The New Chinooks: Boeing’s Modern H-47 Heavy-Lift Helicopters

DII FOCUS articles offer in-depth, updated looks at significant military programs of record; this FOCUS Article covers the CH-47F/MH-47G Chinook helicopter programs, in the USA and abroad. These helicopters’ distinctive “flying banana” twin-rotor design stems from the brilliant work of aviation pioneer Frank Piasecki. It gives Chinooks the ability to adjust their positioning very precisely, while carrying a large airframe whose load capacity has made it the world’s most popular heavy-lift helicopter. The USA expects to be operating Chinooks in their heavy-lift role past 2030.

The CH-47F looks similar to earlier models, but offers a wide range of improvements in almost every aspect of design and performance. While the related HH-47’s $10-15 billion CSAR-X program win was terminated, delivery orders continue for CH-47Fs and for MH-47G Special Forces configuration helicopters. International orders or formal requests have also come in from Australia, Britain, Canada, Italy, the Netherlands, Turkey, and the UAE, with India and other countries expected to follow.

AH-64E Apache Block III: Evolving Battlefield Roles

The AH-64 Apache will remain the US Army’s primary armed helicopter for several more decades, thanks to the collapse of the RAH-66 Comanche program, and the retirement sans replacement of the US Army’s Armed Reconnaissance Helicopter (ARH). Apaches also serve with a number of American allies, some of whom have already expressed interest in upgrading or expanding their fleets.

The AH-64E Guardian Block III (AB3) is the helicopter’s next big step forward. It incorporates 26 key new-technology insertions that cover flight performance, maintenance costs, sensors & electronics, and even the ability to control UAVs as part of manned-unmanned teaming (MUT). In July 2006, Boeing and U.S. Army officials signed the initial development contract for Block III upgrades to the current and future Apache fleet, via a virtual signing ceremony. By November 2011, the 1st production helicopter had been delivered. So… how many helicopters will be modified under the AH-64 Block III program, what do these modifications include, how is the program structured, and what has been happening since that 2006 award? The short answer is: a lot, including export interest and sales.

Snakes and Rotors: The H-1 Helicopter Program

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

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

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

E-2D Hawkeye: The Navy’s New AWACS

Northrop Grumman’s E-2C Hawkeye is a carrier-capable “mini-AWACS” aircraft, designed to give long-range warning of incoming aerial threats. Secondary roles include strike command and control, land and maritime surveillance, search and rescue, communications relay, and even civil air traffic control during emergencies. E-2C Hawkeyes began replacing previous Hawkeye versions in 1973. They fly from USN and French carriers, from land bases in the militaries of Egypt, Japan, Mexico, and Taiwan; and in a drug interdiction role for the US Naval Reserve. Over 200 Hawkeyes have been produced.

The $17.5 billion E-2D Advanced Hawkeye program aims to build 75 new aircraft with significant radar, engine, and electronics upgrades in order to deal with a world of stealthier cruise missiles, saturation attacks, and a growing need for ground surveillance as well as aerial scans. It looks a lot like the last generation E-2C Hawkeye 2000 upgrade on the outside – but inside, and even outside to some extent, it’s a whole new aircraft.

CH-53K: The U.S. Marines’ HLR Helicopter Program

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

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

Germany Upgrading Its CH-53G Helicopters

From 1971-1975, 110 “CH-53G Mittlerer Transporthubschrauber” derivatives of the CH-53D Sea Stallions were built in Germany. Though they share the CH-53E’s ability to lift medium-heavy loads, including up to 2 of Germany’s Wiesel armored infantry support vehicles, the CH-53Gs lack the 3rd engine and additional features of the improved CH-53E Super Stallions that have been operated by the US Marine Corps since 1981. A 2002 decision set a future force goal of 80 CH-53G and upgraded CH-53GS helicopters in the German Army, via modernization and life extension projects.

