they need to be building by module, indoors, while using a number of techniques and technologies.

BAE Systems director of business and transformation Charlie Blakemore argues that Scotstoun requires more up-front work, but leaves the company with a more advanced facility that would allow speed production by 33%, and lower costs compared to a 2-shipyard build. The GBP 200 million investment’s centerpiece would be a 360 yard-long new dock hall capable of building 2 ships at once indoors. The investment would also create steelwork preparation & fabrication facilities, a paint cell, supporting offices and employee welfare facilities, and a quay. Construction would take place from 2015-2017.

In addition to lowering Type 26 costs, Blakemore also believes that the Scoutson plan would leave BAE in a better position to compete with modernized foreign shipyards for exports.

Plan B would invest GBP 100 million across both, and split shipbuilding between them, building partly in the open and moving completed sections between them by barge. Either plan uses the same number of workers, so the union is cautiously leaning toward the Scoutson plan. As GMB union steward John Dolanm reportedly put it: “If we stand still, we will fail in five years”. Sources: Herald Scotland, “Revealed: the £200m plan for a frigate factory on the Clyde” | BBC, “Govan shipyard likely to close in BAE revamp of Clyde facilities” | UPI, “BAE Systems seeks public comment on shipyard plans”.

Nov 6/13: Sea Change. BAE and the UK government agree on a big restructuring of military shipbuilding. The new agreement will replace the Terms of Business Agreement (ToBA) that restructured the sector (q.v. May 20/08, Oct 29/09), as a condition of the carrier contracts. This is just an agreement in principle, so far, but its outlines include changes to the CVF aircraft carrier program, designation of Glasgow shipyards as the site for Type 26 construction (barring a successful independence referendum), a government commitment to pay extra costs involved in shrinking the shipbuilding sector as a whole, and a bridge buy of OPVs.

The original agreement had made BAE responsible for financing slack shipbuilding periods, but if government delays to the Type 26 are the reason for the slack, industry argued that the government should pay. Rather than paying termination and industrial costs to keep the shipyard idle, the UK government is ordering 3 Ocean Class OPV vessels, for delivery by 2017. The River Class OPVs HMS Tyne, HMS Severn and HMS Mersey will probably be retired at the same time. The difference between the 2 classes? The larger Ocean Class adds a flight deck that can handle AW101 Merlin helicopters. Sources: BAE Systems, “UK Naval sector restructuring” | Royal Navy, “New ships for Royal Navy secure UK shipbuilding skills”.

Major shipbuilding restructuring

Nov 2/13: Industrial. BAE removes the dockside portal cranes at Govan shipyard, which sets of a lot of speculation and uncertainty about the shipyard’s future.

Industrially, the firm says the portal cranes haven’t been used for 5 years, as they’ve been replaced by better mobile cranes. The reason for all the nervousness is leaked reports that BAE is considering consolidation, including the closure of one shipyard. Sources: BBC, “Govan: A shipbuilding history” | BBC, “New fears for Govan shipyard’s future”.

MT30

Sept 11/13: Sub-contractors. BAE Systems announces the ship’s initial set of sub-contractors, but doesn’t offer specifics regarding the equipment.

The ship will use a CODOG (Combined Diesel Electric or Gas Turbine) propulsion system, with an MT30 turbine from design partner Rolls-Royce, unspecified MTU diesel generator sets, and a gear box via David Brown Gear Systems Ltd. The 36MW MT30 has already been picked for Britain’s new Queen Elizabeth Class aircraft carriers, so the choice creates future fleet commonality.

Rohde & Schwarz has been selected to design the Integrated Communications System. Sources: BAE, Sept 11/13 release | Defense News, “BAE Selects 4 Firms for Type 26 Frigate Program”.

Type 26, 2013
click for video

Sept 9/13: Lots of news. The Royal Navy unveils the latest concept design for their Type 26 frigate, as well as a short video concept. They confirm that the Type 26 will be 15m longer than the Duke Class at 148m, and add about 500 tonnes at 5,400t. Noticeable changes from the 2012 illustrations include centering the helicopter hangar rather than mounting it on the port side, and moving the mission module space from the stern to a space behind the helicopter hangar.

At the same time, BAE Systems tells Bloomberg that they are pursuing interest from 8 countries for up to 30 ships, including a new air defense variant that Britain isn’t planning to buy. They’ve been burned before by naming countries, however, and won’t offer any details. Supplier selection is underway, with detail design expected to begin in 2014, and construction in 2016.

The UK MoD makes the day a trifecta by signing a GBP 250 million production contract for the Sea Ceptor missile, and confirms that they’ll deploy it on Type 23 ships beginning in 2016. Their move will ensure that the missile will enter service aboard the Type 26 as a proven weapon, but the Type 26’s margin for error is slim: the Type 23s will retire between 2023 – 2026. Sources: Royal Navy, Sept 9/13 release | Bloomberg, “BAE Systems New Global Combat Ship Draws Export Buyer Interest” | DID: I Think I CAMM: Britain’s Versatile Air Defense Missile.

Latest design, Exports & a Missile buy

May 14/13: Mk-41 + MBDA. MBDA signs an MoU with Lockheed Martin to jointly explore the market for the integration of MBDA naval missile systems into Lockheed Martin’s MK-41 Vertical Launch System, and ExLS VLS/cell insert. They’ll begin with a late 2013 demonstration involving Britain’s new CAMM-M Sea Ceptor missile, which makes the Mk-41 system a possible inclusion on board Britain’s forthcoming Type 26 frigates.

That’s also the right move if Britain is positioning its ships for export, and MBDA + MK-41 is a pairing that has the potential to shake up the global naval missile industry. Read “CAMM Opener for the Naval Missile Market: MBDA & LMCO’s MoU” for full coverage.

Jan 18/13: Australia. Britain signs a defense cooperation treaty with Australia. The Type 26 frigate is explicitly discussed, along with broader areas cyber security, defense procurement reform, personnel exchanges, and science and technology generally.

Australia’s 2009 Defence White Paper includes a plan to buy 8 frigates with an anti-submarine focus, but construction isn’t expected to begin until late in the decade. Britain’s invitation includes possible design work, however, which could start earlier. UK MoD | Australian DoD | Joint press conference transcript.

2012

Basic design approved, without CEC. Turkish loss.

T26: 2012 design
(click to view full)

August 20/12: New Design Iteration. The Ministry of Defense and BAE release graphics of the latest Type 26 design from the Assessment phase. What this isn’t, is a detailed design, complete with a defined array of systems and weapons. It’s just the basic requirements and general characteristics – here’s what we know:

“With a basic displacement of around 5,400 tonnes, the Type 26 Global Combat Ship will be around 148m in length (the equivalent of around 15 double decker buses), and one of the most advanced vessels in the Royal Navy’s fleet. It is expected to feature: vertical missile silos capable of housing a range of different weapons; a Medium Calibre gun; a hangar to accommodate a Merlin or Wildcat Helicopter and a Flexible Mission Space for Unmanned Air, surface and underwater Vehicles, or additional boats; and the most advanced sensors available to the fleet.”

The big outstanding questions involve radars, the vertical launch system (which helps determine eligible missiles), the combat system, and secondary weapons. UK MoD | BAE Systems.

Basic design approved

July 5/12: No Portsmouth work? Portsmouth’s The News reports that BAE is leaning toward building the Type 26 frigates in Scotland, which could put thousands of local shipbuilding and sub-contractor jobs at risk, once Portsmouth’s sub-contracted work on Britain’s new carriers finishes around 2014. Apparently, the Portsmouth yard would require additional investment, while the Scottish yards would not.

BAE is said to be pushing for all 13 of the Type 26 frigates to be based in Portsmouth from 2020, which would boost its fleet repair and maintenance operations within the naval base.

June 11/12: No CEC. Speaking during question period in the House of Commons, Defence Secretary Philip Hammond said the Royal Navy had identified Co-operative engagement Capability as a “lesser priority” during the Planning Round 12 process, and decided not to spend around GBP 500 million to implement it on their 6 Daring Class destroyers and forthcoming Type 26 frigates. Media coverage criticized the decision, and the UK MoD’s blog responded that:

“The MoD’s comprehensive assessment of CEC informed the decision made during PR12 that it was not necessary to commit to purchasing the capability at this stage. As the Defence Secretary made clear last month, the MoD budget has headroom of £8bn over the next 10 years for potential new programmes. The Armed Forces Committee will prioritise which projects to commit to when necessary, and not before.”

The American CEC system gives fitted ships the ability to see what other CEC-equipped ships, aircraft, or land stations see, and to fire at targets the launching ship’s radars cannot see. It’s vital for wide-area anti-air defense, and for ballistic missile defense. That makes CEC more important to the Type 45 air defense destroyers, but its absence will push the Type 26 toward an international positioning as a mid-tier frigate, instead of a high-end ship. Daily Telegraph | Defence Management.

No CEC for British ships

May 21/12: Turkish loss. Turkey decides that the Type 26 project doesn’t meet its requirements for the $3 billion, 6-frigate TF-2000 program. Hurriyet Daily News:

“The Defense Ministry last month sent a letter informing their British counterparts that Turkey was “no longer interested” in BAE Systems’ offer, [said] an official familiar with the tender… “BAE has already started the [Type 26] project. It was late to join. Our needs would have increased the cost. Or we would have had to review our requirements in accordance with the British Navy, but our requirements are different. BAE had also asked for a ‘license fee.’ The partnership offer would have become a model in which Turkey was financing BAE’s project,” the source told the Daily News.”

The question is whether the remaining bidder, Lockheed Martin, can do any better. Turkey reportedly wants to take a frigate design, add Aselsan’s Multifunctional Phased Array Radar project (CAFRAD) to Lockheed’s AN/SPY-1 to create what would essentially be a new radar, and use Havelsan’s Genesis combat system from Turkey’s FFG-7 upgrade project instead of Lockheed Martin’s Aegis. Then they want all of this equipment to work with Raytheon’s SM-3 long-range ballistic missile defense missile, assuming that the USA agrees to sell that to them. Making all of these changes is a major development contract in itself. Tying them together so they work properly, and then testing them fully, is another expensive project. Integrating them with Turkey’s ship design is the 3rd project, and could also prove to be rather expensive if required fixes from the previous projects are too far beyond initial ship specifications for space, weight, or power. Time will tell if this is another example of Turkey’s wish lists being too big for their budgets, if negotiations will lead to compromises on the wish list, or if Turkey will give BAE another opening by backing off and re-thinking its program.

Turkey

May 17/12: Alba gu brath – but not shipbuilding. The Scottish National Party’s independence bid gets a setback, as procurement minister Peter Luff and the Prime Minister’s office tell union leaders that an independent Scotland won’t get any future warship contracts. Since Scotstoun, Govan and Rosyth only deal with military orders, and aren’t working on any export orders, that would be it. Confederation of Shipbuilding and Engineering Unions’ regional secretary, Kenny Jordan, estimates that up to 16,000 jobs are at risk in the Scottish defense industry and its local supply chain.

This is a matter of regulation as well as preference. Even if Britain changed its mind, and wanted to outsource shipbuilding work beyond its borders, EU article 346 would force them to bid that work at least across Europe. Those Scottish jobs are currently protected, because there’s an exemption that allows strategic defense projects to be kept in-country. Leaving the country would place Scotland beyond that exemption.

A Scottish decision to buy into the Type 26 program for its own navy could create a way out of the bind, by allowing negotiated work-sharing offsets. That would still be a far smaller share of work on the Type 26, and skills decay could complicate even that plan. If there’s much delay between independence and serious ship orders, the layoffs and exodus of skilled workers could leave the Scottish shipbuilding industry struggling to execute even a reduced role. Defence Management | The Scotsman.

April 10/12: Design. QinetiQ touts BAE’s use of its Paramarine advanced marine design software for the Type 26’s early stage design and structural development, as they work to model various configurations and estimate costs.

That may have something to do with the fact that UK MoD picked Paramarine as its chosen “stability software” some time ago, and uses it for certification. That pushed BAE to use it for the new Astute Class fast attack submarines, Type 45 air defense destroyers, and Britain’s CVF aircraft carrier programs, before they began using it for the Type 26.

2011

CAMM. Canada out? Prospects in Brazil, India?

CAMM-M/ Sea Ceptor
(click to view full)

Sept 13/11: FLAADS-M. MBDA touts recent milestones in its Future Local Area Air Defence System (FLAADS) program, whose CAMM missile will equip Type 26 and Type 23 frigates at sea (FLAADS-M), and also replace the Rapier missile system on land (FLAADS-L).

FLAADS’ Command and Control system currently involves >75% re-use of Sea Viper software from the Type 45 destroyer, and the Platform Data Link is undergoing trials at MBDA. The CAMM missile’s “soft vertical launch” concept has worked in trials, including a successful ejection and turnover trial at Bedfordshire on May 20/11. Finally, MBDA touts “significant progress” with the CAMM radar seeker in air carry trials. Read “I Think I CAMM: Britain’s Versatile Air Defense Missile” for full coverage.

CAMM missiles

Sept 5/11: Requirements. UK magazine The Engineer discusses the process underway to define the Type 26 and its systems. Brian Johnson of BAE surface Ships says that “the requirement specifies eight ships capable of ASW and five ships equipped for more general duties,” with the first few British ships receiving systems from the current fleet of Type 23s, as a way to lower costs and risks. The timeline involved means that some of this “legacy equipment” hasn’t even been installed on the Type 23s yet, during their planned refits and upgrades.

Right now, about 200 engineers and other personnel are working on capability tradeoffs and fine-tuning design, in anticipation of a Capability Decision Point scheduled for November 2011.

Aug 11/11: India. Could India be interested in the Type 26? Their current and planned frigate projects are all Russian designs, but India’s Project 17-A, and Britain’s budget squeeze, might create an opening. Pitches to Brazil and India are showing a common theme: invitations to be part of the ship’s design phase.

“BAE Systems has described to Business Standard how Whitehall envisages the designing and building of the GCS. The countries that eventually form the consortium would join heads to frame broadly common specifications for the warship. Presently, the GCS is planned as a flexi-role frigate. This means each vessel could be optimised for any one of the three traditional frigate roles: anti-submarine, air defence or general-purpose. To cater for these different roles and the different requirements of participating countries, the basic GCS design would have 80 per cent commonality in design and components, with 20 per cent remaining flexible.”

See: India’s Business Standard | Think Defence.

March 6/11: Canada. Jay Paxton, a spokesman for Defence Minister Peter MacKay in Canada’s current Conservative Party minority government, is quoted as saying that:

“Canada will not be pursuing collaboration with the United Kingdom on our new surface combatant fleet.”

This comes after a long set of political questions and industry lobbying by Canada’s shipbuilders, triggered by British admissions that talks were taking place. Soon after this announcement, the government fell on a no-confidence motion, triggering an election that gave the Conservative Party a Parliamentary majority. That could give the government the freedom to re-consider. Or, it could simply set their earlier position in stone. CTV News | Defence IQ | Ottawa Citizen.

Canada out?

Feb 6/11: Brazil. MercoPress refers to Brazilian and British media reports that a GBP 2.9 billion deal (about 7.85 billion Reals, or $4.68 billion) may be about to buy 6 Offshore Patrol Vessels at GBP 60-80 million each, and 5-6 Type 26 frigates at GB 300-400 million each. While the new Rousseff administration is reviewing both the F-X2 fighter purchase and naval plans, the paper cites Brazil’s growing deepwater oil production as a compelling driver for the Marinha do Brazil. MercoPress adds that:

“The articles mention that according to the agreement with BAE Systems and following on Brazilian policy of ‘technology transfer’ the first patrol and frigate units would be built in the UK and the rest in Brazilian yards… Developed countries are most aware of defence dynamics in Brazil since the country’s long term policy is to increase defence expenditure from the current 1.5% of GDP to 2% of GDP by 2030. Since the country’s economy is forecasted to grow a sustained 5% in the coming decades, defence investments will also expand strongly. With a nominal Brazilian GDP of 1.57 trillion US dollars, – IMF figures – if defence expenditure was now 2.2% of GDP, it would represent 34 billion USD.”

See also UPI.

Jan 31/11: Canada. U.K. Defence Minister Gerald Howarth responds to Parliamentary questions by saying:

“I am delighted to say that we are in close discussion with the Canadians [regarding the Type 26]. My right hon. Friend the Secretary of State has just returned from an extremely profitable visit to Malaysia, Australia, New Zealand and Turkey. All those countries have expressed interest in joining the United Kingdom in a collaborative programme that would have the benefit of bringing together not only members of the Commonwealth but some of our key allies, while also driving down costs for the Royal Navy.”

Both Canada and Australia have plans for a “future frigate” competition in their 20-year defense procurement strategies, and BAE can expect strong competition on both fronts. Canada may be a better bet than Australia, where Spain’s Navantia has established a very strong foothold with its current Hobart Class destroyer and Canberra Class LHD programs. UK Hansard transcripts | Defense News.

2010

Assessment phase, requirements.

T26: original concept
(click to view full)

Nov 29/10: Requirements. Rumors surface that the UK government is looking to sharply slash target costs for the Type 26 frigates, from GBP 500 million to GBP 250-350 million ($400 – 550 million), in order to field a large enough Royal Navy fleet.

If the project is properly managed, and British shipyards can be cost-competitive, global precedents suggest that this is still enough to field a capable multi-role frigate. The question is what capabilities get removed, or become options that the frigates are fitted “for, but not with.” The latter approach has been popular in Britain, but it has resulted in expensive ships that lack key capabilities – such as the lack of anti-ship missiles on the Navy’s billion-pound Type 45 destroyers. The Scotsman | Reuters

Oct 26/10: Brazil bid. BAE Systems submits a detailed proposal to the Brazilian Navy for an 11-ship fleet renewal package that include Type 26 frigates, but goes beyond. They are certain to face competition from shipbuilders like France’s DCNS (FREMM/ Gowind), and possibly other competitors like Spain’s Navantia (F100), Royal Dutch Schelde (Sigma), and even South Korea’s Daewoo.

In addition to having Brazil join the Global Combat Ship (Type 26/27) program at the design stage, BAE’s proposal would supply a modified Wave Class fleet tanker and a variant of BAE’s River Class Ocean Patrol Vessel that’s similar to ships being built under technology transfer in Thailand. All ships would be built in Brazil, and BAE Systems Surface Ships division Managing Director, Alan Johnston says that:

“We are in discussions regarding the naval proposal with a number of potential industry partners in Brazil, including shipyards and combat systems developers… and will provide further details in due course.”

See: BAE Systems | Southern Daily Echo.

Sept 14/10: Brazil. Britain and Brazil sign a Defence Cooperation Agreement, which includes an “assured warship procurement package” of BAE Systems’ Type 26/GCS frigates and its 90m blue-water Ocean Patrol Vessels. If Brazil joins early, they can even influence the Type 26/27’s design. BAE Systems’ Managing Director for the West, Dean McCumiskey:

“This [package] is based on proven and versatile ship designs and includes an invitation to become an international partner in our new Global Combat Ship programme. If BAE Systems is selected to support Brazil’s ambitious naval re-equipment programme, the ships we develop will be built at a partner shipyard in Brazil, with maximum content sourced from the wider Brazilian industry.”

The opportunity to provide maintenance etc. for the ships’ 20-30 year lifespan might be even more significant than the order itself. BAE can expect competition from DCNS’ FREMM frigates first and foremost, as well as other contenders like the Dutch Sigma family, Korea’s shipbuilders, et. al. The fact that all of Brazil’s current frigates are British designs (6 Niteroi Class, 3 Type 22) may work in BAE’s favor. UK MoD | BAE Systems | Andover Advertiser | Financial Times |Reuters.

March 25/10: The UK Ministry of Defence signs a 4-year, GBP 127 million contract with BAE Systems, to conduct the Type 26’s Assessment Phase. A team led by BAE Systems Surface Ships, working with the MOD, will consider requirements and design proposals for the new multi-role frigates. An 80 strong joint MOD and BAE Systems team has already been established out of Bristol and this will rise to 300 over the next 4 years.

Britain’s First Sea Lord, Admiral Sir Mark Stanhope:

“These programme announcements are welcome news for the Royal Navy. You simply cannot have an effective Navy without capable frigates, and the Type 26 combat ship will form the future backbone of the Royal Navy’s surface combatant force, alongside the new Type 45 destroyers. These ships will be highly versatile, able to operate across the full spectrum of operations, from war-fighting to disaster relief.”

See: UK MoD | BAE Systems | BBC

Type 26 Assessment Phase

Additional Readings

Readers with corrections, comments, or information to contribute are encouraged to contact DID’s Founding Editor, Joe Katzman. We understand the industry – you will only be publicly recognized if you tell us that it’s OK to do so.

Background: The GCS

• Royal Navy – Type 26

• Naval Technology – Type 26 Global Combat Ship (GCS) Programme, United Kingdom

• UK MoD Defence Equipment & Support, via WayBack – Naval Design Partnering Team

• Information Dissemination (Sept 22/09) – Future Surface Combatant at DSEi 2009

Background: Ancillary Equipment

• Rolls Royce – MT30 Marine gas turbine engine. Will also be featured on Britain’s new aircraft carriers.

• BAE Systems – Artisan 3D Medium Range Radar Type 997 and YouTube video. Will also be featured on upgraded Royal Navy Type 23 frigates, and on their new aircraft carriers. Artisan isn’t confirmed for the Type 26 yet, but illustrations all show it, and its presence on the Type 23 makes it a near-lock.

• DID – I Think I CAMM: Britain’s Versatile Air Defense Missile

• QinetiQ – Paramarine. Advanced marine design software.

Background: Related Ships & Equipment

• Royal Navy, via National Archive – The Future Navy [PDF]. Long-term vision as of 2008.

• Royal Navy – Type 23 Frigates

• Royal Navy, via WayBack – Type 22 Frigates. Now retired.

Naval Doctrine

• Project Gutenberg – Some Principles of Naval Strategy. Sir Julian Corbett’s classic masterpiece.

• Information Dissemination – May 10th, 2019: Missing Nelsons Cruisers. For those who might think that the principles of Nelson’s time are no longer relevant today.

News & Views

• The Engineer, via WayBack (Sept 5/11) – Designing the Type 26 Frigate.

• RUSI, via WayBack (October 2010) – A Global Role for the Global Combat Ship? [PDF].

• The Faster Times, via WayBack (Oct 4-27/10) – BRIC Military Modernization and the New Global Defense Balance. (Part 1 | Part 2).

• RUSI, via WayBack (October 2007) – The Shape of the Future Surface Combatant [PDF].

tag: t26, ukfrigates

Americas

• The Navy is ordering more fire power from BAE Systems. The company is being awarded a contract modification to a previous firm-fixed-price delivery order valued at $224,3 million. The modification provides for the production and delivery of an additional 10,185 Advanced Precision Kill Weapon Systems II (APKWS II). The APKWS program has been devised to give the Hydra 70mm rocket family a new lease of life by converting these ubiquitous rockets into cheap laser-guided precision weapons. The procurement of the additional units will upgrade the current 2.75-inch rocket system to a semi-active laser-guided precision weapon in support of the Air Force, Army, and foreign military sales (FMS) customers. This modification combines purchases for the Air Force ($144,1 million), Army ($58,5 million); Navy ($17,1 million); and FMS ($4,4 million). Work will be performed in Hudson, New Hampshire (70 percent); and Austin, Texas (30 percent), and is expected to be completed in March 2019.

• Raytheon is being tapped to support the Navy’s fleet of EA-18G Airborne Electronic Attack aircraft. The $65,4 million indefinite-delivery/indefinite-quantity contract provides for systems engineering and software development services of the aircrafts ALQ-227 communications countermeasures set. At present, the EA-18G is slated to be the only dedicated electronic warfare aircraft in the USA’s future force. The EA-18 shares a 90% commonality with the standard F/A-18F Super Hornet, sharing its airframe, radar, stores management system and weapon options. The exception is the Super Hornet’s 20mm Vulcan Gatling gun, which has been removed from the nose in favor of electrical equipment. The AN/ALQ-227 communication countermeasures system uses a dedicated, omni-directional antenna for signals detection, analysis, and recording. That system works with the plane’s jamming, in order to perform complex jamming tasks. Work will be performed in Fort Wayne, Indiana, and is expected to be completed in June 2023.

• Superior Forge and Steel is being tapped to produce a number of BLU-137/B bombs. The $476,9 million ceiling indefinite/delivery indefinite-quantity contract provides for the production of the BLU-137/B penetrator warhead bodies with a guaranteed production of 300 bodies during the first year with a possibility of up to 3,500 bodies in the subsequent four years. In development since at least 2015, there aren’t a lot of details about the BLU-137/B or its features. An Air Force FY2018 request added the following statement, “the BLU-137 will increase fuse survivability when used against bunkers, aircraft shelters, and reinforced targets.” In short, this new model will more reliability explode after punching through its target. Work will be performed in Lima, Ohio; Cincinnati, Ohio; and Falconer, New York, and is expected to be completed by May 2020.

Middle East & Africa

• The government of Kuwait is set to receive a boost to its aircraft fleet as part of a US foreign military sale. Boeing will produce 22 F/A-18E and six F/A-18F Super Hornets in support of the middle-eastern nation. The fixed-price-incentive-firm contract is valued at $1.5 billion. The F/A-18E is a single-seat Super Hornet. The 2-seat F/A-18F sacrifices some range, carrying only 13,350 lb. – 900 fewer pounds than the F/A-18E. In exchange for this reduced range, it adds a 2nd crewman with an advanced attack station cockpit to assist in strike roles. Work will be performed at multiple locations, including El Segundo, California; Hazelwood, Missouri; Endicott, New York, and various locations outside the continental US. Work is expected to be completed in January 2021.

Europe

• Swedish defense manufacturer Saab is set to deliver more of units of its multi-role naval radar Sea Giraffe AMB to an undisclosed customer. The company announced that work for the initial phase of the contract will be carried out during the period of 2018-2019 and that there is also an option for the delivery of 10 additional Sea Giraffe AMBs. The Sea Giraffe AMB is a medium range, multi-role surveillance radar optimized for detecting small air and surface targets with high update rate in all kinds of environments, including the littorals. It assists the commander in all kind of naval warfare and give the operators maximum time to react to incoming threats. The system is optimized for, and is in service on, vessels such as the Swedish Visby Class corvette and the US Littoral Combat Ship Independence class. Saab has sold Sea Giraffe in various configurations to customers around the world, including Sweden, Poland and the US.

• Embraer is reportedly on the verge of completing a deal with Portugal confirming the country as the first export customer for the KC-390 tanker transport. It comes just over a year after Portugal opened negotiations to buy five KC-390s, with an option for a sixth, with deliveries starting in 2021. The KC-390 is Brazils bid for the global C-130 replacement market. Competing against the C-130J, A400M, Russia’s AN-12 and China’s Yun-8/9. Embraer reportedly bases its business case on a break-even point of 120 orders, or about 1/7th of the tactical transport market outside of China, Russia, Ukraine and the USA. Four nations originally committed to the military aircraft, which flew for the first time in 2015. However, progress with Argentina, the Czech Republic and Chile appears to have stalled. It remains to be seen if the upcoming sale to Portugal will boost Embraer’s export efforts.

• The UK Royal Air Force will soon take delivery of its first MQ-9B SkyGuardian, which will form the basis of the UK’s future Protector RPAS. The MQ-9B SkyGuardian medium-altitude, long-endurance remotely-piloted air system is a version of General Atomics’ Predator B. The aircraft has been developed under a company-funded effort to address the strict airworthiness type-certification requirements of different military and civil authorities. In May last year, MQ-9B SkyGuardian set a 48-hour continuous flight endurance record for the company’s Predator aircraft series. RAF operations with at least 20 Protector RG1s are due to commence during the 2020s. The platform will replace the service’s current armed Reapers.

Asia-Pacific

• The government of Australia is looking into the purchase of equipment associated with the integration of the CEAFAR 2 Phased Array Radar System with the AEGIS Combat System. The potential foreign military sale is valued at $185 million. CEAFAR is a 4th generation S-band active phased array radar, and it’s designed to be supplemented with the X-band CEAMOUNT Solid State Continuous Wave Illuminator. The combined system of radar, illuminator and central equipment group of power supplies etc. is able to generate and continuously maintain more than 10 simultaneous fire control channels. According to the DSCA, the proposed sale will enhance Australia’s Surface Combatant capability by adding nine AEGIS capable Future Frigates over the next 20 years and by upgrading their existing three AEGIS capable Hobart Class destroyers with the latest technology and capability. This sale enhances Australia’s self-defense capability, while significantly improving interoperability with US Navy AEGIS combatants in the region.

Today’s Video

• Celebrating 50 years of C-5 Galaxy

KC-390 refuels AMXs
(click to view full)

Global competition in the 20-ton air transport segment continues to intensify, with Brazil’s launch of its KC-390 program. Embraer figures reportedly place the global C-130 replacement market at around 700 aircraft. In response, it will develop a jet-powered rival to compete with Lockheed Martin’s C-130J, the larger Airbus A400M, Russia’s AN-12 and its Chinese copy the Yun-8/9, and the bi-national Irkut/HAL MRTA project. Smaller aircraft like the EADS-CASA C-295M, and Alenia’s C-27J, represent indirect competition.

Embraer is extending its efforts and markets by crafting a jet-powered medium transport with a cargo capacity of around 23 tons, that can be refueled in the air, and can provide refueling services to other aircraft by adding dedicated pods. The KC-390 has now become a multinational program, and may be shaping up as the C-130’s most formidable future competitor. A tie-up with Boeing underscores the seriousness of Embraer’s effort, which is now a production program…

The KC-390: Program

KC-390 schedule, 2010
(click to view full)

Brazil’s aerospace industry has made impressive global gains in the civilian business and regional jet segments, and in the military market for primary trainer and counterinsurgency aircraft. Slumping civilian demand recently led to layoffs, but rising Brazilian defense budgets give the government a lever to inject funds into the company, while completing a strategic project that has been under consideration for a couple of years.

Overall, Embraer reportedly bases its business case on a break-even point of 120 orders, or about 1/7th of the tactical transport market outside of China, Russia, Ukraine and the USA.

The initial Brazilian contract covered R&D, and called for 3 development aircraft, with a 28 plane production order to follow. Brazil has held to that, which will allow the KC-390 to restore an existing FAB shortfall and replace the Brazilian Air Force’s 21 C-130E/H and 2 KC-130H Hercules planes. The FAB flew 10 aged DHC-5 Buffalo tactical transports for many years, but had to replace them recently with C295s from Airbus Military. The C295s are very useful for smaller cargo loads, but they have limits as tactical airlifters, so the added KC-390s will fully restore the FAB’s status quo ante.

To date, possible orders stand at 60, including Brazil’s confirmed 28, plus possible orders from Argentina (6), Chile (6), Colombia (12), the Czech Republic (2), and Portugal (6). South Africa’s cancellation of its A400M order may create another opportunity, and Brazil’s F-X-2 fighter competition may lead to even more European orders. Sweden promised to consider the KC-390 to replace its recently-upgraded C-130s with the KC-390 if the JAS-39 Gripen won, and so it will probably become Sweden’s next airlifter at some point.

Embarer’s boast that it has 32 Letters of Intent from various countries indicate that this customer list could grow quickly. Note, however, that there aren’t any formal contracts yet for these export orders. Until prospective orders turn into firm contracts, relying on any numerical commitments is premature.

Meanwhile, development continues on an aggressive schedule. The first prototypes are expected to fly by the end of 2014, with acceptance by Brazil’s air force beginning in 2016.

The aircraft design itself will belong to the Brazilian government, with Embraer as the lead technical and industrial partner. All talks to join the program will be conducted at a government-to-government level, and the process of adding “risk sharing” partners will be a top-down process that results in directives handed down to Embraer.

Note that this kind of arrangement can create program risks, and obstacles to an aggressive schedule, if the partners selected by the Brazilian government fail to perform on an industrial level. Joint Definition Phase partnerships & commitments to date include:

The KC-390: Aircraft

Initial dimensions
(click to view full)

The C-390 was originally supposed to be a militarized ERJ-190 jet that competed in a unique niche between EADS-CASA’s C-295M and Lockheed Martin’s C-130 Hercules, with Brazil’s postal service as its launch customer. The more the engineers worked, the more it diverged from that idea, until it assumed it present T-tailed, high-winged, hump-backed form as a full military aircraft and C-130 competitor.

Compared to a stretched C-130J-30, the renamed KC-390’s cargo compartment is now 17.75m long (vs. 16.9m) and 3.45m wide (vs 3.12m); 2.9m high forward of the wing (vs 2.74m) and 3.2m aft of the wing. The KC-390’s wings were lengthened to 35.03m during the configuration phase, in order to allow helicopter refueling at speeds around 120 kt. With the right engines, the Force Aerea Braziliera (FAB) has confirmed that each aircraft will carry up to 80 troops, or a 23.0 tonne/ 25+ ton total cargo load. That surpasses initial expectations of 19t, and places it slightly above competitors like Lockheed Martin’s C-130J (21.8t).

The airplane will incorporate a modern, night-vision compatible Pro Line Fusion avionics system, including 2 Head-Up Displays (HUD), and will use fly-by-wire technologies instead of all-mechanical control systems.

KC-390 range
(click to view full)

The most unusual feature in current mockups may be a movable pressure bulkhead that retracts into the roof and descends to seal the cargo cabin. While it shortens the cabin from 17.75m to to 12.78m when deployed, it could allow high altitude airdrops from the space behind, without depressurizing the entire cabin. In order to improve airdrop accuracy, the KC-390 will use Computed Air Release Point (CARP) technology integrated with the fly-by-wire system.

As the aircraft grew, its thrust requirement grew beyond the 27,000 pound class. Embraer eventually picked the International Aero Engines joint venture’s V2500-E5, which can supply up to 31,330 pounds of thrust. It beat GE/Safran’s CFM56-5B, which competes with IAE to power many Airbus narrowbody passenger jets.

A complete self-protection system will also be fitted, and Elbit’s AEL has been announced as the key supplier. Other firms may also become involved in supplying warning elements and decoys, to integrate with AEL’s SPS controller and DIRCM.

Contracts and Key Events 2014 – 2018

Core production contract from Brazil and significant funds released; KC-390 Rollout; 32 Letters of Intent?; Argentina finally ready to produce parts.

Embraer re: KC-390

June 29/18: Export to Portugal Embraer is reportedly on the verge of completing a deal with Portugal confirming the country as the first export customer for the KC-390 tanker transport. It comes just over a year after Portugal opened negotiations to buy five KC-390s, with an option for a sixth, with deliveries starting in 2021. The KC-390 is Brazils bid for the global C-130 replacement market. Competing against the C-130J, A400M, Russia’s AN-12 and China’s Yun-8/9. Embraer reportedly bases its business case on a break-even point of 120 orders, or about 1/7th of the tactical transport market outside of China, Russia, Ukraine and the USA. Four nations originally committed to the military aircraft, which flew for the first time in 2015. However, progress with Argentina, the Czech Republic and Chile appears to have stalled. It remains to be seen if the upcoming sale to Portugal will boost Embraer’s export efforts.

April 30/18: BAF delivery update Brazilian airframer Embraer told journalists at a recent earnings call that first deliveries of its KC-390 military airlifter to the Brazilian Air Force (BAF) will take place “closer to end of the year.” The announcement was a forecast update which had been previously scheduled for mid-2018. A slowdown in defense spending by the Brazilian government—the aircraft’s flagship customer—due to a slowing economy had already caused the program to be delayed by two years.

April 6/18: Chilean airshow debut Embraer’s KC-390 tanker-transport prototype that recently returned to testing following an earlier test mishap has featured at the FIDAE air show in Santiago, Chile. The debut appearance in Chile comes eight years after the Chilean government committed to the KC-390 program, however, only Portugal has so far moved forward with plans to buy the aircraft. According to Flight Global, Gen Lorenzo Villalón Del Fierro, chief of the general staff of the Chilean air force, declined to answer any questions about fixed-wing aviation procurements during FIDAE. Damaged during a slow-speed stall test, the prototype had its aerodynamic wing-to-body fairing and the fuel sponsons on the fuselage replaced, returning to service last month.

March 9/18: Prototype returns Flight Global has reported that Embraer’s first KC-390 prototype has returned to flight testing after an accident during a stall test last October put the transport/refueler out of action for several months. A company statement at the time of the crash said that the twinjet “experienced an event beyond the planned limit” while conducting a simulated icing test, which took the aircraft beyond its airspeed and load factor operating limitations. Damage sustained resulted in the plane’s external fairings and access hatches being replaced, with the unexpected additional costs for flight testing the new aircraft resulting in Embraer missing its 2017 profit targets.

February 7/18: Orders-LOA The Singapore airshow has seen Brazilian airframer Embraer sign a letter of intent to sell six KC-390 airlifters to aviation services firm SkyTech. SkyTech is a tie-up between HiFly—an aircraft, complete crew, maintenance, and insurance (ACMI) firm from Portugal—and Adagold Aviation—an Australian aviation services and charter provider—who has had experience in the military charters market by supporting the Australian Defence Force efforts in the Middle East. During this contract, Adagold sub-contracted HiFly to perform this work with an Airbus A340.

December 22/17: Milestone-IOC Embraer’s KC-390 multi-mission transport aircraft has achieved Initial Operational Capability (IOC) from the Brazillian Air Force (BAF). The Milestone, announced by the firm on Wednesday, was achieved following the successful completion of a certification campaign that saw two prototypes accumulate over 1,500 flight hours and more than 40,000 hours of laboratory testing of the aircraft’s various systems. Brazil’s National Civil Aviation Agency (ANAC)—who awarded the tanker its IOC—is expected to issue final Type Certification in 2018, and the aircraft will undergo additional in-flight tests of various military functionalities including the remaining aerial refueling and cargo dropping tests, to fulfill the requirements to receive the final military certification of the aircraft with the achievement of the Final Operational Capability (FOC), followed by deliveries to the BAF.

December 12/17: Testing A 20-person team from Embraer arrived December 4 at an airport in Scottsbluff County, Nebraska in order to conduct cross-wind landing testing on its KC-390 military transport aircraft. Testing was initially scheduled to take place in Texas but weather in the area at the time did not have adequate wind. Instead, Denver International Airport officials referred the team to Scottsbluff, where local winds apparently have been brisk enough for testing the jet’s handling in wind and crosswind. Brazilian manufacturer Embraer brought the KC-390 to its US facility in Jackson, Florida, in November as part of its flight test campaign for certification. A declaration of Initial Operational Capability (IOC) is expected by the end of the year, with first deliveries to commence in 2018.

November 22/17: Testing Embraer’s KC-390 has flown from its test centre in the Brazilian interior to its US base in Jacksonville, Florida ahead of flight tests required for its certification. The dual-role tanker transport aircraft to make the trip is the second of two prototype’s built by Embraer as part of a 30-unit order for the Brazilian Air Force, as the first prototype undergoes minor repairs following a stall speed test incident in early October. Testing to be carried out in Florida includes evaluating avionics systems, crosswind operations and external noise. So far, the KC-390 test fleet has accumulated 1,450 flight test hours since the first example achieved first flight nearly three years ago. Alongside Brazil, Portugal is planning an acquisition of five KC-390s, with an option for a sixth, while Argentina, Chile, Colombia and the Czech Republic have expressed interest in buying a combined 26 more.

November 14/17: Testing Embraer’s KC-390 prototype is scheduled to resume flight testing after receiving minor repairs following a stall speed incident in October. The Brazilian firm said the model, 001, “experienced an event beyond the planned limit” during a simulated icing test, which took the tanker beyond its airspeed and load factor operating limitations and required crew to return immediately to base. The aircraft has not flown since. A detailed inspection carried out by Embraer found that the incident caused no damage to the primary aircraft structure, although some external fairings and access hatches will be replaced before the aircraft returns to the sky. It added that deliveries to the Brazilian air force will not be effected.

November 10/17: Repairs Embraer’s first KC-390 prototype has temporarily stopped flying after stall tests conducted last month pushed the military transporter beyond its operational limits. While no work is needed on the “primary aircraft structure,” the firm does need to repair some of the aircraft’s access hatches and aerodynamic fairings before the resumption of flights. It assured that the incident would not effect the KC-390’s certification schedule and is on course to enter service next year. While Embraer did not address the cause of the test-flight incident, Brazilian trade publication Aero Magazine reported that test equipment inside the plane had come loose during a maneuver, throwing off its center of gravity, according to an unnamed engineer involved in the project.

October 25/17: The crew testing an Embraer KC-390 prototype aircraft had to request an early return to base after completing stall tests on the aircraft. Conducted on October 12, the routine test was part of Embraer’s flight certification efforts for the KC-390 ahead of deliveries next year, however, during the flight, decreased lift force caused an altitude loss that would prematurely call the KC-390 crew back to the firm’s manufacturing and flight test centre at Gavião Peixoto, Brazil. No further details on the incident were given. The tactical transport and tanker aircraft is expected to enter service with the Brazilian Air Force in 2018 with Brasilia expected to receive a total of 28 units.

July 31/17: Portugal’s Council of Ministers has given its Defense Ministry the go ahead to commence negotiations for the purchase of five KC-390 multi-role tanker transport (MRTT) aircraft from Brazil’s Embraer. The ministry will now form a negotiation team with representatives appointed by the Minister of Finance, Of Science, Technology and Higher Education and by the Minister of Economy, for what could be the first foreign sale of the KC-390 after Brazil placed an order for 28 in 2014. In an effort to boost foreign interest in the tanker, Embraer recently completed a 40 day global demonstration tour, visiting 19 prospective markets in Asia, Africa and Europe.

June 19/17: Embraer has commenced a 40-day international sales tour with its KC-390 tanker/transport plane, first stopping in Sweden before debuting the aircraft at the upcoming Paris air show. The company will first perform some demonstration flights for the Swedish military, as the company looks to sell the aircraft to Stockholm as a potential future replacement for its Lockheed Martin C-130H tactical transports. After Paris, the aircraft will stop off at a number of undisclosed European locations before making its way to New Zealand, where the aircraft is being looked at as a potential transport and maritime patrol platform, before returning to Brazil via stops in southeast Asia and north Africa.