Which leads us to the current modernization project, even as Germany and France prepare their European Heavy-Lift Helicopter project for introduction around 2020. That effort is also surrounded by more urgent modifications, including one set that aims to create longer-range combat search and rescue capabilities:

• The Conversions [updated]
  
• Contracts & Key Events [updated]
  

Taiwan’s Force Modernization: The American Side

Despite China’s ominous military buildup across the strait, key weapons sales of P-3 maritime patrol aircraft, Patriot PAC-3 missiles, and diesel-electric submarines to Taiwan had been sabotaged by Taiwanese politics for years – in some cases, since 1997. The KMT party’s flip-flops and determined stalling tactics eventually created a crisis in US-Taiwan relations, which finally soured to the point that the USA refused a Taiwanese request for F-16C/D aircraft.

That seems to have brought things to a head. Most of the budget and political issues were eventually sorted out, and after a long delay, some major elements of Taiwan’s requested modernization program appear to be moving forward: P-3 maritime patrol aircraft, UH-60M helicopters, Patriot missile upgrades; and requests for AH-64D attack helicopters, E-2 Hawkeye AWACS planes, minehunting ships, and missiles for defense against aircraft, ships, and tanks. These are must-have capabilities when facing a Chinese government that has vowed to take the country by force, and which is building an extensive submarine fleet, a large array of ballistic missiles, an upgraded fighter fleet, and a number of amphibious-capable divisions. Chinese pressure continues to stall some of Taiwan’s most important upgrades, including diesel-electric submarines, and new American fighter jets. Meanwhile, other purchases from abroad continue.

Comanche’s Wi’ane: No New Armed Scout Helicopter

The US Army’s Armed Reconnaissance Helicopter (ARH) program aimed to replace around 375 Bell Textron OH-58D Kiowa Warrior helicopters, after the $14.6 billion RAH-66 Comanche program, was canceled in 2004. Instead, the Army would buy a larger number of less expensive platforms, with reduced capabilities. Bell Helicopter Textron initially won the ARH competition with a militarized version of its highly successful 407 single-engine commercial helicopter, but despite significant private investment after Army funding stopped in March 2007, spiraling costs killed the ARH-70 in October 2008.

What hasn’t changed is the battlefield need for on-call, front-line aerial surveillance and fire support. With its existing OH-58D stock wither wearing down, or shot down, the Army needs to do something. But what? The eventual answer: scrap the Kiowa fleet for a combination of attack helicopters and UAVs.

V-22 Osprey: The Multi-Year Buys, 2008-2017

In March 2008, the Bell Boeing Joint Project Office in Amarillo, TX received a $10.4 billion modification that converted the previous N00019-07-C-0001 advance acquisition contract to a fixed-price-incentive-fee, multi-year contract. The new contract rose to $10.92 billion, and was used to buy 143 MV-22 (for USMC) and 31 CV-22 (Air Force Special Operations) Osprey aircraft, plus associated manufacturing tooling to move the aircraft into full production. A follow-on MYP-II contract covered another 99 Ospreys (92 MV-22, 7 CV-22) for $6.524 billion. Totals: $17.444 billion for 235 MV-22s and 38 CV-22s, an average of $63.9 million each.

The V-22 tilt-rotor program has been beset by controversy throughout its 20-year development period. Despite these issues, and the emergence of competitive but more conventional compound helicopter technologies like Piasecki’s X-49 Speedhawk and Sikorsky’s X2, the V-22 program continues to move forward. This DID Spotlight article looks at the V-22’s multi-year purchase contract from 2008-12 and 2013-2017, plus associated contracts for key V-22 systems, program developments, and research sources.

US Carrier Pilots’ T-45 Training System

The T-45 Training System includes T-45 Goshawk aircraft, advanced flight simulators, computer-assisted instructional programs, a computerized training integration system, and a contractor logistics support package. The integration of all 5 elements is designed to produce a superior pilot in less time and at lower cost than previous training systems.

The US Navy uses the Hawk-based T-45TS system to train its pilots for the transition from T-6A Texan II/ JPATS aircraft to modern jet fighters – and carrier landings. This is not a risk-free assignment, by any means. Nevertheless, it is a critical link in the naval aviation chain. This DID FOCUS article covers the T-45TS, and associated contracts to buy and maintain these systems, from 2006 to the end of FY 2014.