June 12/17: The Portuguese government has commenced talks with aerospace manufacturer Embraer for the delivery of at least five KC-390 military transports. Discussions over configuration, price and delivery schedule are expected to be completed within the next three months and will include options for Lisbon to purchase an additional aircraft. Also included in the deal is a full flight simulator, spares, and other support services. Portugal has been one of five tentative buyers for the KC-390, but a 2015 air force modernisation programme for its six Lockheed Martin C-130 Hercules aircraft, looked to put the new acquisition in possible doubt.

April 17/17: Korea Aerospace Industries (KAI) has won a $378 million contract to supply parts for Embraer’s E2 and KC-390 programs. Under the agreement, which is scheduled to last until 2033, KAI will supply wing bottom panels for the E-190 E2 and E-195 E2 regional jets, and panels for both top and bottom of the KC-390 tactical airlifter. Separately, the firm announced that it has completed delivery of all 20 KT-1P basic trainer aircraft ordered by the Peruvian air force.

March 12/17: The Portuguese government is considering the procurement of Embraer KC-390 transport aircraft as a replacement for their fleet of C-130s. While no formal order is in place as of yet, the plan is to acquire up to six KC-390s to progressively replace the C-130 to conduct troop and cargo transport, firefighting, and air-to-air refuelling missions in the Portuguese Air Force. Several Portuguese companies, including OGMA-Indústria Aeronáutica de Portugal (partially owned by Embraer), Embraer Metálicas, Embraer Compósitos, and CEiiA, are participants in Embraer’s KC-390 program.

February 22/17: Embraer has announced that their KC-390 tanker transport aircraft has completed its first dry refueling contact. The milestone test was conducted by a Brazilian Air Force F-5 Tiger which successfully plugged into both refueling hoses on one of the KC-390 prototypes during a sortie near Santa Cruz airbase, Rio de Janeiro, on Feb. 19. Embraer is currently assembling the first product model of the aircraft and believes the aircraft could be a good fit for air arms in the Middle East because of its multi-role capability. The company plans to bring the aircraft back to the Middle East next summer after it has been displayed at the Paris Airshow.

July 19/16: Following its debut at the Farnborough Air Show last week, Embraer’s KC-390 tanker/transport aircraft is to embark on a worldwide demonstration tour. The specifics of the tour stop offs have not been revealed, although interested parties include the Czech Republic and three stops in Europe, the Middle East and North Africa. The Brazilian Air Force will induct the KC-390 in 2018.

May 3/16: Embraer’s second and final test aircraft of its KC-390 program has made its maiden flight test with the company optimistic that it’s sale of 32 of the transport-tankers to Brazil will continue. Brazil, the aircraft’s only confirmed purchaser, is in the midst of political turmoil caused by a mass corruption scandal and slow economy. Further more, a decrease in government spending resulted in payments to Embraer ceasing for several months in 2015, denying the program $300 million in unpaid bills. Both parties have, however, now come to an agreement to continue payments and pay off the balance over the next four years.

April 19/16: Germany’s Rheinmetall has been selected by Embraer to provide a training system for its new KC-390 transport aircraft. The deal is expected to exceed $112 million, and will see the company provide a full suite of training equipment over a 10-15 year period. Drawing upon its experience in providing the cargo hold simulator for the Airbus A400M, Rheinmetall’s scope will include training for cargo handling, procedures and maintenance, plus flight and mission training.

April 11/16: A decision on the replacement of Portugal’s C-130 fleet is expected to be made soon, with Embraer’s latest KC-390 a likely option. The comments were made by defense minister, Azeredo Lopes, after a visit to the Brazilian company’s two Portuguese plants in Evora, where parts for the heavy-lifter are manufactured. Lopes added that despite recent NATO standard modernizations to the C-130 fleet, the planes only had about ten years left before retirement. If Embraer get the go ahead, they will provide up to six KC-390s to Portugal.

April 1/16: Embraer has announced that their KC-390 cargo aircraft is now back on schedule, after delays last year ran the risk of affecting potential customers. A direct challenge to Lockheed Martin’s Hercules, the KC-390 promises capabilities to fly higher, fuller, and faster, at a lower price than its competitor. Customers for the Brazillian airlifter include 28 contracts to deliver the KC-390 to Brazil, and 32 “letters of intention” with other countries, including South American neighbors Chile, Argentina and Portugal.

October 29/15: Embraer’s KC-390 transport aircraft has resumed flight testing following an eight-month break, forced on the program by a falling Brazilian Real and slow payments to the company by the Brazilian Defense Ministry. The aircraft’s schedule has been pushed back, with the company signing an agreement in late July to extend the KC-390’s entry into service from late 2016 to 2018.

Aug 3/15: Brazilian flagship firm Embraer has been hit heavily by a falling real and defense sector cuts, downsizing its 2015 revenue forecast by $300 million. The delivery of first KC-390 transport aircraft to the Brazilian Air Force (FAB) has been pushed back by eighteen months, to the first half of 2018. Certification is now scheduled for the latter half of 2017, with the tactical transport/tanker registering its first test flight in February.

Oct 21/14: Rollout. Embraer rolls out the 1st of 2 KC-390 testing prototypes during a ceremony at its Gaviao Peixoto plant. The event was attended by the Brazilian Minister of Defense, the Commander of the Brazilian Air Force,, and delegations and representatives from more than 30 countries. Looks like the statements about widespread Letters of Intent (q.v. May 21/14) were on the money, though even this turnout is just 30 of the claimed 32.

Next steps: initial systems evaluations before the 1st engine run, then ground vibration tests and the other planned ground tests en route to 1st flight. Sources: Embraer, “Embraer rolls out KC-390 military airlift”.

Rollout

Oct 1/14: Brazil’s COPAC has approved $1.926 billion for Embraer to buy materials and begin production of 28 KC-390s (q.v. May 21/14, part of a BRL 7.2B / $3.26B deal), with funds released according to the physical and financial schedule of the contract, effective until 2026. COPAC chair Air Brigadier Jose Augusto Crepaldi Affonso says there will be enough resources over time to produce the batch of 28 aircraft plus ground support equipment, initial logistics and pilot and mechanic training. On the other hand, he also says that some potential shortfalls are being worked out:

“Quanto aos valores que estavam contingenciados (cerca de R$ 500 milhoes segundo o Valor apurou), o brigadeiro da Copac disse que todo o orcamento previsto para 2014 foi liberado, mas que ainda ha carencias de recursos. Ele ressaltou, no entanto, que o projeto continua com andamento normal, buscando as solucoes necessarias em coordenacao com os orgaos do governo.”

Sources: Brazilian Government, “Extrato De Inexigibilidade De Licitacao Nº 1/2014 Nº Processo: 67701.003019/2014-95.” | defesanet, “KC-390 – Recebera U$ 1,9 Bi”.

Oct 4/14: Argentina. It took a lot of work and investment, but Fabrica Argentina de Aviones, which was forcibly nationalized in 2009, has finally made good on the 2011 MoU and opened a production line for KC-390 parts. They’ll make wing spoilers, flap fairings, nose landing gear doors, a tail cone, and the ramp door. Their journey shows why partner readiness cannot just be assumed in extended supply chains.

The former Lockheed Martin facility had a lot of work to do after 2011, but the 10-year agreement led the state to allocate over $35 million dollars to upgrade the Cordoba factory, which has added 180 direct jobs. It has tripled its capacity in composite materials, added advanced machining centers, and brought in equipment for forming, processing and heat treating primary aluminum parts. That was accompanied by about 80,000 hours of training and AS9100 certification, which triggered improvements to production processes and non-destructive testing. Sources: defesanet, “KC-390 – FAdeA Inaugura Linha de Producao de Componentes”.

Aug 18/14: Embraer personnel from the KC-390’s interior outfitting, test, and training groups have been participating in Brazilian operations, from the recent Campo Grande exercise to C-130 operations in Antarctica. Some design changes have dropped out of the Antarctic operations in particular, which the Swedes will certainly appreciate once they become customers. The FAB release also implied that interior placement of wiring and outlets had changed, in order to accommodate medical equipment.

Continued refinement is commendable, but shouldn’t these efforts and changes take place before design finalization (q.v. March 11-22/13)? Sources: Brazil FAB, “Embraer participa de exercicio da FAB para aperfeicoar nova aeronave”.

May 21/14: Brazil. Embraer signs the core BRL 7.2 billion ($3.263 billion) KC-390 series production contract for 28 planes, plus spare parts and maintenance. They also hold the opening ceremony for the 30 million square meter KC-390 production line, with President Dilma Rousseff in attendance.

The KC-390 program directly employs about 1,500 workers, which will expand with more orders. Embraer Defense & Security President Jackson Schneider adds that they have 32 Letters of Intent signed with other countries, which goes far beyond announced candidates. The challenge now involves converting some of them into orders, and the opening of the production line starts that clock running in earnest.

Embraer will formally enter Brazil’s contract on its books within 90 days, when the complementary documentation goes into effect. Deliveries are expected to begin in 2016. Sources: Ministerio da Defensa, “Com presenca da presidenta da Republica, FAB assina contrato de compra do aviao brasileiro KC-390” | Embraer, “Embraer opens final assembly hangar for the KC-390, in Gaviao Peixoto, SP, Brazil” | Brazil Poder Aero, “Com Dilma, Embraer inaugura ‘linha de montagem’ do KC-390”.

Brazil orders 28

May 20/14: Engines. International Aero Engines AG announces that they’ve shipped all 6 prototype V2500-E5 powerplants for Embraer’s new KC-390, which are rated for 31,330 pounds of thrust. They’ll be used in KC-390 flight tests, set to begin in 2014, and civil certification for the E5 engine is expected in Q3 2014.

The engines are assembled at UTC Pratt & Whitney’s Engine Center in Middletown, CT, then shipped to UTC Aerospace Systems – Aerostructures in Foley, AL to install the nacelles, thrust reversers and engine build-up equipment. The first 3 were delivered to Embraer ahead of schedule earlier in 2014, and the remaining 3 instrumented powerplants were shipped earlier in May 2014. Sources: IAE, “V2500-E5 Engines Shipped to Embraer”.

2013

Agreement with Boeing; CDR; Embraer & forecasters on the addressable market; Opportunity in Sweden, just not immediately; KC-390 officially ready for sale.

KC-390 concept
(click to view full)

Nov 19/13: Sub-contractors. BAE Systems announces that they’ve finalized an industrial cooperation contract with the Brazilian Air Force, as part of an agreement to provide the flight control system and active side sticks for Embraer’s KC-390. BAE General Manager of Commercial Aircraft Solutions and Dr. Ehtisham Siddiqui says that it involves “…software development training and maintenance, repair, and overhaul services for the KC-390 flight control system that will be performed in Brazil. BAE Systems has also proposed performing some final assembly work for its KC-390 products in the country.” Sources: BAE, “Brazilian Air Force Receives More Than Just Flight Controls for KC-390”.

Dec 18/13: Sweden. A somewhat unexpected announcement by the Ministerio da Defesa confirms that Brazil has picked Saab’s Gripen-NG as their preferred bidder, and expects to buy 36 planes for $4.5 billion. That’s currently just an estimate, as negotiations need to sort themselves out, including financing and industrial offset arrangements. A final contract and financial arrangements are expected in December 2014, and deliveries are expected to begin 4 years later.

Sweden is now almost certain to fly the KC-390 after its 8-plane C-130H2 Hercules fleet retires (q.v. Oct 4/09), but in-depth upgrades performed from 2006 – 2009 mean that they won’t be needing new transports any time within the next few years. One obvious alternative involves replacing existing Swedish Saab 105/ SK60 trainers with the Super Tucano. That needs to happen around 2017, and Saab’s recent tie-up with Boeing to produce a supersonic jet trainer for the USAF’s T-X doesn’t change that. The SK60 jet is used in a basic-intermediate trainer role, and the Flygvapnet’s 18 serving JAS-39D Gripens won’t be upgraded to Gripen NG status. That would give them the option to use Gripen-Ds for use as lead-in fighter trainers to the JAS-39E, while still needing to replace the SK60s.

The coming year of Gripen NG negotiations will involve the Swedish government, and the agreement’s provisions could tip the scales on Swedish acquisition plans as well. Read “F-X2: Brazil Picks Saab’s JAS-39 Gripen-NG over Rafale, Super Hornet” for full coverage.

Aug 22/13: Turkey. Turkey and Brazil are forming a number of working groups on defense cooperation. Their release specifically mentions that the aeronautics working group will be studying the assembly of Turkish helicopters in Brazil. The T129 is the only candidate that fits. Note that Brazil already fields a handful of Russian Mi-35M attack helicopters, with a limited secondary capability as transports. On the other hand, they could definitely use more armed helicopters, and local production appeals to them.

The flip side is that Turkey would be studying the assembly of Brazilian aircraft in Turkey. Embraer offers the Super Tucano, a number of military aircraft based on their ERJ 145 regional jetliner, and the KC-390 medium transport. Turkey is committed to buy 10 A400M medium transports, but they have 32 C160 and C-130 medium transports to replace, so a future KC-390 buy is possible. Other possibilities are more restricted, as Turkey already has projects or orders in those categories: KAI’s KT-1 for training, Boeing’s E-737 AWACS for aerial surveillance, and Airbus ATR-72s and CN-235s for maritime patrol. Sources: Brazil MdD [in Portuguese].

June 18/13: Boeing agreement. Embraer and Boeing sign an agreement to market the KC-390 in limited international venues, building on the June 26/12 MoU. Boeing will be the lead for KC-390 sales, sustainment and training opportunities in the USA, UK and “select Middle East markets.”

The UK has committed its defense airlift budgets to a combination of C-130Js, A400Ms, and C-17s, so their inclusion doesn’t mean much. The USA is also an unlikely customer, as Lockheed Martin has a hard lock on the medium tactical airlifter segment. Absent some angle on civil sales, US SOCOM is about the only (remote) possibility. The Middle East offers a more promising market, with interest already expressed by Boeing’s C-17 customer in the UAE, but it will depend on which countries are within the agreement’s scope.

The biggest effect will probably be felt elsewhere, as one more positive factor in Boeing’s competition to supply its F/A-18E/F Super Hornets as Brazil’s new F-X-2 fighter. Boeing | Embraer.

May 29/13: Sub-contractors. Curtiss-Wright Controls, Inc. announces a new 5-year agreement from Embraer to harmonize flight test data-gathering equipment and database structures across the firm. The KC-390 is the 1st platform, using an Acra KAM-500 system with 46 chassis and 14 network switches.

This initial contract is $4 million, within an overall agreement whose lifetime value could rise to $30 million. Shipments of data acquisition units began in Q4 2012, and will continue in line with Embraer’s flight test programs.

April 9-13/13: For Sale. Embraer Defense & Security uses the LAAD 2013 expo to officially announce that the KC-390 is finalized and available for sale on the global market, with a 23-ton capacity and a maximum cruising speed of 465 knots (860 km/h). Engineering drawings are being released to suppliers, and Embraer maintains its promise to hold its 1st flight by the end of 2014.

Hopes of landing the plane’s 1st sale at LAAD were dashed. Embraer | Flight International.

April 3/13: KC-390’s origins. Defense News interviews Embraer CEO Luis Aguilar, which provides an interesting insight into the plane’s origins:

“When we thought about this airplane, it was the first time we looked at the international market also, not just the Brazilian requirements…. We looked at the market and then came back to the Brazilian Air Force to talk with them about what they think about their cargo airplanes for the future. They said they were probably going to replace with more C-130s, and we started talking and showed them we were able to develop something in a very feasible way. It took two years working together to launch and sign the contract. It was a much more sophisticated process. We are on schedule, and I think we have a great chance to sell abroad.”

April 2/13: Forecasts. Flight International takes a closer look at Embraer’s evolution, from its 2012 dependence on major aviation projects for 75% of its defense revenue, to a projected figure of just 58% by 2020. Domestic security and surveillance offerings are expected to grow in relative importance over that time, thanks to experience and products developed under Brazil’s $400 million SISFRON project, its 50/10/40 Haripa UAV partnership with Avibras and Elbit Systems, etc.

There are rumors that the LAAD 2013 expo will see Brazil announce the initial production order for 28 planes, but the larger question is how many orders Embraer can expect over the longer term. Rebecca Edwards of Forecast International says Embraer hopes to convert all of their MoUs into 60 firm orders by the end of 2013, and sees potential for production of 98 KC-390s by 2021, and up to 234 by 2027. The Teal Goup, on the other hand, sees most of the KC-390’s target market locked up in the USA, and only 25 planes built by 2021. Given a break-even production run of 120, Embraer has to hope that FI’s prediction is closer to their 2021 reality. For Teal, the key to the KC-390’s success is a price point in the $50 million range, but that won’t be easy:

“One factor which could drive up prices is that the Brazilian government has mandated the use of as many local suppliers as possible, depriving programme managers of the ability to choose the best components at the lowest possible cost, [Teal’s] Aboulafia says. Local subsystems tend to cost more than their international counterparts because of economies of scale and development costs. “It’s not a killer, it’s just something that hobbles designers, especially when they’re trying to keep costs down,” he says.”

Teal sees the KC-390 as more of a straight cargo plane than the C-130, with higher load capacity, modern features like fly-by-wire, and a faster cruising speed. The C-130’s use of turboprops is better for avoiding foreign object damage from unimproved landing strips and for low altitude operation, which makes them better suited to roles like special forces support. Flight International.

March 11-22/13: CDR. The Brazilian Air Force (FAB) and Embraer Defense & Security successfully conduct the KC-390’s Critical Design Review (CDR) at Embraer’s facilities in Sao Jose dos Campos.

The aerodynamic and structural configurations are now set, along with the architecture and systems installations. The next step is to begin building the prototypes. Embraer.

CDR

Feb 1/03: Forecasts. Aviation Week talks to Embraer about its schedule and forecasts. The firm forecasts a total market for 700 medium tactical transport aircraft over 10 years, worth more than $50 billion. The grounds for this number is that there are currently more than 2,000 older airlifters, mainly Lockheed Martin C-130s and Russian Antonovs, that will need replacing within 10 years. Which is true, but many are in countries like the USA. The KC-390 is competing well elsewhere, however, and it seems that summer 2013 will begin the big push for contracts:

“The [Critical Design Review] is to be completed by this quarter. “[By June] we will be ready to go to market with terms and conditions and a final configuration,” says [Embraer DS CEO] Luiz Carlos Aguilar…. following the April 2012 signing of a memorandum of understanding with Boeing…. “We will partner with them in some specific countries,” he says. “We are still discussing that, and will announce a commercial agreement in a few months.” Meanwhile, a “sharing process” is under way with Boeing engineers visiting Embraer, and vice versa.”

2012

Limited Boeing partnership; Sub-contractors picked; Possibilities in Canada & Indonesia?

KC-390 concept
(click to view full)

Nov 15/12: Canada? The Ottawa Citizen’s David Pugliese writes:

“The recent industry day on the Canadian Forces fixed wing search and rescue (FWSAR) project brought a new player into the mix. Brazilian aircraft manufacturer Embaer was invited to attend.”

The KC-390’s faster cruising speed would give it advantages in a SAR/special forces role, and Embraer might be tempted to offer Canada a deal, in order to secure a high-end market endorsement. The bad news for Embraer is that they’re seen as a major competitor by Canadian aerospace firms, and especially by Bombardier. FWSAR’s rear ramp requirement caused Bombardier to bow out of the recent Industry Day. The political optics of shutting out Quebec’s flagship firm Bombardier, while giving the contract to their biggest competitor, make a KC-390 victory almost impossible to imagine.

Sept 26/12: Sub-contractors. Embraer picks 2 Brazilian companies to provide KC-390 components. Aerotron in Itajuba, Minas Gerais, will provide ballistics protection for the entire aircraft. LH Colus, from Sao Jose dos Campos, Sao Paulo, will provide seats and stretchers. Embraer.

Aug 13/12: Indonesia. Aviation Week reports that Indonesia is considering the KC-390. They’re already a customer for Embraer’s armed EMB-314 Super Tucano turboprop, but at the same time, earlier C-130 Hercules versions already serve with Indonesia’s TNU-AI. With respect to Indonesia’s choices:

“Asked if the Brazilians have been pitching the KC-390 to Indonesia, [Air Marshal Eris Herryanto] replied: “Yes. Prior to meeting you, we were shown a mockup today [Aug. 7] of the KC-390.” He says Indonesia needs a lot of military transports and wants to strengthen its capability to carry out disaster-relief operations.”

The other option for Indonesia, given its vast spaces, is to solve its issues with a larger number of smaller transports, like the Airbus Military CN-235s and C295s that IAe already manufactures. Indeed, industrial considerations are likely to play a significant role in any Indonesian buy, for reasons that go beyond the country’s procurement culture of corruption and bribes. A bill is being introduced to standardize required defense industrial offsets for equipment bought abroad, and it’s likely to raise the bar when it passes. Indonesia didn’t get its desired co-production deal from Embraer for the EMB-314 turboprops, but the KC-390 is also a different opportunity case. Within the Southeast Asia region, Australia (C-130J), India (C-130J, Irkut MTA), and (Malaysia A400M) are already committed to other medium transports. Bangladesh can’t afford much more than modernization of its aged C-130Es, and Myanmar doesn’t offer much potential. That leaves Vietnam, whose Russian and Indian relationships make a future MTA buy more likely, or C-130 customer Pakistan. This constellation means that some sort of regional sales arrangement for the KC-390 would be much more of a low-risk, good payoff venture for Embraer, as opposed to the medium risk, low to negative payoff option represented by Embraer/IAe co-production and marketing.

June 26/12: Boeing steps in. Boeing and Embraer announce an agreement to share some specific technical knowledge regarding the KC-390, and to evaluate markets where they may join their sales efforts for medium-lift military transports. It’s part of a broader agreement signed in April 2012, and its immediate significance is limited. On the other hand, it has the potential to turn Boeing into a medium transport rival to C-130 maker Lockheed Martin, while extending Embraer’s marketing reach to match Lockheed Martin and Airbus. Embraer Defense & Security CEO Luiz Carlos Aguiar:

“Boeing has extensive experience in military transport and air refueling aircraft, as well as deep knowledge of potential markets for the KC-390, especially those which were not considered in our original marketing plan.”

That’s the sort of thing that could change the KC-390’s global prospects, but it’s still too early to tell. Boeing | Embraer.

May 8/12: Sub-contractors. Thales announces a contract by Embraer Defence and Security to provide their civil-certified High Performance Inertial Reference System (HPIRS) as the KC-390’s Inertial Navigation System/ GPS navigation system.

May 7/12: Sub-contractors. United Technologies’ Goodrich Corp. is picked to provide more KC-390 components. Their SmartProbe air data system eliminates pneumatic lines, ice detectors, and they’ll also be supplying windshield ice protection controllers, and fuel gauges that include built-in-test capabilities. Initial hardware deliveries from Goodrich’s Sensors and Integrated Systems teams in Minnesota and Vermont are expected to begin in 2013. Goodrich.

April 18/12: Sub-contractors. Goodyear Tire & Rubber Co. announces that Embraer is continuing their decades-long partnership by equipping the KC-390 with Goodyear military aviation tires.

Jan 19/12: Sub-contractors. Embraer adds the KC-390’s Auxiliary Power Unit (APU) to Hamilton Sundstrand’s responsibilities.

APUs are small gas turbine engines that provide electric power, instead of propulsion. They’re used most often on the ground, providing electricity, compressed air, and/or shaft power for main engine start, air conditioning, electric power and other aircraft systems. They can also provide backup electric power during in-flight operation. The KC-390’s APU is derived from a commercial unit, adapted to military specifications. Hamilton Sundstrand.

Jan 18/12: Sub-contractors. Embraer picks Safran Group subsidiary Sagem DS to supply the KC-390’s Horizontal Stabilizer Trim System. It uses electric actuators, instead of hydraulic systems. Development work will be carried out at Sagem’s R&D center in Massy, near Paris. Sagem DS.

2011

Sub-contractors picked; Civil C-390 confirmed; Portuguese subsidies; Design changes.

KC-390 concept
(click to view full)

Dec 14/11: Sub-contractors. Embraer picks United Technologies Corp. subsidiary Hamilton Sundstrand in Windsor Locks, CT to supply the KC-390’s Electric Power Generating System. The system will be based on the firm’s 90 kVA integrated drive generator, which is currently used in a variety of military and commercial applications. Hamilton Sundstrand.

Dec 14/11: Sub-contractors. Portugal takes another step. Embraer Defense and Security signs a partnership contract with OGMA Industria Aeronautica de Portugal and Empresa de Engenharia Aeronautica, for the KC-390 program. Reports indicate that EEA and the Centre for Excellence and Innovation in the Automotive Industry (CEIIA) will do engineering work for 3 unspecified segments of the jet. The segments designed and tested in Portugal will then be manufactured by OGMA, along with a central fuselage section.

The industrial contract follows Portugal’s Sept 10/10 Declaration of Intent to replace its 6 C-130H/C-130H-30 transports with 6 KC-390s. That purchase contract is the next step. Note that state-owned OGMA was privatized in 2003, and its ownership structure is now 45.5% Embraer, 19.5% EADS, and 35% government. Embraer | Macau Hub | Portugal Daily View | See also Flight International follow-up | Flight International on 2003’s A400M backout.

Nov 10/11: Portugal. Diario da Republica announces that Embraer is expected to receive up to EUR 87 million from Portugal’s National Strategic Benchmark Framework (QREN), or other public funding sources, in order to establish the necessary industrial infrastructure for KC-390 work. Macau Hub.

Oct 25/11: Sub-contractors. Elbit Systems wins an initial order worth $25 million. They’ll supply the KC-390’s pilot Head-Up Display, the Self-protection suite to coordinate warning systems and decoy/jammer defenses, and the DIRCM jammer for use against infrared guided missiles. All equipment will be provided through their Brazilian subsidiary, AEL, which also supplies the KC-390’s mission computer. Elbit Systems | Embraer.

Oct 19/11: Sub-contractors. Embraer and the Brazilian Air Force hold a workshop, to encourage more Brazilian companies to bid as suppliers of KC-390 parts, components, systems and services. The Nationalization Index of the aircraft, as calculated according to the criteria of the Brazilian Economic and Social Development Bank (BNDES), is currently estimated at 60%.

Embraer notes that the NI can’t realistically rise above 70%, since there is no Brazilian manufacturer for the engines. It’s also realistic to expect downward pressure on that Brazilian “nationalization” from foreign workshare, which will be required as part of export efforts. At the same time, the KC-390 is part of an industrial strategy for Brazil, whose government will want to see a wider group of Brazilian firms involved. Around 80 Brazilian companies participated in the workshop. Embraer.

Sept 29/11: Sub-contractors. Safran Group’s Hispano-Suiza gets the award to supply the KC-390’s Emergency Electric Power Generator System (EEPGS). The EEPGS deploys in dire emergency situations, and uses the guaranteed existence of airflow to create power and keep key on-board systems running. It includes a Ram Air Turbine (RAT), RAT electric generator and generator control unit, and a deployment/ restow mechanism.

Sept 8/11: Sub-contractors. Cobham is picked to put the ‘K’ in “KC-390,” and supply its wing-mounted Aerial Refuelling Pods. That’s followed by an order with an initial contract value over of US$60 million. Cobham is a leading global supplier of such systems, which equip Airbus’ A330 MRTT, as well as the new Boeing KC-46A. Embraer | Cobham plc [PDF]

Sept 8/11: Sub-contractors. Embraer Defense and Security picks Italy’s SELEX Galileo to supply their T-20 Gabbiano Tactical Radar.

The T-20’s solid state amplifier technology is designed for better Mean Time Between Failures, reduced energy consumption, and smaller size relative to previous generation technologies. What’s even more important to Brazil is the fact that it’s usually carried on UAVs and surveillance aircraft, and can perform basic land and sea surveillance, in addition to navigation functions. Embraer | SELEX Galileo [PDF] | Gabbiano Family product sheet [PDF].

Sept 8/11: Sub-contractors. Embraer picks Elbit’s Brazilian subsidiary AEL Sietemas to supply the KC-390’s mission computer. AEL has worked with Embraer to supply mission computers and full avionics systems for most Brazilian combat aircraft, and losing the KC-390’s avionics suite competition to Rockwell Collins was a disappointment. This award gets them back into the program. AEL [in Portuguese]

July 26/11: Sub-contractors. Embraer Defense and Security chooses BAE Systems to provide some flight control electronics hardware, embedded software, system design and integration support. BAE has a history of producing fly-by-wire systems, and the firm will supply flight control computers and actuator control electronics for the KC-390. The system will be developed in Rochester, United Kingdom; and Johnson City, New York, USA. Embraer.

July 26/11: Sub-contractors. Embraer chooses Goodrich Corp. to provide the electro-hydrostatic actuators (EHA), electro-backup hydrostatic actuators (EBHA), actuator electronics, and electrical controls for the KC-390’s primary flight control system. Goodrich will develop and deliver the system through the joint efforts of its businesses Actuation Systems and Engine Control & Electrical Power Systems, as well as the Goodrich Electronic Systems Center. Embraer.

July 25/11: Sub-contractors. Embraer chooses International Aero Engines AG’s V2500-5 engine for the KC-390. Engineering work on this military variant of their V2500 engine has already started at IAE’s shareholder companies, and 1st deliveries of powerplants for prototype aircraft are scheduled to begin in 2013, with flight tests to start in 2014. Production engines are anticipated for 2015, with entry into service projected for later that year. Deliveries are anticipated to last at least through 2030. Embraer | IAE.

June 22/11: Civil C-390. Embraer confirms plans to launch a stretched C-390 for the civil cargo market, adding a section ahead of the wing for a cargo door, and a section behind for balance and space. If launched, it will compete with offerings like civil Hercules aircraft, cargo conversions of passenger narrowbody planes like the 737, a possible commercial version of Kawasaki’s similar C-2, etc.

This is not an unexpected move, vid. the Feb 18/09 entry, and also the need for 120 orders to break even (q.v. April 5/11 entry). On the other hand, crossovers in this area are less common than you’d think, because the key traits of military and civil cargo planes don’t quite line up. Civil operators want low-cost operation, and generally transport predictable palletized loads. Military operators want performance for operations like fast ingress/egress, short runways, and loads that place a lot of weight on smaller sections of the plane. That often leads to higher-cost tradeoffs like more powerful engines that consume more fuel, highly strengthened floors that add more weight, and airframes optimized for lift rather than super-efficient cruise. The steady progression of the KC-390 design away from a standard Embraer ERJ 190 airframe is a classic example of those tradeoffs at work.

Embraer officials are nonetheless predicting 200-250 C-390 orders, from the plane’s projected launch in 2018 to 2030 or so. If they can sell even half that number, the military program will become more competitive as costs and prices drop, and Embraer will do extremely well financially. They do have a slight advantage in that their original intended C-390 customer, Brazil’s postal service, is almost certain to be their launch customer. Beyond that, their target market is likely to be with operators serving sectors like resource industries, who can use them to haul medium loads into remote locations. See Flight International.

Note that by the mid-2020s, their most significant competitor may not be an airplane at all.

June 21/11: Sub-contractors. Embraer Defense and Security announces that Esterline Control Systems in Sylmar, CA, USA will supply the KC-390’s autothrottle system. Modern aircraft have a significant computer control element. The autothrottle system’s 2 throttles and integrated controls calculate and transmit thrust demands from aircrew controls or autopilot functions, to the Full Authority Digital Engine Control (FADEC) electronics running the engines. Embraer.

June 16/11: Sub-contractors. Embraer Defense and Security announces that Liebherr-Aerospace Toulouse SAS in Toulouse, France will provide the KC-390’s environmental and cabin pressure control systems. The firm has a long-standing civil relationship with Embraer in this area, and the KC-390’s system will feature an integrated control architecture along with the pneumatic and mechanical components. Embraer.

May 5/11: Sub-contractors. Embraer picks Rockwell Collins’ Pro Line Fusion avionics system for the KC-390 cockpit, which will feed into 5 high-resolution 15″ LCD displays. It will include:

– An Integrated Flight Information Systems (IFIS) with electronic charts and enhanced maps;
– Advanced Flight Management Systems (FMS) with Wide Area Augmentation System that supports Localizer Performance with Vertical guidance approaches; (WAAS/LPV) and Required Navigation Performance (RNP) capabilities
– Advanced graphical flight planning capability; and
– An Information Management System (IMS) to manage databases and facilitate wireless interaction with ground systems.

Rockwell’s system already complies with the most recent CNS/ATM requirements for flight in international civilian airspace, and the Pro Line fusion cockpit will give KC-390s commonality with the systems on some of Embraer’s Legacy business jets. Because it’s a commercial system, it also sidesteps any American ITAR legal restrictions on future aircraft sales. The loser is IAI/EAE, whose proposal (vid. Jan 5/11 entry) failed to win. Embraer | Rockwell Collins | Flight International.

April 13/11: Sub-contractors. At the LAAD Defense and Security conference in Rio de Janeiro, Embraer Defense and Security signs contracts with the Czech Republic’s Aero Vodochody and Fabrica Argentina de Aviones to join the KC-390’s Joint Definition Phase, and produce parts for the program. Their acceptance is another step toward the commitments each government has made to buy the production aircraft.

Aero Vodochody will supply the rear fuselage II section, crew and parachutist doors, emergency door and hatches, cargo ramp and fixed leading edge for the prototypes, and for the future serial production aircraft. Embraer.

FAdeA will manufacture the spoilers (plates on the top surface of a wing for controlling wing lift), doors for the nose landing gear, ramp door, flap fairings, tail cone, and electronic cabinet. Embraer.

Embraer adds that “The program is running on schedule. Production of the first prototype is expected to start in 2013, followed by the first flight in 2014.”

April 6/11: Sub-contractors. Embraer publicly designates its subsidiary ELEB Equipamentos Ltda. of in São José dos Campo, Brazil to develop and produce the KC-390’s landing gear.

April 5/11: Break-even = 120. A Flight International report places the KC-390’s break-even point at 120 aircraft sold, about double the current commitments if all parties follow through.

That’s about 17.1% of the expected available tactical airlifter market, which Embraer reportedly places at of 700 or so replacement aircraft outside of China, Russia, and the USA. On its face, that seems a somewhat challenging but achievable total, given that other key buyers like India (MRTA with Russia) are also no-go markets. Contemplation of how many customers that entails at various purchase numbers, however, makes one wonder if their 700 aircraft figure has become too optimistic. A long future of austerity budgets due to the welfare state’s fiscal explosions may restrict remaining sales opportunities in “advanced” markets, to the point that even an expected uptick in rising regions like Asia and parts of Africa can’t compensate. Even a smaller overall market wouldn’t make Embraer’s success impossible, but it would change the relative ratio of required wins against powerful competitors.

Break-Even = 120

March 22/11: Sub-contractors. Finmeccanica subsidiary DRS Training & Control Systems in Fort Walton Beach, FL gets an undisclosed contract from Embraer S.A. to design, develop, test, produce, and support the KC-390 Cargo Handling and Aerial Delivery System (CHS/ADS).

The KC-390 CHS/ADS is one of the 5 major aircraft subsystems, used for loading both palletized cargo and rolling stock onboard, and for rolling out cargo on paradrops. CHS/ADS includes an electrical pallet locking system, an electronic load master control subsystem with DO178 level A software certification, retractable guide-rails, invertible cargo rollers, tie-down devices, and other floor panel components. DRS Technologies.

Feb 25/11: Sub-contractors. Embraer has frozen the configuration of its KC-390 tanker/transport, and plans to begin the joint definition phase in May 2011, once final decisions are made on major sub-contractors. Aviation Week describes a full scale mockup at Embraer’s plant in Sao Jose do Campos.

Recent KC-390 changes include longer wings (now 35.06 m), to enable slower 120 kt flight for helicopter refueling with the hose-and-drogue pods. Some customers are reportedly interested in a refueling boom as well, and Embraer is looking into this but doesn’t have a design it likes yet. The most unusual feature may be a movable pressure bulkhead that retracts into the roof and descends to seal the cargo cabin. While it shortens the cabin to 12.78m, it would allow high altitude airdrops from the space behind, without depressurizing the entire cabin.

Jan 5/11: Flight International reports that IAI and Synergy’s EAE joint venture is offering cockpit avionics and aircraft self-protection systems for the KC-390, under a 2009 cooperation pact.

IAI already has a presence in Brazil, supplying radars and maintenance services, and rumors of electronic intelligence or airborne early warning system KC-390 variants would play to IAI strengths. It’s worth remembering, however that both Embraer (ERJ-145 based R-99A) and IAI (Gulfstream G550 based CAEW) already have established AWACS offerings based on efficient, long endurance business jets. This makes the business case for an E-390 AWACS offering problematic for both parties.

2010

Letters of Intent from Argentina, Chile, Colombia, and Portugal; UAE may be interested; Infrastructure in Portugal.

Looking beyond.

Nov 23/10: Portugal. Embraer begins the 1st phase of its new EUR 48 million, 330,000-square-foot (30,660-square-meter) facility in Evora, Portugal, dedicated to manufacturing complex airframe structures and components in composite materials. Construction is expected to be complete by the end of 2011, though production phase wouldn’t start until 2013. A 2nd phase will focus on metallic airframe structures.

Evora lies in the Alentejo region, 130 km east of Lisbon. Recently, the city developed an aerospace sector by creating a 9.4 million-square-foot (873,290-square-meter) aerospace industrial park, located near the municipal airfield. Embraer was the first investor. Ramos Catarino S.A. in Febres, Portugal is handling the excavation work, foundations and infrastructures. Construction was spurred by a wider strategy, but If Portugal goes ahead with a KC-390 buy, these facilities will already be in place for industrial offset work, and their construction costs may also count. Embraer.

Oct 29/10: Argentina intent. Embraer announces that:

“As a result of the conversations held between the Brazilian and the Argentine Defense Ministries, the ministers Nelson Jobim and Nilda Garre signed, this week, a Declaration of Intent regarding the South American neighbor’s participation in the development program of the KC-390 military transport jet. The agreement marks the beginning of negotiations for the involvement of Fábrica Argentina de Aviões “Brig. San Martín” S.A. – FAdeA in the manufacture of the new airplane, as well as the future acquisition of six KC-390 aircraft by the Argentine government.”

FAdeA was Lockheed Martin Aircraft Argentina during its privatized period, but is now state-owned again. The firm has collaborated with Embraer on a twin-prop regional airliner (the canceled CBA 123) and refurbished C-130s, but it also has a long history of aircraft development. Its best-known product is probably the IA-58 Pucara counter-insurgency aircraft, and they are currently developing an IA-73 basic jet trainer to go with their IA-63 Pampa advanced jet trainer. Flight International.

Argentina intent: 6

Sept 21/10: UAE. Reports indicate that Brazil and the UAE are negotiating an an umbrella agreement for military cooperation, with sales of Super Tucano trainer/light attack turboprops and KC-390 transports as key building blocks. Brazilian defense minister Nelson Jobim told reporters that Brazil would present the UAE with a draft agreement within 2 weeks, and hopes the deal could be signed within 2 months of a mutual draft.

The UAE would be a very significant customer. It has modernized its transport capabilities with a major C-17 buy, but negotiations to complement its 6 C-17As with 12 C-130J-30 Super Hercules planes have been bogged down for 18 months. A switch to the KC-390, and participation in its development, would attract considerable notice in global military circles, and offer a bridge to further middle eastern sales. Abu Dhabi’s The National.

Sept 13/10: Sub-contractors. The Brazilian and Czech Ministries of Defence sign an agreement for Aero Vodochody a.s. to cooperate with Embraer in developing and building the KC-390. The firm has considerable experience in aerostructure manufacturing, and the Czech defense ministry believes they could end up manufacturing the KC-390’s rear fuselage, doors, and wing leading edges

Specific terms are expected to be signed by the end of 2010, and the Czech Republic is reportedly looking to buy up to 2 KC-390s as a complement to their C-295M fleet. Aero Vodochody | Aviation Week | Flight International.

Czechs join – up to 2?

Sept 10/10: Portugal intent. Portuguese defense minister Augusto Santos Silva, signs a Declaration of Intent to join the KC-390 development program, and begin negotiations to finalize the terms and buy up to 6 planes.

The 6 KC-390s would replace the current fleet of 6 PoAF C-130H/C-130H-30 Hercules turboprops. Embraer | Reuters | In Portuguese: Portugal’s MDP | EFE | O Globo.

Portugal intent: up to 6

Sept 1/10: Colombia intent. Colombian defense minister Rodrigo Rivera announces that the country is negotiating to join the KC-390 partnership, and have signed a Declaration of Intent. They are reportedly interested in buying up to 12 planes to replace their existing fleet of 7 C-130B/H Hercules aircraft, and possibly other models in the FAC’s inventory. In return, they would join as industrial partners, via Colombian Aeronautics Industry Corp. The FAC is familiar with Brazilian aircraft, flying EMB 312 Tucanos, EMB 314 Super Tucanos, and a pair of EMB 110 Banderiante twin-turboprop light passenger/ transport planes.

The DoI was signed along with a broader set of agreements between Colombia and Brazil, covering economics, technology, environment and security. Marco Aurelio Garcia, a special adviser on Brazil’s international affairs, reportedly reaffirmed that the conflict with FARC’s narco-guerillas was solely Colombia’s internal issue, and Brazil would become involved only if Colombia requested it. That declaration is an obstacle to efforts by FARC and its backers in countries like Venezuela, who wish to pressure Colombia by internationalizing the conflict. Aviation Week | Defense News | defpro | Flight International | China’s Xinhua || In Spanish: La Republica | Terra Colombia | Vanguardia Liberal || DID: Colombia’s Defense Modernization

Colombia intent: up to 12

.

Aug 24/10: Chile intent. Embraer publicly announces an signed Declaration of Intention from Chile to join the KC-390 program. That allows Chile’s Empresa Nacional de Aeronautica (ENAER) to join discussions about participating in its development, and acting as a supplier to the KC-390 and other programs. Embraer’s Phenom 100/300 and Legacy 450/500 business jets have been mentioned in that context. The DoI also begins negotiations with Chile’s FACh to buy up to 6 planes.

Chile has been discussing the purchase of 3 Airbus A400Ms for over 5 years now, but had not come to any agreement. It seems likely that any KC-390 purchase would supplant that buy. ENAER has been supplying structures for Embraer’s 50-seat ERJ 145 regional jet since the 1990s, and Chile’s FACh already flies 12 of Embraer’s EMB-314 Super Tucanos. Embraer | Defense News | Mercopress. In Spanish: Diario Financiero | EFE. In Portuguese: O Globo | ANSA Latina | DCI.

Chile intent: up to 6

July 21/10: Brazil to buy 28. At the Farnborough 2010 show, Embraer and the Brazilian Air Force (FAB) announced the FAB’s intent to buy 28 KC-390s, and reveals additional details about the design.

The preliminary studies phase is done now, including wind tunnel tests, and aerodynamic, structural, and systems designs are all frozen. First flight is expected in 2014 and entry into service expected at the end of 2015. Embraer.

Brazil intent: 28

May 31/10: Brazil’s FAB offers an update, in the wake of their initial Workshop on KC-390 Offsets, held with 16 foreign firms at the Technology Park of Sao Jose dos Campos (SP), on May 25-26/10. Brazil’s Department of Aerospace Science and Technology (DCTA) organized and promoted the workshop.

Some of the KC-390’s equipment, from engines to instrumentation, will come from outside Brazil. Those firms will be required to offer industrial offsets to Brazilian firms, as the price of their participation in the project. Offsets could include production contracts for the KC-390 or other sales, or a range of activities from staff training, technology transfer, joint development of systems and supply of machine tools, etc.

The FAB adds that according to studies made by Embraer, there is a potential market of 700 aircraft in this class over the next 10 years. That may be so. Embraer will have to beat plenty of competitors, in order to secure its share of those orders. Brazil’s FAB [in Portuguese].

2007 – 2009

Development contract; Program will be international; Links to Brazil’s potential fighter buy.

KC-390 sign-on
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Oct 4/09: F-X2 & KC-390 linked? Brazil’s FAB confirms that revised bids are in from all 3 short-listed fighter contenders, and Saab’s offer clearly has significant support from the Swedish government.

Gripen International’s revised bid offers a wide range of elements, including: Full involvement in the Gripen NG development program; Complete technology transfer and national autonomy through joint development; Independence in choice of weapons and systems integration; Production in Brazil of up to 80% Gripen NG airframes, via a full Gripen NG assembly line; and Full maintenance capability in Brazil for the Gripen NG’s F414 engine. That last offer would largely remove the threat of future American interference, and it would be interesting to see how Gripen International proposes to achieve it. Gripen International touts “significantly lower acquisition, support and operating costs” for its plane, and all this would be backed by a firm proposal for full long-term financing from the government’s Swedish Export Credit Corporation.

The additional offers are equally significant. Brazil will have the sales lead for Gripen NG in Latin America, with joint opportunities elsewhere. Saab would join the KC-390 program as a development and marketing partner, and Sweden will evaluate the KC-390 for its long term tactical air transport needs, as a future replacement for its recently-upgraded but aging C-130 Hercules aircraft. Saab also proposes to replace Sweden’s aged fleet of about 42 SK60/ Saab 105 jet trainers with Embraer’s Super Tucano, but it received a SKr 130 million ($18.8 million) deal in September 2009 to upgrade the planes’ cockpit systems, and current Swedish plans would see the SK60s continue in service until mid-2017. FAB release [in Portuguese] | Gripen International release.

Sept 5/09: France. Brazil’s Ministerio Da Defesa announces that Brazil has secured French cooperation to develop Embraer’s KC-390 medium transport. Other reports indicate that France is set to buy 10-12 of the aircraft when they’re introduced. This would give the Armee de l’Air a small fleet that would offset the risks of late A400M delivery, provide a second source of immediate relief for the ancient C-160 Transall fleet, and offer a lower-capacity option that could either be used as a transport supplement, or converted to specialty roles.

The KC-390 announcement is part of an incipient deal for France’s Rafale fighters, and French technology transfer across a broad range of projects was reportedly the critical factor in the deal. President Luiz Inacio Lula da Silva described the Rafale buy as “definitively consolidating a strategic partnership we started in 2005.” Brazil will now produce helicopters (EC725), submarines (nuclear-powered and diesel-electric), transport aircraft (KC-390) and possibly fighters (Rafale) in cooperation with France, under a broad strategic partnership in the defense arena. MDD announcement [Portuguese] | Agence France Presse | France24 | CS Monitor | Reuters.

June 15/09: International. Aviation Week reports that Brazil is in talks with other countries to make the KC-390 an international program. Embraer’s EVP for defense and government programs, Orlando Jose Ferreira Neto, expects that foreign partners could be added as early as the end of 2009. He adds that it will be a top-down government process, with accompanying directives handed down to Embraer.

The article adds that Embraer’s choice of its 27,000 pound thrust class engine will also be made in the next 24 months. Safran has reportedly said they will bid one of their GE partnership’s CFM engines. Pratt & Whitney and Rolls Royce are also obvious contenders.

May 1/09: South Africa. South Africa’s Engineering News reports interest among South African industry, but the country is already committed to buying 8-14 of Airbus’ larger A400M transport. Some of the skills involved in that order would definitely transfer, but a South African KC-390 order would be fiscally difficult. Excerpt:

“In February, Denel Saab Aerostructures (DSA) CEO Lana Kinley told Engineering News Online that “we are very interested in having Embraer as a customer, and in being a risk-sharing partner on the C-390″. DSA sister company Denel Dynamics is already involved in a partnership with the FAB to develop the A-Darter air-to-air missile.”

April 14/09: Development contract. At the 7th Latin America Aero and Defence (LAAD) trade fair in Rio de Janeiro, Embraer announces a contract from the Brazilian government to develop the KC-390. Figures are not disclosed, but the project’s scope is reported in other venues as around $1.4 – 1.5 billion over 7 years, with the aim of manufacturing 23 planes for Brazil, and inducting the first operational aircraft in 2015.

Embraer Defence VP Orlando Ferreira Neto tells Aviation Week that the program will help Embraer toward the goal of increasing its defense business to 20% of revenues, from 8% in 2008. As noted below, Colombia has expressed interest in a partnership. South Africa’s Engineering News reports that South Africa’s Denel Saab Aerostructures may also be interested in part

Hydras & Hellfires
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The versatile Hydra 70mm rocket family is primed for a new lease on life, thanks to widespread programs aimed at converting these ubiquitous rockets into cheap laser-guided precision weapons. Conversion benefits include cost, use on both helicopters and fighters, more precision weapons per platform, low collateral damage, and the activation of large weapon stockpiles that couldn’t be used under strict rules of engagement.

Firms all over the world have grasped this opportunity, which explains why strong competition has emerged from all points of the compass. America’s “Advanced Precision-Kill Weapon System (APKWS)” is one of those efforts, but the road from obvious premise to working weapon has been slow. After numerous delays and false starts since its inception in 1996, an “APKWS-II” program finally entered System Design and Development (SDD) in 2006. In 2010, it entered low-rate production, and it was fielded to the front lines in 2012. That date will still put APKWS on the cutting edge of battlefield technology, as a leading player in a larger trend toward guided air-to-ground rockets.

The USA’s APKWS Programs

BAE/GD APKWS
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Lockheed Martin, Raytheon, and BAE Systems were all battling for the APKWS program, which could pick up large US and international orders, and remain in production for a long time. BAE Systems’ team won in April 2006, but Lockheed Martin and Raytheon both proceeded with independent efforts to develop their own products. Meanwhile, the Army’s APKWS budget request was “zeroed” out in FY 2008.

Fortunately for BAE and General Dynamics, the US Navy kept them in the game. In November 2008, they formally picked up the APKWS-II System Design & Development (SDD) contract, and kept it going. SDD finished in November 2009, and evaluations wrapped up in January 2010. APKWS-II was approved through Milestone C in April 2010, and initial production orders followed in July 2010. A February 2011 JCTD contract will add APKWS to fixed-wing fighters: the USMC’s AV-8B Harriers, and the USAF’s A-10C Thunderbolt close air support planes. By January 2012, the 1st fixed-wing test firing had added the AT-6C turboprop light attack plane to this list, and showed clear potential for broader fielding. The US military fielded APKWS in March 2012, beginning with US Marine Corps UH-1 utility and AH-1 attack helicopters. The 1st Full Rate Production order was placed at the end of July 2012.

APKWS: Concept and Weapon

APKWS
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The BAE and General Dynamics team offered an unusual approach to APKWS-II, in order to solve the problems inherent in launching several guided rockets at once. Instead of adding a guidance unit to the rocket’s nose, where it could be damaged or confused by the flames, corrosive soot, overpressure etc. created by nearby rocket firings, they opted for a mid-body guidance approach. BAE’s Distributed Aperture Semi-Active Laser Seeker (DASALS) uses fiber-optic connections to a set of optical sensors, distributed within the rocket’s pop-out fins.

Since the fins are folded and sealed during firing, their seekers are protected. The technical challenge after that, is making sure that the pop-out fins don’t flex or vibrate a lot in flight. The use of distributed sensors can compensate for some movement, but too much movement would create accuracy problems for the DASALS optical bench.

The entire guidance section screws in between the warhead section and the rocket motor section, and can be added in the field. Since the seeker is a semi-active laser, rather than a beam-rider, APKWS can be directed by laser sources beyond its launcher, so long as they have the correct laser modulation code. This is a standard approach for laser guided missiles, but some competitors still use beam-riding guidance. Thales’ low-end LMM missile, for instance, will begin as a beam rider. Most other competitors, however, will use semi-active laser or imaging infrared seekers.

By 2019, APKWS will be able to use the new 13.7 pound M822 tri-mode penetrating/ blast/ incendiary warhead, which can punch through 40″ of reinforced concrete or 1″ of steel, while creating over 1,500 fragments and a 2,000F degree zirconium burn. Instead of just 1 AGM-65 Maverick per hardpoint, or 3 MBDA Brimstone missiles, certified aircraft would have 7 anti-armor weapons that can defeat many armored personnel carriers, and all lesser vehicles.

Compatible Platforms

F/A-18C fires Hydras
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APKWS has been qualified for use aboard USMC UH-1Y Venom utility and AH-1W Super Cobra attack helicopters, and from Bell’s militarized 407GT scout helicopter. The next targets are the US Navy’s MH-60S utility helicopter (2014) and MH-60R anti-submarine & strike helicopter (2015), and the USMC’s AH-1Z attack helicopter (2015), using a digital LAU-61G/A 19-rocket pod.

Successful tests have been conducted from an AH-64D Apache attack helicopter, and Australia has tested APKWS from its EC665 Tiger ARH scout/attack helicopter, while using Forges de Zeebrugge’s FZ90 rocket instead. No modifications were required, and that combination could also be in service by 2015.

APKWS Fixed-Wing is actually a different rocket, because it has to survive and perform through the freezing temperatures of high-altitude flight, as well as the high turbulence produced by high speed aircraft. That means a cartridge activated device to force open the control canards during high speed launches, and a modified guidance control system for the rocket.

On the fixed-wing front, successful APKWS-FW tests have been conducted from AT-6 turboprops, and from A-10C Thunderbolt II, AV-8B Harrier II, and F-16 jets. The US Navy plans to certify it aboard USMC F/A-18C/D Hornet fighters in 2017-2018.

Why APKWS? Combat Advantages

Click for video

A 70mm rocket’s size and warhead are good enough for most military targets, offering both reduced collateral damage compared to larger missiles, and greater warhead flexibility. Precision rockets can carry infantry-killing flechettes, dispersed bomblets, small unitary warheads, and more. Adding thermobaric warheads creates a system that can kill personnel, destroy most armored personnel carriers and lighter vehicles; and even collapse buildings, if the Marines’ SMAW experiences in Fallujah are any indication. All without incurring the high-end price of full anti-armor missiles like the TOW RF, Hellfire, etc.

Using 70mm rockets also benefits the platforms carrying them to the battlefield. Laser-guided rockets would expand the range of aircraft, helicopters, and UAVs carrying precision weapons, as well as increasing the number of precision weapons each platform carries. The future of warfare may even see small rocket pods mounted on some ground vehicles, if recent experiments with Boeing’s Humvee-mounted Avenger system are any indication. That would conserve valuable missile rounds by eliminating easy targets like UAVs, provide a second type of guidance threat against incoming helicopters and aircraft, and create the option of using the system in ground combat against infantry positions or vehicles.

Each of those changes, individually, is a significant increase in combat power. All of those changes together would make US Army precision fires nearly ubiquitous on the battlefield, alongside weapons fired from UAVs, and guided ground-launched rockets, mortars, and artillery shells. When coupled with persistent surveillance concepts like Task Force ODIN, it nudges the Army and USAF toward a more equal footing of “federated airpower” in counterinsurgency fights. In full-scale battles like the 1991 Desert Storm, it can turn NATO’s long-standing “assault breaker” doctrine of tactical decapitation into routine procedure, as enemies showing leadership behaviors are quickly targeted from the air or ground, and eliminated.

Beyond the USA, laser guided 70mm rockets open up a large market for counterinsurgency weapons. Many countries operate older fixed wing planes as their primary strike force, but haven’t been able to afford the expensive conversions and weapons that precision attack requires. With guided rockets, that goal is suddenly within reach. Rocket pods are a universal weapon option, almost all countries have existing stocks of unguided rockets, and targeting can even be done by troops on the ground. This setup can work with very basic aircraft integration, so the technical and cost requirements aren’t difficult. What’s difficult, is the training and coordination required to make close air support effective. Which may not stop eager customers.

Contracts and Key Developments

APKWS is designed as a screw-in insert to existing 70mm rockets, so it’s bought as mid-body “guidance sections.” BAE Systems Information and Electronics in Nashua, NH is the official prime contractor, though they’re partnered with General Dynamics. US Naval Air Systems Command (NAVAIR) in Patuxent River, MD manages the contracts.

FY 2014 – 2018

Orders: USA, Jordan; Testing on AH-64D; US Navy begins program for MH-60R/S; Australia wants APKWS for EC665 Tiger and MH-60RS.

APKWS numbers

June 29/18: More orders The Navy is ordering more fire power from BAE Systems. The company is being awarded a contract modification to a previous firm-fixed-price delivery order valued at $224,3 million. The modification provides for the production and delivery of an additional 10,185 Advanced Precision Kill Weapon Systems II (APKWS II). The APKWS program has been devised to give the Hydra 70mm rocket family a new lease of life by converting these ubiquitous rockets into cheap laser-guided precision weapons. The procurement of the additional units will upgrade the current 2.75-inch rocket system to a semi-active laser-guided precision weapon in support of the Air Force, Army, and foreign military sales (FMS) customers. This modification combines purchases for the Air Force ($144,1 million), Army ($58,5 million); Navy ($17,1 million); and FMS ($4,4 million). Work will be performed in Hudson, New Hampshire (70 percent); and Austin, Texas (30 percent), and is expected to be completed in March 2019.

April 19/18: Super Hornet firing After being delivered to the Marine Corps’ F/A-18 Super Hornet squadrons in February, fighters from VMFA-115 fired the Advanced Precision Kill Weapon System (APKWS) during recent training. The low-cost 2.75 rocket utilizes a laser guidance kit that gives it a precision-kill capability and allows the Super Hornet pilots to maintain a forward-firing, moving-target capability while increasing available ordnance per aircraft and provides a more efficient weapons match versus target sets currently seen in theater. Prior to the firing, the squadron’s crews completed ground training and in-flight training to ensure the weapon worked effectively. The F/A-18 is the second Navy fixed-wing platform to carry APKWS. It is also employed from the AV-8B as well as rotary-wing platforms including the UH-1Y, AH-1Z and MH-60S/R. The Navy and USMC have fired thousands of combined fixed- and rotary-wing shots and hundreds in combat scenarios.

April 11/18: FMS Clearance Qatar has been cleared by the US State Department to proceed with the purchase of Advanced Precision Kill Weapon Systems (APKWS) II to arm its AH-64E Apache attack helicopters. A Defense Security Cooperation Agency (DSCA) statement released Monday, said the foreign military sale (FMS) package contains requests for 5,000 Advanced Precision Kill Weapon Systems (APKWS) II Guidance Sections, 5,000 MK66-4 2.75 inch rocket motors, 5,000 high explosive warheads for airborne 2.75 inch rockets, inert MK66-4 2.75 inch rocket motors, inert high explosive warhead for airborne 2.75 inch rockets. Also included are any spares, training and support associated with the program. Estimated total cost is set at $300 million with BAE tapped as the FMS’ principal contractor. According to the DSCA, the APKWS “will provide Qatar with a low-cost precision strike capability, decreasing collateral damage and expanding its options for counterterrorism operations.”

March 6/18: Hornet-cleared! US Marine Corps F/A-18 Hornet aircraft is ready to deploy the Advanced Precision Kill Weapon System (APKWS) onboard, Jane’s reports. The reveal was made in a picture posted by NAVAIR to Twitter last week where the weapon was spotted loaded on the pylons of a Hornet assigned to VMFA-314. APKWS II is a precision-guided 2.75-inch rocket system that integrates a low-cost Distributed Aperture Semi-Active Laser Seeker (DASALS) guidance section with existing Hydra 70 rocket motors and either the Mk 152 or M282 warheads. Previously, the AV-8B was the only fast jet in the USMC cleared to operate the laser-guided weapon.

June 14/17: BAE Systems will provide Advanced Precision Kill Weapons System (APKWS) upgrade kits to the US Navy. The $181 million deal is funded under a recently announced indefinite delivery / indefinite quantity contract and will allow BAE to keep up with increased demand for APKWS rockets instead of more expensive laser-guided munitions such as the Hellfire missile. The APKWS mid-body guidance kit transforms standard unguided Hydra 70 (2.75-inch) rockets into highly accurate precision munitions by easily screwing into place between the warhead and the motor. Export customers can purchase the technology through the Foreign Military Sales (FMS) program.

October 27/16: BAE has received a maximum value $600 million deal to provide Advanced Precision Kill Weapon System (APKWS) laser-guided munitions. Aimed at speeding the delivery of the rockets to the US military and its allies, the contract involves a three-year, indefinite delivery/indefinite quantity contract with an initial award of more than $130 million. Export customers of the APKWS include Jordan, Iraq, and Lebanon.

June 10/16: The USAF has acquired the Advanced Precision Kill Weapon System (APKWS) laser-guided rockets for its A-10s and F-16s operating in Afghanistan and Iraq under an urgent field requirement. To fulfill the urgent need, the service will acquire its initial supply of rockets out of the current Navy inventory. The BAE-developed guidance kit was first tested on the AV-8B Harrier, F-16 and A-10 during flight demonstrations in May 2013, the company said. It is already widely used on Navy and Marine Corps helicopters such as the Bell AH-1Z Viper, and was acquired last year by the Army for the Boeing AH-64 Apache gunship. The addition of the kits will allow current “Hydra” rockets to act as a precision-guided munition capable of destroying soft targets like hostile boats, vehicles, and exposed enemy combatants instead of using more expensive guided bombs and missiles.

April 1/16: The US Navy has delivered the first fixed-wing aircraft variant of the Advanced Precision Kill Weapons System (APKWS), to be attached to AV-8B Harriers and operated by the Marine Attack Squadron (VMA). Initially integrated onto MH-60S, MH-60R, and AH-1Z helicopters, the new design just took seven months to be incorporated onto the Harrier. The new capability will quickly provide the AV-8B with a low-cost, low-collateral damage, high-precision weapon in support of combat operations.

December 2/15: Jordan is the first nation to receive shipments of the Advanced Precision Kill Weapons System (APKWS). 110 units of the system were requested by the Jordanian government back in 2014 and will be equipped on CN-235 gunships allowing for greater flexibility and precision engagement. The US has received 13 requests for the system to be sold and buyers will include Iraq, the Netherlands and Tunisia. Since the deployment of the system on the US Navy’s MH-60 Seahawk and Marine Corps UH/AH-1 light attack helicopters in 2007, APKWS has been fired more than 100 times, boasting a success rate of 94%.

September 23/15: MBDA and BAE Systems have agreed to a marketing partnership for the latter’s advanced precision kill weapon system (APKWS) in an aim to flag the system to European customers. MBDA will lead the marketing charge for the APKWS in Europe, with the system developed by BAE Systems’ US subsidiary. The system bolts onto unguided 70mm rockets to transform them into a low-cost laser-guided weapon, which has been integrated with several platforms in the US inventory, including the Cobra and Huey helicopters, Apache AH-64D and A-10.

Nov 12/14: The US DSCA announces the Shi’ite government of Iraq’s official export request for up to 2,000 APKWS rockets, weapon and test support equipment, spare and repair parts, publications and technical documentation, personnel training and training equipment, transportation, and other forms of US government and contractor support. The estimated cost is up to $97 million.

Iraq’s most likely platform for these rockets is its IA-407 armed scout helicopters, which are qualified for 70mm rockets and can also carry Hellfire missiles. Its AC-208B Combat Caravan prop planes might need additional integration, but their current tiny load of just 2 Hellfire missiles has been an operational problem. Adding laser-guided rockets would greatly improve their combat effectiveness.

The principal contractor will be BAE Systems in Nashua, NH. The proposed sale will involve multiple trips to Iraq involving U.S. government and contractor representatives for approximately 3 years for program management, program and technical reviews, training, maintenance support, and site surveys. Sources: US DSCA #14-35, “Iraq – Advanced Precision Kill Weapon System (APKWS)”.

DSCA request: Iraq (2,000)

Nov 3/14: USMC Plan. The USMC’s Aviation Plan to 2030 deals with weapons as well. The AH-1Z attack helicopter will be added to the AH-1W in 2015, which will also see integration on the MH-60R naval ASW helicopter. So far, use in the field on AH-1W, MH-60S, and UH-1Y helicopters is going reasonably well:

“APKWS II has been operationally successful, generating a direct hit rate of nearly 90% during contingency operations.”

By 2019, APKWS will be able to use the 13.7 pound M822 tri-mode penetrating/ blast/ incendiary warhead. Instead of just 1 AGM-65 Maverick per hardpoint, the Hornet fleet will have 7 anti-armor weapons that can defeat many armored personnel carriers, and all lesser vehicles. Sources: USMC, Marine Aviation Plan 2015 [PDF].

Oct 13/14: Australia. APKWS is about to get its 2nd export customer, as Australia finishes testing APKWS-II aboard its EC665 Tiger ARH scout/attack helicopters. August 2014 trials at Woomera were conducted by Airbus subsidiary Australian Aerospace’s Operational Support Group, and saw APKWS go 7-for-7 in tests while mounted on a new 70mm rocket: Forges de Zeebrugge’s FZ90.

BAE director of precision guidance solutions David Harrold touts the no-modifications use of APKWS on the FZ90 as a testament to the mid-body design’s versatility, but Australia has a 2nd reason to prefer APKWS. BAE’s system will be integrated on American MH-60R Seahawk naval helicopters, and Australia bought that type off the shelf as their future naval helicopter. Once the US Navy is done developing and testing its MH-60R upgrade, Australia can adopt it at very low cost. The tests pave the way for Australia to place an order, then field the laser-guided rockets on its Tiger and Seahawk helicopters beginning in 2015. Sources: BAE Systems, “Laser-Guided Rocket Successfully Demonstrates Precision Strike Capability for Australian Defence Forces”.

Sept 30/14: MH-60. Lockheed Martin Mission Systems and Training in Owego, NY receives $6.9 million for integration of APKWS Digital Rocket Launcher capabilities into MH-60R and MH-60S avionics software. $2.6 million in FY 2014 Navy RDT&E budgets is committed immediately.

APKWS will give equipped MH-60S and MH-60R helicopters 7 guided weapons per hardpoint, instead of 4 Hellfires. The rockets don’t pack the same punch as a Hellfire against larger naval targets or main battle tanks, but against small boat swarms and most targets ashore, there are no degrees of dead.

Work will be performed in Owego, NY (95%), and Patuxent River, MD (5%), and is expected to be complete in July 2016. Naval Air Systems Command in Patuxent River, MD manages the contract (N00019-14-G-0019, DO 4007).

AC-235 concept
(click to view full)

May 7/14: Jordan. Jordan has formally signed a Letter of Offer and Acceptance via the US Navy for BAE’s APKWS-II laser-guided 70mm rocket, which will be deployed on the kingdom’s CN-235 light gunships. This marks the guided rocket’s 1st export sale.

APKWS rockets give the gunships an intermediate option between the 30mm gun, and heavier AGM-114 Hellfire laser-guided missiles. A 70mm rocket is perfectly adequate for most counter-insurgency situations, is less expensive than a Hellfire, and can be carried in a pod that holds 7 guided rockets on the hardpoint instead of 2 Hellfires. Sources: BAE, “Kingdom of Jordan to Purchase BAE Systems’ Precision Rockets to Strengthen Military”.

Jordan is 1st export sale

March 28/14: FRP-3. A $37.4 million firm-fixed-price contract buys 1,372 APKWS-II WGU-59/B Guidance Sections, the Navy shipping and storage container; and supporting technical and program documentation. That makes 4,758 kits ordered so far.

All funds are committed immediately, using FY14 USN & USMC ammunition budgets. Work will be performed in Nashua, NH (70%); and Austin, TX (30%), and is expected to be complete in September 2015. This contract was not competitively procured, pursuant to FAR 6.302-1 (N00019-14-C-0044).

FRP-3 order

Dec 18/13: MH-60R/S: H-60 Program Manager Capt. James Glass discusses programs to arm the MH-60S naval utility and MH-60R strike and ASW helicopters with APKWS rockets.

The MH-60S is slated to integrate APKWS by March 2014, using a new 19-rocket LAU-61G/A launcher. and is about to begin test-firing the same M197 3-barrel 20mm gatling gun used on Cobra attack helicopters.

The MH-60R is slated to integrate APKWS by March 2015, by which time the LAU-61G/A launcher should have full mixed-rocket capabilities. Sources, Military.com, “Navy Arms MH-60S Helicopter with Gatling Gun” | US Navy, “NSWC IHEODTD Supports Digital Rocket Launcher Early Operational Capability”.

Oct 22/13: Testing. BAE announces that the US Army has finished 8 successful tests from an AH-64D Apache. Shots were fired at up to 150 knots, from as far as 5 kilometers from the target, at altitudes between 300 and 1,500 feets. This earns it an an Airworthiness Qualification, which allows existing AH-64D customers to order APKWS.

BAE director of precision guidance solutions David Harrold had an interesting addendu,m, when he noted that “…the final shot from the Apache hit within inches of the laser spot – despite the rocket and warhead being visibly scorched from two adjacent firings”. No doubt that was part of BAE’s motivation for using mid-body guidance sensors, which are inherently protected from such effects. Sources: BAE, “Laser-Guided Rocket Successfully Qualified to Support Apache Crews”.

FY 2011 – 2013

Fixed-wing, Apache tests. IOC; combat deployment. FRP-2.

APKWS loading, AT-6C
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Sept 27/13: Testing. CENTCOM releases a Military Utility Assessment (MUA) confirming that the APKWS FW fixed-wing variant has met its performance targets in test shots from the USAF’s A-10C Thunderbolt IIs and F-16s, and the USMC’s AV-8B Harrier II V/STOL fighters. The rocket has also been tested from AT-6 turboprops, but that work took place under the Light Air Support program.

APKWS FW is actually a different rocket, because it has to survive and perform through the freezing temperatures of high-altitude flight, as well as the high turbulence of high speed aircraft. That means a different guidance control system for the rocket, and a redesigned deployment mechanism for the 7-rocket pod. Sources: US NAVAIR, “Rocket safe for fixed wing aircraft, ends demonstration phase”.

April 2/13: Testing. Eglin AFB announces successful tests of the APKWS laser-guided 70mm rocket from an A-10C, marking the 2nd test from a fixed-wing aircraft (a Beechcraft AT-6B was the 1st). For the final A-10C test sortie, 2 APKWS rockets were fired at a surface target at altitudes of 10,000 and 15,000 feet. The first rocket hit within inches, and the 15,000 foot shot hit within 2 meters despite a 70-knot headwind.

The USAF used a US Navy rocket launcher, because the guidance section adds 18″ to the Hydra rocket. If the USAF continues to move forward with APKWS on the A-10C and F-16, they’ll buy the Navy’s modified launchers to replace their 7-rocket LAU-131s. The US Navy is preparing to qualify APKWS on the MQ-8C VTUAV, USMC AV-8B Harrier II V/STOL jets, and F/A-18 family fighters. Pentagon DVIDS.

March 4/13: Bell 407 qualified. BAE Systems announces that APKWS is now qualified on Bell Helicopters 407GT, after a 7-shot test at Yuma, AZ. The Bell 407 joins that firm’s AH-1Z Viper and UH-1Y Venom helicopters, and Beechcraft’s AT-6B light attack turboprop, as qualified APKWS platforms. Northrop Grumman’s MQ-8B Fire Scout helicopter UAV is expected to follow shortly.

BAE Precision Guidance Solutions director David Harrold says that the qualification “is significant because [the 407GT] is Bell Helicopter’s first commercially qualified, armed helicopter…” It’s also significant because the US Navy is about to introduce its MQ-8C UAV based on the 407, and Iraq has already fielded armed Bell 407s. The MQ-8C combines a Bell 407 airframe with Fire Scout electronics.

Nov 27/12: FRP-2. A $41.4 million firm-fixed-price contract modification, exercising an option for 1,476 APKWS-II WGU-59/B Guidance Sections, shipping and storage containers, and support technical data. That makes 3,386 production kits ordered so far.

Work will be performed in Nashua, NH (70%), and Austin, TX (30%), and is expected to be complete in September 2014. All contract funds are committed (N00019-12-C-0006).

FRP-2 order

July 31/12: FRP begins with FY 2012 order. A $28.1 million firm-fixed-price contract for 985 APKWS-II WGU-59/B guidance sections, Navy shipping and storage containers; and support technical data. That makes 1,910 production APKWS kits ordered so far.

Work will be performed in Nashua, NH (70%), and Austin, TX (30%), and is expected to be complete in December 2013. This contract was not competitively procured pursuant to FAR 6.302-1 by US Naval Air Systems Command in Patuxent River, MD (N00019-12-C-0006). A subsequent BAE release confirms that this is the beginning of Full Rate Production, and confirms that APKWS is available for foreign military sales.”

Full-rate production &
Export ready

April 17/12: APKWS to Afghanistan. BAE announces that APKWS was cleared for fielding by Marine Corps HQ, and shipped to Afghanistan in March 2012. The cite over 100 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.

The rockets will initially be deployed on USMC AH-1W Super Cobra attack helicopters, and UH-1Y Venom utility helicopters.

The Program’s Manager Navy Captain Brian Corey said that Initial Operating Capability (IOC) had been declared on March 27. The Navy is working to integrate the weapon on MQ-8 Fire Scouts by 2013. US NAVAIR | BAE Systems.

IOC & combat deployment

January 2012: 1st Fixed-Wing Shots. APKWS is fired from a HawkerBeechcraft AT-6C turboprop light attack plane at Eglin AFB, its 1st fixed-wing shots. BAE says they’re still working to upgrade APKWS so it can handle high-speed, high-g firings from fighter jets, per the Feb 10/11 JCTD contract.

The AT-6C shots were step 1, and involved 2 rockets: an unguided round as a demonstration of safety and basic operation, followed by a guided shot from 3 miles that “successfully hit within inches of the center.” As an added demonstration, BAE Systems personnel added the APKWS mid-bodies and assembled the rockets on site. Time from beginning of assembly to flight and the successful shot was 3 hours.

The shots will help both BAE and HawkerBeechcraft, whose setback in the 20-plane American LAS competition was mitigated by an initial sale of 6 “weapons capable” T-6C+ to Mexico. Mexico has used existing Pilatus trainers against domestic insurgencies before. The T-6C family’s proven ability to fire laser-guided rockets makes the new planes more valuable to Mexico, and to other potential customers. BAE | HawkerBeechcraft | Aviation Week.

1st fixed-wing shot

Sept 9-13/11: New warhead. USMC UH-1Y helicopters successfully fire 6 APKWS-II rockets at targets 1.5km – 5 km away (3 miles maximum) on the range at China Lake, CA. The tests are part of APKWS’ low-rate initial production phase, and mark the 1st time that the new, safer Mk152 warhead has been fired from any air vehicle.

New warhead

APWKS-II fielding is still set for 2012. BAE Systems.

Feb 10/11: Fighter JCTD. BAE Systems in Nashua, NH receives a $19.7 million cost-plus-fixed-fee contract for development of the fixed wing APKWS-II for deployment on USMC AV-8B Harriers and USAF/ANG A-10C aircraft, as a joint capability technology demonstration.

American fast jets must currently rely on aging AGM-65 Maverick missiles for laser-guided strikes. An update and production relaunch is underway, but a full-size Maverick missile can be overkill. Using laser-guided 70mm rockets instead would sharply increase the number of laser precision strike weapons on board, using cheaper weapons. It’s not a perfect substitute, but it would be an excellent complement.

Work will be performed in Nashua, NH, and is expected to be complete in May 2013. $7.5 million will expire at the end of the current fiscal year, on Sept 30/11. This contract was not competitively procured, pursuant to FAR 6.302-1, by US Naval Air Systems Command in Patuxent River, MD (N00019-11-C-0033).

APKWS for fighters, too

Jan 3/11: LRIP-2 order. BAE Systems Information and Electronics in Nashua, NH receives a $17.3 million firm-fixed-price contract for the 2nd Low Rate Initial Production Lot (LRIP-II) of 600 APKWS II guidance sections for the US Navy, including shipping and storage containers.

Work will be performed in Nashua, N.H., and is expected to be completed in November 2012. US Naval Air Systems Command, Patuxent River, MD manages the contract, which is presumably issued under N00019-10-C-0019.

FY 2008 – 2010

SDD. Milestone C.

APKWS concept
(click to view full)

July 30/10: LRIP-1 order. BAE Systems Information and Electronics in Nashua, NH receives a $15.3 million firm-fixed-price contract for the first Low Rate Initial Production Lot (LRIP-I) of 325 APKWS II guidance sections for the US Navy, including shipping and storage containers. The contract will also fund integration with the Marines’ new UH-1Y utility helicopter, technical and training manual updates, and support equipment and support test equipment.

Work will be performed in Nashua, NH, and is expected to be complete in October 2012. This contract was not competitively procured by US NAVAIR, pursuant to FAR 6.302-1 (N00019-10-C-0019). BAE Systems.

April 9/10: Milestone C, LRIP OKed. The US Navy has approved low-rate production of the APKWS after the weapons system passed its Milestone C. The USMC plans to initially deploy APKWS on its AH-1W Super Cobra helicopters. The Navy decision follows successful testing of the weapons system from the AH-1W helicopter in January (see Jan 11-18/10 entry). BAE Systems release

Milestone C

Jan 11-18/10 The USMC completes APKWS’ operational assessment, scoring 8 direct hits from AH-1W Super Cobra helicopters in live-warhead trials over 2 weeks. The final step in the APKWS development program is system qualification for the environments in which it might be employed, transported, and stored. That testing is expected to be finalized in time to allow the Navy to complete a production decision within the next 60 days, leading to low-rate initial production if the decision is positive. BAE Systems release.

Jan 4/10: Fixed-Wing JCTD. US FedBizOpps announces, in solicitation #N00019-10-C-0028:

“Naval Air Systems Command (NAVAIR) intends to award a sole source contract to BAE Systems, Nashua, NH for the FY10-12 development of the Fixed Wing (FW) Advanced Precision Kill Weapon System (APKWS) II for AV-8B and A-10 platforms to support a Joint Capability Technology Demonstration (JCTD). It is anticipated that the resultant contract shall be Cost-Plus Incentive Fee type for the development of FW APKWS II weapons that show operational utility upon integration with AV-8B and A-10 platforms. Fifty (50) FW APKWS II plus FW APKWS II tests units (quantities TBD) including Navy Shipping and Storage Containers (NSSC) are to be delivered for technical demonstrations and operational assessments.”

The AV-8B is a USMC aircraft, while A-10s are operated by US Air National Guard and some USAF units.

Jan 4/10: In the combined synopsis/solicitation #N00421-10-T-0042, US FedBizOpps announces an RFQ on a firm fixed-price, sole-source basis with Summit Instruments, Inc., for APKWS-related electronics. Summit makes accelerometers and inertial measurement systems, which can be used to help precision weapons establish their position, just as a simpler set of accelerometer + software in an iPod Nano can tell you how far you’ve jogged today.

CLIN 0001 – Quantity 5 each, Repackage 65210E to fit in 2.75″ diameter rocket body and add 2GB memory… Award is expected 04 Jan 2010.

Nov 23-27/09: SDD done. During the final phase of SDD testing, 4 APKWS rockets fired from a U.S. Marine Corps AH-1 Cobra attack helicopter hit laser-designated moving and stationary targets under a variety of operational scenarios while the rockets were fired at varying altitudes and airspeeds. Each shot strikes well within the required distance from the laser spot.

Navy and BAE Systems representatives confirm that APKWS has undertaken 28 guided flights over the last 7 years. The weapons are known to have hit their targets 22 times since September 2002, and most of those firings (12) have been from USMC AH-1 Cobra attack helicopters. In the latest test series, there have been no APKWS issues.

The rockets are approaching Milestone C decision that approves a system’s performance, durability, safety, and successful integration with specified systems, and allows Low Rate Initial Production to begin. The US Navy will begin Operational Assessment of APKWS in January 2010, with 8 live fire events. In the next 12 to 14 months, the Navy expects to shoot approximately 90 weapons in combined developmental and operational testing, on the road to the program goal of Initial Operational Capability in 2011. BAE Systems.

Nov 13/09: BAE Systems announces that APKWS has entered its final phase of testing, intended to confirm both production readiness and reliable accuracy. According to BAE, APKWS has hit its targets 18 times since September 2002 in ground and air-launched shots, including a recent firing from a USMC AH-1 attack helicopter against a stationary target. That test firing initiated a sequence of more than 20 firings that will comprise the program’s final test phase, to be completed by the end of 2009.

BAE Systems and the Navy are preparing for Navy demonstration test flights and full government qualification testing, with a goal of production in 2010.

APKWS from Cobra
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Nov 4/08: BAE Systems announces that the APKWS contract has been transferred from the U.S. Army to the Department of the Navy.

Development funding will also be used for testing and qualification of APKWS for use on the Marine Corps’ AH-1W Super Cobra helicopter, and BAE Systems’ Nashua facility plans to begin producing the rockets at the end of 2009.

July 15/08: BAE Systems announces that the Department of the Navy will assume the $45.7 million APKWS development contract with BAE Systems to complete demonstrations of the system. The Navy is expected to assume that contract by end of August 2008, and the contractor team plans to begin APKWS production in 2009.

April 9/08: Saved by the Navy. Congress approves the APKWS-II Reprogramming Request. In combination with the President’s Budget Request for FY09 (submitted to Congress the first week of February), the Reprogramming approval makes APKWS-II’s development phase a fully-funded program. This development represents a major breakthrough for the BAE/GD offering, which now looks as if it will survive long enough to reach the competitive market.

Whether their APKWS-II can continue its success, and win volume orders against a growing set of rival systems from Lockheed Martin, ATK, Raytheon, et. al., remains to be seen at this point. As noted below, the US Navy is also funding a LOGIR program with Korean cooperation. It’s also a guided 70mm rocket, but it uses Imaging Infrared instead of laser seekers. That makes it especially effective against swarm attacks by enemies like small boats, as there’s no need for ongoing guidance.

Saved by the Navy

FY 2005 – 2007

BAE win. Emerging competitors.

APKWS on target
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Sept 19/07: Testing. BAE Systems shoots 2 guided APKWS rockets from a U.S. Marine Corps Cobra helicopter at NAS China Lake, marking the weapon’s first flights from an aircraft. Following the launches, both APKWS rockets were guided by a laser designator to a ground target. The first rocket was guided to the target by a ground-based laser designator. The pilot guided the second rocket to the target using laser designation equipment onboard the helicopter. Both rockets struck the target board well within accuracy requirements established by the Army and Marine Corps.

The flights, held in partnership with the U.S. Navy program office, were designed to confirm the APKWS rocket’s compatibility with the Cobra’s carriage and launch systems, and to demonstrate that APKWS can be launched from the platform without requiring aircraft integration or modifications. The tests also proved again the weapon’s ability to acquire, track, and hit a laser-designated target. BAE Systems North America release.

BAE informs DID that the US Navy and USMC continue to pursue funding of APKWS-II within the FY 2008 appropriations process, with the goal of completing SDD and entering Milestone C in the second quarter of CY 2009. Meanwhile, development continues using FY 2007 funds.

April 11/07: BAE Systems’ APKWS II successfully completes environmental tests. They verified protection from sand, dust, vibration, ice, and other environmental hazards likely to be found in combat situations. Locating the weapon’s Distributed Aperture Semi-Active Laser Seeker (DASALS) within the rocket’s mid-body, with wings and optics sealed within the guidance section, certainly helps. In addition, a fully assembled 35-pound rocket dropped directly on its nose from a height of 3 feet sustained no damage to the guidance section. BAE Systems release.

March 19/07: Zeroed? BAE Systems informs DID that APKWS II funding has been zeroed out in the FY 2008 budget request, and they are putting the program on hold. Congressional reinstatement is always possible – but if it fails BAE may face an uphill battle getting its product to market, given the advance of competitors like Lockheed Martin’s DAGR and the US-Korean LOGIR.

DAGR launch test
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March 7/07: Competitor – DAGR. Lockheed Martin may have lost, but it didn’t give up. While “Hellfire Jr.” is an apt description of the class as a whole, it’s especially apt in this case. The DAGR (70mm Direct Attack Guided Rocket, not to be confused with DAGR hand-held GPS locators) completed development with private company funding, leveraging existing Hellfire and Joint Common Missile technology to create semi-active guided rockets that offer a wider aiming cone and full Hellfire functionality. Indeed, they can be launched from any platform that currently supports the Hellfire missile, removing any requirements for additional training or infrastructure.

The DAGR rocket was formally unveiled as complete and for sale on Sept 11/07, at Britain’s DESi defense exhibition, and remains a strong competitor in the USA and beyond. See “Guided Hydra Rockets: Program Halts & New Entries” for more information and updates re: competitive programs from Lockheed Martin, Korea, Raytheon, ATK, et. al.

March 2/07: USN Competitor – LOGIR. Korea and the United States have agreed to cooperate in developing guided air-launched rockets, signing a memorandum of understanding (MOU) for “LOGIR” (Low-Cost Guided Imaging Rocket) development. The budget for this project is reportedly more than $60 million. See “Guided Hydra Rockets: Program Halts & New Entries” for more information and updates.

BAE/GD APKWS
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April 27/06: The U.S. Army Aviation and Missile Life Cycle Management Command (AMCOM) awards a 3-year, $45.7 million contract to BAE Systems in Nashua, NH for the system development and demonstration of the Advanced Precision Kill Weapon System (APKWS) II. The contract includes priced options for qualification of the system and 2 years of Low Rate Initial Production that could begin as early as 2007. The total program, if all options are exercised, will be $96.1 million.

Interestingly, BAE Systems uses a mid-body guidance approach. The guidance component is its Distributed Aperture Semi-Active Laser Seeker (DASALS), which is also used in the Army’s Precision Guided Mortar Munitions Program. BAE Systems is partnered with General Dynamics (who makes the Hydra rockets) and Northrop Grumman, and is reported to be on track to provide the first production baseline units for evaluation prior to the Critical Design Review in July 2006. See also BAE North America release.

DID’s focus article for the Hydra-70 rocket family goes into more detail re: the past history of the APKWS effort, including its cancellation and replacement by the APKWS II competition.

BAE wins SDD

Sept 29/05: BAE Systems announces [BAE North America release | different BAE Systems release] 2 successful flight tests at the U.S. Army’s Yuma Proving Ground in Arizona. Their 70mm rockets scored direct hits on laser-designated stationary and moving targets.

BAE also announced that it will bid on APKWS II as a prime contractor, along with Northrop Grumman Corp. and General Dynamics. They join other consortia already in the APKWS II competition, led by Lockheed Martin and Raytheon.

Additional Readings

Readers with corrections, comments, or information to contribute are encouraged to contact DID’s Founding Editor, Joe Katzman. We understand the industry – you will only be publicly recognized if you tell us that it’s OK to do so.

• BAE Systems – Advanced Precision Kill Weapon System (APKWS). See also video page.

• BAE Systems – Distributed Aperture Semi-Active Laser Seeker (DASALS)

• DID Spotlight article – Guided Hydra Rockets: Program Halts & New Entries. Covers Lockheed Martin’s competing DAGR, which was formally unveiled as a complete, for-sale system on Sept 11/07, the US-Korean LOGIR program, and efforts from Canada, Israel, the UAE, France, and beyond. APKWS-II will have a lot of competitors.

• DID FOCUS article – Hydra-70 Rockets: From Cutbacks to the Future of Warfare.

EA-18G at Pax

The USA’s electronic attack fighters are a unique, overworked, and nearly obsolete capability. With the retirement of the US Air Force’s long-range EF-111 Raven “Spark ‘Vark,” the aging 4-seat EA-6B Prowlers became the USA’s only remaining fighter for radar jamming, communications jamming and information operations like signals interception [1]. Despite their age and performance limits, they’ve been predictably busy on the front lines, used for everything from escorting strike aircraft against heavily defended targets, to disrupting enemy IED land mine attacks by jamming all radio signals in an area.

EA-6B Prowler
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All airframes have lifespan limits, however, and the EA-6B is no exception. The USA’s new electronic warfare aircraft will be based on Boeing’s 2-seat F/A-18F Super Hornet multi-role fighter, and has 90% commonality with its counterpart. That will give it decent self-defense capabilities, as well as electronic attack potential. At present, however, the EA-18G is slated to be the only dedicated electronic warfare aircraft in the USA’s future force. Since the USA is currently the only western country with such aircraft, the US Navy’s EA-18G fleet would become the sole source of tactical jamming support for NATO and allied air forces as well.

DID’s FOCUS articles offer in-depth, updated looks at significant military programs of record. This article describes the EA-18G aircraft and its key systems, outlining the program, and keeping track of ongoing developments, contracts, etc. that affect the program.

Growler: The EA-18G Program

EA-18G: The Platform

EF-111 “Spark ‘Vark”
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While other electronic warfare platforms like the EC-130H Compass Call exist, their slow speed makes their use as tactical jamming aircraft during airstrikes problematic. The most common tactical option for electronic attack, therefore, takes an existing fighter such as the A-6 Intruder (EA-6B Prowler) or F-111 Aardvark (the recently-retired EF-111 Raven, aka. “Spark Vark”), then modifies it via new wiring, changes to the airframe, and additional pods. The price has typically been reduced performance, reduced weapons capability, and sometimes even a larger basic radar signature for the airframe.

The current EA-6B is an excellent example. The good news? Since it’s based on Grumman’s robust A-6 Intruder attack aircraft, it offers excellent range, ample carrying capacity, and efficient subsonic performance. The bad news? Poor self-defense against aerial opponents, a large radar signature, and difficulty keeping up with friendly aircraft traveling at high subsonic cruise speeds.

EA-18G primer

The EA-18G Growler/ Grizzly has avoided many, but not all, of these typical tradeoffs.

The EA-18 is more than 90% common with the standard F/A-18F Super Hornet, sharing its airframe, AN/APG-79 AESA radar, AN/AYK-22 stores management system, and weapons options. The exception is the Super Hornet’s 20mm Vulcan gatling gun, which has been removed from the nose in favor of electrical equipment.

EA-18G: key systems
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Additional electrical equipment is added throughout the airframe, and Raytheon’s internally-mounted AN/ALQ-227 communication countermeasures system uses a dedicated, omni-directional antenna for signals detection, analysis, and recording. That system works with the plane’s AN/ALQ-99 high and low-band jamming pods, in order to perform complex jamming tasks. Northrop Grumman’s ALQ-218v2 is a digital wideband radio frequency receiver, with selective jamming and geo-location capabilities. It currently equips the EA-18G’s wingtip pods.

The use of pods comes with certain penalties. The increased drag of the external pods, coupled with the shorter range of the F/A-18 E/F base platform vis-a-vis the A-6 it replaces, means that external fuel tanks will be needed. The presence of those fuel tanks on the aircraft’s “wet” pylons, and of the pods on its wingtips and underwing pylons, doesn’t leave much space for other weapons. Despite these limitations, Growlers will be more capable of aerial self-defense than their predecessors. EA-18Gs will typically be armed with a pair of AIM-120 AMRAAM medium range air-air missiles mounted under the engine intakes, and another pair of AGM-88 HARM (High Speed Anti-Radiation) or AGM-88E AARGM (Advanced Anti-Radiation Guided) missiles on underwing stations for destroying enemy radar sites.

EA-18: Looking Beyond

NGJ early promo

Boeing has also surveyed future users of the EA-18G “Growlers” to find out what upgrades they might like to see after the US Navy starts fielding the EA-18G. While the AN/ALQ-99 radar jamming pod has received positive reviews, and will be a critical component of the EA-18G’s initial kit, reports consistently cite it as a maintenance and reliability problem. The US Navy’s EA-18G program manager has said that it might eventually have to be replaced, and the USA’s Next-Generation Jammer program is already in motion to do just that.

The EA-18 program would receive tremendous benefits from Advanced Super Hornet design improvements, from the large displays and upgraded computing to the nearly dragless conformal fuel tanks. The program is also exploring adding more weapon types and replacing the satellite communications receiver, as part of the budget planning process.

RAAF EA-18G
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Meanwhile, exports beckon. That would be something of a departure, as the USA has traditionally been the only country to field tactical electronic attack aircraft. As anti-aircraft missiles on the global market become more and more sophisticated, however, serious players are going to need this kind of capability.

Australia has already stepped up, becoming the 1st EA-18G export customer. Their F/A-18F contract specified that 12 of its 24 new planes would have all of the internal modifications required to become an EA-18, if the right equipment is added. August 2012 saw Australia take that next step, at a cost of about $1.56 billion (around $130 million more per plane).

A less expensive “EA-18 Lite” export version could reply on the ALQ-218 wingtip pods, and the internally-mounted ALQ-227 system. The APG-79 AESA radar that equips all EA-18Gs could also be used as a jammer, if future software development is forthcoming along those lines. The resulting “EA-18 Lite” combination would be a stronger SEAD (suppression of enemy air defenses) option than the F/A-18F, with more range and available weapons than a full EA-18G, but less jamming than the full EA-18G, and less stealth than the F-35A. EA-18 Lites would be able to identify and geo-locate enemy radars, for instance, and immediately target them with GPS-enabled anti-radar missiles like AARGM. Jamming in low-intensity environments, such as the use of EA-6B Prowlers in Iraq to jam enemy land mine detonation frequencies over key convoys, would also be possible. Even so, the removal of the expensive and fragile ALQ-99 pod would remove the plane’s most advanced jamming, unless ECM pods from other global sources could be integrated instead.

As the Super Hornet production line heads to a close around 2015, the availability of this unique conversion option is an important argument for Boeing, as it tries to sell prospective customers on the F/A-18 Super Hornet as their future fighter.

EA-18G: Industrial Program

Rollout ceremony
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Naval Air Systems Command (NAVAIR) PMA-265 is the U.S. Navy acquisition office for the EA-18G. Boeing is the prime contractor, building the forward fuselage and wings and conducting final assembly. Northrop Grumman, who designed the YF-17 lightweight fighter that became the F/A-18 family, is the principal subcontractor. They supply the center and aft fuselage and act as the airborne electronic attack subsystem integrator. The Hornet Industry Team will divide key EA-18G component production across Boeing, Northrop Grumman, General Electric (F414 engine) and Raytheon (AN/APG-79 AESA radar) manufacturing facilities.

The EA-18G has faced its share of normal development challenges. A $7 million supplemental contract was required, in order to make its wingtip-mounted AN/ALQ-218 (V)2 radio-frequency receiver systems durable enough to withstand harsh weather. Managing the human interface complexities of going from 4 crew in the EA-6B to just 2 crew in the EA-18G is also an ongoing focus. The EA-18Gs were set to receive their production software and hardware build in July 2007, which is the last major challenge through the end of test and evaluation. Software build 2.0 will fix deficiencies discovered in the first software tape, add 36% more software functionality, and roll in capabilities for communications jamming and Multi-mission Advanced Tactical Terminal systems hardware. The pace of testing provided the team an extra 2 months to incorporate fixes into that software push.

The Growler’s level of commonality with its Super Hornet predecessor helps to keep development costs down, but complex integration is still required for the various electronic components, and testing is still necessary. At the moment, however, the program is slightly under expected cost, as it nears the end of a 5-year system design & development contract.

EA-18G flight testing and Operational Evaluation is taking place at the Navy’s Patuxent River, MD and China Lake, CA test sites, and on Navy carriers, through 2008 and 2009. Fielding is also beginning at NAS Whidbey Island, WA.

At present, industrial partners include:

• Boeing (F/A-18, EA-18G prime contractor)
  
• GE (F414 engines)
  
• Northrop Grumman in Bethpage, NY; El Segundo, CA; St Augustine, FL, Baltimore, MD (F/A-18 structures, EW systems and software incl. ALQ-218 and wingtip pods, EW support)
  
• ITT in Thousand Oaks, CA (ALQ-99 jamming pods, INCANS interference canceling)
  
• Raytheon in El Segundo, CA; Ft. Wayne, IN; and Largo, FL (APG-79 AESA radar, ALQ-227 CCS)
  
• Alion Science and Technology Inc. in Annapolis, MD (EM analysis)
  
• Ball Aerospace, Westminster, CO (MATT antenna)
  
• Cobham’s Sensor and Antenna Systems division in Landsdale, PA (low band antennas)
  
• GKN Inc. in St. Louis, MO (complex parts fabrication)
  
• Harris Corp in Melbourne, FL (data storage devices)
  
• Nurad in Baltimore, MD (wingtip pod radome)
  
• Times Microwave in Wallingford, CT (RF/IF coaxial cables)

EA-18G: Numbers & Budgets

INCANS: RDT&E…
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The current plan for the EA-18G program is up to 114 planes, and the FY 2015 budget could push that to 137. The number has risen steadily from the original 90, after growing awareness of this mission’s importance reversed a slight decline to 88 earlier in the program.

The EA-18G received DoD approval to enter Full Rate Production on Nov 23/09. Initial early deliveries to Fleet Replacement Squadron VAQ-129 have begun, which allows the Navy to begin general aircrew training and develop standard operating procedures. Initial EA-18G Operational Capability was achieved in September 2009 with the US Navy electronic attack squadron VAQ-132 located at Whidbey Island, WA where the Navy’s current EA-6B squadrons are based. The US Navy expects a complete transition of all production Growlers to the fleet by 2015.

Excel
download

Budgetary figures below are based on Pentagon documents. All figures are in millions, and deliveries tend to occur 2 fiscal years after orders are placed:

As of November 2012, NAS Whidbey Island had 79 EA-18Gs: 41 in the VAQ-129 Fleet Replacement (training) squadron, plus 6 operational and 1 transitioning squadron of 5 planes each (35), and then 3 more planes. The desired total is 11 operational squadrons, and if 22 more planes are bought in FY 2015, each operational squadron will rise to 7 planes. The USN’s 6 EA-6B squadrons will all transition to EA-18Gs by 2016, but the USMC will keep its EA-6Bs in service until 2019, when F-35Bs are expected to replace USMC electronic warfare capabilities with stealth.

EA-18G: Contracts & Other Developments

EA-18G and F/A-18F
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In general, this FOCUS article will only cover purchases that refer exclusively to the EA-18G, unless the EA-18G items are specifically broken out, or their inclusion helps make later EA-18 program buys more comprehensible.

As noted above, many procurement items will be shared between the EA-18G and the F/A-18 E/F Super Hornets, on which the platform is based. DID’s Spotlights on the MYP-II (FY 2005-2009) and MYP-III (FY 2010-2014) multi-year Super Hornet contracts cover all airframes and integration from 2005-2014. Fleet support costs are also part of the F/A-18E/F contracts, due to aircraft commonality; while common “Government-Furnished Equipment” items like APG-79 radars, GE’s F414 engines, etc. are bought through separate contracts of their own.

“Airborne Electronic Attack” (AEA) Kits include the AN/ALQ-218 wingtip pods, and AN/ALQ-227 Communication Countermeasures Set/Electronic Attack Unit, as well as other unique internal electronics and gear that make the plane an EA-18G instead of an F/A-18F. What they do not include, is the AN/ALQ-99 pods carried underneath the Growlers. Those are simply moved over from retiring EA-6B Prowlers, following minor hardware and software compatibility modifications.

Unless otherwise specified, all awards are made to Boeing subsidiary McDonnell Douglas Corp. in St. Louis, MO, and/or are awarded by the Naval Air Systems Command (NAVAIR) in Patuxent River, MD.

FY 2016 – 2018

Boeing gets $897M contract modification.

EA-18G landing
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June 29/18: Upgrades Raytheon is being tapped to support the Navy’s fleet of EA-18G Airborne Electronic Attack aircraft. The $65,4 million indefinite-delivery/indefinite-quantity contract provides for systems engineering and software development services of the aircrafts ALQ-227 communications countermeasures set. At present, the EA-18G is slated to be the only dedicated electronic warfare aircraft in the USA’s future force. The EA-18 shares a 90% commonality with the standard F/A-18F Super Hornet, sharing its airframe, radar, stores management system and weapon options. The exception is the Super Hornet’s 20mm Vulcan Gatling gun, which has been removed from the nose in favor of electrical equipment. The AN/ALQ-227 communication countermeasures system uses a dedicated, omni-directional antenna for signals detection, analysis, and recording. That system works with the plane’s jamming, in order to perform complex jamming tasks. Work will be performed in Fort Wayne, Indiana, and is expected to be completed in June 2023.

April 27/18: REAM contracts Northrop Grumman received Wednesday, April 26, a $7.2 million contract from the US Navy. The agreement tasks the firm with machine learning algorithms (MLAs) for the Reactive Electronic Attack Measures (REAM) program. According to the Pentagon statement, the REAM program is a future naval capabilitiesenabling capability with the objective of transitioning MLAs to the EA-18G airborne electronic attack suite to achieve capabilities against agile, adaptive, and unknown hostile radars or radar modes. Work will take place at Bethpage, New York, wrapping up in December 2019.

February 28/18: Lucky Escape A US Navy EA-18G Growler crew had a lucky escape after the electronic warfare aircraft’s environmental control system (ECS) failed during a flight from NAS Whidbey Island to NWS China Lake on January 29. During the flight, the temperature inside the cockpit dropped to -30 degrees and a layer of ice engulfed the canopy and instrument panels. Flying blind, the crew used their Garmin watch for navigation back to Whidbey Island while breathing on oxygen from emergency equipment. The crew suffered from frostbite with “severe blistering and burns on hands,” and one crew member is already back in flight status after treatment while the other is expected to make a complete recovery.

December 8/17: Upgrades-Proposals Northrop Grumman is proposing the inclusion of a canister-launched UAV as part of Block II upgrades to the EA-18G Growler electronic warfare aircraft. The firm will partner with composites manufacturer VX Aerospace to offer the UAV—known as Dash-X—which when deployed, can collect and share electronic warfare information in flight with the manned aircraft. In term of the UAV’s survivability, Northrop argue that the aircraft’s 60kt speed and tin airframe are what will allow Dash X to fly close to its target and evade enemy detection systems.

July 11/17: The Naval Air Systems Command (NAVAIR) has issued a request to potential bidders for its Next Generation Jammer increment 2 program, which looks to develop a low-band jamming pod for the Boeing EA-18G Growler and complement the service’s ongoing work on Increment 1’s mid-band frequency jammer. Industry has been asked to show how existing technologies can meet requirements for a new low-band transmitter, which are generally used to jam early warning radars and voice communication frequencies. The contract will only ask to demonstrate, not mature, technology for increment 2, and will explore frequency coverage, effective isotropic radiated power (EIRP), spatial coverage and spectral purity.

March 1/17: Boeing has won a $678 million DoD contract to supply seven Lot 40 EA-18G Growlers and five F/A-18E Super Hornets to the US Navy. Delivery of the aircraft is expected to be completed by February 2019 after production and assembly at various US locations. The EA-18s will come with airborne electronic attack kits which support the Growler’s communication jamming capabilities.

October 28/15: The Navy has handed Boeing a $897.5 million contract modification for the production of fifteen EA-18G Growler aircraft and electronic attack kits. The order is part of the program’s Lot 38 production, with the head of the Navy’s Chief of Naval Operations stating last November that the service requires more Growlers to fulfil its Electronic Attack requirements. The aircraft received additional funds as part of a list of unfunded priorities, with the Senate approving the funding increase in June.

FY 2015

Environmental Impact Statement for 36 more EA-18Gs, as Navy considers asking for some in FY 2016; Australia to get their own TOFT; US Navy’s EA-6Bs all retire.

July 30/15: Boeing has revealed the first Australian EA-18G Growler electronic attack aircraft, with this the first of twelve Growlers ordered through a Foreign Military Sale contract in June 2014. The Australian government requested a F/A-18E/F Super Hornet and EA-18G Growler sustainment program in April 2015, estimated to value $1.5 billion. A second Growler is scheduled to complete testing in August, with the pair of aircraft then set for delivery to Naval Air Weapons Station China Lake for RAAF pilot training, before delivery to Australia in 2017.

Boeing was also awarded a $20.5 million delivery order on Thursday for intermediate-level support service for the twelve Australian EA-18G Growlers, as well as for the provision of support equipment for the US Navy’s new squadron of Growlers, set for stand-up in 2017. $15.2 million of the contract total has been allocated for the US Navy and the remaining $5.3 million for the Royal Australian Air Force.

April 15/15: The Navy’s EA-18G Growlers could use their electronic warfare capabilities to locate insurgents for targeting through the triangulation of intercepted signals, with three aircraft working as a team. However, before this can happen, the aircraft need new, faster data links in order to corroborate intercepts and locate the source of the tracked signals. A USN study recently argued that the Navy needs more of the aircraft to meet future operational demand. A Pentagon Electronic Warfare Committee was also stood up in March, highlighting the continued relevance of these non-stealthy workhorses despite uncertainty over the aircraft’s future production line.

Nov 19/14: AEA kits. A $194.8 million contract modification to a previously awarded fixed-price-incentive contract for 21 Full Rate Production Lot 38 EA-18G airborne electronic attack kits. All funds are committed immediately, using FY 2014 US Navy aircraft budgets.

Work will be performed in Baltimore, MD (51%); Bethpage, NY (33%); St. Louis, MO (12%); and Fort Wayne, IN (4%), and is expected to be complete in December 2016 (N00019-14-C-0032).

21 AEA kits

Nov 16/14: The US Navy is reportedly looking at buying a few more EA-18Gs in 2016, to go with the 12 they’re likely to get as an “unfunded priority” item in FY 2015. Chief of Naval Operations Admiral Jonathan Greenert:

“Before we close the books and call it quits on Growlers, we want to make sure we’ve got the electronic attack right…”

Especially given recent realizations that F-35s will probably need EA-18G support of some kind (q.v. April 7/14, April 25/14). On the other hand, the USMC’s distributed EW approach (q.v. Nov 3/14) suggests a different path the Navy could pursue to supplement its force. Sources: MarineLink, “U.S. Navy Expects Further Orders of Boeing Jets” | St. Louis Post-Dispatch, “Navy mulls over more EA-18G Growlers in 2016 budget”.

EA-6B
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Nov 15/14: EA-6Bs. The VAQ-134 Garudas have returned from the US Navy’s last EA-6B deployment. the squadron will now begin its transition to the EA-18G, which is expected to finish early in 2015. Whidbey News-Times, “Saluting an old workhorse, the EA-6B Prowler” | Foxtrot Alpha, “The Navy’s EA-6B Prowler Completes Its Final Carrier Cruise”.

USN EA-6Bs retiring

Nov 3/14: USMC Plan. The USMC’s Aviation Plan to 2030 deals with jamming as well. Their 4 EA-6B squadrons will begin retiring in 2016, and leave service at the end of FY 2019. The F-35B has been discussed as a replacement plan, but the inability to put a 2nd crew member in makes a full EA-35B questionable.

Instead of turning toward EA-18Gs, the Marines are moving toward a more distributed, platform-agnostic approach that wouldn’t depend on any 1 aircraft type. The EW Services Architecture (EWSA) will serve as a common back end, while ALQ-231 Intrepid Tiger II EW payloads would deploy on AV-8B and F/A-18C/D fighters, and on future UAVs. F-35Bs will also receive software updates to use the AN/APG-81’s radar jamming capabilities at some point, and payload additions are also a possibility. If the Navy wants to buy more EA-18Gs in the meantime, of course, the Marines won’t object to having a few more on call. Sources: USMC, Marine Aviation Plan 2015 [PDF].

Oct 25/14: EA-6Bs. The USS Carl Vinson [CVN 70] strike group, which is conducting strikes in Syria and Iraq, will be the last deployment of the EA-6B by the US Navy. Navy VAQ-134 will transition to EA-18Gs upon its return, though the USMC will still be operating EA-6B squadrons. Sources: Whidbey News-Times, “NAS Whidbey Prowlers returning from final mission”.

Local objections

Oct 11/14: Politics. The Navy says it is revising its Environmental Impact Statement (EIS) on the EA-18G Growlers to base up to 36 additional EA-18Gs at NAS Whidbey Island, WA. The EIS is looking at Growler operations at both Ault Field at NAS Whidbey and Outlying Field Coupeville, where most Growler touch-and-go training takes place. An additional scoping period through Nov 24/14, will push the completion of the draft EIS from 2015 to spring 2016, with a published decision planned for spring 2017.

The environmental impact process is now tied to the receipt of extra EA-18Gs in VAQ-143 and VAQ-144, with a local paper reporting that the request for additional Growlers has been “placed on hold pending the results of the EIS.” Note that even planes ordered in 2015 won’t be delivered before 2017, so the timing isn’t a problem yet. Nor is this a commitment from the Navy to 36 planes – but if you’re going to have extra planes tied up in red tape, you might as well ask for more than you expect, so you only have to run the process once. Sources: Whidbey News-Times, “Navy Environmental Impact Statement to include up to 36 Growlers at Whidbey Island Naval Air Station” | SeaPower Magazine, “Navy Delays Formation of Expeditionary EA-18G Squadron”.

Oct 9/14: Australia. L-3 Communications Corp. in Arlington, TX receives a $12.1 million firm-fixed-price delivery order for 2 EA-18G Tactical Operational Flight Trainers (TOFT), 1 brief/debrief Station, 2 F/A-18 retrofit kits, spares, and associated technical documentation for the government of Australia under the foreign military sales program.

Work will be performed in Arlington, Texas, and is expected to be completed in November 2015. Foreign military sales funds in the amount of $12,086,117 will be obligated at time of award, none of which will expire at the end of the current fiscal year. The Naval Air Warfare Center Training Systems Division, Orlando, FL, is the contracting activity (N61340-12-G-0001, PO 0004).

Oct 8/14: Australia. A $7.5 million delivery order for peculiar support equipment and spares, to outfit emerging squadron stand-ups for extended Australian deployment of F/A-18F and EA-18G aircraft. In addition, this order includes a support equipment integrated logistics support package. All funds are committed immediately.

Australian F/A-18Fs are currently based at Al Minhad AB in the UAE, where they are conducting strikes in Iraq against The Islamic State.

Work will be performed in St. Louis, MO, and is expected to be complete in October 2016. US Navy Naval Air Systems Command in Lakehurst, NJ acts as Australia’s FMS agent (N68335-10-G-0012, DO 0057).

FY 2014

Battle in Washington over Navy request for another 22 EA-18Gs; 100th EA-18G delivered; 100th jamming set delivered; Various contracts for EA-18G equipment beyond the core multi-year aircraft contract.

EA-18G
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Aug 28/14: HARM computers. Raytheon in Tucson, AZ receives $24.6 million for a firm-fixed-price delivery order to provide 158 High Speed Anti-Radiation Command Launch Computers for the U.S. Navy (121) and the government of Australia (37) for F/A-18 E/F and EA-18G aircraft. These CLCs work with AGM-88 HARM and AARGM missiles, which are designed to destroy enemy air defense radars. All funds are committed immediately, using FY 2012 – 2013 US Navy ($20.5M / 83.5%) and Australian ($4.1M / 16.5%) budgets.

Work will be performed in Tucson, AZ, and is expected to be complete in February 2018. US NAVAIR in Patuxent River, MD manages the contract (N00019-10-G-0006, DO 0060).

Aug 24/14: Infrastructure. Korte Construction Company in St. Louis, MO wins a $23.8 million firm-fixed-price contract to design and build EA-18G Facility Upgrades at NAS Whidbey Island, WA. The contract also contains 3 unexercised options, which could raise the contract’s value as high as $26.6 million. All funds are committed immediately, using FY 2014 US Navy construction budgets.

Work will be performed in Oak Harbor, WA, and is expected to be complete by May 2017. This contract was competitively procured via Navy Electronic Commerce Online, with 12 proposals received by US NAVFAC Northwest in Silverdale, WA (N44255-14-C-5004).

Aug 18/14: EA-18s. General Dynamics Advanced Information Systems in Minneapolis, MN receives a $16.3 million firm-fixed-price contract for the full-rate Lot 38 production of 60 Advanced Mission Computer Type 3s for EA-18Gs ordered by the US Navy (48 AMCs / $9.8 million / 60%) and the government of Australia (12 AMCs / $6.5 million / 40%). All funds are committed immediately, using FY 2014 US Navy aircraft budgets and Australian FMS funds.

Work will be performed in Bloomington, MN and is expected to be complete in August 2016. This contract was not competitively procured pursuant to 10 USC 2304 (c)(1) by US Naval Air Systems Command in Patuxent River, MD (N00019-14-C-0068).

Aug 11/14: Engines. General Electric Co. in Lynn, MA receives a $311.5 million firm-fixed-price contract modification for 75 F414-GE-400 engines and associated devices: 48 production installs for the US Navy ($194.9 million / 63% / all production installs), and 27 for Australia ($116.6 million / 37% / 24 EA-18G production installs and 3 spares), under Production Lot 14. In addition, this modification provides for spare after burner modules, fan modules, high pressure combustor modules, combustor modules, and high and low pressure turbine modules for the US Navy and the government of Australia. All funds are committed immediately, using FY 2013-14 US Navy aircraft budgets, and Australian funds.

Work will be performed in Lynn, MA (59%); Hooksett, NH (18%); Rutland, VT (12%); and Madisonville, KY (11%), and is expected to be complete in September 2016. US Naval Air Systems Command in Patuxent River, MD manages the contracts (N00019-11-C-0045).

July 18/14: Testing. Commander Jeannie Groeneveld, who is the spokeswoman for the US Pacific Fleet’s naval air force, says that May and June tests with extra EA-18Gs on deck went well. It would be surprising if she had said anything else, under the circumstances. Sources: Reuters, “AIRSHOW-Carrier test with extra EA-18G jets went well U.S. Navy”.

July 17/14: Politics. The US Senate Appropriations Subcommittee on Defense approves 12 additional E/A-18G Growler aircraft during the markup of the FY 2015 defense spending bill. The full House Appropriations Committee has also approved 12 EA-18Gs, so this move improves the odds that 12 planes will be the final buy after reconciliation. Sources: Bloomberg, “Senate Panel Rejects Pentagon Cuts in Spending Bill”.

July 16/14: Industrial. Super Hornet program manager Capt. Frank Morley says that the U.S. Navy might agree to accept slower deliveries than 2 planes per month to help extend the company’s production line by a year to the end of 2017. On the other hand, “my marching orders are not to do that at any additional cost to us.”

He adds that Boeing has already used some of its own funds to pay for early procurement for another 12 EA-18G jets, which does seem to be the way things are working out in Congress. Sources: Reuters, “AIRSHOW-U.S. open to slower Boeing deliveries, but no extra cost”.

July 11/14: AEA support. Northrop Grumman Aerospace Systems in Bethpage, NY receives a 5-year, $198.9 million indefinite-delivery/ indefinite-quantity, cost-plus-fixed-fee contract to provide Airborne Electronic Attack software configuration set upgrades and ancillary hardware. They’ll support EA-6B and EA-18G aircraft owned by the United States ($179.0 million / 90%) and the government of Australia ($19.9 million / 10%). $675,697 is committed immediately from FY 2014 US Navy O&M funds.

Work will be performed in Point Mugu, CA, and is expected to be complete in July 2019. This contract was not competitively procured pursuant to FAR 6.302-1 by the US Naval Air Warfare Center Weapons Division in China Lake, CA (N68936-14-D-0018).

June 30/14: EA-18Gs. Boeing in St. Louis, MO receives a $1.939 billion fixed-price-incentive-fee contract for full rate production of 11 FRP Lot 38 F/A-18E aircraft for the US Navy, and 33 EA-18G aircraft for the US Navy (21) and the government of Australia (12 for $533.4 million, which is 27.3% of the total). The USN’s total is $1.406 billion, using USN FY 2013 (F/A-18E) and 2014 (EA-18G) aircraft budgets (72.7%).

The extra F/A-18Es come from a $605 million Congressional markup in FY 2013. Which is why FY 2014 may not be the very last Super Hornet family order, if Congressional mark-ups of the 2015 National Defense Authorization bill or defense appropriations bill survive the budget process. The House Armed Services Committee has approved 5 Growlers, and the House Appropriations Committee has approved funds for 12 Growlers.

Work will be performed in El Segundo, CA (46%); St. Louis, MO (30%); Fort Worth, TX (2%); East Aurora, NY (1.5%); Irvine, CA (1percent); Ajax, Ontario, Canada (1%), and various locations within the United States (18.5%), and is expected to be complete in December 2016. This contract was not competitively procured pursuant to 10 USC. 2304(c)(1). US NAVAIR in Patuxent River, MD manages the contracts for the US Navy, and acts as Australia’s agent (N00019-14-C-0032). See also US NAVAIR, “Contract awarded to produce F/A-18 Super Hornets, EA-18G Growlers” | Seapower, “Boeing Awarded to $1.94 Billion Contract for F/A-18 Super Hornets, EA-18G Growlers”.

44 bought: 11 F/A-18Es, 33 EA-18Gs

June 27/14: ALQ-99. Exelis Inc. in Clifton, NJ receives a sole-source, $15.3 million cost-plus-fixed-fee contract for the design, engineering analysis, program, manufacture and test of the AN/ALQ-99 tactical jamming system’s universal exciter upgrade’s shop replaceable assembly redesign. ALQ-99s are the EA-6B Prowler and EA-18G aircraft. This procurement is to design and manufacture three components of the universal exciter: the modulation direct digital synthesizer, the direct digital synthesizer and the oscillator switch to eliminate the use of obsolete parts. This contract combines purchases for the U.S. Navy (10%), and the government of Australia (90%), under the Foreign Military Sales program. All funds are committed immediately.

Work will be performed in Amityville, New York (97%), and Clifton, New Jersey (3%), and is expected to be complete by June 2017. This contract was not competitively procured pursuant to the authority of 10 U.S.C. 2304(c)(1), by the US Naval Surface Warfare Center in Crane, IN (N00164-13-G-WM01).

May 6/14: Politics. House Armed Services Committee (HASC) chair Buck McKeon [R-CA] is proposing to add $450 million to fund 5 EA-18Gs and their equipment in the FY 2015 budget, instead of the 22 on the unfunded priorities list. The committee’s proposed changes would also preserve all F-35 funding, while cutting the Navy’s unmanned UCLASS R&D budget in half to $200 million.

Meanwhile, Missouri Lawmakers say that they’ve already gathered over 80 signatures from Republicans and Democrats in the House of Representatives, and the International Association of Machinists will be weighing in. The HASC markup will make their lobbying job more challenging, and they’ll need to more than triple that number of allies in order to get the full 22 planes. As the saying goes – show me. Sources: Flightglobal, “House bill promotes EA-18G and U-2S, but hits UCLASS” | Reuters, “Boeing, backers to fight for funding for 22 Boeing jets”.

May 5/14: #100. Boeing [NYSE: BA] delivers the 100th EA-18G Growler to the US Navy, and the ceremony was turned into one more element of Boeing’s push to increase the Navy’s buy from 114 to 136. Sources: US Navy, “Navy’s Newest Electronic Attack Aircraft Reaches Centennial Milestone” | Boeing, “Boeing Delivers 100th EA-18G Growler to US Navy” | Reuters, “Boeing, backers to fight for funding for 22 Boeing jets”.

100th EA-18G

April 25/14: The US Navy has decided to add 22 EA-18Gs to its FY 2015 unfunded priorities list, and its plan to cut FY 2015 – 2019 buys of the stealthy F-35C from 69 to 36 fighters has led to questions about its longer-term priorities. The truth is, the F-35C won’t be fully tested and ready until the end of this period anyway. Every deleted fighter is just 1 less plane to fix later. CNO Adm. Greenert has said to Congress that:

“[Stealth] is needed for what we have in the future for at least 10 years out there and there is nothing magic about that decade… But I think we need to look beyond that. So to me, I think it’s a combination of having aircraft that have stealth but also aircraft that can suppress other forms of radio frequency electromagnetic emissions so that we can get in.”

It’s unwise to pair a non-stealthy Growler with F-35s, because that just gives away everybody’s position. On the other hand, a strike package of EA-18Gs, F/A-18E/Fs, and F-35s could be an interesting “watch my right hand” option for future commanders. Ultimately, if the F-35s are deemed to need jamming of their own 15+ years down the road, they’re likely to get a rearranged version of the Next-Generation Jammer that’s designed to fit internally, with some possible external carriage in external structures that could fit like like Terma’s multi-role gun pod. Sources: Military.com, “Boeing Builds the Navy an F-35C Exit Strategy”.

April 24/14: The US Navy’s Carl Vinson [CVN 70] Carrier Strike Group will conduct a 3-day exercise in May, in order to test paper analysis that says raising the number of EA-18Gs Growlers on an aircraft carrier from 5 to 7-8 would be more effective overall. If the results confirm the paper analysis, an added buy in FY 2015 becomes a lot more likely. Sources: St. Louis Post-Dispatch, “New Growler construction may depend on upcoming Navy exercise”.

April 7/14: Boeing continues to lobby for inclusion of 22 EA-18Gs in the Pentagon’s final FY 2015 budget. They’re stressing the Growler’s effectiveness across the electro-magnetic spectrum, vs. the F-35’s stealth optimization in limited bands. They add that “Increasing computing power, advanced sensors and evolving aircraft detection methods are degrading the benefits of stealth.” Meanwhile, the USAF is planning to mothball half of its 14 quad-turboprop EC-130 electronic attack aircraft.

All of these points are valid, and it helps that Advanced Super Hornet tests hit their marks regarding radar signature reduction and flying quality. It’s also true that stealth aircraft work earlier in the detect – track – reach – kill chain, preventing coordinated responses rather than having to defeat them. Sources: Aviation Week, “Growler Advocates Outline Stealth Vulnerabilities” | Breaking Defense, “F-35?s Stealth, EW Not Enough, So JSF And Navy Need Growlers; Boeing Says 50-100 More” | Flight Global, “Navy pleased with “Advanced” Super Hornet tests, wants more Growlers” | Military.com, “Boeing: Growler Eclipses F-35’s Stealth Advantage”.

March 11/14: Budgets. CNO Adm. Jonathan Greenert has confirmed that the Navy has placed 22 more EA-18Gs on their FY15 unfunded request submission. The Pentagon’s FY14 budget already contains a $75 million option for advance procurement, as a result of Congressional additions. If the Navy’s FY15 suggestion is approved for inclusion by the Secretary of Defense and Joint Chiefs of Staff, the $2.14 billion request would receive more momentum toward a possible Congressional insert in FY15.

It’s important not to make too much of this yet. First of all, inclusion is a big “if.” Second, the unfunded requests list has a number of items on it. If Congress does decide to fund 22 EA-18Gs above and beyond the proposed budget, the US Navy would use it to raise some squadron rosters to 7 jets, while Boeing would extend the Super Hornet production line by a year or more. Sources: Reuters, “UPDATE 1-U.S. Navy confirms Boeing jets on ‘unfunded’ priority list”.

March 4/14: FY15 Budget. The Navy unveils a preliminary budget request briefing. It doesn’t break down individual programs into dollars, but it does offer planned purchase numbers for the Navy’s biggest programs from FY 2014 – 2019. Short answer: no plans to buy any more Super Hornets or EA-18Gs, but that doesn’t mean that Congress couldn’t add some later. Source: US Dept. of the Navy, PB15 Press Briefing [PDF].

Jan 24/14: NGJ. The US Navy reaffirms Raytheon’s Next-Generation Jammer contract award, after carrying out a new cost and technical analysis of all 3 original bids. Technology development efforts resume after a 6-month delay, but it moves the entire program back. A Milestone C/ Low-Rate Initial Production decision won’t happen until winter 2019 at the earliest. That means the 2020 fielding goal for the mid-band NGJ Increment 1, which would replace the EA-18G’s underwing AN/ALQ-99 pods, is already under strain. Read DID’s “The USA’s NGJ Strike Jammers” for full coverage.

Nov 26/13: AEA #100. Northrop Grumman delivers the 100th EA-18G Airborne Electronic Attack kit to Boeing. Sources: NGC, “Northrop Grumman Delivers 100th EA-18G Airborne Electronic Attack Kit”.

FY 2013

Instead of ending production, FY 2014 USN budget orders 21; Australia import request for 12 more EA-18Gs; EA-18 mechanic shortage.

EA-18G on CVN 73
(click to view full)

September 2013: Land Basing. The USNI’s Proceedings magazine has an article by VAQ-132 squadron Commander Dave Kurtz, whose EA-18Gs deployed widely across a series of Pacific land bases in 2012–13. The lessons from this experience, he says, argue for a dual carrier/ land-based role that more closely resembles past employment of the US Navy’s P-3 sea control aircraft, rather than its F/A-18 hornets.

Fleets would still have their designated carrier-borne squadrons, such as the Pacific theater designated squadron aboard USS George Washington [CVN 73]. The ability to fly new squadrons in or carry them on ship lets the Navy add planes to theater as needed, and gives airborne electronic attack a maneuvering element within the theater that has more options, and isn’t tied to the carrier’s primary missions. On the other hand, if the carrier needs to re-embark them, or add their it can. Sources: USNI Proceedings, Sept 2013 [subscription req’d].

Sept 25/13: Testing. A $41.8 million cost-plus-fixed-fee delivery order for 10 pre-production Operational Test Program Sets in support of the EA-18G. All funds are committed immediately.

Work will be performed in St. Louis, MO, and is expected to be complete in August 2018. The US Naval Air Warfare Center Aircraft Division in Lakehurst, NJ manages this contract (N68335-10-G-0012, 0046).

Sept 23/13: ECP. A $38.2 million fixed-price, incentive-fee delivery order for F/A-18E/F and EA-18G trailing edge flap retrofit kits. The flaps were redesigned as part of an engineering change proposal, and the order includes 48 trailing edge flap kits, 48 left hand units, and 48 right hand units. All funds are committed immediately.

Work will be performed in St. Louis, MO, and is expected to be completed in July 2017 (N00019-11-G-0001, 0073).

Sept 20/13: Testing. Northrop Grumman Systems Corp. in Bethpage, NY receives a $10.9 million firm-fixed-price, indefinite-delivery/indefinite-quantity contract related to work on the EA-18G’s core avionics program (known as the “Operational Flight Program”), avionics subsystem emulation, and some of its electronic attack units. The plane’s avionics and jammers need to work well together, or the plane will be in trouble. Northrop Grumman will provide up to 3 EA-18G systems emulation laboratory systems; up to 2 electronic attack unit/communication countermeasures sets/ALQ-99 integration test systems for the plane’s main jammer pods; 1 electronic attack unit/ALQ-99 integration test system; and one ALQ-218(V)2 integration test system for the plane’s signals interception and geo-location pods.

Just under $1 million is committed immediately, Work will be performed in Bethpage, NY (65%); Baltimore, MD (33%); and Camarillo, CA (2%), and is expected to be completed in January 2017. This contract was not competitively procured pursuant to FAR 6.302-1, since Northrop Grumman makes the plane’s jamming equipment. The US Naval Air Warfare Center Weapons Division at China Lake, CA manages the contract (N68936-13-D-0036).

Aug 8/13: TTNT. Boeing touts July 15-19/13 flights of an EA-18G Growler equipped with “sensor system upgrades and its newest data network.” Subsequent conversations with Boeing reveal that the network is Rockwell Collins’ TTNT (Tactical Targeting Network Technology), which has been in development since 2001.

TTNT creates high-bandwidth, on-the-fly networks by using an IP-based wireless waveform for mesh networking, with real-time bandwidth allocation and ad hoc security authentication. Latency is low enough that it can be used for safety-of-flight applications like positioning and controlling the carrier-based X-47B UCAS-D drone. Individual weapons like missiles can also join, mesh participants can be moving at up to Mach 8, and range is reportedly over 300 nmi. Slower Time Division Multiple Access waveforms like Link 16 will still be used, and will continue to receive improvements, but TTNT looks like the long-term future foundation.

EA-18G operational deployment of TTNT is expected in 2018, making it just the 2nd plane in the fleet to receive TTNT as a production capability, after the E-2D Hawkeye AWACS plane. TTNT will also be retrofitted into existing EA-18Gs, and will eventually become ubiquitous within the US military. Boeing and the Navy will work closely with supplier partners Northrop Grumman, Harris Corporation, L-3 Communications and Rockwell Collins to upgrade the EA-18G fleet. Sources: Boeing Aug 8/13 release & inquiries; see “Additional Readings and Sources” for more on TTNT.

July 17/13: EA-18G mods. Boeing in St. Louis, MO receives a $17 million cost-plus-incentive-fee, cost-plus-fixed-fee delivery order for phase I of the NGJ pod’s EA-18G hardware integration. $10 million is committed immediately. According to the July 10/12 RFP, the EA-18G will need a number of minor changes in order to work with the new pods. NAVAIR acknowledges possibilities that include improved fiber networks and switches on board; plus modifications to NGC’s ALQ-218 onboard tactical jamming receiver, mission computer and stores management system, digital memory devices, mission planning software, and specialized onboard jamming equipment including the EIBU, EAU, and Jammer Technique Library.

Work will be performed in St. Louis, MO, and is expected to be complete in October 2014. US Naval Air Systems Command in Patuxent River, MD manages the contract (N00019-11-G-0001, #2049).

May 10/13: ALQ-99. L-3 Communications Corp. in San Carlos, CA receives an $8.4 million indefinite-delivery/ indefinite-quantity contract, in order to establish a depot for repair of the AN/ALQ-99 (V) Band 4 pod’s L8003 output traveling wave tube. $1.9 million is committed immediately.

Work will be performed in San Carlos, CA, and is expected to be complete in April 2018. This contract was not competitively procured in accordance with FAR 6.302-1 by the Naval Surface Warfare Center in Crane, IN (N00164-13-D-WS59).

May 9/13: F414. General Electric Co. in Lynn, MA receives a $22.2 million firm-fixed-price contract modification, exercising an option for 6 F414-GE-400 engines, pre-installed in 3 EA-18Gs. Most F414 contracts are shared between EA-18s and F/A-18E/Fs.

Work will be performed in Lynn, MA (59%); Hooksett, NH (18%); Rutland, VT (12%); and Madisonville, KY (11%), and is expected to be complete by in March 2015. $22.2 million will be obligated at time of award, none of which will expire at the end of the current fiscal year (N00019-11-C-0045).

April 10/13: FY 2014 budget. The Obama administration finally releases its budget proposals, including the Pentagon’s FY 2014 requests. One of the most notable changes in the Navy’s “Procurement by Weapon” file is the addition of 21 more EA-18Gs, with a $2 billion budget. At the same time, plans to buy 13 F/A-18E/F fighters for around $1.14 billion were canceled. The $274 million in FY 2014 involves spares, and shared costs related to the EA-18G. In effect, the Super Hornet order was transmuted into Growlers, raised pro rata by about $375 million total for that switch, then had 8 more planes added to it.

The shift into an all-Growler buy was helped by the Australian purchase of 12 Airborne Electronic Attack kits, which lowered costs for added US orders. Strike while the iron is hot, and all that. The other story associated with this shift involves the F-35B/C. The F-35 program is improving, but it has basically stood still or even gone backwards over the last 5 years. That means late introduction, and even later Initial Operating Capability. Especially given the poor progress of software development, and the additional progress required to create a combat-ready F-35. Not having stealth-enhanced F-35s is more than a fighter gap – it’s also a strike gap against improving air defenses. The most obvious way to close that gap is to add to the EA-18G fleet, in order to help existing naval fighters get through enemy defenses before F-35s start contributing some time in the early 2020s. Even after F-35s arrive, EA-18Gs will remain invaluable to coalition warfare for a long time, and have real utility in small wars that feature remotely-detonated bombs.

FY 2014 is expected to end Super Hornet family orders, barring exports outside the USA. That leaves the USN’s Super Hornet program finishing with 552 fighters bought (though DID’s records show 549), and the EA-18G program finishing with a higher-than-expected 135 planes. Recall that at one time, the planned buy of EA-18Gs was just 80.

Feb 28/13: Australia. The US DSCA announces [PDF] Australia’s official request to buy another 24 Super Hornet family planes and associated equipment, which could be worth up to USD $3.7 billion. The split includes 12 more EA-18Gs, but its special equipment is missing from the request: the AN/ALQ-99F-V jamming pods, ALQ-218 jamming pods, CN-1717/A INCANS to prevent the plane from jamming itself, and equipment associated with radar-killing HARMN/AARGM missiles.

Without those things, Australia would be left with another 12 pre-wired F/A-18Fs, though they can always share the items bought under the May 22/12 special equipment DSCA request throughout the fleet. Or place a follow-on order for the AEA kit and pods, just as they did with their first 12. Read “Australia’s 2nd Fighter Fleet: Super Hornets & Growlers” for full coverage.

Australia requests 12 more

Dec 28/12: F414. General Electric Co., Lynn, MA receives a $67.1 million firm-fixed-price contract modification, exercising an option for 18 F414-GE-400 Production Lot 17 install engines, and 24 “devices”. They’ll be used in EA-18Gs.

Work will be performed in Lynn, MA (59%); Hooksett, NH (18%); Rutland, VT (12%); and Madisonville, KY (11%), and is expected to be complete in March 2015. Contract funds in the amount of $67,141,518 will be obligated on this award, none of which will expire at the end of the current fiscal year. The Naval Air Systems Command, Patuxent River, MD manages the contract (N00019-11-C-0045).

Dec 20/12: Boeing in St. Louis, MO receives a $164 million firm-fixed-price contract, exercising an option to begin procurement of 12 Airborne Electronic Attack Group B-Kits and 4 Equivalent Ship-sets of spares for the Royal Australian Air Force.

Work will be performed in Baltimore, MD (41.1%); St. Louis, MO (36.3%); Bethpage, NY (19%); and Fort Wayne, Ind. (3.6%), and is expected to be complete in March 2015. All contract funds are committed immediately. US Naval Air Systems Command in Patuxent River, MD manage the contract on behalf of its Foreign Military Sale client (N00019-09-C-0086). Note that the entire conversion of 12 aircraft is expected to cost about $1.5 billion (vid. Aug 23/12).

Australian orders begin

Dec 4/12: Training. Under a new 5-year, $56 million contract, Boeing will maintain U.S. Navy aircrew training devices for the P-8A, its P-3C predecessor, EP-3 Aries electronic eavesdropping planes, EA-6B Prowler and EA-18G Growler electronic warfare jets, and older SH-60B Seahawk helicopters.

Mark McGraw, Boeing’s VP for Training Systems and Government Services, says the firm is looking to offer these services internationally. It’s a somewhat natural extension for its own products, like the EA-18G. It’s less natural for Lockheed Martin’s P-3s, Northrop Grumman’s EA-6s, and Sikorsky’s SH-60s.

The training devices are located at Naval Air Station (NAS) Jacksonville, FL; Marine Corps Air Station Kaneohe Bay, HI; NAS Whidbey Island, WA; and Kadena Air Base, Japan. Boeing.

Nov 15/12: AOL Defense reports that the US Navy’s buildup of EA-18G fighters reflects a distrust of stealth. Given ongoing advances in technologies like passive radars, mistrust might be justified, but we don’t see it. The Navy’s commitment to F-35 variants is huge, and efforts like UCAS-D and UCLASS require stealth in order to make much sense. Verbal hemming and hawing doesn’t mean much until it’s embodied in budgets, and Ockham’s Razor suggests that the urgency around more EA-18Gs and Super Hornets traces to F-35 delays rather than distrust.

With respect to the EA-18Gs, the fleet’s biggest shortage is mechanics and support technicians. They’re pulling them from EA-6B squadrons so quickly, that the Navy has had to hire over 200 contractors from L-3 to keep the 6 Prowler squadrons running. Why not just hire them for the EA-18G? Because you can find civilians who were former EA-6B techs, but none who were EA-18G techs.

FY 2012

Australia goes ahead with 12 Growler kits; GAO report says ALQ-99 pods have poor reliability, won’t be as effective beyond 2018; DOT&E says EA-18G reliability is improved; Structural changes continue.

EA-18G refuels
(click to view full)

Aug 23/12: Australia. Minister for Defence Stephen Smith and Minister for Defence Materiel Jason Clare announce their decision to proceed with the conversion of 12 Super Hornets into Growlers for about A$ 1.5 billion (about $1.557 billion), with availability expected for 2018.

All 24 of Australia’s F/A-18F Block II Hornets have already been delivered. This conversion will take takes the 12 Australian F/A-18Fs that were pre-wired for EA-18G conversion (vid. Feb 27/09 entry), and adds the internal electronics and pods. Australia DoD.

Australia decides on EA-18G conversions

Aug 7/12: Australian costs. Australia’s Canberra Times gets some clarification on the difference between the Australian government’s A$ 300 million estimate to convert 12 F/A-18Fs into EA-18Gs, and the USD 1.7 billion mentioned in the May 22/12 DSCA request. Short answer: The difference is the $1.4 billion cost of the 34 AN/ALQ-99 jamming pods, if they are bought outright:

“Australia wasn’t planning to buy the ALQ-99 electronic warfare pods, just the systems and hardware to allow them to be fitted on an ”as required” basis… a Defence spokesman has explained. ”The initial proposal that underpinned the 2009 cost estimate would have provided a lesser capability than Defence now proposes to acquire”. The pods would have had to be obtained from the United States Navy whenever Australia wanted them, a source said.”

March 29/12: GAO Report. The US GAO releases “Airborne Electronic Attack: Achieving Mission Objectives Depends on Overcoming Acquisition Challenges. The EA-18G isn’t a problem, and the program gets high marks. GAO’s larger concerns involve an integrated electronic warfare plan that has had key planks removed at stand-off ranges (B-52 pod canceled), and in close against high end systems (no stealth UCAVs), even as plans to mount systems on UAVs are faltering because they’re too dangerous to the UAVs carrying them. The other problem is the AN/ALQ-99 pods that will be moved over from the EA-6Bs to the EA-18G, and accelerated wear among the EA-6Bs carrying them:

“By the end of fiscal year 2012, 32 EA-6Bs will be upgraded to the [most modern] ICAP III configuration. Navy officials told us that persistent operations in Iraq and Afghanistan, however, have degraded the condition of EA-6B aircraft… The Navy’s Low Band Transmitter upgrade to the AN/ALQ-99 system is intended to replace three aging legacy transmitters that suffer from obsolescence and reliability problems. According to Navy officials, persistent use of these transmitters in support of operations in Iraq and Afghanistan has exacerbated system shortfalls… However, Navy officials project that even with [maintenance & operations] improvements, system capabilities will be insufficient to counter anticipated evolutions in threat radars and missiles beginning in 2018. This shortfall is expected to be addressed by the new Next Generation Jammer.”

Feb 23/12: ALQ-99. Sensor and Antenna Systems, Inc. in Lansdale, PA receives a $39 million firm-fixed-price contract modification, exercising exercise an option for 48 low band transmitters, 13 vertical polarized antennas, and 28 horizontal polarized antennas associated with the AN/ALQ-99 low band transmitter. The ALQ-99 isn’t used exclusively on EA-18Gs, but they will all migrate to the Growler as the EA-6Bs are replaced.

Work will be performed in Lansdale, PA, and is expected to be complete in August 2014. US Naval Air Systems Command in Patuxent River, MD manages the contract (N00019-10-C-0047).

Feb 22/12: Australia. Adelaide’s The Advertiser reports that March 2012 will feature Defence Minister Stephen Smith announcing an A$ 200-300 million decision to upgrade 12 of Australia’s Super Hornets to EA-18 electronic warfare planes.

“News Limited understands that the first [EA-18] aircraft will be converted at the Boeing factory in St Louis and the remainder at Amberley RAAF base near Brisbane.”

It also reports that the Minister favors a September 2012 decision to buy another 12 F/A-18Fs, in order to make up for the F-35A’s expected lateness. The RAAF is reportedly against this, given expected defense reductions this year, and worries that the cost will eventually be paid for by fewer future F-35s. Which may be true. On the other hand, Australia needs to keep its fleet combat-capable while it waits.

Feb 1/12: A $132.8 million contract modification, exercising an option for 12 sets of EA-18G airborne electronic attack kits and the associated non-recurring engineering, as part of Lot 36 Full Rate Production. This figure is very much in line with last year’s order, vid. June 29/11. Note, too, the use of “Lot 36 FRP”. The EA-18G hasn’t had time for nearly that many production lots, but the Hornet airframe has. EA kits comprise the various specialized technologies that distinguish the EA-18G from the F/A-18F.

Work will be performed in Baltimore, MD (41.1%); St. Louis, MO (36.3%); Bethpage, NY (19%); and Fort Wayne, IN (3.6%). Work is expected to be complete in September 2014 (N00019-09-C-0086).

12 AEA kits

Jan 17/12: DOT&E mixed. The Pentagon releases the FY2011 Annual Report from its Office of the Director, Operational Test & Evaluation (DOT&E). The EA-18G is included, and the news is pretty good:

“Emerging 2011… results suggest the EA-18G remains operationally effective, while operational suitability has notably improved… the EA-18G system met the threshold for operational availability. The point value for reliability met the 14-hour threshold, but the 80% confidence level (lower bound) fell below the threshold. Maintainability did not meet the threshold level but only by a small measure, and built-in test performance was largely improved since IOT&E. Maintenance documentation was improved from IOT&E, but Navy personnel still rated the system as difficult to use and incomplete in some areas. DOT&E analysis of test data is still ongoing and a complete assessment will be published in early FY12.”

Nov 1/11: Spares. Northrop Grumman Systems Corp. in Bethpage, NY receives a sole source, firm-fixed-price, maximum $26 million contract from the US Navy for airborne electronic attack spares and radio frequency switches. Since much of this equipment is common to the EA-18G and EA-6B platforms, the Growler’s share isn’t entirely clear, but it will be growing over the performance period.

Work will be performed in Bethpage, NY and Linthicum, MD, running until July 31/14 and paid for by FY 2012-2014 Navy Working Capital funds. The US Defense Logistics Agency Aviation Strategic Acquisitions group in Philadelphia, PA manages the contract (SPM4AX-12-D-9401).

Oct 19/11: Australia. During an interview with Australia Broadcasting Corporation Radio, Labor government defense minister Stephen Smith discusses the possibility of turning 12 of Australia’s Super Hornets into EA-18G Growler electronic warfare fighters, whose conversion price tag is described by the interviewer as “upwards of A$ 300 million.” The EA-18G recently saw their its combat use over Libya, and:

“We’ve just started the process of making a judgment about whether acquiring [them] would be in our national interest or our national security interest… we took the sensible precaution of wiring up half of our Super Hornets for this potential. But it is a very expensive capability. We’re just going through the process… this possibility would come as no surprise to our friends and neighbours in the region. It’s been on the public record before and part of the [2009 Defence] White Paper.”

The minister does not contradict the price figure, and in a related ABC TV interview, he mentions costs of “hundreds of millions.” The minister also implied that further delays or issues with the F-35A could make an EA-18 conversion more likely, as a way to strengthen Australia’s air capability in the interim. ABC radio transcript | ABC24 TV news transcript.

Oct 3/11: Innovation. Boeing discusses recent changes to the Super Hornet family’s wing frame, which sharply reduced the number of parts, and the amount of assembly time. Modern manufacturing technologies let them replace a large number of components from different subcontractors, with a machined 1-piece component that makes up much of the wing frame. That reduces rework and labor assembly time, while improving the wing’s reliability. Boeing (incl. video).

FY 2011

1st combat deployments to Iraq & Libya; AARGM radar-killing missile test; DOT&E report says EA-18G is effective, but not reliable, esp. re: software; Next-generation jammers.

VAQ-132 returns
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July 29/11: Support. Northrop Grumman Systems Corp. in Bethpage, N.Y receives a $54.8 million, 3-year indefinite-delivery/ indefinite-quantity contract for engineering, technical and program support services for ongoing development & maintenance of EA-6B operational flight software, EA-6B “unique planning component,” and EA-18G operational flight software. Both aircraft types are handled by the Navy’s Airborne Electronic Attack Integrated Product Team.

Work will be performed in Point Mugu, CA (90%), and Bethpage, NY (10%), and is expected to be complete by July 2014. $200,000 will expire at the end of the current fiscal year, on Sept 30/11. This contract was not competitively procured pursuant to FAR 6.302-1 (N68936-11-D-0028).

July 9/11: Deployment returns. VAQ-132’s EA-18G Growlers all return to their home base at NAS Whidbey Island, WA, after completing an 8-month land-based deployment to Iraq and Libya. Deployed EA-18Gs now include VAQ-141 aboard the USS George H.W. Bush [CVN 77], marking the Growler’s first sea-based deployment. They’re part of Carrier Air Wing 8, operating in the Mediterranean and Persian Gulf. Boeing mentions that “a third electronic attack squadron, VAQ-138, recently deployed to a land-based location,” which could mean that they’ve replaced VAQ-132 over Libya.

By the end of 2015, 3 expeditionary squadrons and 10 carrier-based squadrons are scheduled to transition from the EA-6B Prowler to the EA-18G Growler. US NAVAIR | Boeing.

June 29/11: AEA FRP-2. A $130 million firm-fixed-price contract modification for 12 airborne electronic attack kits and associated engineering, as part of EA-18G orders in Super Hornet family full rate production Lot 35. Note that this isn’t ordering airframes, or radars, or engines – just the electronic attack equipment. Some simple division should help readers get a better sense of how much “government furnished equipment” can add to the price of a fully functional fighter, especially a very specialized plane like the EA-16G.

Work will be performed in Baltimore, MD (43.3%); St. Louis, MO (33.3%); Bethpage, NY (17.8%); and Fort Wayne, IN (5.6%), and is expected to be completed in July 2013 (N00019-09-C-0086).

AEA Kits

May 25/11: AARGM. The Navy’s new AGM-88E AARGM radar-killer missile successfully completes its 1st EA-18G Growler test, during a captive-carry flight at China Lake, CA. Growler work will continue, in parallel with the ongoing AARGM Integrated Test & Evaluation phase using FA-18C/D Hornets.

The test squadrons have also used Super Hornets, and Cmdr. Chad Reed, deputy program manager for Anti-Radiation Missiles within the Direct and Time Sensitive Strike program office (PMA-242), says that F/A-18E/F Super Hornet and EA-18G Growler testing since November 2010 totals 25 flight hours, compared to over 150 flight-hours on F/A-18C/D Hornets. US NAVAIR.

March 30/11: Support. A $40 million awarded fixed-price-incentive-fee contract modification for one-time engineering services in support of the F/A-18E/F and EA-18G’s next generation advanced mission computer system.

Work was performed in Bloomington, MN (53.7%), Baltimore, MD (33.3%), and St. Louis, MO (13%). This is a retroactive contract, with the Pentagon noting that “Work was completed in December 2010” (N00019-09-C-0019).

March 30/11: Support. Northrop Grumman Systems Corp. in Bethpage, NY receives an $8.6 million cost-plus-fixed-fee, indefinite-delivery/ indefinite-quantity contract modification to provide engineering and software services in support of EA-6B Prowler and EA-18G Growler aircraft. Services will include design, development, integration, test and distribution of the operational flight programs, flight test and aircraft integration support, and engineering support to transition the electronic attack mission from the EA-6B to the EA-18G.

Work will be performed at the Naval Air Warfare Center Weapons Division in Point Mugu, CA, and is expected to be complete in December 2011. The Naval Air Warfare Center Weapons Division at Point Mugu, CA manages the contract (N68936-08-D-0026).

March 20/11: Combat debut. The EA-18G makes its combat debut during opening strikes against Libyan air defenses, using the 5-plane Scorpions squadron that had been deployed to Al-Asad in Iraq (vid. Feb 1/11). They’re currently operating out of NAS Sigonella and Aviano Air Base, in Italy. US Navy | CNN.

Combat debut

Feb 3/11: DOT&E. A January 2011 report by the Pentagon’s Director of Operational Test and Evaluation (DOT&E) rates the EA-18G as “operationally effective,” (can perform its mission), but not “operationally suitable” (supportable in a sustainable way). Software stability in particular is seen as an ongoing issue.

The US Navy disagrees. They say it’s both effective and suitable, and argue that the DOT&E included items outside the scope of the program for its 2010 report. “None of the anomalies were showstoppers,” says the Navy, and scheduled testing in early 2011 should tell them how many of the remaining issues are still a problem. Aviation Week | See also past DOT&E 2009 report (2010 release, PDF).

Feb 1/11: 1st deployment. DLA Aviation discusses the challenges it has faced working to support the EA-18G’s 1st expeditionary deployment, at Al-Asad AB, Iraq. VAQ-132’s deployment began in mid-November 2010, but a 2009 change placed them on land, instead of on the USS Carl Vinson (CVN-70).

The removal of the carrier’s inherent support infrastructure was just the first of many issues as DLA planned for the land-based deployment. Another was an expected increase in flight hours from 30 hours per month, to over 100 hours. Having about 30,000 parts in common with the F/A-18F helps, as DLA also supports Super Hornets in theater. Even so, a delay in receiving Navy requirements forced DLA to do a lot of expediting, finding lateral support, and asking for spot buys, in order to ensure 100% inclusion of the items they believed they’d need to keep the lanes running. In the end, the pack up kit of consumable parts for the 5 EA-18Gs included about 900 of the most needed items.

Nov 29/10: Support. A $6.7 million firm-fixed-price delivery order under the basic ordering agreement. Boeing will provide operational level (front line, not depot-level) support equipment that’s specific to the EA-18G, and not common to other Super Hornet aircraft. This will help new EA-18G aircraft squadrons stand up with everything they need.

Work will be performed in St. Louis, MO, and is expected to be complete in November 2012. All contract funds will expire at the end of the current fiscal year. The Naval Air Warfare Center Aircraft Division in Lakehurst, N.J. manages this contract (N68335-10-G-0012).

Nov 19/10: EW Trends. Aviation Week, “Directed Energy Weapons Attack Electronics” :

“The lightning rod for rapid fielding of directed energy (DE) weapons and advanced sensors will be the military’s next-generation jammer programs that exploit technologies like active electronically scanned arrays (AESAs) antennas and high-power microwave (HPM) capabilities, say senior U.S. government and industry officials at the 13th Directed Energy Conference.

Radars on the Lockheed Martin F-22 and F-35, and Boeing F/A-18F and EA-18G, already have the potential to fire focused beams of energy as soon as funding is available to develop the necessary advanced algorithms.”

FY 2010

SAR costs go up because EA-18G numbers do, in light of F-35 delays; Full-Rate Production approved; 2nd squadron declared ready for action; New facilities at NAS Whidbey Island, WA to serve as key hub for the Growler fleet; 1st new crew graduates for EA-18G;

EA-18G, carrier landing
(click to view full)

Aug 6/10: Spares. A $5.9 million ceiling priced delivery order for repairable support for advanced electronic attack components of the EA-18G aircraft.

Work will be performed in Baltimore, MD (84%); Bethpage, NY (8%); Whidbey Island, WA (3%); Melbourne, FL (2%); St. Augustine, FL (2%); and Fort Wayne, IN (1%). Work is expected to be complete by January 2011. The Naval Inventory Control Point in Philadelphia, PA manages this contract (N00383-06-G-006B, #0012).

May 28/10: Support. Raytheon Network Centric Systems in Fort Wayne, IN received an $8.7 million cost-plus-fixed-fee, indefinite-delivery/ indefinite-quantity contract to provide performance-based engineering services in support of the EA-18G’s AN/ALQ-227 communication countermeasure systems. Support services will include systems engineering, testing, product assurance, logistics, training, and production.

Work will be performed in Fort Wayne, IN, and is expected to be complete in May 2015. This contract was not competitively procured, pursuant to FAR 6.302-1, by the US Naval Air Warfare Center Weapons Division in China Lake, CA (N68936-10-D-0013).

May 24/10: Infrastructure. A ribbon-cutting ceremony marks Hangar 5’s recapitalization at Naval Air Station (NAS) Whidbey Island, WA. The $55.8 million design-build project began in January 2008. The improved facility will house 5 EA-18G Growler squadrons, the Electronic Attack Weapons School and Commander, Electronic Attack Wing, U.S. Pacific Fleet. US Navy photo release.

April 1/10: SAR. The Pentagon releases its April 2010 Selected Acquisitions Report, covering major program changes up to December 2009. The USA wants more EA-18Gs:

“EA-18G – Program costs increased $2,901.0 million (+33.5%) from $8,649.1 million to $11,550.1 million, due primarily to a quantity increase of 29 aircraft from 85 to 114 aircraft (+$2,342.5 million) and associated schedule and estimating allocations (+$7.8 million), and an increase in support costs for 26 expeditionary aircraft associated with the quantity increase (+$547.6 million).”

SAR – more EA-18Gs

March 5/10: 1st graduates. The US Navy’s EA-18G Fleet Replacement Squadron trainers in VAQ-129 graduate Class 09-08, the first class of 5 “Category 1” EA-18G aircrew that come straight from flight school. The squadron had previously trained veteran EA-6B pilots from VAQ-132 and VAQ-141, where the new “Cat 1s” will be assigned.

The 9-month course included a wide range of activities, from computer-based training, to lectures, simulators, and flights. Flights include day and night formation flying, basic radar mechanics, air-to-air fighter tactics, airborne electronic attack, in-flight refueling, and day and night carrier qualification. The Airborne Electronic Attack portion of the syllabus is new, and is being refined with each successive class.

Unlike the EA-6B, where student pilots carrier qualify with a veteran instructor in the right seat, the CAT 1’s must take the Growler to the boat as a “crew solo”: a student in the front, and a student in the back. US Navy.

Feb 12/10: 2nd squadron. The “Shadowhawks” of VAQ-141 are declared “Safe for Flight” in their new EA-18G Growlers at Naval Air Station (NAS) Whidbey Island, WA, following an 8-month training period under fleet replacment squadron VAQ-129. The Shadowhawks are the 2nd operational squadron to achieve this qualification, after the “Scorpions” of VAQ-132. Both squadrons had previously flown EA-6B Prowlers. US Navy.

Jan 12/09: Support. Wyle Laboratories, Inc. in Huntsville, AL received a $10.8 million cost-plus fixed-fee, indefinite-delivery/ indefinite-quantity contract to provide airborne electronic attack engineering support for the EA-6B, EA-18G, and other advanced electronic attack derivatives at the Naval Air Warfare Center Weapons Division (NAWCWD) in Point Mugu, CA.

Work will be performed at NAWCWD, Point Mugu, CA (85%); NAWCWD, China Lake, CA (5%); Naval Air Warfare Center Aircraft Division, Patuxent River, MD (5%); and Naval Air Station, Whidbey Island, WA (5%). Work is expected to be complete in January 2015. This contract was not competitively procured pursuant to Federal Acquisition Regulations by NAWCWD in China Lake, CA (N68936-10-D-0014).

Feb 3/10: F-35 vs. F/A-18. Ranking House Armed Services Seapower subcommittee Rep. Todd Akin [R-MO] publicly supports building more Super Hornet family aircraft, and advocates a multi-year buy approach for the F/A-18E/F and EA-18G, similar to the 2005-2009 contract. In Rep. Arkin’s release, he says that:

“I remain concerned that the Department of Defense is not taking the Navy’s strike fighter shortfall seriously… The Super Hornet is an active production line, and is dramatically cheaper than the JSF, which may not deliver anywhere close to on time… In this case, a multi-year procurement could save hundreds of millions of dollars, but the DoD seems to have their head in the sand. Secretary Gates mentioned that he thinks we need to have a 10% savings before we use a multi-year agreement. However, the Congress already gave DoD the authority to use a multiyear in this situation, even if the savings is less than 10%… A multiyear procurement could save nearly half a billion dollars over the next few years. To not pursue that savings is just irresponsible.”

Jan 7/10: F-35 delay. Media reports surface that Defense Secretary Robert Gates has ordered a delay in the Lockheed Martin Corp. F-35 program, cutting planned purchases from 2011 – 2015 in order to fund research, development, testing & evaluation (RDT&E). In FY 2011-12, the US Navy will reportedly compensate for the implicit F-35C delays, by buying another 24 Boeing Super Hornet family planes for $2.4 billion.

A Bloomberg report confusingly mentions “F/A-18E/F planes that are capable of jamming enemy radar,” which could indicate the addition of 24 EA-18Gs. The Growlers would help to fill immediate gaps in airborne jamming, which is in high demand. They would also help maintain long-term fighter numbers with aircraft that would remain operationally viable farther into the future than standard Super Hornets. Bloomberg | Business Week | Fort Worth Star-Telegram.

Nov 30/09: AEA FRP-1. A $386 million modification to a previously awarded firm-fixed-price contract (N00019-09-C-0086) for the procurement of 22 EA-18G Lot 33 Full Rate Production (FRP) airborne electronic attack (AEA) kits, 22 EA-18G Lot 34 FRP AEA kits, and the associated non-recurring engineering.

Work will be performed in Baltimore, MD (46.5%); Bethpage, NY (22.7%); St. Louis, MO (13.5%); Melbourne, FL (5.5%); Fort Wayne, IN (3.7%); Thousand Oaks, CA (3.7%); Wallingford, CT (2.6%); Nashua, NH (1.1%); and Westminster, CO (0.7%), and is expected to be complete in December 2012.

AEA Kits

Nov 30/09: 22 conversions. A $9.4 million modification to a previously awarded firm-fixed-price contract (N00019-04-C-0014) to incorporate engineering change proposals 6251 and 6251R1 and convert 22 Lot 33 F/A-18F aircraft to EA-18G aircraft. Work will be performed in St. Louis, MO (62%); El Segundo, CA (36%); and Mesa, AZ (2%), and is expected to be complete in September 2011.

EA-18Gs start out as F/A-18F base airframes, then receive additional wiring and other changes, before the full airborne electronic attack set is integrated.

Nov 23/09: The US Department of Defense approves Full Rate Production (FRP) of the EA-18G Growler. The EA-18G program now can proceed from Low Rate Initial Production to quantities of 20+ aircraft per year, as budgeted in FY 2010.

The EA-18G achieved Initial Operational Capability in September 2009 with US Navy electronic attack squadron VAQ-132, based at Naval Air Station Whidbey Island in Washington State. Boeing release.

FRP approved

Oct 29/09: A maximum $51 million firm-fixed-price, sole source contract for 23 line items in support of the EA-18G’s FY 2010 program. There was originally 1 proposal solicited with 1 response, and the date of performance completion is Dec 31/12. The Defense Logistics Agency Philadelphia, in Philadelphia, PA manages this contract (N00383-06-D-001J-TH05).

Oct 28/09: FY 2010. President Obama signs the FY 2010 defense budget into law. That budget provides funding for 22 EA-18Gs, and Congress increased related F/A-18 E/F Super Hornet purchases from 9 to 18. White House | House-
Senate Conference Report summary [PDF] & tables [PDF].

FY 2009

OpEval has EA-18G declared operationally effective and suitable; Carrier moniker will be “Grizzly”; Australia pre-wires 12 F/A-18Fs for future conversion; EA-18 Growler Lite?; EA-35s?; F-22 Raptor killed by EA-18G.

EA-18G from below
(click to view full)

July 28/09: IOT&E. The US Department of Defense releases the EA-18G Growler’s initial operational test and evaluation (IOT&E) findings, which recommended it for use in the fleet and gave it the best rating of “operationally effective, operationally suitable.” Effectiveness refers to mission performance evaluations, while suitability focuses on maintainability and reliability.

The initial EA-18G combines 2 fielded systems, in the F/A-18F airframe and the same Improved Capability III (ICAP III) electronic warfare suite used on current EA-6B Prowlers. That lowers risk, but it’s still a new combination. As it happens, software anomalies were discovered during the IOT&E process. The EA-18G team is developing a software update release, to be implemented during the normal verification and correction of deficiencies (VCD) period later this year. US Navy NAVAIR.

July 1/09: A $27.9 million modification to a previously awarded firm-fixed-price contract (N00019-09-C-0086) for additional time-critical parts in support of EA-18G Full Rate Production.

Work will be performed in St. Louis, MO, and is expected to be complete in September 2009. The EA-18G has a set manufacturer, so this contract was not competitively procured.

June 8/09: EA-18G Grizzly. Gannett’s Navy Times reports that the EA-18G’s “Growler” moniker sounded too close to the EA-6B’s “Prowler”, so the EA-18G will now be known as the “Grizzly” in operational situations, in order to avoid any confusion or mistakes. Presumably, the standard NATO “G” phonetic alphabet call of “Golf” was seen as somewhat lacking. “Growler” will remain the EA-18G’s primary moniker outside of carrier decks.

The Navy does something similar with the F/A-18F, which is colloquially called the “Rhino”. F/A-18Fs were the first Super Hornets to get new and improved AN/APG-79 AESA radars in their nose cones.

“Grizzly” moniker

April 29/09: Support. Northrop Grumman Systems Corp. in Bethpage, NY received a $9.9 million cost plus fixed fee contract for various products, and 73,571 hours of engineering services, in support of the EA-18G Airborne Electronic Attack (AEA) Integrated Product Team. The firm will provide assistance with design, development, integration, test and distribution of Electronic Attack Unit software, technical evaluations, and testing of changes; and will support follow-on test and evaluation integration and test.

Work will be performed at Point Mugu, CA, (85%); Bethpage, NY, (10%); and China Lake, CA, (5%), and is expected to be completed in April 2012. This contract was not competitively procured pursuant to the FAR 6.302-1. The Naval Air Warfare Center, Weapons Division in China Lake, CA manages this contract (N68936-09-D-0026).

Feb 27/09: Australia. Australia is pre-wiring 12 of its planned 24 F/A-18F Super Hornets, in order to allow future conversions to EA-18 Lite status. The additional cost for the pre-wiring on the production line is A$ 35 million, out of an order now cited as A$ 6.6 billion. Completing that fit out to “Growler Lite” status is expected to involve an additional A$ 300 million, with the go/no-go decision set for 2012.

Characteristically, the new Labor Party government’s release ends with a shot at the procurement policies of the previous Liberal Party government:

“If the Howard Government had taken a more prudent approach in making the Super Hornet decision rather than rushing to fill their impending air combat capability gap, they may have realised that this was a more effective approach to take.”

Feb 25/09: EA-18L Growler Lite? Media reports indicate that an export variant will soon be offered. The ALQ-99 radar jamming pod is still considered top secret, even though some of its hardware is a generation or two behind, and the program to field its replacement Next Generation Jammer has already begun.

Instead, export versions would reply on 2 components. Northrop Grumman’s ALQ-218v2 is a digital wideband radio frequency receiver, with selective jamming and geo-location capabilities. It currently equips the EA-18G’s wingtip pods, and the US Navy’s EA-6B Prowlers. Raytheon’s internally-mounted ALQ-227 communication countermeasures system makes use of a dedicated, omni-directional antenna for signals detection, analysis, and recording; but the removal of the ALQ-99 pods would remove its complex jamming functions, unless a foreign-made pod could be integrated with it instead. The export EA-18 would also ship with Raytheon’s APG-79 AESA radar, which equips existing EA-18Gs and F/A-18E/F Block II aircraft, and could be used as a jammer with additional software development.

The combination would be a strong SEAD (suppression of enemy air defenses) option, albeit one with less stealth than the F-35A. It would allow EA-18 Lites to geo-locate identified radar emitters, for instance, then target them with GPS-enabled anti-radiation missiles like AARGM. These capabilities could also be supplemented by foreign radar jamming pods bought on the international market, in order to create an aircraft with capabilities comparable to the EA-18G. Flight
International | StrategyPage.

Feb 25/09: Raptor Killer. Stephen Trimble photographs a kill decal on EA-1, the 1st of 2 Lot 27 F/A-18Fs converted into flying EA-18G prototypes. Turns out, the kill decal is a F-22A Raptor, making EA-1 one of the few aircraft to ever achieve this feat:

“I did learn the EA-18G kill was courtesy of a well-timed AIM-120 AMRAAM shot. And I learned the simulated combat exercise took place at Nellis AFB. How the EA-18G escort jammer got the shot, and whether its jamming system played a role in the incident were not questions the pilot was prepared to answer.”

F-22 kill

Dec 23/08: AEA FRP-1. An unfinalized contract with a ceiling price of $50.3 million, to buy time critical parts (TCP) for 22 Full Rate Production (FRP) Airborne Electronic Attack systems. They will be fitted into the FY 2009 buy of 22 EA-18Gs. Work will be performed in St. Louis, MO and is expected to be complete in May 2009. This contract was not competitively procured (N00019-09-C-0086).

Dec 23/08: Support. A $21.2 million firm-fixed-price, cost plus fixed fee modification to a previously awarded delivery order contract (N00383-06-D-001J) for integrated contractor engineering, logistics, and equipment to support the EA-18G.

Work will be performed in Bethpage, NY (60%) and St. Louis, MO (40%), and is expected to be complete in December 2010, but $7.2 million will expire at the end of the current fiscal year.

Dec 1/08: Spares. A $95 million delivery order under a previously-awarded Performance Based Logistics contract for spares in support of the EA-18G Growler. Work will be performed in St. Louis, MO (40%), and El Segundo, CA (60%), and is expected to be complete by September 2011. The Naval Inventory Control Point manages this contract (N00383-06-D-001J-TH00).

Nov 30/08: EA-35s? Aviation Week reports that the USAF (F-35A) and US Marines (F-35B STOVL) are moving toward plans that would let them convert F-35s into electronic attack aircraft that would serve alongside the EA-18Gs. Plans aren’t yet firm, but officials apparently hope that the F-35’s extremely advanced electronics and sensors, combined with parallel efforts like the Next Generation Jammer program, will allow the planes to be used as “EA-35s” without requiring dedicated and modified airframes.

In a world where small pods that can clip onto any fighter in the fleet have completely replaced dedicated “RF-” reconaissance fighters, the idea of a parallel development for “EA-” fighters does not seem ridiculous. See DID’s October 2005 “Supersonic SIGINT…” for more. Nevertheless, any program to create a full EF-35 capability will face challenging technical questions. An EW specialist interviewed by Aviation Week explained some of them:

“…if it’s in an external pod, [the extra radar reflectivity] will give away the aircraft’s location. Yet, if you put the guts of an NGJ into the weapon bays of a single-engine single-generator aircraft in order to maintain all-aspect stealth, you are rapidly going to run out of available power to run it… [And] If the aircraft has to maintain all-aspect stealth, then how can you do the necessary jamming… [Plus,] electronic attack is one area where size does matter… an EB-52 carrying large-aperture, active electronically scanned array radar with the output of an electronic techniques generator routed through it can be a very long-range electronic weapon. [Large ilitary aircraft of many types] are also possible platforms for the Next-Generation Jammer. Finally, unmanned aircraft of the [RQ-4] Global Hawk and [MQ-9] Reaper size could have the necessary size, power and payload.”

Nov 21/08: Training. Boeing delivers its first EA-18G Growler maintenance trainer to Whidbey Island Naval Air Station, WA, 2 weeks ahead of schedule. Boeing delivered the first fleet EA-18G and an EA-18G aircrew trainer to VAQ-129 in June 2008.

The EA-18G Maintenance Trainer (EAMT) is a set of 3 devices. One is a hardware mockup that represents the gun bay and pallet, and the second represents a wingtip pod. The mockups are used to support training on installation and removal procedures for the Growler’s unique equipment. The third device is the Visual Environment Maintenance Trainer, where student interacts with the trainer via a fully replicated cockpit and displays to test and troubleshoot, while an instructor/operator station controls the simulations and 2 touch-screen displays provide graphical representations of the aircraft and support equipment. Boeing release.

Nov 4/08: OpEval. NAVAIR announces that the EA-18G Growler has moved to Operational Evaluation (OpEval), following initial sea trials on the USS Dwight D. Eisenhower [CVN-69] from July 31/08 through Aug 5/08.

Oct 30/08: Support. A $6.5 million modification/ delivery order under a previously awarded contract to purchase repair-of-repairables support for the E/A-18 G Growler. Work will be performed in St. Louis, MO and the contract will end when the fiscal year does on Sept 30/09. The Naval Inventory Control Point in Philadelphia, PA manages this contract (N00383-06-D-001J, #0004).

Oct 2/08: OpEval. The Kitsap Sun reports that Air Test and Evaluation Squadron 9 has been using the USS John C. Stennis [CVN 75] as part of the EA-18G’s Operation Evaluation (OpEval), which includes carrier night landings and tests of the new electronic components’ durability under the controlled crash conditions of carrier landings.

Cmdr. Al Bradford, the squadron’s electronic warfare branch head, described this effort as “the final exam for the aircraft.”

FY 2008

SAR cites rising costs due to more planes; 1st delivery to fleet training squadron; 1st HARM radar-killer missile test; Support center inaugurated.

EA-18G sea trials
(click to view full)

Sept 25/08: AEA LRIP-2. A $206.7 million modification to a previously awarded firm fixed price contract (N00019-07-C-0035) for 21 Airborne Electronic Attack Kits: 18 EA-18G low-rate initial production II kits, 3 EA-18G FY 2008 supplemental funding Kits, and associated non-recurring engineering. These kits are installed during conversion of the F/A-18F airframe to an EA-18G aircraft; see also June 13/08 entry.

Work will be performed in Baltimore, MD (45%); Bethpage, NY (22%); St. Louis, MO (13.5%); Melbourne, FL (5%); Fort Wayne, IN (4.7%); Thousand Oaks, CA (4.2%); Wallingford, CT (2.5%); Nashua, NH (2.4%); and Westminster, CO (0.7%), and is expected to be complete in November 2010.

AEA Kits

Sept 25/08: Trade studies. A $6.7 million modification to a previously awarded cost plus award fee contract for 13 EA-18G trade studies to delineate technical solutions for improved EA-18G functionality and/or correction of identified deficiencies.

Work will be performed in St. Louis, MO (60%); Bethpage, NY (30%); and Baltimore, MD (10%), and is expected to be complete in September 2009 (N00019-04-C-0005).

Sept 18/08: Spares. A $14.6 million ceiling-priced delivery order contract for spares in support of the EA-18G Growler aircraft. Work will be performed in St. Louis, MO and is expected to be complete by March 2011. The Naval Inventory Control Point manages this contract.

Sept 18/08: Support. A $13 million ceiling priced modification to delivery order under a previously awarded contract for support equipment and engineering support for the EA-18G Growler aircraft. Work will be performed in St. Louis, MO and is expected to be complete by April 2010. This contract was not competitively procured by The Naval Inventory Control Point (N00383-06-D-001J, #0004).

Aug 5/08: +3. A $659.2 million modification to a previously awarded firm-fixed-price contract (N00019-04-C-0014), exercising the option for 13 F/A-18Fs and 3 E/A-18G aircraft for the U.S. Navy. Note that these are just airframes, without key components like radar, engines, and other associated equipment. The full cost of the delivered aircraft is significantly higher.

Work will be performed in St. Louis, MO (28.7%); El Segundo, CA (25%); Goleta, CA (8.6%); Clearwater, FL (2.3%); Greenlawn, NY (2.1%); Burnsville, MN (2.1%); Johnson City, NY (2.1%); Brooklyn Heights, OH (2%); Vandalia, OH (2%); Grand Rapids, MI (2%); South Bend, IN (2%); Mesa, AZ (1.8%); Fort Worth, TX (1.8%); and at various locations across the United States (17.5%), and is expected to be complete in January 2012.

Aug 5/08: HARM. The EA-18G Test Team at NAWCWD China Lake conducts its first AGM-88 High-Speed Anti-Radiation Missile (HARM) test. HARM is designed to seek and destroy enemy air defense radars; it will be replaced by the AGM-88E AARGM beginning in 2010. Source.

July 31/08 – Aug 5/08: Initial sea trials on the USS Dwight D. Eisenhower [CVN-69] involve 319 approaches, 62 catapult shots and 62 arrested landings. They had originally been scheduled over 10 days, but that time was cut in half. VX-23 Sqn’s EA-18G department head, Cmdr. Jaime Engdahl describes some of their innovative responses in the NAVAIR release, and notes their combined use of developmental testers and operational testers in the cockpit at the same time. Engdahl:

“In OpEval, the operational testers already have hundreds of hours of flight testing, they know what the systems are like, they have input into design changes and potential problems. The real benefit is the Fleet gets a better product earlier.”

July 23/08: The EA-18G Test Team at NAWCWD China Lake conducts its first AIM-120 Advanced Medium Range Air-To-Air Missile (AMRAAM) live fire. While jamming threat systems located at Echo range, the Growler engaged and fired on the BQM-74E target drone. Airborne chase cameras as well as optical trackers on the target drone confirmed safe weapon separation, followed by a very close missile pass to the target drone. It was scored as a hit, since the AMRAAM warhead uses a proximity fuze.

This event marks the first release of any live weapons by an EA-18G. It also distinguishes the EA-18G by virtue of its air-air capability; other electronic warfare aircraft have traditionally relied on short range missiles like Sidewinders for self-protection. NAVAIR release.

June 24/08: Spares. Contract modification #0012 to a previously awarded contract for the purchase of initial spares in support of the E/A-18G Growler. Orders will be placed as needed, but this contract cannot exceed $45.7 million.

Work will be performed in St. Louis, MO, and will be complete July 2010. The Naval Inventory Control Point (NAVICP) in Philadelphia, PA manages the contract (N00383-06-D-001J, order number 0004).

June 13/08: 18 conversions. A $17.6 million modification to previously awarded firm-fixed-price contract N00019-04-C-0014 will incorporate engineering change Proposal 6251 and 6251R1. That proposal involves converting 18 of production Lot 32’s F/A-18F aircraft to EA-18G aircraft. Work will be performed in St. Louis, MO (70%), El Segundo, CA (29%), and Mesa, AZ (1%), and is expected to be complete in September 2010.

Boeing representatives confirm that this contract involves the routine process of converting basic F/A-18F production airframes into EA-18Gs, as part of the joint multi-year contract (Super Hornet MYP-II). This particular contract will install all of the required fittings et. al. that are necessary for the Growler’s specialized equipment. The actual contract for that equipment (wingtip pods, electronics “black boxes” etc.) and its installation will follow later, as another modification.

June 3/08: Delivery. Boeing delivers the first fleet EA-18G Growler airborne electronic attack (AEA) aircraft to the U.S. Navy’s VAQ-129 Vikings Electronic Attack Squadron at Naval Air Station Whidbey Island, WA ahead of schedule and within budget. The Vikings are a Fleet Readiness squadron, which means they’ll be the training squadron for all EA-18G pilots.

The delivery follows 5 test aircraft, and the Growler is scheduled to enter Operational Evaluation in September 2008. If OpEval goes well, the aircraft will be moved from Low-Rate Initial Production (LRIP) to full-rate production. Boeing release | US Navy.

1st delivery

May 14/08: Infrastructure. Boeing holds a grand opening for its new EA-18G Growler Support Center (GSC) at Naval Air Station Whidbey Island, WA. The center will provide technical and logistics support for the EA-18s once the Navy accepts the first fleet Growler at the aircraft’s NAS Whidbey Island home base in early June of 2008.

The GSC will house approximately 24 representatives from the Navy and the Hornet/Growler industry team of Boeing, Northrop Grumman, Raytheon and General Electric. The center, along with the base’s existing supply chain management facility, will ensure that logistics support for new Growlers is readily available, per the FIRST performance-based maintenance contract for the US Navy’s Super Hornet fleet. Boeing release.

March 14/08: AEA LRIP-2. A $28.2 million modification to a previously awarded firm-fixed-price contract (N00019-07-C-0035) for time-critical parts in support of the EA-18G’s Low Rate Initial Production II (LRIP II) Airborne Electronic Attack kits. Work will be performed in St. Louis, MO, and is expected to be complete in April 2008.

March 5/08: Infrastructure. Small business and native business qualifer Alutiiq International Solutions, LLC in Anchorage, AK received a $21.2 million firm-fixed-price design/build contract for facility improvements at the Naval Air Station, Whidbey Island. The firm will upgrade existing facilities, and undertake some new construction in order to support the EA-18G aircraft.

Work will be performed in Oak Harbor, WA, and is expected to be complete by April 2011. This contract was competitively procured via the Naval Facilities Engineering Command e-solicitation website, with 2 proposals received by the Naval Facilities Engineering Command, Northwest in Silverdale, WA (N44255-08-C-6009).

Nov 19/07: Re-baselined. The Pentagon releases their latest Selected Acquisition Report, and the EA-18G is on it:

“The SAR was submitted to rebaseline the report from a Development to a Production estimate following approval of Low Rate Initial Production (Milestone C) in July 2007. Program costs increased $321.5 million (+3.8%) from $8,368.0 million to $8,689.5 million, due primarily to a quantity increase of five aircraft from 80 to 85 aircraft.”

SAR

FY 2007

Low-rate production of EA-18G Airborne Electronic Attack kits begins; EA-18G system development tests done.

EA-18G takeoff
(click to view full)

Aug 31/07: AEA LRIP-1. A $122.3 million cost-plus-incentive-fee modification to a previously awarded firm-fixed-price contract for 8 of the EA-18G’s Low-Rate Initial Production I (LRIP I) Airborne Electronic Attack (AEA) Kits and associated non-recurring engineering. In addition, this modification includes an unfinalized contract action for one FY 2007 supplemental funding EA-18G LRIP I AEA Kit, which would bring the total to 9.

The AEA kits involve internal electronics that distinguish the EA-18G from an F/A-18F, plus the ALQ-218 wingtip jammer pods.

Work will be performed in Baltimore, MD (51.2%); St. Louis, MO (11.1%); Bethpage, NY (10.2%); Melbourne, FL (8.5%); Fort Wayne, IN (8.5%); Thousand Oaks, CA (4.4%); Wallingford, CT (2.6%); Nashua, NH (2.6%); and Westminster, CO (0.9%), and is expected to be complete in December 2009 (N00019-07-C-0035).

AEA Kits begin LRIP

Aug 31/07: Industrial. A $13 million modification to a previously awarded cost-plus-award-fee contract (N00019-04-C-0005) for the procurement of additional factory test equipment in support of the EA-18G aircraft. Work will be performed in Baltimore, MD (78.3%); St. Louis, MO (11.6%) and Bethpage, NY (10.1%), and is expected to be complete in April 2009.

Aug 22/07: Spares. $40 million for delivery order #0002 under previously awarded contract, to purchase initial spares in support of the E/A-18 G Growler. Work will be performed at St. Louis, MO and is to be complete by May 2009. The Naval Inventory Control Point in Philadelphia, PA issued the contract.

August 6/07: Radomes. A $10 million ceiling-priced modification to a previously awarded cost-plus-award-fee contract (N00019-04-C-0005) for the design, development, fabrication/assembly and qualification of up to 20 EA-18G Extended Low Band Radomes. Radomes are an interestingly tricky. They need to be tough enough to handle the buffeting at the front of the fighter, while being transparent to radar signals from the fighter. The EA-18G adds even more electro-magnetic challenges to that equation.

Work will be performed in St. Louis, MO (55%) and Mesa, AZ (45%), and is expected to be complete in September 2009 (N00383-06-D-001J).

July 2007: Milestone C. The EA-18G receives Milestone C approval, clearing it to move ahead into Low-Rate Initial production.

Milestone C

April 21/07: Testing. NAVAIR announces that the EA-18G Growler has finished an ambitious regimen of flight tests, concurrently completing both system developmental testing and an independent fleet operational assessment within the first 90 days of flight test. Feedback from operational testers is being immediately incorporated into development of the platform and its systems.

The EA-18G mission systems test team and aircrew from Flight Test and Evaluation Squadrons VX-23 at Pax River, VX-31 and VX-9 at NAWS China Lake, CA and Boeing contractor crews used EA-18G prototypes EA-1 and EA-2, logging over 100 hours of flight tests plus additional range testing as of late March 2007.

As one example of its success, the program schedule required the Growler to radiate ALQ-99 pods in a Pax River chamber by the end of February. As a result of early software delivery and solid system performance, the EA-18G test team was able to demonstrate this jamming capability in December 2006, radiate jammers in-flight by the end of January 2007, and ensure that jamming functions did not interfere with safe operation of any on-board systems across the entire ALQ-99 radiation spectrum. See full NAVAIR release: “Growler zaps through initial testing.”

Feb 16/07: AEA LRIP-1. A $6.5 million firm-fixed-price contract for time-critical parts in support of the EA-18G Low Rate Initial Production I Airborne Electronic Attack kits. Work will be performed in St. Louis, MO and is expected to be complete in April 2007. This contract was not competitively procured (N00019-07-C-0035).

FY 2005 – 2006

Formal rollout ceremony; 1st test aircraft delivered; 1st test flight with all jamming pods; 1st AEA kits ordered; INCANS verified – and what’s that;

EA-18G Growler
(click to view full)

Sept 22/06: Delivery. The first test aircraft EA-1 is delivered to Naval Air Station Patuxent River, MD. EA-2 is scheduled to follow it by the end of 2006.

Aug 3/06: Rollout. At the formal rollout ceremony for the EA-18G, Boeing presented the aircraft to a crowd of more than 750 U.S. Navy customers, industry partners and Boeing employees at its Integrated Defense Systems facilities in St. Louis, MO. U.S. Navy Adm. Michael G. Mullen, Chief of Naval Operations and guest speaker at the ceremony, said: “It is clear that the demand for electronic warfare is not only going to remain high, but is going to grow…”

Rollout & delivery

June 30/06: AEA kits. An $82.4 million cost-plus-award-fee modification to a previously awarded cost-plus-award-fee contract for the first production representative lot of airborne electronic attack (AEA) kits for the EA-18G aircraft. This modification provides for 4 AEA kits, spares, and support equipment.

Work will be performed in Baltimore, MD (42.5%); Bethpage, NY (28.2%); St. Louis, MO (18%); Fort Wayne, IN (4.8%); Nashua, NH (2%); Melbourne, FL (1.6%); Wallingford, CT (1.6%); and Westminster, CO (1.3%), and is expected to be complete in September 2008.

June 29/06: SDD. A $19 million firm-fixed price modification to the previously awarded firm-fixed-price with economic price adjustment F/A-18E/F airframes Multi-Year II (MYP II) contract. This modification provides for incorporation of Engineering Change Proposal 6251 to convert 4 of the Lot 30 F/A-18F aircraft to EA-18G system development and demonstration aircraft. Work will be performed in St. Louis, MO (55%); El Segundo, CA (42%); and Mesa, AZ (3%), and is expected to be complete in September 2008.

May 30/06: Testing. The Boeing EA-18G program test team flew a modified F/A-18F equipped with wingtip antenna and high- and low-band jamming pods for the first time, as part of ongoing flying qualities and carrier suitability testing to validate the EA-18G’s shipboard effectiveness. See Boeing release.

Feb 17/06: Displays. Honeywell International, Inc., Defense and Space Electronic Systems in Albuquerque, NM receives a $7.9 million modification to a previously awarded firm-fixed-price contract (N00019-05-C-0033) to exercise an option for the full rate production of five-inch-by five-inch (5″ x 5″) forward and aft advance multi-purpose displays (AMPDs) for forward fit in Lot 30 F/A-18E/F and EA-18G aircraft, and retrofit into Lots 22-24. This option provides for the procurement of 96 forward AMPDs (84 for forward fit into F/A-18E/F, 8 for forward fit into EA-18G, 8 for retrofit, and 9 spares) and 40 aft 5 x 5 AMPDs (26 for forward fit into F/A-18E/F, 8 for forward fit into E/A-18G, 4 for retrofit, and 2 spares). Work will be performed in Albuquerque, NM, and is expected to be complete in February 2008.

EG-18 FAST lab
(click to view full)

Feb 06/06: Testing. Boeing announces that the U.S. Navy has approved their test plans and processes for integrating several key subsystems into the EA-18G Growler. Successful completion of its first two test readiness reviews (TRR) in January 2005 and November 2005 allows Boeing to begin developing and integrating the systems at Boeing labs in St. Louis. The reviews focused on several key areas of the aircraft’s software: mission computer, electronic attack unit, the stores management system, interference blanking unit, the ALE-47 countermeasures system, EA-18G instrumentation system, mission planning and integration of the digital memory device.

Engineers will now focus on integration of EA-18G Build 1, the first of two builds of the airborne electronic attack aircraft software. The aircraft’s initial flight is scheduled for fall 2006 or early 2007, and EA-18G lab features like high-speed links and the Facility Automated Set-up and Test, or FAST architecture are designed to help engineers to meet the integration schedule. See Boeing release for further details.

Jan 31/06: Training. A $19.7 million modification to a previously awarded cost-plus-award-fee contract (N00019-04-C-0005) for modeling and simulation, design, and development of a training system for the EA-18G aircraft. Work will be performed in Arlington, TX (50%) and St. Louis, MO (50%), and is expected to be completed in June 2008.

Jan 24/06: Testing. The EA-18G completes Jammer Flight Testing at Naval Air Warfare Center (NAWC), Patuxent River, MD. EA-18G department head (VX-23) Cmdr. Jaime W. Engdahl notes that the tests exercised all available jamming types for Build 1.5 in Bands 7/8/9, with “no notable EMC issues” and “no surprises.”

Naval Surface Warfare Center, Crane, IN is the cognizant Technical Authority for the plane’s AN/ALQ-99 Tactical Jamming System (TJS) Pod, and is teamed with Boeing, Northrop Grumman, and NAWC Point Mugu, CA to integrate the pod onto the EA-18G.

The word “pod” implies a level of plug-and-play that isn’t there; this effort required major electrical and structural modifications to the ALQ-99, including the development of the Pod Interface Unit, followed by 2 years of extensive environmental, flight performance, and integration testing performed at Crane, IN; Boeing in St. Louis, MO; and at NAWC Point Mugu and NAWC Patuxent River. US Navy.

Nov 8/05: INCANS. Boeing completes the initial laboratory verification of the EA-18G tactical aircraft’s Interference Cancellation (INCANS) system, and demonstrates the system’s capabilities during aircraft ground testing at Naval Air Station Patuxent River, MD. The INCANS system will allow the EA-18G to conduct voice communications over UHF radio with friendly forces while simultaneously jamming enemy communications, a difficult trick. The current EA-6B Prowler, for example, can’t do this. See Boeing release.

INCANS verification

EA-18G Prototype
(click to view full)

Sept 1/05: Mission planning. An estimated value $6.4 million modification to a previously awarded cost-plus-award-fee contract to develop, integrate, test and deliver 13 mission planning interfaces for the EA-18G aircraft. Work will be performed in Melbourne, FL (79%) and St. Louis, MO (21%), and is expected to be complete in August 2008 (N00019-04-C-0005).

Aug 17/05: Training. An $8.3 million ceiling-priced modification to a previously awarded cost-plus-award-fee contract to provide modeling and simulation; design and development for a training system for the EA-18G aircraft. Work will be performed in St. Louis, MO (50%), and Arlington, TX (50%) and is expected to be completed in June 2008 (N00019-04-C-0005).

July 13/05: Training. A $500 million not-to-exceed indefinite-delivery/ indefinite-quantity contract for the procurement of new F/A-18 E/F and EA-18G Trainer and Training Systems, upgrading existing systems, and including a full range of analysis; modeling and simulation; design, development; production; modification; test and evaluation, delivery; refurbishment; relocation; and product support of all training systems for the U. S. Navy and U. S. Marine Corps’ aircraft platforms.

Work will be performed in St. Louis, MO, and is expected to be completed in July 2010. This contract was not competitively procured by the Naval Air Warfare Center Training Systems Division in Orlando, FL (N61339-05-D-0003).

Oct 21/04: Boeing Begins Work on First EA-18G Test Aircraft.

FY 2002 – 2004

ALQ-218 wingtip pods have issues; Milestone B approval; Initial flight demonstration.

EA-18G rollout
(click to view full)

Sept 27/04: ALQ-218 issues. A $7 million ceiling-priced modification to a previously awarded cost-plus-award-fee contract to provide additional fault isolation in the ALQ-218 (V)2 Tactical Jamming Receiver components in support of the EA-18G System Development and Demonstration. Work will be performed in Baltimore, MD (73%); St. Louis, MO (14%) and Bethpage, NY (13%); and is expected to be complete in September 2009 (N00019-04-C-0005).

Dec 29/03: A $979 million ceiling-priced cost-plus-award-fee contract for system development and demonstration (SDD) of the E/A-18G weapon system.

Work will be performed in St. Louis, MO (55%); Bethpage, NY (25%); Baltimore, MD (15%); El Segundo, CA (2%); St. Augustine, FL (1%); Hollywood, MD (1%); and Camarillo, CA (1%), and is expected to be complete in December 2009. This contract was not competitively procured (N00019-04-C-0005). The 5-year SDD program for the EA-18G runs from FY 2004 until early FY 2009 and encompasses all laboratory, ground test, and flight tests from component level testing through full-up EA-18G weapons system performance flight-testing. See also Boeing corporate release.

EA-18G system development

Dec 18/03: The US Naval Air Systems Command (NAVAIR) receives Milestone B approval to proceed into EA-18G System Development and Demonstration (SD&D). Approval was granted by Michael Wynne, acting under secretary of defense, (Acquisition, Technology and Logistics).

The EA-18G contract team received its first pre-SD&D contract in September 2002 to support preparation efforts for the SD&D phase, and an SD&D contract is expected shortly. The 5-year SD&D program is expected to run from FY 2004 to mid FY 2009, and encompasses all laboratory, ground test, and flight tests from component level testing, through full-up EA-18G weapons system performance flight-testing. NAVAIR announcement.

Milestone B

Nov 15/01: Boeing Successfully Completes Initial EA-18 Flight Demonstration.

Appendix A: The EA-18G and the Future Force Mix

F-22A & F/A-18E
(click to view full)

The question of exactly where and how the new Growlers will fit into the future force remains a live issue. There has been a serious absence of integrated direction and planning in the Pentagon over the last decade re: the future of airborne electronic warfare platforms, and a relatively low priority assigned to dedicated “Wild Weasel” (anti-SAM) or electronic attack capabilities. This has arguably taken place in an environment where current capabilities remained “good enough.” The result, however, may be a lack of a clear niche in terms of establishing the EA-18G’s mission breadth and concept of operations (CONOPS).

At the moment, the assumption must be that the EA-18G will do it all for the US military as a tactical strike jammer. Despite the existence of the turboprop-driven EC-130H Compass Call, wavering interest in EB-52 SOJ long-range bomber jammers for the USAF, and the potential to create USAF and US Marine electronic attack F-35 Lightning IIs and F-22A Raptors by leveraging their vast installed capabilities, the EA-18G Growler is currently slated to be the only dedicated aircraft in this niche.

While EA-18Gs will fit in very well with the USAF’s F-16s and F-15 Strike Eagles, and with their Super Hornet counterparts, operational challenges arise in pairing them with the stealthier F-35 Lightning II fighters slated for use by the USAF, Marines, and Navy; or with “Global Strike” teams of stealthy F-22As and B-2 bombers. Long-range aircraft like the B-52 or B-1 also present potential operational challenges, due to the EA-18G’s range.

As effective AWACS aerial surveillance aircraft and ever more sophisticated anti-aircraft missile systems being exported around the world, the answers to such challenges will matter. The Growlers aren’t scheduled to enter service until 2009, and the F-35 Lightning II may be delayed to 2015. The EA-18Gs will be invaluable during that 6 year interim and beyond, as a key accompaniment to the legacy force. By 2010, however, with the F-22 production line coasting to a close, Reagan-era aircraft beginning to retire, and a new set of partner aircraft and threat capabilities on the horizon, deeper thinking about the US military’s long-term airborne electronic attack capabilities and composition will be required.

The Growler squadrons will undoubtedly be necessary – but will they be enough?

Footnotes

EC-130H Compass Call
(click to view full)

(1) This doesn’t make the EA-6Bs the USA’s only electronic warfare aicraft. The US also has 13 “Compass Call” EC-130H Hercules variants, and these 4-engine turboprops offer long-endurance coverage that extends over very wide areas. Unlike an EA-6B or EA-18G, they won’t accompany strike packages directly. They do train to support tactical aircraft as they cross behind the forward edge of the battlespace (FEBA), while remaining behind the FEBA line themselves and blanketing a wide area with bogus primary targets, secondary targets, and targets of opportunity for enemy missiles and aircraft. They are also very well suited to providing persistent coverage for key convoys and other missions in-theater during “small wars” campaigns, and monitoring cell phone frequencies over wide areas.

The pending growth in stealthy and/or supercruising opposing fighters, coupled with longer-range air-to-air and ground-launched anti-aircraft missiles, is going to push FEBAs back sharply during state-to-state conflicts. That’s likely to magnify the strategic EW fleet’s role, in order to provide a protective cloak of misdirection that lets key strategic assets like aerial tankers and AWACS planes remain close enough to support allied fighters. The future strategic EW fleet will involve a tension between follow-on EC-130Js or similar aircraft to replace the EC-130H fleet, vs. a more distributed capability based on the USA’s Next-Generation Jammer, or similar pods that might equip most strategic assets sent near harm’s way. [return to article]

Additional Readings and Sources

A quick note to readers. The aircraft’s official program name is the EA-18G Growler. On carrier decks, however, it’s called a “Grizzly,” just as its F/A-18F counterpart is a “Rhino” rather than a Super Hornet. This makes it impossible to confuse similar sounding names, amidst the thunderous cacophony of a carrier deck.

Background: Core Platform

• DID FOCUS Article – The USA’s 2005-2009 Multi-Year Hornet Procurement Contract. It covers F/A-18 E/F Super Hornets, and a number of common equipment sets shared with the EA-18G. See also the follow-on Super Hornet Fighter Family MYP-III: 2010-2013 Contracts.

• Boeing – EA-18G Airborne Electronic Attack Aircraft. See also Boeing’s quick platform overview [PDF format].

• US Navy NAVAIR – EA-18G Growler

• SoldierTech, via WayBack – ON THE PROWL: The EA-18G Growler.

Background: Ancillary Technologies Radar & Jamming Technologies

• DID Spotlight Article – New APG-79 AESA Radars for Super Hornets. AESA radars can and will become part of the reception and jamming array.

• Raytheon – AN/APG-79 AESA Radar.

• US NAVAIR – ALQ-99 Tactical Jamming System.

• GlobalSecurity.org – AN/ALQ-99 Tactical Jamming System (TJS).

• Northrop Grumman – AN/ALQ-218 RWR/ESM/ELINT Sensor System.

• Avionics Magazine, via WayBack (March 2008) – Teeth of the Growler.

• Australian Air Power (updated 2005) – Anatomy of the TacJammer.

Other Important Technologies

• GE Engines – Model F414.

• Rockwell Collins, via SLDINFO – Tactical Targeting Network Technology and Connectivity [PDF].

• Boeing – Wings of change for F/A-18, EA-18G Programs. Boeing redesigned the wing frame to reduce part numbers, rework, and costs.

• Boeing – Ramping up for delivery. A video feature that looks at the final stages of integration and delivery for EA-18G Growler and Super Hornet jets.

Official Reports

• US GAO (Mar 29/12, #GAO-12-175) – Airborne Electronic Attack: Achieving Mission Objectives Depends on Overcoming Acquisition Challenges.

• US Congressional Research Service – Navy F/A-18E/F Super Hornet and EA-18G Growler Aircraft: Background and Issues for Congress.

News and Views

• The Diplomat (Aug 21/14) – The F-35 vs. The VHF Threat. Includes lessons from the shootdown of an American F-117 stealth fighter over Serbia, and the importance of working with jamming aircraft under NIFC-CA doctrine.

• Aviation Week (April 29/14) – Opinion: Jamming Is Needed Against Agile Radar Threat.

• Daily Beast (April 28/14) – New U.S. Stealth Jet Can’t Hide From Russian Radar. Stealth isn’t invisibility. It’s small. The radars in question reduce stealth and claw back some detection range, but the headline implies that they negate it.

• Government Technology (March 17/14) – Advances in Electronic Warfare Fly Under the Public’s Radar. Ties the EA-18G and its future into cyber-attacks as well.

• WIRED Danger Room (July 14/09) – U.S. Boosts Secretive Jammer Fleet. “Last week, the small [EC-130H] Compass Call detachment at Bagram airbase, in Afghanistan, marked its 2,000th Afghanistan mission…”

• ELP Defenc(s)e Blog (June 16/09) – EA-35 – Fantasy meets more fantasy. “The electrical power budget is lacking, the number of aircrew are lacking and the whole thing depends on the next-gen surviving the budget axe yet again… The [F-35’s] APG-81 and its kind will only be able to have an effect on threats within its field of view – the forward cone of the aircraft. It will only be able to do electronic attack within its frequency band (X-band).”

• WWWP, via WayBack (May 6/08) – Not much Grrrrrr! for the Growler. The ALQ-99 is its biggest weakness: expensive to maintain or upgrade, won’t last forever, and sharply curtails aircraft range when carried.

• US Air Force Association Magazine, via WayBack (May 18/07) – Resurrecting the Standoff Jammer. The B-52 SOJ may fly despite a previous program cancellation, thanks in part to development work done on the EA-18G. Problem: the B-52 SOJ won’t fly until 2015, 3 years after the EA-6B Prowlers are retired… and Navy officials say the EA-18G is not the perfect solution to completely fill that gap. See also this March 27/07 short report.

• DID (Jan 26/06) – Electronic Warfare Systems a $28 Bn Market Over Next Decade.

• US Navy, Navy Enterprise magazine (Nov 1/06) – PBL Drives F/A-18 E/F and EA-18G Maintenance Efficiency

• DID (Nov 22/05) – More F-18 Super Hornets Possible for USA, Exports.

• Aviation Week’s Aerospace Daily (Nov 9/05) – U.S. Navy Eyes New Jammer, Other Upgrades For EA-18G [dead link].

• DID (Oct 28/05) – Jamming With the B-52s. Re the EB-52 SOJ proposal, which was cut.

• DID (Oct 22/05) – Supersonic SIGINT: Will F-35, F-22 Also Play EW Role?

• Winds of Change.NET (Jan 16/03) – Interview with a Weasel Pilot.

Americas

• The Air Force is moving ahead with its F-16 service life extension program. Cherokee Nation Aerospace and Defense is being awarded a $403 million firm-fixed-price, indefinite-delivery/indefinite-quantity contract that sees for the procurement of F-16 service life extension program (SLEP) kits in support of the fleet. The F-16 SLEP will keep the jets flying until nearly 2050. The program combines a dozen structural modifications into one repeatable package – from bulkheads to wings and canopy. The jets, which became operational in 1979, and were originally deemed air worthy for up to 8,000 flight hours, will have their life extended up to 12,000 flying hours. Work will be performed in Stilwell, Oklahoma, and is expected to be complete by May 2029.

• Raytheon is being tapped by the Office of Naval Research for the development of Low-Cost UAV Swarming Technology (LOCUST). The $29,6 million cost-plus-fixed-fee contract provides for research, testing and evaluation of a LOCUST Innovative Naval Prototype (INP). LOCUST can launch swarming UAVs to autonomously overwhelm an adversary. The deployment of UAV swarms will provide Sailors and Marines a decisive tactical advantage. The LOCUST program includes a tube-based launcher that can send UAVs into the air in rapid succession. The breakthrough technology then utilizes information-sharing between the UAVs, enabling autonomous collaborative behavior in either defensive or offensive missions. Raytheon’s Coyote UAS platform already demonstrated its ability to deliver varying payloads as part of a swarm that accomplished completely autonomous synchronization and formation flight. Work will be performed in Tucson, Arizona, and work is expected to be completed by January 2020.

• Armtec Countermeasures is set to provide the Marine Corps and the Navy with countermeasures for their aircraft. The firm-fixed-price job order is valued at $9 million and sees for the production of airborne expendable infrared countermeasures. The evolution of the IR seeker and its ability to reject flares continually drives the development of expendable countermeasures and their tactical use. As a result of the evolving threat, the expendable countermeasure has also seen significant improvements in the type of material used, spectral coverage, kinematic behavior and deployment tactics. Airborne expendable infrared countermeasures are designed with this kind of evolving threat in mind. They provide spectrally-tailored infrared signatures to defeat the discrimination logic of advanced missile seekers. Work will be performed in Camden, Arkansas, and is expected to be completed by June 2019.

• The Space and Naval Warfare Systems Center is procuring a multi-million information warfare research project. Advanced Technology International (ATI) is being awarded a $100 million expenditure-based other transaction agreement that provides for work on a variety of technology areas that are of interest to the Navy’s warfighting capabilities. Those areas include Cyber Warfare, which focuses on defensive and offensive technologies used to operate, configure, control, secure, maintain, and restore the infrastructures and resident data; and Battlespace Awareness, which focuses on advanced means to rapidly sense, collect, process, analyze and evaluate information content to exploit the warfighting operating environment. ATI will build a consortium of premier traditional and non-traditional government contractors, small and large businesses, for-profit and not-for-profit entities, and academic organizations to perform R&D prototyping efforts in support of the Navy. Work will be performed in Summerville, South Carolina, and other various places depending on the award of prototype project awards. Work on this contract has an expiration date of June 2021.

Middle East & Africa

• The government of Lebanon is set to receive 120mm high explosive rounds as part of a US foreign military sale. Medico Industries is being awarded a $35 million contract modification that sees for the production of 85,251 120mm high explosive rounds, 184,519 120mm full range practice charges, 23,187 120mm smoke shell bodies and relevant fuse adapters to be integrated into the shell bodies. This contract also includes FMS sales to Bosnia and Herzegovina. Work will be performed in Wilkes Barre, Pennsylvania, with an estimated completion date of July 2020.

• Jane’s reports that, the Israel Defense Forces is currently deploying a new type of torpedo on its submarine fleet. In a statement the IDF said, that “the torpedo systems possess advanced capabilities and characteristics, including increased precision and range.” The Kaved is a newly developed quieter, faster and more intelligent kind of torpedo. It has been described as a very high-speed weapon that could hit both surface and sub-surface targets, including those at depths of hundreds of meters. Unlike the Navy’s previous type, the new torpedo has a digital sonar guidance system that allows for upgrades without the need to change the hardware. The torpedoes will equip Israel’s three older Dolphin submarines as well as the new three new-generation boats, the last of which is expected to be delivered by the German company TKMS in 2019. The Israeli military so far did not disclose the name of the weapons manufacturer.

Europe

• The government of Spain is looking into purchasing five Aegis Weapon Systems from the US. The DSCA announced that it has made a determination to approve the requested foreign military sale valued at $860,4 million. Aegis, named after the legendary protective shield of Zeus, is deployed on over 80 serving naval ships around the globe. It equips Spain’s fleet of F100 Alvaro de Bazan Class frigates. Its radar system can perform search, track and missile guidance functions simultaneously, with the ability to track over 100 targets at over 100 miles. The Aegis combat system software takes input from a number of systems in order to create a unified picture of the threat environment. The proposed deal also includes the purchase of MK 54 torpedoes, SM-2 Block IIIB missiles and countermeasure systems. Spain currently operates five Aegis frigates and is proficient at using the AEGIS system to its fullest capability. The prime contractors will be Lockheed Martin, Raytheon and General Dynamics.

Asia-Pacific

• The Royal Thai Army (RTA) is currently adding four Hermes 450 drones to its inventory. The long-endurance tactical unmanned aerial vehicles are produced by Israel’s Elbit System. The Hermes 450 is a common medium surveillance UAV, with a 10 m wingspan and a maximum take-off weight of 1,212 lb. The 450 offers about 17-20 hours endurance at up to 18,000 feet altitude, and about 396 lb. of payload capacity via up to 2 body mountings and optional wing pylons. The UAVs will be used for operations including target designation; intelligence, surveillance, and reconnaissance (ISR), and mapping. The system is also expected to be used to track insurgency movements and drugs smuggling. The procurement of the Hermes 450 drones was finalized in 2017 at a total cost of $30 million.

Today’s Video

• HMS Queen Elizabeth returns to Portsmouth after completing a series of helicopter flying trials

AEGIS-BMD: CG-70
launches SM-3
(click to view full)

The AEGIS Ballistic Missile Defense System seamlessly integrates the SPY-1 radar, the MK 41 Vertical Launching System for missiles, the SM-3 Standard missile, and the ship’s command and control system, in order to give ships the ability to defend against enemy ballistic missiles. Like its less-capable AEGIS counterpart, AEGIS BMD can also work with other radars on land and sea via Cooperative Engagement Capability (CEC). That lets it receive cues from other platforms and provide information to them, in order to create a more detailed battle picture than any one radar could produce alone.

AEGIS has become a widely-deployed top-tier air defense system, with customers in the USA, Australia, Japan, South Korea, Norway, and Spain. In a dawning age of rogue states and proliferation of mass-destruction weapons, the US Navy is being pushed toward a “shield of the nation” role as the USA’s most flexible and most numerous option for missile defense. AEGIS BMD modifications are the keystone of that effort – in the USA, and beyond.

The AEGIS Naval Ballistic Missile Defense System What Is AEGIS?

AEGIS Combat Control
(click to view full)

Aegis, named after the legendary protective shield of Zeus, is deployed on over 80 serving naval ships around the globe, with many more Aegis-equipped ships planned or under contract. It’s the primary weapons control system on board American Ticonderoga Class Cruisers (CG-47) and Arleigh Burke Class Destroyers (DDG-51), as well as Japan’s Kongo & Atago Class destroyers, Korea’s KDX-III Class destroyers, Norway’s Fridtjof Nansen Class frigates, and Spain’s F-100 Alvaro de Bazan Class frigates. Australia’s Hobart Class F100 derivatives will join this set shortly.

The heart of these ships’ defensive suites is the AN/SPY-1 Radar System, a 3D air/surface search and tracking radar. This high-powered phased array radar is able to perform search, track and missile guidance functions simultaneously, with the ability to track over 100 targets at over 100 miles. Terminal guidance depends on mounted illuminators, since current SM-2 missiles are limited to semi-active radar homing.

Partial AN/SPY-1

The other key to Aegis is the Aegis combat system software, which takes input from a number of systems in order to create a unified picture of the threat environment. AEGIS equipped ships are key elements in modern carrier and battleship battle groups, providing fleet area defense and communicating an integrated air picture for more effective deployment of naval aircraft.

Most Aegis suites can be converted to missile defense, with the addition of hardware upgrades and a set of software updates. We refer to these upgraded systems as AEGIS BMD. The AN/SPY-1B radar variants that equip Ticonderoga class cruisers CG 59-73, and the AN/SPY-1D variant that equips DDG-51 destroyers and foreign Aegis ships in Japan, South Korea, and Spain, can be upgraded to support missile defense. On the other hand, the AN/SPY-1A radar on some Ticonderoga class cruisers is reportedly ineligible. The much smaller AN/SPY-1F hasn’t received a BMD upgrade design, and may or may not be capable.

Aegis was designed from the outset to operate with the Standard missile family, and both systems reach their maximum potential when deployed together. The current mainstay for air defense is the SM-2 Block IIIB. For missile defense, the longer-range SM-3 is the system’s main option, and it’s capable of exo-atmospheric kills up to 200 miles away, as ballistic missile prepare to re-enter the atmosphere. The “Burnt Frost” intercept showed that modified SM-3s were even capable of killing satellites in lower orbits.

A new variant of the SM-2 Block IV is being revived and fielded as the Near Term Sea-Based Terminal weapon (NT-SBT), for last-phase endo-atmospheric intercepts as the warhead descends toward its target. The new SM-6 will begin taking over that terminal defense role as of 2015.

As a ship combat system, Aegis can and does operate with a variety of other weapons, but Raytheon’s Standard family missiles are the only ones with ballistic missile defense capabilities.

AEGIS BMD: Versions & Capabilities

SM-3 Launch –
note rocket booster

AEGIS BMD went to sea with its initial operating capability in October 2004. During at-sea tests, the system and its missiles have been successful in 25/31 interception attempts – and 80.6% success rate.

AEGIS BMD 3.0. Its Long Range Surveillance & Tracking (LRS&T) wasn’t recommended for engaging ballistic missiles, but it reportedly extended the ship’s radar tracking range to 500 km/ 300 miles. That allowed equipped vessels to support engagements by other ships. Over time this version was phased out, as AEGIS BMD ship systems were upgraded.

AEGIS BMD 3.6 Supports full engagement, and was certified for tactical deployment by the U.S. Navy and the USA’s Missile Defense Agency in September 2006. The most recent certified version as of November 2014 is AEGIS BMD 3.6.3. This system retains long range tracking, can engage enemy missiles, and adds the capability to target short-range ballistic missiles as they re-enter the atmosphere in their final stage of flight. This allows them to make full use of SM-2 Block IV variants like NT-SBT, alongside longer-range options like the SM-3. Testing has demonstrated some unplanned bonus capabilities, including the ability to launch using another system’s tracking data, and to intercept MRBMs (1,000 – 3,000 km range).

AEGIS BMD 4.x Improvements include both hardware inserts and software development. Incorporation of the Aegis Ballistic Missile Defense Signal Processor (Aegis BSP) into the AN/SPY-1 radar helps the system detect, track and classify objects more effectively, in order to defeat more complex ballistic missile threats like decoys and multiple warheads. The Aegis BSP, which has been installed in all new Aegis destroyers beginning in 2010, is an open architecture design. BMD 4.x also adds an adjunct computing suite that will continue AEGIS BMD’s migration toward open architecture electronics, and supports the improved SM-3 Block IB missile. The 4.0.2 sub-version on a number of current ships changes the timing of SM-3 rocket pulses, as a response to the FTM-16E2 test failure.

BMD capability will be included in modernized, open architecture combat systems in Aegis cruisers and destroyers starting in 2012, and even US Navy Aegis ships that are not slated for BMD will be changing over to a full open architecture (OSA/ MOSA) system as part of ongoing upgrades to the DDG-51 and CG-47 ships. The move lets the Navy buy commercial electronics components from a much wider variety of suppliers, saving money and ensuring easier future upgrades.

AEGIS BMD 5.0. AEGIS BMD 5.0 is expected to complete the system’s open architecture shift, with a new multi-mission processor and new computing workstations and display systems. There are proposals to upgrade all American Aegis ships with AN/SPY1B/D radars to have AEGIS BMD capability, so the full OSA/MOSA migration could prove significant.

In 2015 – 2016, a BMD 5.0 CU upgrade will restore terminal phase intercept capability within the atmosphere, allowing ships to use the SM-6 as a 2nd line of defense. This upgrade is also known as Aegis Baseline 9.C1, and has already been fitted to some ships, but they haven’t tested terminal intercept capability yet.

SM-3 evolution
(click to view full)

AEGIS BMD 5.1. The next big step forward for AEGIS BMD will be a new missile, coupled with the AEGIS BMD 5.1 software. The SM-3 Block IIA will use a different design that’s 21″ in diameter, instead of 13.5″ like the Block Is. That will allow for more powerful rocket motors, and considerable increases in range. The SM-3 Block I is mostly designed for use against short and medium-range ballistic missiles (SRBMs/MRBMs), and lacks the range to defend countries like Poland or The Czech Republic from the sea.

The Block II’s range will put most of the Czech Republic and Poland within range of inshore ships, and could allow just 2 ships to offer full coverage of Japan. Its improved range and speed will add effectiveness against Intermediate Range Ballistic Missiles (IRBMs) that have ranges of 3,000 – 5,000 km, as well as some capability against full Intercontinental Ballistic Missiles (ICBMs). It’s due in 2018.

AEGIS BMDS: The Program

CEC Concept
(click to enlarge)

Tracking program spending on ship modifications is difficult to do in isolation, as Pentagon budget documents tend to treat “AEGIS BMDS” as a single category, which includes both ship upgrades and SM-3 missiles. The floating “SBX” radar deployed in the Pacific is also used in naval ballistic missile defense, but it is not an Aegis system and so does not come under AEGIS BMD budgets.

Based on Pentagon documents and outside sources, funding patterns include R&D, ship conversions, and SM-3 missile purchases. A GAO study gives totals over the years as:

FY 1995: $75 million.
FY 1996: $200.4 million.
FY 1997: $304.2 million.
FY 1998: $410 million.
FY 1999: $338.4 million.
FY 2000: $380 million.
FY 2001: $462 million.
FY 2002: $476 million.
FY 2003: $464 million.
FY 2004: $726.2 million.
FY 2005: $1.16 billion.

Beyond that:

The US MDA states that an in-service Aegis ship with no BMD capability can be given AEGIS BMD 3.6.1 capability for about $10 million to $15 million, or a AEGIS BMD 4.0.1 capability for about $53 million. An in-service ship with AEGIS BMD 3.6.1 installed can be upgraded to AEGIS BMD 4.0.1 for about $45 – $55 million more, for a total upgrade cost of $55 – $70 million if you have to do it twice.

BMD Ships & Deployment

We talked to the US Navy in order to confirm the ships, homeports, and combat system details of the fleet’s ships. As of October 2013, every ship from DDG 51 – DDG 77 will have received AEGIS BMD or have entered conversion. Conversions will continue within the fleet, and new ships under the current multi-year contract for DDG 117 – DDG 123 will all be delivered with BMD capabilities pre-installed – likely 5.0CU to start.

It has been a steady rvolution for the fleet, as it morphs toward its new “shield of the nation” role.

In March 2007, just 6 American warships had the ability to engage ballistic missiles, while another 10 were equipped with AEGIS Long Range Surveillance & Tracking version 3.0.

By July 2009, the number of fully BMD-capable ships had grown to 18, with 42 SM-3 missiles and 47 SM-2 Block IV variants available for use.

By the time CRS issued its FY 2012 report, there were 22 ships with AEGIS BMD 3.6.1, 2 with BMD 4.0.1, a store of 104 SM-3 missiles (92 Block IA and 12 Block IBs) to accompany about 100 SM-2 Block IVs.

The FY 2012 budget brought the total number of ordered BMD ship conversions to 35, and a combination of conversions, upgrades, and new-build ships will keep growing that number. From a FY 2013 CRS report:

(click to view full)

In the end, these CRS charts reinforce the belief that a significant portion of America’s destroyer and cruiser fleets will eventually receive these upgrades. Indeed, the US Navy’s FY 2015 – 2043 long-term plan will plateau between 80 – 97 BMD-capable ships.

AEGIS BMD Test History

Beyond the USA

JS Kongo into Pearl
(click to view full)

American ballistic missile defense ships won’t be alone on the seas. Japan has its own AEGIS BMD program, and began full installation of AEGIS BMD 3.6.1 systems in its Kongo Class Aegis destroyers in 2007. All 4 ships have now finished their installations, deployed SM-3 Block I missiles, and participated in BMD tests. The Japanese are also partnered with the USA to develop the SM-3 Block II: a larger, faster missile variant with an improved kill vehicle. This implies long-term upgrades for JMSDF combat systems to AEGIS BMD 5.1.

According to the US Congressional Research Service, other countries that the US military views as potential naval BMD operators of American equipment include the United Kingdom (Type 45 Daring Class, PAAMS/Aster-30 and possibly SM-3 too), the Netherlands (De Zeven Provincien Class, Thales BMD/SM-x), Spain (F100 Class, AEGIS BMD/SM-x), Germany (F124 Class, Thales/SM-x), Denmark (Ivar Huitfeldt Class, Thales/SM-x), South Korea (KDX-III, AEGIS/SM-6 confirmed), and Australia (Hobart Class, AEGIS/SM-6 confirmed, could add SM-3). Note that all countries listed here as potential operators could add SM-3s to Mk.41 vertical launch systems on board, as well as shorter-range SM-6 point defense BMD missiles. Infrastructure for one equals infrastructure for the other.

Aegis ships operate variants of the passive array SPY-1D radar, and one country has already taken steps. Spain already has ships equipped with AEGIS Long Range Surveillance & Tracking version 3.0, and ESPS Menendez Nunez has participated in US missile defense exercises as a tracking ship. The non-Aegis European countries mentioned here use variants of Thales’ SMART-L for long-range scans, coupled with modern active-array fire control radars. The Dutch De Zeven Provincien Class ship HNLMS Tromp has participated in US missile defense exercises as a tracking ship, sporting its Thales combat system and advanced Thales APAR/SMART-L active array radars. The Dutch are currently working to extend the class’ radar range even farther, in preparation for full BMD capabilities.

The US CRS omits France and Italy, even though they host the PAAMS combat system and BMD-capable Aster-30 missile on their 4 Horizon Class ships. France is also committed to building a national BMD system, so their omission is especially puzzling.

Contracts & Updates FY 2015 – 2018

1st BMD 5.0CU test.

FTM-25 explained

June 28/18: FMS request by Spain The government of Spain is looking into purchasing five Aegis Weapon Systems from the US. The DSCA announced that it has made a determination to approve the requested foreign military sale valued at $860,4 million. Aegis, named after the legendary protective shield of Zeus, is deployed on over 80 serving naval ships around the globe. It equips Spain’s fleet of F100 Alvaro de Bazan Class frigates. Its radar system can perform search, track and missile guidance functions simultaneously, with the ability to track over 100 targets at over 100 miles. The Aegis combat system software takes input from a number of systems in order to create a unified picture of the threat environment. The proposed deal also includes the purchase of MK 54 torpedoes, SM-2 Block IIIB missiles and countermeasure systems. Spain currently operates five Aegis frigates and is proficient at using the AEGIS system to its fullest capability. The prime contractors will be Lockheed Martin, Raytheon and General Dynamics.

May 17/18: Zeus upgrades his shield The Missile Defense Agency (MDA) is contracting Lockheed Martin’s Rotary and Mission Systems Division in support of the Aegis Ballistic Missile Defense system. The awarded modification of $12.8 million allows for the procurement of material necessary to support the Aegis 6.0 modelling and simulation. Aegis, named after the legendary protective shield of Zeus, Aegis has become a widely-deployed top-tier air defense system. It is deployed on over 80 serving naval ships around the globe, with many more Aegis-equipped ships planned or under contract. The Aegis combat system software takes input from a number of systems in order to create a unified picture of the threat environment. Aegis equipped ships are key elements in modern carrier and battleship battle groups, providing fleet area defense and communicating an integrated air picture for more effective deployment of naval aircraft. Modeling and simulations are computer representations that simulate the system’s performance to assess the capabilities and limitations of how elements or the BMDS perform under a wider variety of conditions than can be accomplished through the limited number of flight tests conducted. Ground tests enable MDA to repeatedly conduct scenarios that may be too costly or subject to constraints as a flight test. The modification increases the total cumulative contract value to $2.8 billion. Work will be performed in Moorestown, New Jersey and is scheduled for completion by September 2018.

January 3/18: Contracts-Sustainment Support Lockheed Martin received last Thursday, a $20.5 million contract for upgrades and services for the AEGIS weapon system (AWS). Under the terms of the agreement, Lockheed will provide for logistics and sustainment support for the in-service AEGIS ship fleet in order to prevent delays in the delivery of the AWS upgrades and schedule and operational impacts to the effected ship availabilities. Options, if exercised, will bring the cumulative value of the contract to $27.05 million. Work will be performed in Moorestown, New Jersey, with contract completion scheduled for December 2018.

November 8/17: Japan’s Defense Minister Itsunori Onodera is scheduled to visit the US Navy’s Aegis Ashore test facility in Hawaii during a visit to the volcanic archipelago US state next January. Washington conducts missile intercept tests at the complex on Kauai Island, and Onodera will visit to learn more about the operation of the system and issues it should take into account when introducing the system to its self-defense forces. Tokyo is keen to procure the system as part of its land-based air defense network from North Korean ballistic missiles.

August 31/17: Japan is seeking powerful new radar from the US to boost the operational range of its planned procurement of a land-based version of the Aegis ballistic missile defense (BMD) system, due in 2023. So far, previous efforts by Tokyo to acquire the AN/SPY-6 AESA radar have not come to fruition, leaving them to rely on existing radar technology that has less range than a new generation of BMD interceptor missiles available. While the US Navy is seemingly behind Japan receiving the technology, there may be a reluctance from the MDA, which is responsible for developing BMD technology, to release such advanced technology before it is fully fielded by the US. Developed by Raytheon and integrated into the Aegis system by Lockheed Martin, SPY-6 radars will also form part of the Pentagon’s new Aegis-equipped Arleigh Burke-class destroyers, due to be operational in 2022. In order for Japan to receive the Spy-6 in time for the planned deployment of its Aegis Ashore system in 2023, it will need to be cleared long before that 2022 date, in order to give the manufacturers time to build the system.

May 25/17: General Dynamics Ordnance and Tactical Systems has received a $40.8 million modification to an existing contract for production of the MK 82/MK 200 Missile Fire Control System director controller equipment. The Navy contract calls for the delivery of fully functional systems with testing and engineering support and covers systems scheduled to be delivered as part of the Aegis Weapon System for the Republic of Korea and Japan under the Foreign Military Sales Program. The work is not expected to affect current ship deployment or operational use and is expected to be completed by December 2021.

April 30/17: Japan is moving ahead with a study into the possibility of deploying the Aegis Ashore missile defense system in the country. Seen as a cheaper alternative to the high profile deployment of the Terminal High Altitude Area Defense (THAAD) system in South Korea, only two Aegis sites (compared with six THAAD sites) would be needed to cover the entire country from a potential ballistic missile launch from North Korea. At present, Tokyo’s air defense network includes naval-based Aegis destroyers as well as the Patriot system. However, the inclusion of a permanently deployed, land-based Aegis system will allow Japanese forces to respond much quicker to any incoming missile threats.

December 19/16: Recent testing on board the USS John Paul Jones by the US Missile Defense Agency have successfully demonstrated the ability of the Aegis baseline 9.C1 to tackle against a “complex medium-range ballistic missile target. A salvo of two SM-6 Dual I interceptors was fired during the December 14 exercise, using their explosive warheads to defeat the target. Program officials will continue evaluating system performance based upon telemetry and other data obtained during the test.

October 19/16: October 19/16: Aegis or THAAD? With the expectation that Tokyo will request additional money external link to fund missile defense upgrades to repel North Korean ballistic missiles, a study will be funded on whether to buy the Terminal High Altitude Area Defence (THAAD) system or Aegis Ashore. It’s believed that money will also be provided to improve their existing PAC-3 air defense system as well. However, any purchases or modernizations will take time to implement as North Korea continues with its escalation of missile tests.

September 7/16: The US Navy will field-test the latest Aegis Baseline 9.2C alongside the first intercept test for the SM-3 Block 2A interceptor next month. A new feature added to the software build is the “engage-on-remote” capability that will allow the SM-3 missile to target a ballistic missile during data derived from another sensor such as a satellite. However October’s test will not see that feature tested.

August 22/16: The US Missile Defense Agency (MDA) has scheduled the testing of the SM-3 Block 2A ballistic missile defense interceptor this October. A joint development involving both the MDA and Japan, the interceptor has been previously flight tested twice by the agency without any target intercepts initially planned. October’s test will see it engage and destroy a medium-range ballistic missile target. If successful, the SM-3 will be in full-rate production in 2017.

August 18/16: Lockheed Martin has received $112 million as part of the 2016 Aegis modernization program. The US Navy contract modification covers the production of multi-mission signal processor equipment sets, ballistic missile defense 4.0.2 equipment, Aegis weapon system modernization upgrade equipment, as well as associated spares to support the fielding of Aegis modernization capabilities to the fleet. Under the program, vessels receiving the upgraded systems will experience increased computing power as well as improved detection and reaction capabilities of its radars.

August 17/16: Japanese and South Korean destroyers are to receive the latest variant of the Aegis combat system after contracts were issued by the US DoD. Two upcoming Japanese and three new Korean vessels will receive the Aegis Baseline 9 system alongside all future US Navy destroyers. Completion of the $490 million deal is expected for June 2022.

June 27/16: Lockheed Martin has been awarded a $357 million contract for Advanced Electronic Guidance and Instrumentation System (AEGIS) in-service combat systems for several nations. The contract will see the company provide computer program maintenance, annual inspection and regular overhaul execution support, in-country support, and staging. Replacement of legacy cathode ray tube character readout devices for Japan, logistics depot support for Norway unique line replaceable unit, and AEGIS implementation studies for future Foreign Military Sales (FMS) AEGIS shipbuilding programs to fulfill AEGIS lifetime support requirements of the Japan Maritime Self Defense Force, Republic of Korea Navy, Spanish Armada, Royal Australian Navy, and Royal Norwegian Navy. Completion is expected for November 2019.

June 2/16: Raytheon has been awarded a $365.8 million contract for the production of Aegis Weapon System AN/SPY-1D(V) Radar Transmitter Group, Missile Fire Control System MK 99 equipment, and associated engineering services. The contract combines purchases for the US Navy, South Korea, and Japan and contain options that could amount to $423 million. Completion of the contract is expected by October 2022.

May 26/16: USS John Paul Jones was used to validate the ability of the Aegis Baseline 9 to track Medium Range Ballistic Missile (MRBM) targets within the Earth’s atmosphere recently. Supported by the Navy, Missile Defense Agency, and Lockheed Martin the use of the missile destroyer marks the first demonstration of Aegis’s ability to conduct a complicated tracking exercise against an MRBM during its endo phase of flight. The development comes as targets and threats have become more advanced, with Aegis BMD evolving over the last 20 years from a tracking experiment to today’s capability in which it can detect, track and engage targets.

December 9/15: The crew of the USS John Paul Jones got quite a workout while testing the Aegis combat system during an exercise off Wake Island on October 31. They first intercepted a short range air launch target (SRALT) missile with the THAAD missile defense system. The Aegis was then tested as a C-17 then launched an extended medium range ballistic missile (EMRBM) through the debris of the first intercept. If that wasn’t enough, the crew were simultaneously engaging a BQM-74E air-breathing target with a Standard Missile-2 Block IIIA guided missile at the time. The tests were aimed at improving and enhancing the Aegis Ballistic Missile Defense, which is the naval component of the Missile Defense Agency’s Ballistic Missile Defense System.

Nov 6/14: FTM-25. USS John Paul Jones [DDG 53] successfully engages 1 short-range ballistic missile target with an SM-3 Block IB missile, and 2 cruise missiles with a par of SM-2 Block IIIAs, in the FTM-25 Stellar Wyvern test.

DDG 53 has the Aegis 9.C1 combination, which represents the next evolutionary step. It finishes the system’s open architecture shift, adding a new multi-mission processor and new computing workstations and display systems. The upgrade’s goal is to rapidly switch between BMD and the area air defense role, allowing full use of SM-6 missiles in a terminal BMD role as well as multiple engagements like this one.

Other test participants included discriminating sensors flown on two MQ-9 Reaper unmanned aerial vehicles and sensor systems ashore; Command and Control, Battle Management, and Communications (C2BMC) Enterprise Sensors Lab; C2BMC Experimentation Lab; and the Aegis Ashore Missile Defense Test Complex located at PMRF. Sources: US MDA, “Aegis Ballistic Missile Defense System Completes Successful Intercept Flight Test” | Defense Update, “System upgrades are key in Aegis destroyer’s success defeating ballistic, cruise missile raid on the recent test”.

Oct 17/14: FTX-20. USS John Paul Jones [DDG 53] engages in the FTX-20 tracking test of a ballistic missile target, testing both the combined Aegis 9.C1 combat system (Aegis Baseline 9 with BMD 5.0 Capability Upgrade), and the ability to launch and engage based solely on tracks from remote airborne sensors.

Other test participants included the Sea-Based X-band Radar (SBX), Space Tracking and Surveillance System (STSS) Demonstrators; Discrimination Sensor Technology (includes a UAV – likely MQ-9 – with an MTS-B optical sensor turret); Command and Control, Battle Management, and Communications (C2BMC) Enterprise Sensors Lab; C2BMC Experimentation Lab; and the Aegis Ashore Missile Defense Test Complex located at PMRF. Sources: US MDA, “Aegis Ballistic Missile Defense System Detects and Tracks Medium-Range Ballistic Missile Target”.

FY 2014

BMD 5.0 contracted for development, but won’t become universal; CRS highlights program cuts, GAO highlights software glitches and Euro deployments.

FTM-22 test

Jan 15/15 29/14: Raytheon announced that the Navy has approved the SM-6 for additional Aegis systems, to include those Arleigh Burke-class guided missile destroyers from the 1994-keel-laid The Sullivans (DDG-68) onward.

This appears to put to rest concerns that the Zumwalt-class (DDG-1000) program wouldn’t be able to employ (see “Weapons” section) the standard family of missiles.

Sept 29/14: Lockheed Martin Mission Systems and Training in Moorestown, NJ receives an $8.1 million contract modification for a single FY 2015 AEGIS BMD 4.0.2 ship installation, bringing the contract’s total value to date to $2.0106 billion.

Work will be performed at Moorestown, NJ, with an expected completion date of March 27/16. The US Missile Defense Agency in Dahlgren, VA manages the contract (HQ0276-10-C-0001, PO 0154).

Aug 8/14: 4.1/ 5.0. Lockheed Martin Mission Systems and Training in Moorestown, NJ receives a $193.6 million contract modification for necessary material, equipment, and supplies to define, develop, integrate and test Aegis Ballistic Missile Defense 4.1 and 5.0 Capability Upgrade baselines through their respective certifications. At present 4.0.2 is the most recent fielded version. $19.5 million in FY 2014 Navy RDT&E funds is committed immediately, and the entire modification brings the contract’s cumulative face value to $2.003 billion.

Work will be performed at Moorestown, NJ, with an expected completion date of May 31/16. fiscal 2014 research, development, test and evaluation funds in the amount of $19,500,000 are being obligated at time of award. The Missile Defense Agency, Dahlgren, Virginia, is the contracting activity (HQ0276-10-C-0001, PO 0150).

July 23/14: Lockheed Martin Mission Systems and Training in Moorestown, NJ receives a $40.7 million not-to-exceed contract for 1 multi-mission signal processor equipment set, ballistic missile defense 4.0.2 equipment (the most modern fielded variant), and Aegis Weapon System upgraded equipment to support fielding Aegis modernization capabilities to the fleet. $20.3 million is committed immediately, using FY 2014 budgets.

Work will be performed in Moorestown, NJ (57.8%); Clearwater, FL (41.5%); and Owego, NY (0.7%), and is expected to be complete by March 2016. This contract was not competitively procured, pursuant to 10 U.S. C. 2304(c)(1), as implemented by FAR 6.302-1. US NAVSEA in Washington, DC manages the contract (N00024-14-C-5106).

May 27/14: Limited Upgrades. USNI reports that many existing BMD ships won’t receive an upgrade to Aegis Baseline 9, which lays a foundation for the use of missiles like the new SM-6 beyond the ship’s radar range, and for terminal ballistic missile defense:

“Out of 28 early Arleigh Burke-class DDGs (Flight I/II), 21 will not receive a full upgrade to their Aegis combat systems and instead have a midlife upgrade that will focus on the mechanical health of the ship and some will have upgrades to the ships’ anti-submarine warfare systems as part of a cost saving strategy, Naval Sea Systems Command told USNI News on Friday…. The estimated cost of the reduced upgrades is about $170 million per ship for the news systems and testing. The full upgrade costs about $270 million…. Ships without a combat system refresh at some point — usually during a midlife upgrade — only average from 17 to 19 years in the fleet, several naval experts told USNI News.”

Our chart of BMD ships has been updated accordingly. Sources: USNI, “Navy Quietly Downscales Destroyer Upgrades”.

April 8/14: CRS Report. The Congressional Research Service updates their backgrounder covering the Aegis Ballistic Missile Defense system. They confirm DID’s charts regarding these areas, though CRS doesn’t divide general naval BMD from the land-based European implementation.

The FY 2015 budget cuts 132 SM-3 missiles from the FY 2014 budget’s 2015-2018 buys, and it will also change the composition and makeup of the naval BMD fleet via a combination of slower upgrades, and the mothballing of 4 BMD ships. The US Navy’s FY 2015 decision to sideline its 11 newest Ticonderoga Class cruisers (CG 63 – 73) will remove 4 ships from the BMD fleet until the late 2020s, and the damaged USS Port Royal will probably never return to service. Expected returnees include CG 67 USS Shiloh (2024, BMD 4.0.1 now), CG 70 USS Lake Erie (2026, BMD 4.0.2 now) and CG 72 USS Vella Gulf (2027, BMD 3.6.1 now).

Aegis BMD 4.0 is at an advanced stage, but there are still a few things everyone would like to see. They include a test featuring remote authorized engagement with an SM-3 Block IB against a medium/intermediate-range ballistic missile target, operationally realistic testing using its improved engagement coordination with THAAD and PATRIOT missiles, and
an Aegis BMD 4.0 test featuring simultaneous BMD/cruise missile intercepts.

April 7/14: Lockheed Martin Mission Systems and Training in Moorestown, NJ receives a $13.7 million modification to contract for support of Aegis BMD Program Office advanced concepts initiatives, to identify technology for introduction into present and future Baselines/Spirals. This modification brings the total cumulative face value of the contract to $1.789 billion, from $1.775 billion.

All funds are committed immediately, using MDA FY 2014 RDT&E budgets. Work will be performed at Moorestown, NJ, with an expected completion date of June 30/14. The US Missile Defense Agency in Dahlgren, VA manages the contract (HQ0276-10-C-0001, P00138).

April 1/14: GAO Report. GAO-14-351 focuses on acquisition goals and reporting for missile defense in general. A 17 month delay in the modernized Aegis system is at a problematic point:

“Discovery of software defects continues to outpace the program’s ability to fix them; fixes may have to be implemented after software is delivered.”

March 14/14: GAO report. The GAO releases GAO-14-248R, regarding the USA’s EPAA plans for defending Europe from ballistic missiles. With respect to Aegis Ashore, they note that the Phase 2 system in Romania will be installed with an interim version of its software. The final version won’t be ready until 2017, which makes one wonder about the AEGIS BMD v5.1 software that supposed to be ready for deployment by 2018. This is a wider theme for GAO, who say that:

“A highly concurrent schedule for Aegis Ashore installations and Aegis weapon system development mean issues discovered during testing could require fixes, possibly after operational deployment. DOD believes that concurrency risk is properly balanced… flight testing will not affect technical design.”

March 4/14: MDA Budget. The MDA finally releases its FY15 budget request, with information spanning from FY 2014 – 2019. AEGIS BMD has a number of related budget lines: Aegis Ashore Phase II & III construction, BMD Aegis R&D, Land-Based SM-3 R&D, Aegis SM-3 Blk IIA R&D, Aegis Initial Spares procurement, Aegis Ashore Phase III procurement and AEGIS BMD O&M.

That’s $2.135 billion in FY15, for a diverse set of programs from missiles to ship refits to land-based installations. If BMD testing and BMD targets are added, on the grounds that most MDA testing involves AEGIS BMD systems, the FY15 total rises to $3.006 billion.

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 SM-3 Block IA went 4/5 this fiscal year, thanks to a faulty IMU chip in the FTI-01 test’s missile (q.v. Oct 25/12). That chip is only present in a few Block IAs, and isn’t in Block IB. The SM-3 Block IB went 3/3 in FY13, but after a string of 5 successful flights, the report notes an issue with the 2nd missile’s TSRM cold gas regulator during FTM-21. Overall:

“With the completion of FTM-21 and FTM-22, the IOT&E flight testing phase for Aegis BMD 4.0 and SM-3 Block IB guided missiles is nearly complete. However, the program needs to complete Flight Test Other-18 (FTX-18) and planned HWIL testing of raid engagement capability and Information Assurance testing using accredited models and simulations in the test runs-for-the-record before an assessment of effectiveness and suitability can be made. Additionally, the program needs to test Aegis-Aegis, Aegis-THAAD, and Aegis-Patriot engagement coordination; only the first of these three types of engagement coordination is planned for live-target testing before the SM-3 Block IB Full-Rate Production decision in 4QFY14.”

Oct 3/13: FTM-22. An SM-3 Block IB missile from the cruiser USS Lake Erie destroys a medium-range, separating ballistic missile target that was launched from the Pacific Missile Range Facility on Kauai, Hawaii. It represents the 5th successful test in a row of the SM-3-IB/ AEGIS BMD 4.0.x combination since the September 2011 failure. Sources: MDA release, Oct 4/13 | Lockheed Martin release, Oct 4/13 | Aerojet Rocketdyne release, Oct 4/13.

FY 2013

BMD 5.x development contracts; BMD 4.x installation contracts; SM-3 Block IIB is terminated after reports cast doubts on it; Glitches in FTI-01 test, but successes in 3 others.

FTM-20 launch
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Sept 23/13: R&D. Lockheed Martin Mission System and Training in Moorestown, NJ receives a $20 million sole-source cost-plus-award-fee contract modification. They’ll identify technology for introduction into present and future Aegis Ballistic Missile Defense Baselines and upgrades. Initial funding begins with just $50,000 in RDT&E dollars.

Work will be performed in Moorestown, NJ, with an estimated completion date of June 30/14. The US Missile Defense Agency in Dahlgren, VA manages the contract (HQ0276-10-C-0001, P00125).

Sept 18/13: FTM-21. USS Lake Erie [CG 70] ripple-fires 2 SM-3 Block IB missiles at a short range, separating ballistic missile target. As it happens, missile #2 isn’t needed, because the 1st one hits. The bad news is that missile #2’s TSRM cold gas regulator, which was redesigned after the FTM-15 fail, glitched out during the 2nd pulse rocket motor firing. It didn’t affect the score, but the Navy wants to know if there’s a common underlying root cause they haven’t quite fixed.

As usual, the test centers around the Pacific Missile Range Facility on Kauai, Hawaii. It’s the 4th consecutive success for the SM-3 Block IB since the Sept 1/11 failure. Sources: the FY 2013 Annual Report | US MDA release, Sept 18/13 | Lockheed Martin release, Sept 19/13.

Sept 10/13: FTO-1. A successful joint test of AEGIS BMD and land-based THAAD missiles from the Pacific Kwajalein Atoll/Reagan Test Site destroys 2 medium range target missiles.

The test involved full inter-operation. A land-based TPY-2 radar was positioned forward as the warning radar. It acquired the targets, and passed that onto the joint C2BMC (Command, Control, Battle Management, and Communications) system. C2BMC cued DDG 74 USS Decatur, outfitted with AEGIS BMD 3.6.1 and the SM-3 Block IA missile. Decatur acquired the track, then launch and killed its target. C2BMC also passed the track to a land-based THAAD battery’s own TPY-2 radar, which provided the intercept guidance for a successful pair of THAAD missile shots. The 2nd THAAD missile was actually aimed at the SM-3’s MRBM, in case it had failed to achieve intercept, but that turned out not to be necessary this time. Sources: US MDA, Sept 10/13 release | Lockheed Martin, Sept 11/13 release | Raytheon, Sept 10/13 release.

July 1/13: 5.1 + Increment 2. Lockheed Martin Mission Systems and Training in Moorestown, NJ, receives a sole-source, cost-plus-incentive-fee/cost-plus-award-fee/cost-plus-technical-schedule incentive fee contract modification worth $295 million, raising the total contract value to date to $1.73 billion. This covers system engineering and program management for BMD 5.1 software through the Critical Design Review (CDR), and SM-6 interceptor Increment 2 through Preliminary Design Review (PDR).

Work will be performed in Moorestown, NJ until March 2015. SM-6 Increment 2 will provide terminal-phase ballistic missile defense capability, allowing the missiles to act as a 2nd layer beneath SM-3. BMD 5.1 software and SM-6 Increment 2 are scheduled to reach Initial Operational Capability (IOC) by 2018 (HQ0276-10-C-0001).

May 16/13: FTM-19. An SM-3 Block IB missile is launched from the cruiser USS Lake Erie [CG 70, BMD 4.0.2], and hits a separating, short-range ballistic missile target. This is the 3rd consecutive successful test for the SM-3 Block IB, after its September 2011 failure. Which should clear the way for the full FY 2013 missile order. Overall, this test brings the SM-3 family to 25/31 (about 80%) in ballistic missile intercept tests. US MDA | US DoD | ATK | Lockheed Martin.

April 25/13: BMD 5.0. Lockheed Martin Mission Systems and Training in Moorestown, NJ receives a $69.4 million sole-source, cost-plus-incentive-fee, cost-plus-award-fee contract modification to continue developing AEGIS BMD 5.0, increasing the total contract value from $1.34 billion to $1.41 billion.

Work will be performed in Moorestown, NJ, and is expected to be complete by May 31/14. The US Missile Defense Agency in Dahlgren, VA manages the contract (HQ0276-10-C-0001).

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 biggest news is the SM-3 Block IIB Next-Generation Aegis Missile’s effective termination into a technology demonstration program. Its ability to defend the USA from European bases became questionable, and its timelines were never realistic. The USA will buy the originally-planned number of land-based GBI missiles instead.

March 15/13: R&D. Lockheed Martin MS2 in Moorestown, NJ receives a sole source, cost-plus-award-fee contract modification. The $24 million option supports Program Office efforts to identify technology for introduction into present and future Aegis Ballistic Missile Defense Baselines/Spirals. The total contract value jumps from $1.316 billion to $1.34 billion.

The work will be performed in Moorestown, NJ through Dec 31/13. The contract has no Foreign Military Sale components, and the US Missile Defense Agency in Dahlgren, VA manages it (HQ0276-10-C-0001).

Feb 13/13: FTM-20. CG-70 USS Lake Erie uses AEGIS BMD 4.0.2 and an SM-3 Block IA missile to hit a medium-range ballistic missile target, based on tracking data from in-orbit Space Tracking and Surveillance System-Demonstrator (STSS-D) satellites. The 4.0.2 system incorporates the changes made in the wake of the FTM-16E2 failure, and changes the timing of SM-3 rocket pulses.

Tracking from space can extend ship launch ranges, which allows one ship to cover a larger area. On the other hand, a September 2012 NRC report saw the system’s PTSS successor constellation as a waste of money, which provides very little value beyond existing satellites. They recommended that the USA should invest in upgrading the land-based GMD and its radars instead, in order to improve ICBM intercepts.

The missile target was launched from the Pacific Missile Range Facility, as usual. The SM-3 destroyed its target, and initial indications are that all components performed as designed. MDA’s release says that FTM-20 is the 24th successful SM-3 intercept in 30 flight test attempts since intercept tests began in 2002. US MDA | US DoD | ATK | Lockheed Martin | Northrop Grumman | Raytheon.

Feb 11/13: GAO Report. GAO-13-382R: “Standard Missile-3 Block IIB Analysis of Alternatives” throws cold water on the idea that the SM-3 Block 2B can defend the USA from bases in Poland or Romania. The geometry isn’t very good, and success may require a boost-phase intercept. Those are very tricky, and have limited range, because you have to hit the enemy missile within a very short time/ distance.

Some members of the military think it’s possible, at an initial estimated budget of $130 million extra. The problem is the tradeoffs. Liquid propellants can boost speed, but are unsafe on Navy ships due to the fire risks. On the other hand, the middle of the North Sea offers much better missile intercept geometries. Maybe Block 2B shouldn’t be land-based at all, but then why replace Block 2A in such an expensive way? MDA still needs to set the future missile’s performance requirements and limits. Where should the tradeoffs be made?

This brings us to the GAO’s point about the MDA developing the SM-3 Block IIB under a framework that dispenses with a good chunk of the usual paperwork, including an Analysis of Alternatives. On reflection, this is more than a bureaucratic point driven by “records show that programs doing the paperwork usually fare better.” One of the EPAA’s key underlying assumptions is now in question, and the proposed solution must now be in question as well. Is the best solution for land-based European missile defense still SM-3 Block IIB? What are the tradeoffs vs. using a system like the NRC’s recommended GMD-I from the USA (vid. September 2012 entry), and making Block 2B a ship-deployed missile? Does Block 2B even make sense now? Without good answers regarding capability, options, and maintainability, how does the MDA decide – or pick the right winning combination among the Block 2B competitors? A full AoA could improve those answers, and hence the odds of a smart pick.

Feb 7/13: +3 destroyers. Lockheed Martin Mission Systems and Sensors in Moorestown, NJ has its sole-source-cost-plus-incentive-fee/ cost-plus-award-fee contract limit raised by $30.2 million, in order to install AEGIS BMD 4.0.1 on 3 US Navy destroyers. This raises the overall contract from $1.286 billion to $1.316 billion.

Work will be performed in Moorestown, NJ; Pearl Harbor, HI; San Diego, CA, and Norfolk, VA through March 15/15. Initial funding will use FY 2013 Research, Development, Test and Evaluation funds. The Missile Defense Agency, Dahlgren, Va., is the contracting activity (HQ0276-10-C-0001).

Oct 25/12: FTI-01. The US Army and Navy conduct a combined developmental and operational tests that involves the back-end C2BMC system, Army PATRIOT PAC-3 and THAAD missile intercepts, and Navy SM-2 and SM-3 missiles launched from USS Fitzgerald [DDG 62]. The PAC-3, THAAD, and SM-2 intercepts all work. The SM-3 Block IA intercept does not.

“The flight test began with an Extended Long Range Air Launch Target (E-LRALT) missile airdropped over the broad ocean area north of Wake Island from a U.S. Air Force C-17 aircraft, staged from Joint Base Pearl Harbor-Hickam, Hawaii. The AN/TPY-2 X-band radar, located with the THAAD system on Meck Island, tracked the E-LRALT and a THAAD interceptor successfully intercepted the Medium-Range Ballistic Missile. THAAD was operated by Soldiers from the 32nd AAMDC.

Another short-range ballistic missile was launched from a mobile launch platform located in the broad ocean area northeast of Kwajalein Atoll. The PATRIOT system, manned by soldiers of the 94th AAMDC, detected, tracked and successfully intercepted the target with a PAC-3 interceptor. Additionally, a second PAC-3 interceptor also intercepted a low flying cruise missile target over water.

The USS FITZGERALD (DDG 62) successfully engaged a low flying cruise missile over water. The Aegis system also tracked and launched an SM-3 Block 1A interceptor against a Short-Range Ballistic Missile (SRBM). However, despite indication of a nominal flight of the SM-3 Block 1A interceptor, there was no indication of an intercept of the SRBM.”

Sources: US MDA, “MDA completes BMDS FTI-01 live-fire demonstrations” | Lockheed Martin, “Lockheed Martin’s Missile Defense Systems Engage Multiple Targets During First Ever Integrated Ballistic Missile Defense System Test” | Raytheon, “U.S. Military Engages Targets With Raytheon Equipment in Largest Missile Defense Test in History”.

FTI-01: mixed results

FY 2012

BMD 4.0.1 certified; BMD 5.0 install contract Navy wants to scrap 7 cruisers, Congress wants to keep damaged CG 70; CRS report lays out BMD ship plans; European deployments to Rota planned; 2 tests go well; Key NRC report analyzes ballistic missile defense in-depth, says SM-3-IIB can’t protect USA from European bases.

FY 2013 Budget fight
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Sept 28/12: Keep USS Port Royal? In the wake of Senate Appropriations Committee support, and partial agreement from the House Appropriations Committee support, the US Navy is now saying that it wants to keep USS Cowpens (CG-63), USS Anzio (CG-68), USS Vicksburg (CG 69) and USS Port Royal (CG-73) in service, instead of decommissioning them in March 2013.

USS Port Royal, which ran aground off of Hawaii in 2009 (q.v. Feb 8/09 entry), is the only BMD-capable ship in that set, and her required repairs will pose a separate problem for the Navy and for Congress. It may well be cheaper to pay $55 million and convert one of the other 3 rescued cruisers for the BMD role, than it would be to repair USS Port Royal. Naval Technology.

Sept 25/12: Lockheed Martin Mission Systems & Sensors in Moorestown, NJ receives a $27 million contract modification to previously awarded contract for the production of 2 multi-mission signal processor equipment sets that upgrade a SPY-1D radar for BMD, 3 AEGIS BMD 4.0.1 equipment sets, and 5 Aegis Weapon System upgraded equipment sets.

Work will be performed in Moorestown, NJ (74%); Clearwater, FL (25%); and Akron, OH (1%), and is expected to be complete by December 2014. $11.8 million will expire at the end of the current fiscal year, on Sept 30/12. US Naval Sea Systems Command in Washington, DC manages the contract (N00024-11-C-5118).

Sept 14/12: Lockheed Martin Mission Systems & Sensors in Moorestown, NJ receives a $58.1 million contract modification to produce 1 one FY 2012 multi-mission signal processor equipment set (which upgrades a SPY-1D radar for BMD), 2 AEGIS BMD 4.0.1 equipment sets, and 1 upgraded Aegis weapon system equipment set.

Work will be performed in Moorestown, NJ (74%); Clearwater, FL (25%); and Akron, OH (1%), and is expected to finish by December 2014. US Naval Sea Systems Command in Washington DC (N00024-11-C-5118).

September 2012: NRC report. The US National Research Council publishes “Making Sense of Ballistic Missile Defense: An Assessment of Concepts and Systems for U.S. Boost-Phase Missile Defense in Comparison to Other Alternatives.” The report staff have deeply impressive backgrounds related to missile defense, and their main conclusion is that very fundamental reasons of geography and physics make boost-phase defense systems a waste of time.

This includes AEGIS BMD systems. The report explains very clearly that the window for stopping a warhead before it has enough energy to hit “defended” areas makes it difficult to impossible to position a ship in a place that allows even future SM-3 Block II missiles to hit their target. The report still believes that AEGIS BMD has a strong role to play, and will form the core defense of critical locations like Hawaii.

Aug 29/12: BMD 5.0 for 4. Lockheed Martin Mission Systems and Sensors in Moorestown, NJ receives a $7.9 million sole source cost-plus-incentive fee/ cost-plus-award-fee contract modification. It exercises an option to install, test and check out the Aegis Ballistic Missile Defense Baseline 5.0 Weapon System on up to 4 Arleigh Burke Class Destroyers, raising the total contract value from $1.272 billion to $1.28 billion. These ships will enter service in FY 2013 and FY 2014.

BMD 5.0 will finish the system’s migration into the DDG Modernization Program’s Open Architecture (OA) efforts, which would allow the installation of Aegis BMD capability as a retrofit to all serving American destroyers. Firing the longer-range US/Japanese SM-3 Block IIA missile will require another upgrade, however, to AEGIS BMD 5.1.

Work will be performed in Moorestown, NJ from Aug 29/12 through Dec 31/15. FY 2012 Research, Development, Test and Evaluation funds will be used, but they won’t expire at the end of the current fiscal year. The US Missile Defense Agency in Dahlgren, VA manages the contract (HQ0276-10-C-0001).

Aug 10/12: CRS Report. The US Congressional Research Service issues its latest update of “Navy Aegis Ballistic Missile Defense (BMD) Program: Background and Issues for Congress” [PDF]. Key issues highlighted or examined by Mr. O’Rourke include the cost of forward-deploying 4 destroyers to Spain, the FY 2013 budget’s proposal to slow the 2013-2020 ramp-up rate for BMD ships, the potential for European contributions to naval BMD, the inability to simulate China’s DF-21 ship-killing ballistic missile, SM-3 Block IIB risks, and concurrency and technical risk in the AEGIS BMD program generally.

Issues involving the SM-3 Standard missile family are covered in that FOCUS article, while European missile defense is covered in a separate DID Spotlight piece. Other key excerpts:

“As can be seen Table 4, under the FY2013 budget, there are to be 36 BMD-capable Aegis ships by FY2018 [32 converted + 4 new destroyers], or 7 less than projected under the FY2012 budget for FY2018 [37 converted + 6 new destroyers]. The proposal under the FY2013 budget to retire seven Aegis cruisers early, in FY2013 and FY2014… may explain part of the difference… Some observers have been concerned that demands for BMD-capable Aegis ships are growing faster than the number of BMD-capable Aegis ships… [in addition] The Navy projects that implementing the 30-year plan would result in a cruiser/destroyer force that remains below 90 ships every year… except FY2027, and that reaches a minimum of 78 ships… in FY2014-FY2015 and again in FY2034. The projected cruiser-destroyer shortfall is the largest projected shortfall of any ship category…”

June 27/12: FTM-18. USS Lake Erie [CG-70] with its AEGIS BMD 4.0.1 system successfully launches an SM-3 block IB missile to hit a separating ballistic missile target. This is the same configuration that will be used for the land-based Phase 2 of the USA’s European missile defense plan, and represents an important success for the SM-3 block IB after the FTM-16 failure. This firing makes the AEGIS & SM-3 combination 23/28 in intercept tests so far (82.1%), vs. 31/40 (77.5%) for all other missile defense system intercept tests.

The Aegis BMD 4.0.1 configuration and its improved signal processor were certified in March 2012. It is now operational on 2 Navy ships, with installations underway on 2 more. US MDA | Lockheed Martin | Raytheon.

May 9/12: FTM-16E2a. This test goes better than FTM-16E2 (q.v. Sept 1/11), as USS Lake Erie [CG 70] successfully fires its SM-3 Block IB missile and intercepts the target. Sources: US MDA, “Second-Generation Aegis Ballistic Missile Defense System Completes Successful Intercept Flight Test”.

March 15/12: Scrapping CG 73. The US Navy proposes to scrap 7 Ticonderoga Class cruisers, in order to reduce operations and refit expenses as part of proposed budget cuts. USS Port Royal, an AEGIS BMD capable cruiser that ran aground in 2009, is scheduled for scrapping in March 2013. Information Dissemination on NAVADMIN 087/12.

Feb 16/12: DDGs to Europe. The US Navy announces the 4 Arleigh Burke Class guided-missile destroyers which will be forward deployed to Rota, Spain in FY 2014 and 2015. See also DoD Buzz.

“The four include three from Norfolk, Va; USS Ross, USS Donald Cook, and USS Porter, and one from Mayport, Fla., USS Carney. The ships are in support of President Obama’s European Phased Adaptive Approach to enhance the security of the European region… Ross and Donald Cook will arrive in fiscal 2014 and Carney and Porter in fiscal 2015.”

FY 2011

Equipment and test event contracts; DSB reaffirms support for Aegis/SM-3 combination; CRS lays out ballooning demand, upgrade costs; GAO criticizes MDA’s baselines and cost estimates; FTM-15 test shows early launch-on-remote capability, but FTM-16 Event 2 fails.

DDG-70 fires SM-3
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Sept 1/11: FTM-16E2. The first ABM test of the new SM-3 Block 1B missile does not go well, as the launch from the AEGIS BMD 4.0.1-equipped USS Lake Erie [CG-70] fails to intercept the target missile during “FTM-16, Event 2”. The US MDA is now 21/26 for SM-3 missile intercept attempts, plus one successful satellite kill.

The root cause of failure turns out to be abnormal performance in the 3rd stage, during thrust pulses for final rocket maneuvers. That stage is common to Block IA and Block IB missiles, so the program decides that the least disruptive approach is to change the ship’s Aegis BMD 4 software to control the timing between pulses. There are no further problems in the next 3 SM-3 Block IB tests. US MDA | Aviation Week pre-test | GAO report explains cause.

FTM-16E2 test failure

Aug 23/11: BMD 5.1. Raytheon Missile Systems Co. in Tucson, AZ receives a $9.8 million sole-source, cost-plus-award-fee contract modification. The CLIN 0008 option, “Future Upgrades and Engineering Support,” will help the Missile Defense Agency execute technical analysis for the Aegis BMD 5.1/SM-3 Block IIA combination, and increases the total contract value from $276.7 – $286.5 million.

Work will be performed in Tucson, AZ through Sept 30/16, and will be incrementally funded by FY 2011 research, development, test, and evaluation funds. Though the SM-3 Block IIA is a cooperative program with Japan, this is not a foreign military sales acquisition. The US MDA in Dahlgren, VA manages the contract (HQ0276-10-C-0005, PO 0015).

July 29/11: Mod Kits. Lockheed Martin Mission Systems & Sensors in Moorestown, NJ receives a $118.6 million fixed-price-incentive contract for 2 multi-mission signal processor (MMSP) equipment sets; 3 AEGIS BMD 4.0.1 equipment sets; and 5 Aegis Weapon System upgraded equipment sets, to support fleet BMD modernization. Sets will be delivered to 7 ships: the Ticonderoga Class cruisers USS Princeton [CG 59]; USS Cowpens [CG 63]; and USS Gettysburg [CG 64]; and the Arleigh Burke Class destroyers USS Arleigh Burke [DDG 51]; USS Barry [DDG 52]; USS John Paul [DDG 53]; and USS Benfold [DDG 65].

Work will be performed in Moorestown, N.J. (74%), Clearwater, FL (25%), and Akron, OH (1%), and is expected to be complete by September 2013. This contract was not competitively procured by US Naval Sea Systems Command in Washington Navy Yard, DC (N00024-11-C-5118).

July 6/11: In an open letter, the US Defense Science Board aims to dispel impressions that they recommended against the SM-3, which by its nature is a mid-course or terminal phase interceptor:

“The DSB concluded that the Missile Defense Agency is on the right track in developing European Phased Adapted Approach (EPAA) options, including continued evolution of the SM-3 family of missiles… The DSB also examined the potential in the EPAA context for EI [Early Intercept] in regional defense against short-range missiles before threat payloads could be deployed, and concluded that this was not a viable option because of technical constraints… The fact that this form of EI is not viable in shorter-range regional applications does not imply that either SM-3 family interceptors or the EPAA concept are flawed… MDA is on the right track in pursuing this capability for national missile defense, and examining the potential application in regional defense as a function of the range of threat missiles.”

June 23/11: CRS Report. The US Congressional Research Service releases the latest update of “Navy Aegis Ballistic Missile Defense (BMD) Program: Background and Issues for Congress” [PDF]. Key excerpts:

“Some observers are concerned… that demands from U.S. regional military commanders for BMD-capable Aegis ships are growing faster than the number of BMD-capable Aegis ships. They are also concerned that demands from U.S. regional military commanders for… BMD operations could strain the Navy’s ability to provide regional military commanders with Aegis ships for performing non-BMD missions… Options for Congress include, among other things, the following: accelerating the modification of Aegis ships to BMD-capable configurations, increasing procurement of new Aegis destroyers, increasing procurement of SM-3 missiles, and providing funding for integrating the SM-2 Block IV BMD interceptor missile into the 4.0.1 version of the Aegis BMD system.

…MDA states that an in-service Aegis ship with no BMD capability can be given a 3.6.1 BMD capability for about $10 million to $15 million, or a 4.0.1 BMD capability for about $53 million. MDA states that an in-service ship with a 3.6.1 BMD capability can be upgraded to a 4.0.1 BMD capability for about $45 million to $55 million.”

July 5/11: Testing. Lockheed Martin has begun testing its AEGIS ACB-12/ Baseline 9 combination (SPY-1 radar & multi-mission signal processor (MMSP)) against live aircraft in a “stressing electronic-attack environment.” The instrumented, pod-equipped Learjets are operated by firms like L-3, on behalf of the US Navy.

ACB-12 will equip both retrofitted ships and new DDG-51 destroyers. Lockheed Martin’s delivery date for Baseline 9 is November 2012, with certification about a year later. Next steps include simulations of a modern Midway-style scenario involving enemy aircraft and ballistic missiles, which have gained new urgency with reports of China’s DF-21 ballistic anti-ship missile. Jim Judd is currently Lockheed Martin’s technical director for ACB-12. Aviation Week.

June 3/11: FTM-16. Raytheon Missile Systems in Tucson, AZ receives a $219.5 million cost-plus-award-fee, cost-plus-incentive-fee, and cost-plus-fixed-fee contract modification, finalizing work for the FTM-16 ballistic missile defense test. This finalizes the total contract at $294.5 million, which includes the engineering, development, testing, support and material necessary to deliver an SM-3 Block 1B missile; and to provide engineering support, production engineering and obsolescence, surveillance and flight test support, and travel during the 55-month (about 4.5 year) performance period.

FTM-16 is scheduled for late summer 2011. It will demonstrate AEGIS BMD 4.0.1 mounted in USS Lake Erie [CG 70], in conjunction with the 1st flight test of the SM-3 Block IB interceptor. Work will be performed in Tucson, AZ through Sept 30/15, and about $32 million in FY 2011 research, development, test and evaluation (RDT&E) funds will be used. The US Missile Defense Agency at Dahlgren Naval Base, VA manages this contract (HQ0276-11-C-0002). See also US MDA testimony to HASC [PDF].

June 1/11: Support. Photon Research Associates in San Diego, CA receives a $9.5 million cost-plus-fixed-fee contract for specialized technical systems analysis services in support of Aegis Ballistic Missile Defense, as well as the land-based THAAD program, on behalf of the US Navy ($8 million/ 85%) and the government of Japan ($1.4 million/ 15%).

These services involve operations research support, physics analysis, test plans and procedures, test data collection analysis and test data review, test monitoring, real-time mission support, technical management support, technical reports and briefing preparations, in support of test and evaluation and systems engineering activities related to various national test ranges as required.

Work will be performed in San Diego, CA (70%), and the Pacific Missile Range Facility at Barking Sands, Kauai, HI (30%). Work is expected to be complete in May 2013, and $401,000 will expire at the end of the current fiscal year, on Sept 30/11. This contract was not competitively procured pursuant to FAR 6.302-2, by the US Naval Air Warfare Center Weapons Division at China Lake, CA (N68936-11-C-0023).

April 15/11: FTM-15. Flight Test Standard Missile-15 fires an SM-3 Block 1A missile against an intermediate-range (officially, 1,864 – 3,418 miles) target, based on AN/TPY-2 ground-based radar data, before the USS O’Kane (DDG 77, equipped with AEGIS BMD 3.6.1) could pick the target up using its own radar. Initial indications are that all components performed as designed, and the missile recorded the 21st successful AEGIS BMD intercept in 25 tries.

The target missile was launched from the Reagan Test Site, located on Kwajalein Atoll in the Republic of the Marshall Islands, approximately 2,300 miles SW of Hawaii. The AN/TPY-2 radar, which is also used as part of the THAAD missile system, was located on Wake Island, and crewed by Soldiers from the 94th Army Air and Missile Defense Command. It detected and tracked the missile, then sent trajectory information to the 613th Air and Space Operations Center’s C2BMC (Command, Control, Battle Management, and Communications) system at Hickam Air Force Base, HI. That was relayed to USS O’Kane, sailing to the west of Hawaii, which launched the SM-3-1A missile about 11 minutes after target take-off. O’Kane’s own AN/SPY-1 radar eventually picked up the incoming missile itself, and controlled the missile until impact.

FTM-15 was less dramatic than the SM-3’s 2008 satellite kill, but it’s equally significant. Launch on remote track was supposed to wait for AEGIS BMD 5.1, and SM-3 Block IB was supposed to begin addressing IRBMs, with full capability only in SM-3 block II. Instead, the test also combined to extend the current system’s proven capabilities, while validating the difficult connections that make a missile defense system more than the sum of its parts, and proving out an important early warning element (STSS satellites) in the system. US MDA | Lockheed Martin | Raytheon | Lexington Institute.

Launch-on-Remote, anti-IRBMs come early

April 6/11: BMD 4.0.1. Lockheed Martin Mission Systems and Sensors in Moorestown, NJ receives a $34.4 million cost-plus-incentive-fee/ cost-plus-award-fee modification with technical/schedule performance incentives. That money will be used to fund schedule and “within scope” adjustments to AEGIS BMD Baseline 4.0.1 development, and to multi-mission signal processor (MMSP) development under two separate contract line items (CLINs). Work will be performed in Moorestown, NJ, and runs through December 2014. FY 2011 research, development, test and evaluation funds will be used to fund this effort, and the US Missile Defense Agency manages the contract (HQ0276-10-C-0001).

For AEGIS BMD 4.0.1, the contract funds an initial delay in the certification schedule, and an adjustment to the original test plan.

For MMSP, it covers an extension to the development schedule, to account for alignment with changes to the ACB-12 overall combat system development and integration program plan. Those changes are “attributable to a delay in delivery of government furnished equipment.”

March 31/11: Raytheon Integrated Defense Systems in Sudbury, MA receives a not-to-exceed $10.4 million delivery order for a set of AEGIS BMD radar electronics upgrades. Items include a stable master oscillator (STAMO); radio frequency (RF) combiner; ordnance alteration kits; and associated spares, material and installation services. The STAMO provides a very precise and pure RF source that is amplified in the Continuous Wave Illuminator, so the Fire Control System can illuminate targets for a missile engagement. The RF Coherent Combiner modification improves the accuracy of power and phase monitoring, reducing the need for sphere tracks to assess radar performance.

Raytheon confirmed to DID that these items were AEGIS BMD related. Work will be performed in Norfolk, VA (45%); Burlington, MA (28%); and Andover, MA (27%), and is expected to be complete by August 2013 (N00024-11-G-5116, #0010).

March 24/11: GAO Report. The US GAO issues report #GAO-11-372: “Missile Defense: Actions Needed to Improve Transparency and Accountability.” Key excerpts:

“In 2010, MDA was able to meet or exceed its delivery goals for several MDA activities, such as missile defense upgrades to Aegis ships… MDA finalized a new process in which detailed baselines were set for several missile defense systems… [but] GAO found its unit and life-cycle cost baselines had unexplained inconsistencies and documentation for six baselines had insufficient evidence to be a high-quality cost estimate… GAO makes 10 recommendations for MDA to strengthen its resource, schedule and test baselines, facilitate baseline reviews, and further improve transparency and accountability. GAO is also making a recommendation to improve MDA’s ability to carry out its test plan. In response, DOD fully concurred with 7 recommendations. It partially concurred with 3…”

FY 2010

Equipment and test event contracts; Multi-year support contract; BMD on 21 ships now; Navy panel on Aegis readiness issues.

USS Lake Erie [CG 70]
(click to view full)

Jan 5/10: Update. Lockheed Martin provides a year-end update of AEGIS BMD progress to date. It is now installed on 21 American ships, as well as all 4 of Japan’s Kongo Class destroyers.

AEGIS BMD 4.0.1 was formally tested in June 2010, with at sea tracking exercises of medium and intermediate range targets during the last quarter of 2010. That iteration will finish AEGIS BMD’s transition an open electronic architecture during the “Advanced Capability Build 12” software and hardware upgrades, scheduled for 2012.

July 7/10: AEGIS Readiness Issues. A Gannett’s Navy Times story discusses their copy of a fleet review panel report. The panel, headed by Vice Adm. Phillip Balisle (ret.), says that:

“The SPY radar has historically been the best supported system in the surface Navy, and coincidentally supports one of the most critical Navy missions today: ballistic-missile defense. Yet SPY manpower, parts, training and performance are in decline… it can be assumed that less important systems could well be in worse material condition.”

Problems behind the rise in requests for technical assistance, and poor performance in inspection reports, include a lack of top-qualified personnel, sailors who aren’t fully trained on maintaining the radars, and a Navy bureaucracy and maintenance funding shortages that make it so difficult to order replacement parts, crews are giving up and commanders are choosing to take risks with lower performance, in order to avoid sidelining the ship. Retired Office of Naval Intelligence analyst and longtime “Combat Fleets of the World” editor A.D. Baker III, offered this summation:

“The Aegis readiness shortfall is just one of a vast number of problems related to pushing people too far and not giving them the training or funding resources to carry out their duties properly… This will significantly affect our putative BMD capability. The money is going to missile development and procurement, not to maintenance of the detection and tracking system – without which the best missiles in the world won’t be of much use.”

June 14/10: Lockheed Martin, Mission Systems and Sensors in Moorestown, NJ receives a $131.6 million modification to previously awarded contract (N00024-09-C-5101) for 4 multi-mission signal processor equipment sets, 4 ballistic missile defense 4.0.1 equipment sets, and 6 Aegis weapon system upgraded equipment sets.

Work will be performed in Moorestown, NJ (82%); Clearwater, FL (13%); and Eagan, MN (5%), and is expected to be complete by September 2013. $9.1 million will expire at the end of the current fiscal year, on Sept 30/10. The Naval Sea Systems Command in Washington Navy Yard, DC manages this contract.

April 26/10: BMD 4.0.1. Lockheed Martin Maritime Systems and Sensors in Moorestown, NJ receives a $151.9 million cost-plus-incentive-fee/ cost-plus-award-fee modification, exercising options to complete the development and test of the Aegis BMD Baseline 4.0.1, then install and verify it in 4 Aegis cruisers or destroyers.

Work will be performed in Moorestown, NJ from April 2010 through Dec 31/13, and $10 million in research, development, test and evaluation funding from the FY 2010 budget will be used to get this effort underway for the US Missile Defense Agency (HQ0276-10-C-0001).

Feb 10/10: Testing. Lockheed Martin announces that the US Navy awarded the company a $160 million follow-on contract for technical and engineering support at its land-based test facility for the Aegis Ballistic Defense (BMD) System. The Combat Systems Engineering Development Site (CSEDS) in Moorestown, NJ, develops and integrates computer software for the Aegis BMD System. In addition to ongoing support for CSEDS, the new contract calls for Lockheed Martin to support, operate and maintain the Naval Systems Computing Center (NSCC) and the SPY-1A naval radar test suite located near CSEDS.

AEGIS BMD, 2009
(click to enlarge)

Nov 12/09: +6 ships. The U.S. Missile Defense Agency announces the next 6 ships that will be modified for AEGIS BMD. All will be stationed on the East Coast, which currently has just 2 BMD-capable ships. Defense News.

Oct 21/09: AEGIS BMD. Lockheed Martin Maritime Systems and Sensors in Moorestown, NJ receives a Cost-Plus-Incentive-Fee / Cost-Plus-Award-Fee contract with a total value of $1.035 billion, to serve as the Aegis Ballistic Missile Defense Combat System engineering agent and the Aegis Ballistic Missile Defense Weapon System design, development and computer program source for Aegis cruisers and destroyers.

Work is to be performed in Moorestown, NJ from Oct 1/09 through Dec 31/14. FY 2009 RDT&E funding will be used to incrementally fund this effort for $15.2 million. The Missile Defense Agency in Dahlgren, VA issued the contract (HQ0276-10-C-0001).

FY 2007 – 2009

Equipment and test event contracts; Satellite killer; Japanese score 1st foreign intercept; Pacific Blitz test failure; USS Port Royal runs aground; BMD 4.0.1 developed and installed; BMD 3.6 testing complete.

USS Port Royal: Oops.
(click to view full)

June 23/09: BMD 4.0.1. Lockheed Martin announces that it has installed the latest BMD 4.0.1 evolution and new Aegis BSP signal processor on the cruiser USS Lake Erie [CG-70]. Over the next year, USS Lake Erie will complete a series of tests, leading up to full certification of the system upgrade by the U.S. Navy in early 2011.

BMD 4.0.1 installed

May 12/09: Mod Kit. Raytheon, Integrated Defense Systems in Sudbury, MA received a $6.5 million cost-plus-fixed-fee delivery order, with delivery incentives, for one AN/SPY-1 radar transmitter multi-mission capability ordnance alteration kit, including radio frequency monitor coherent combiner, technical manual changes and installation/checkout spares.

The AN/SPY-1 radar transmitter multi-mission capability modifications are part of the Aegis modernization program along with the multi-mission capability enhancement, a commercial-off-the-shelf based multi-mission signal processor which is being developed in parallel with this procurement. The multi-mission signal processor, and these transmitter modifications, will provide the AN/SPY-1D radar system with near AN/SPY-1D (V) radar performance, augmented with full AEGIS ballistic missile defense signal processor capabilities.

Work will be performed in Norfolk, VA (67.5%); Sudbury, MA (20.5%); and Andover, MA (12%), and is expected to be complete by October 2010. This contract was not competitively procured by the Naval Sea Systems Command in Washington Navy Yard, DC (N00024-06-G-5109).

Feb 8/09: Aegis, Involuntarily Ashore. The guided missile cruiser USS Port Royal [CG-73], one of just 3 cruisers with AEGIS BMD installed, runs aground off of Hawaii. The warship suffers heavy damage to the underwater bow sonar dome and to her propellers and propeller shafts, and is drydocked. Bubbleheads has a link roundup.

Port Royal runs aground

Nov 1/08: Pacific Blitz. The US Navy has 2 ships fire SM-3s at 2 incoming ballistic missiles. Only 1 of them hots its target. USS Paul Hamilton [DDG 60] fired 1st and was successful, but USS Hopper’s [DDG 70] ability to successfully detect, track and engage the target wasn’t enough to get an interception. The US Navy’s record for intercept tests is now 16 of 19. Sources: US MDA, “Navy Intercepts Ballistic Missile Target in Fleet Exercise Pacific Blitz”.

Mixed test results

Oct 21/08: BMD 3.6. Operational Testing of the Aegis BMD 3.6 System completed.

BMD 3.6 testing done

Burnt Frost

Feb 20/08: Burnt Frost. USS Lake Erie [CG 70] launches a modified SM-3 missile, aimed at a malfunctioning American reconnaissance satellite [USA-193] instead of an enemy missile. The intercept is successful, adding a new dimension to American BMD capabilities.

The 5,000 pound satellite was probably a radar satellite, but the fact that the USA had lost control shortly after launch on Dec 1/06 meant that most of its toxic hydrazine fuel was still on board. Analysis from the Joint Space Operations Command at Vandenberg AFB, CA says that the on-board hydrazine propulsion fuel was successfully and completely neutralized, with “nearly 100 percent of the debris safely burned-up during reentry within 48 hours,” and the remainder of the satellite expected to safely re-enter the atmosphere and burn up “within the next few days.” Sources: US MDA, “One-Time Mission: Operation Burnt Frost” | USAF, “Operations Group blazes new trail during Operation Burnt Frost”.

Satellite kill!

JS Kongo fires SM-3
(click to view full)

Dec 17/07: Japan test. Japan’s JS Kongo AEGIS destroyer [DDG-173] becomes the first ship beyond the US Navy to destroy a ballistic missile, launching an SM-3 Block 1A to successfully intercept a medium-range ballistic missile target fired from the U.S. Navy’s Pacific Missile Range Facility on Kauai, Hawaii. The veteran ABM test participant USS Lake Erie [CG 70] sailed from its homeport of Pearl Harbor to participate as a secondary, using its radar to track the target.

This marks the 12th successful intercept overall for the SM-3. Read “Japanese Destroyer JS Kongo Intercepts Ballistic Missile” and “Japan’s Fleet BMD: Upgrades & UORs” for more in-depth coverage. We won’t be covering further Japanese tests beyond the article’s master chart.

Japan: 1st BMD intercept

March 10/07: Support. General Dynamics Information Technology announces a contract by Naval Sea Systems Command (NAVSEA) to provide support to the Missile Defense Agency’s Aegis Ballistic Missile Defense (BMD) program directorate. The contract has a total potential value of $191 million over 5 years, if all options are exercised. Under the contract, General Dynamics will provide systems engineering and program management assistance to Aegis BMD for production, fleet introduction and fleet operations and support. The company also will provide test and evaluation engineering management and safety, quality and mission assurance engineering; and support international programs including Foreign Military Sales (FMS) and cooperative development activities.

Feb 28/07: BMD 4.0.1. Lockheed Martin Maritime Sensors and Systems in Moorestown, NJ received a $979.2 million cost-plus-award-fee contract modification to continue design, test, and deliver the AEGIS Ballistic Missile Defense (BMD) Block 2006/2008 (Consolidated) Weapon System capability (BMD Baseline 4.0.1). Updates will include an improved signal processor, and continue the AEGIS BMD’s migration to open architecture electronics.

Work will be performed at Moorestown, New Jersey and is expected to be complete by Dec. 2010. The contract funds will not expire at the end of the fiscal year. FY2007 research and development funds will be used. The Naval Sea Systems Command, Washington, D.C. is the contracting activity (N00024-03-C-6110).

Additional Readings Background: AEGIS BMD and Missile Defense

• US MDA – Aegis Ballistic Missile Defense: Future Capabilities

• Wikipedia – AEGIS Combat System

• US NAVSEA – AEGIS upgrade. Details Advanced Capability Build 2012 (ACB 12) and Technical Insertion 2012 (TI 12).

• GlobalSecurity.org – AEGIS Weapon System Mk7

• HighFrontier.org – Sea-Based Platforms

• GlobalSecurity.org – AN/SPY-1 Radar. Interesting analysis of some of the systems weaknesses as well.

• Information Dissemination (Sept 23/09) – Fact Check – Technicals of AEGIS BMD

Background: Other BMD Assets

• DID FOCUS Article – Raytheon’s Standard Missile Naval Defense Family. Includes ongoing information re: naval anti ballistic missile tests.

• DID FOCUS Article – Dead Aim, Or Dead End? The USA’s DDG-1000 Zumwalt Class Program. Its Raytheon SPY-3 active array radar is not an AEGIS family component, but it will have superior performance and offer its own built-in ballistic missile defense capability, while allowing Cooperative Engagement Capability with AEGIS ships. In addition, the Open Architecture listing in the article’s Additional Readings section contains more materials on that topic.

• DID Spotlight – Japan’s Fleet BMD Upgrades. Covers their Kongo Class AEGIS destroyers.

Official Reports

• US GAO (April 11/14, #GAO-14-314) Ballistic Missile Defense: Actions Needed to Address Implementation Issues and Estimate Long-Term Costs for European Capabilities.

• US Congressional Research Service (#RL33745) – Navy Aegis Ballistic Missile Defense (BMD) Program: Background and Issues for Congress [PDF]. Last update April 8/14.

• US GAO (April 1/14, #GAO-14-351) – Missile Defense: Mixed Progress in Achieving Acquisition Goals and Improving Accountability.

• US GAO (Apr 26/13, #GAO-13-432) – Opportunity to Refocus on Strengthening Acquisition Management. Despite the bland title, it had a lot to say re: naval BMD.

• USN PEO-IWS, via WayBack (April 11/11) – Surface Navy Combat System Development Update [PDF]. Presented to The Navy League Sea Air and Space Symposium by Bill Bray. AEGIS evolution features prominently.

• US GAO (March 24/11, #GAO-11-372) – Missile Defense: Actions Needed to Improve Transparency and Accountability

News & Views

• Aviation Week (Jan 8/09) – Sea-Based BMD Gains Credibility. Dead link.

• Marshal Institute (Aug 3/09) – “Update on Aegis Ballistic Missile Defense and the Navy Air and Missile Defense Center,” Rear Admiral Alan B. Hicks

• DID (Dec 18/07) – US Missile Defense Shifting Toward More Realistic Testing?

• Information Dissemination (June 21/07) – US Navy Ballistic Missile Defense. Well researched article covering the USA’s plans in this area, including ships slated to receive ABM capability.

• Lockheed Martin, via WayBack (Feb 28/07) – Lockheed Martin Awarded $ 979 Million For Aegis Ballistic Missile Defense

• US NOAA, via WayBack (July 10/02) – NOAA Researchers Helping Develop Radar of the Future. Apparently, it has uses in weather forecasting.

Hermes 900
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Elbit Systems has enjoyed considerable domestic and export success with its Hermes 450, which sits at the smaller end of the MALE (Medium Altitude, Long Endurance) UAV spectrum. As UAVs proved themselves, Elbit wasn’t interested in ceding the market for larger and more capable MALE UAVs to the likes of IAI and General Atomics.

They invested company funds to create the larger Hermes 900, but those kinds of investments eventually need a buyer. In 2010, their home country of Israel stepped up, and became the anchor buyer for the “Kochav” (“Star”). They weren’t the last. A comparison with the popular Hermes 450 is instructive…

Hermes 450 vs. Hermes 900

Hermes 450
(click to view full)

The Hermes 450 is a common medium surveillance UAV, with a 10 m wingspan and a maximum take-off weight of 550 kg/ 1,212 pounds. The 450 offers about 17-20 hours endurance at up to 18,000 feet altitude, and about 180 kg/ 396 pounds of payload capacity via up to 2 body mountings and optional wing pylons. Satellite communications can be attached, but it requires changes to the aircraft body.

It serves in Israel as a dual surveillance/attack UAV, where it has reportedly been modified to carry fuel tanks, or up to 2 RAFAEL Spike missiles. It also serves unarmed with a number of international customers, including Azerbaijan, Brazil, Georgia, Mexico, Singapore, and the US Border Patrol; and with Britain as the Watchkeeper WK450B ISTAR (Intelligence, Surveillance, Target Acquisition and Reconnaissance) UAV.

Hermes 900
(click to view full)

The Hermes 900 offers a larger platform, whose 15m wingspan and 1,180/ 2,204 pound maximum takeoff weight is comparable to the MQ-1 Predator, or to Israel Aerospace Industries’ popular Heron family. Compared to the 450, it offers a higher flight altitude of up to 30,000 feet, with a longer flight time of up to 30-36 hours, and a 350 kg/ 772 pound payload capacity that’s about double the 450’s.

The Hermes 900 incorporates an Internal Auto Takeoff and Landing system that enables auto-landing even on alternate non-instrumented runways, and has advanced features including built-in autonomous emergency procedures, Air Traffic Control radio, radio relay, and an IFF (Identification, Friend or Foe) transponder. Satellite communications can be installed for additional control range.

Payloads can include the SELEX Gabianno T-200 X-band SAR/GMTI and MPR land and maritime surveillance radar, the DCoMPASS surveillance and targeting turret, AES 201V ESM/ELINT signal interception and location equipment, the Skyfix/ Skyjam–COMINT/DF communication snooping & optional COMJAM jamming system, or a Communications relay for friendly troops. A maritime configuratoin can add an Automatic Identification System (AIS) to ID compliant ships, Communications relay that lets the operator ‘talk through’ to vessels at sea, and Windward Ltd.’s MarInt satellite-based maritime intelligence analytic system.

Known customer nations to date include Israel, Brazil, Chile, Colombia, and Mexico. Elbit actually claims 8 total customers, leaving the missing service branches or countries unclear.

Both the Hermes 450 and Hermes 900 are controlled by Elbit Systems’ Universal Ground Control Station, which can control 2 UAVs at any given time from a single station, with a single operator.

Contracts & Key Events 2014-2018

Order from Brazil; Switzerland picks Hermes 900; Hermes 900 becomes a Star.

Swiss testing
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June 28/18: Hermes to fly in Thailand The Royal Thai Army (RTA) is currently adding four Hermes 450 drones to its inventory. The long-endurance tactical unmanned aerial vehicles are produced by Israel’s Elbit System. The Hermes 450 is a common medium surveillance UAV, with a 10 m wingspan and a maximum take-off weight of 1,212 lb. The 450 offers about 17-20 hours endurance at up to 18,000 feet altitude, and about 396 lb. of payload capacity via up to 2 body mountings and optional wing pylons. The UAVs will be used for operations including target designation; intelligence, surveillance, and reconnaissance (ISR), and mapping. The system is also expected to be used to track insurgency movements and drugs smuggling. The procurement of the Hermes 450 drones was finalized in 2017 at a total cost of $30 million.

August 25/17: Elbit Systems’ Hermes 900 UAV has been declared fully operational by the Israel Air Force following the successful completion of evaluations by the service. The inspection carried out included assessments of the aircraft’s operation and maintenance, and the squadron’s flight department’s capability to receive a mission from HQ and complete it successfully, among others. Nicknamed Kochav, it is the most advance UAV in the Israeli Air Force UAV division.

August 22/17: The Hermes 900 UAV is likely to have its full operational capability (FOC) declared by the Israeli Air Force before the end of the month. Developed by Elbit Systems, it is expected that the number of Hermes 900s in use with the air force will be increased once FOC is awarded. The MALE UAV was first used in combat during Israel’s 2014 Protective Edge operation in the Palestinian Gaza Strip, accumulating hundreds of flight hours throughout the campaign, flying in excess of 100 times with what the service described as an extremely high success rate. Switzerland and Brazil have also expressed interest in purchasing the UAV.

July 26/17: Elbit Systems announced that it has flown a number of demonstration flights of its Hermes 900 UAV for an interested Philippine Air Force (PAF). Manila is in the market for new intelligence reconnaissance and surveillance capabilities for both patrolling its territorial waters and tackling an insurgency on the archipelago by jihadists affiliated with the Islamic State. Earlier this month, neighboring Singapore offered to send UAVs and urban warfare assets to help the Philippine military tackle the insurgency, platforms which contains fellow Israel firm IAI’s Heron 1—which has a range of 200km and can stay in the air for 24 hours—and the Hermes 900’s predecessor, the Hermes 450—which has half the range and a shorter flying time of 14 hours. The Hermes 900 meanwhile, boasts an endurance of 36 hours and a flight range of 1,850km.

November 15/16: A joint venture agreement has been finalized between Elbit Systems and Adani Enterprises to manufacture UAVs for the Indian market. The joint venture will pitch Elbit’s Hermes 450 and 900 systems in an effort to break the stranglehold currently held by fellow Israeli firm IAI. Having recently joined the Missile Technology Control Regime (MTCR), New Delhi is forging ahead with procuring armed UAVs in order to tackle militants operating in areas such as the disputed region of Kashmir.

August 26/16: Thales UK is now operating three Hermes 900 as part of the United Nations (UN) Multidimensional Integrated Stabilisation Mission in Mali. A three year contract had been signed back in December and holds options for a further two years. The contract covers the deployment of three aircraft (two for operational duties, the third as a spare) with two control stations and flight crews to enable the simultaneous use of both aircraft.

April 5/16: Elbit Systems has signed a number of joint venture agreements with Indian companies in order to offer its UAV systems to the country’s market. Adani Aero Defence and Alpha Design Technologies are to co-operate with the Israeli UAV giant to offer their Hermes 450 and Hermes 900 UAVs to the Indian armed forces. The agreement will see local manufacture at a production facility in India for the airframes and payloads, and meets the terms of the government’s “Make in India” policy that encourages foreign investment and partnership with Indian industry.

November 27/15: Switzerland is to buy six Hermes 900 Heavy Fuel Engine (HFE) UAVs from Elbit Systems in a deal worth $200 million. The delivery of the UAVs is expected to be completed by 2020 when the current UAVs in service are retired. The Hermes are thought to provide a considerable increase in the capability of the Swiss Air Force, who currently operate the Ruag Aerospace ADS 95 Ranger for their reconnaissance and surveillance needs. The Hermes saw extensive action during Operation Protective Edge in Gaza last year as well as being used by Brazil when it hosted the World Cup.

September 29/15: Israel’s Elbit Systems has been awarded a $70 million contract by an undisclosed Latin American buyer for the Hermes 900 UAV system. The company was awarded a similar contract in June 2011, also to an undisclosed customer in the region, with the Swiss parliament approving the $250 million acquisition of six Hermes 900 UAVs earlier this month.

June 6/14: Switzerland. The Swiss UAS 15 program picks the Hermes 900 with a heavy fuel engine over IAI’s Super Heron-1, while stressing that their UAVs will remain unarmed. The UAS 15 program has a budget of SFR 250 million (about $280 million), and it will be submitted as part of Switzerland’s 2015 armaments program bill. This isn’t a contract yet, and there won’t be one until the money is approved. The Swiss government confirms that the purchase will involve:

“1 system with 6 drones including sensors, ground components, logistics package, training resources and training.”

The Hermes 900 HFEs will replace Switzerland’s ADS 95 Ranger collaboration between IAI, Oerlikon, and RUAG, which was also exported to Finland. Those tactical UAVs have served since 2000, and the state of the art has moved on since then. Ranger UAVs have an excellent safety record in-country over populated areas, but after the government’s recent tepid and failed defense of its fighter procurement, we’re going to go out on a limb and predict that this will become a major political issue. Absent a serious defense this time, public antipathy to drones in general could hand the government and defense forces another loss.

IAI and Elbit’s UAVs were short-listed as finalists after pre-testing (q.v. Sept 6/12), but the Swiss say that “Hermes 900 HFE has been favoured because it delivered the better overall result in all assessed criteria” during the full evaluation. Regardless of what happens with the Swiss buy, that will be a positive boost for Elbit’s marketing efforts. Swiss Air Force, “ADS 95 Ranger” | Swiss government, “Armed Forces reconnaissance drone system to be replaced” | Elbit Systems, “Elbit Systems Selected as Preferred Supplier for Swiss UAS program”.

Swiss pick Hermes 900

March 26/14: Elbit Systems Ltd. announces a contract from the Brazilian Air Force (“FAB”) for 1 Hermes 900 system, to be delivered within 2 months and equipped with “a new and advanced intelligence gathering system considered as a breakthrough operational solution.” It will form part of the security measures for the 2014 FIFA World Cup, and will be operated by FAB in combined missions with their existing Hermes 450 fleet, which was bought in 2011.

Elbit’s AEL SYSTEMAS S.A. subsidiary will supply technical and engineering support, as well as spares and maintenance services.

Elbit’s UAS Division General Manager, Elad Aharonson, is quoted in Ha’aretz calling this sale “…the eighth customer to be equipped with this leading platform…”. That indicates no less than 3 unannounced customers, after Israel, Brazil, Colombia, Chile, and Mexico. Note that different armed branches within the same country are counted separately. Mexico’s Federal Police bought the Hermes 900, but if the Mexican Air Force and Navy ever decided to their own ink orders, that would make 3 customers in Mexico. Announcements made so far don’t indicate that sort of thing, but they’ve also been vague, and one can expect them to often be partial. If there are unannounced external sales beyond the core 5 countries, Azerbaijan, Georgia, and Kazakhstan are good places to start the search, and we’d be curious about Nigeria. Sources: Elbit Systems, “Elbit Systems Awarded Contract to Supply Brazil with Hermes 900 UAS” | Ha’aretz, “Israel’s Elbit System wins contract to supply Brazil with Hermes 900 drone”.

Brazil buys

March 20/14: Kochav. Israel gives the Hermes 900 a name: Kochav (Hebrew for “Star”). Sources: IAF, “A Star Is Born: A Name Is Chosen For the “Hermes 900″ UAV'”.

2012 – 2013

Orders from Israel, Colombia & Mexico; Maritime patrol configuration introduced.

Hermes 900-MP
(click to view full)

Oct 7/13: Chile. The Chilean Navy is reportedly evaluating the Hermes 900 for maritime patrol tasks. The UAV already serves with the Chilean Air Force (FACh). Sources: Flight Global, “Chilean navy considers Hermes 900 deal”.

Feb 6/13: Maritime. At Aero India 2013 in Bangalore, Elbit Systems launches a Hermes maritime configuration. It includes the SELEX Gabbiano T200 radar (q.v. June 27/11), an Automatic Identification System (AIS) to ID compliant ships, radio relay that lets the operator ‘talk through’ to vessels at sea, and Windward Ltd.’s MarInt satellite-based maritime intelligence analytic system. Sources: AIN, “Elbit Takes New Orders for Hermes 900, Develops Maritime Version of UAS” | Defense Update: “Hermes 900 Takes on Maritime Missions”.

Jan 27/13: Israel. Elbit Systems announces a $35 million contract from the Israel Ministry of Defense to develop “advanced features for Unmanned Aircraft Systems (“UAS”) to be supplied within three years. One of the mission requirements is the quick re-configuration of the UAS’ payloads.”

This isn’t as specific as one would like, but the rest of the release focuses exclusively on the Hermes 900, and links this contract to the Dec 31/12 announcement.

Dec 31/12: Israel. Elbit Systems announces $315 million in contracts from Israel, including $90 million for more Hermes 900 UAS, to be supplied within 3 years, and 8 years of maintenance services.

Another $25 million funds “advanced observation and long-range target acquisition systems… to be supplied over a three-year period.” No word on whether they’re air, land, or sea systems.

Israeli follow-on order, and platform R&D

Sept 6/12: Switzerland. Out of the 11 systems made by 9 companies that were originally in the running for Switzerland’s UAS contract, IAI’s Heron-1 and Elbit’s Hermes 900 are the finalists. In-flight evaluations will take place in September and October 2012 from the Emmen airbase, over central Switzerland and in the Jura region. Hermes 900 flights end on Oct 19/12.

The chosen UAV will replace an older Israeli UAV, the Ranger from RUAG, Oerlikon, & IAI. Sources: armasuisse, “Evaluation ADS 15” | UAS Vision, “Hermes 900 and Heron 1 in Final Flight Tests for Swiss Air Force Contract”.

Aug 5/12: Colombia. Elbit announces yet another Latin American customer. This sale involves Hermes 450 and 900 unmanned aircraft systems (UAS) to “a Latin American customer.” The buyer is later identified as Colombia, while Elbit’s own release confirms its 1st export sale as Chile.

Elbit said the contract includes the Hermes Universal Ground Control Stations (UGCS), Elop’s DCoMPASS surveillance turrets, and satellite communication systems that allow the UAVs to operate over remote areas. Deliveries will be made over the next 2 years. Elbit Systems | Israel’s Arutz Sheva | Asian Defense News | Flight International.

Colombia buys 450s and 900s

Jan 3/12: Mexico. Israel’s Elbit Systems announced a $50 million contract to supply Hermes 900s to:

“…a governmental office of a country in the Americas. The UAS will be operated in a variety of perimeter security missions…. The contract includes Universal Ground Control Stations (UGCS) and a variety of payloads and capabilities including: the Electro-Optics Elop Division’s advanced payloads systems, the Elisra Division’s intelligence COMINT systems, SAR/MPR multi mode radar and additional sensors.”

Some sources claim Colombia as the destination, but that turns out to be a subsequent order. The buyer is later identified as Mexico’s Federal Police. Elbit Systems | Aviation Week | Defense Update.

Mexico Federal Police

2007 – 2011

From unveiling to orders from Israel & Chile; Radar picked.

Israeli Hermes 900
(click to view full)

June 27/11: Radar. Elbit Systems has picked Selex Galileo’s Gabbiano-series X-band surveillance radars for the Hermes 450 and Hermes 900. The Hermes 450 will get the 43kg T20 radar, while the Hermes 900 will carry the more powerful 62kg T200 for land and maritime surveillance. defpro | Flight International.

June 6/11: Chile. Elbit Systems announces its 1st export sale for the Hermes 900 UAV, plus ground control, DCoMPASS surveillance systems, and an unidentified radar system, to “a customer in Latin America.”

Other press sources point to Chile, which had already chosen the Hermes 900. The 2010 earthquake demonstrated the need for advanced, rapid response, long endurance aerial surveillance systems. In response, Chile’s competition looked at 4 Israeli UAVs: Elbit’s Heron 900 and IAI’s Heron at the high end, and the Hermes 450 and Aeronautics DS Aerostar at the low end. Defense Update.

1st export: Chile

May 18/11: Chile. Flight International reports that Elbit Systems’ Hermes 900 has been picked over IAI’s Heron-1 by the Chilean defence forces.

Jan 10/11: Testing. Elbit Systems’ 1st Hermes 900 UAV has accumulated 350 flight hours, while its 2nd prototype will soon enter flight testing.

A follow-on order from Israel is expected within the framework of the nation’s next multi-year plan. Flight International.

May 5/10: Israeli order. Elbit Systems of Haifa, Israel announces a 3-year, $50 million contract to supply the Israeli Defence Forces with its brand new Hermes 900 systems, along with additional Hermes 450 UAVs. The contract also includes “enhancement of [the IDF’s] existing UAS intelligence capabilities,” which presumably means sensor improvements and extensions.

The award continues ongoing contracts from Israel, including a $30 million contract for Hermes 450 systems in November 2007. Elbit release | Globes | Aviation Week | Defense Update | Flight International.

1st order: Israel

Dec 14/09: Testing. Elbit Systems announces that its Hermes 900 UAV has completed a successful Maiden Flight, and will enter serial production following additional flight tests.

April 1/09: Flight delays. Elbit Systems unveiled the Hermes 900 in mid-2007, but the UAV’s 1st flight has been delayed. The firm is reportedly accelerating efforts to make that flight before the end of 2009, so potential customers can evaluate the design. Flight International.

June 12/07: Elbit announces its Hermes 900 UAV offering, which will share ground control infrastructure with the smaller Hermes 450. Defense Update.

Additional Readings The UAV

• Elbit Systems – Hermes 900 [PDF]. They also advertise a maritime patrol version [PDF].

• Airforce Technology – Hermes 900 Unmanned Air Vehicle (UAV), Israel.

• Defense Update – Hermes 900.

• Israeli Weapons – Hermes 900.

Ancillary Systems & Payloads

• Elbit Elisra – AES-201/V. ELINT and ESM system. Podded on the Hermes 900.

• Elbit Systems of America – DCOMPASS. Day/night surveillance and targeting turret.

• SELEX ES – Gabbiano Multi Mode data sheet [PDF].

• Windward Ltd. – MarInt – Predictive Maritime Analytics.

• Elbit Elisra – Sky Fix. COMINT system, podded on the Hermes 900.

• Elbit Elisra – Skyjam. Communications jamming, built for each platform out of customizable, interoperable and interconnected airborne COMJAM payload components.