Rotary Wing Aircraft Mods
by Marty Kauchak, SOTECH Correspondent
An ambitious and well-funded upgrade and recapitalization program is in place for USSOCOM’s manned rotary aircraft fleet of A/MH-6 light helicopters, MH-60 helicopters and MH-47 heavy assault helicopters. Significant material enhancements made to A/MH- 6 and MH-47 airframes, combined with new MH-60Ms will allow the command’s service components to deploy these high-demand assets well into the future.
As upgrade and recapitalization plans move forward for the fleet’s three venerable weapons platforms, USSOCOM is also eyeing innovative technologies for its next generation rotary aircraft.
ENHANCED LITTLE BIRDS
The AH-6J/MH-6J Mission-Enhanced Little Bird (MELB) program provides a significant modification to the existing A/MH-6 fleet in service with the U.S. Army’s 160th Special Operations Aviation Regiment (Airborne). A Boeing-led industry team is transforming the legacy fleet through a series of SOFspecific modifications that are changing the look and performance of the aircraft.
A refurbished MELB aircraft has a sixblade main rotor system, a four-blade tail rotor, full complement of weapon systems, digital cockpit and an increase of the maximum gross weight to 4,700 pounds (2,132 kilograms). An improved drivetrain and the Allison 250-C30R3 full authority, digitalengine control improves the MELB’s performance in harm’s way. Rolls Royce delivers the Allison engine.
The fleet is also undergoing a Block 1.0 upgrade to reduce operational weight, add an additional ARC-231 radio, and improve forward-looking infrared radar.
The ARC-231 radio is supplied by Raytheon. The radio is an airborne VHF/UHF/ line-of-sight (LOS) and Demand-Assigned Multiple Access (DAMA) satellite communications communication system.
“Future modifications to the Little Bird include upgrades to the mission processor, an infrared exhaust suppression system, lightweight Hellfire missile, and minor modifications to the assault version to better support the customer,” noted Air Force Captain Wes Ticer, USSOCOM public affairs spokesman.
The infrared exhaust suppression system will supply passive countermeasures compatible with the high-performance Allison engine. The effort to field the lightweight Hellfire launcher and control system is programmed to start in fiscal year (FY) 2009 according to the USSOCOM’s FYs 2008/2009 budget estimates for the Procurement, Defense Wide (P, DW) account document distributed in February 2007.
While these improvements are made, the sun continues to set on the A/MH-6J fleet. In FY 2013, $6.3 million in procurement funds is set aside to modify and qualify an Armyprovided Armed Reconnaissance Helicopter as a potential replacement platform for the A/MH-6 fleet.
MODERNIZED BLACK HAWKS
The MH-60M modernization program will receive 70 UH-60M aircraft from the program manager, Utility Helicopter, Program Executive Office Aviation, through FY 2013. This is a huge program for industry, with about $792 million in procurement funds programmed in FYs 2008-13, noted the command’s FYs 2008/09 budget estimates.
These Sikorsky-built aircraft will be modified to the SOF-unique MH-60M configuration to replace MH-60K Black Hawk and MH-60L Direct Action Penetrator rotary aircraft, which have experienced accelerated aging due to the global war on terror’s operations tempo and associated harsh flight regimes.
“The UH-60M aircraft will be delivered equipped with a dual digital automatic flight control system, wide-chord blades, a digital intercom system, rotor brakes, ARC-201D SATCOM-capable radios, the common missile warning system, and the AN/AVR-2B laser detecting set,” indicated Ticer. “Program Executive Office–Rotary Wing (PEORW) and Technical Application Program Office (TAPO) will add GE YT706-GE-700 engines with greater horsepower (2,500 shaft horsepower) than the standard UH-60 in order to provide a more capable assault platform for high altitude/hot (10,500 feet (3,200 meters))/(68.5 degrees Fahrenheit (20.3 Celsius)) environments,” he added.
An August 13, 2007, press release from GE Aviation, the provider of the engine, stated, “The YT706 is based on the Federal Aviation Administration-certified CT7-8A engine. Compared with the T700 currently powering H-60 helicopters, the YT706 has a larger compressor, hot section improvements and a full authority digital engine control.” The release continued, “The YT706 provides up to 30 percent more power than the current T700-701C and will increase the hot-and-high mission capability of the MH- 60M Black Hawk.”
The SOCOM procurement is part of a U.S. government and Sikorsky five-year, multi-service contract signed on December 12, 2007, for 537 H-60 helicopters to be delivered to the U.S. Army and U.S. Navy.
“The UH-60M and HH-60M helicopters will give the U.S. Army survivable, supportable Black Hawk helicopters with the latest rotor, propulsion and cockpit technologies to enhance performance,” said Sikorsky President Jeffrey Pino, in a company press release dated December 12, 2007.
Initial production deliveries of the baseline UH-60Ms are scheduled to start this year. PEO-RW and TAPO will further modify the UH-60M airframes with aerial refuel probes, external rescue hoists, electro-optical sensor systems, advanced aircraft survivability equipment, multi-mode radar and other SOF-unique equipment.
MH-47G SLEP
The MH-47G service life extension program (SLEP) provides for airframe improvement by reducing vibration, changing the design of high-crack propagation areas, reducing susceptibility to corrosion and meeting other objectives. The SLEP is expected to extend the average life of the aircraft for an additional 20 years.
This is a another significant industry program, with about $163 million in procurement funds programmed for the contract’s remaining years (FYs 2008-11), stated the command’s FYs 2008/2009 budget estimates.
A Boeing-led team is converting legacy AFSOC MH-47D and E, and U.S. Army CH-47 rotary aircraft, into a fleet-common MH-47G Chinook rated at a maximum gross weight of 54,000 lbs. The remanufactured aircraft is provided with post-production modifications, which include the new common avionics architecture system cockpit, long-range (2,000 gallon) fuel tanks, aerial refueling probe, expanded gunner’s window, multi-mode radar and other advanced systems to ensure the aircraft’s relevance in current and future operations.
The MH-47G has successfully completed operational testing, has received a full air worthiness release, and fielding and deployment release, and deployed to combat in February 2007.
Boeing will complete delivery of 61 MH-47G aircraft in FY 2011.
“The MH-47G SLEP is on cost, on schedule and meeting performance criteria,” reported Ticer.
OTHER FLEET UPGRADES
Other enhancements are also planned for avionics, weapons and other systems across multiple platforms.
A key survivability upgrade in USSOCOM’s budget is the AN/ALQ-211 suite of integrated radio frequency countermeasures (SIRFC). The command programmed about $104 million in FYs 2008-2010 for SIRFC procurement and installation, stated its FYs 2008/09 budget estimates.
ITT Electronics Systems has delivered the family of SIRFC suites for DoD aircraft.
The system provides state-of-the-art warning receivers and technologicallyadvanced radar jamming capabilities for increased threat detection, enhanced situational awareness and defensive countermeasures on a variety of the services’ and USSOCOM’s rotary platforms.
“We’re on a contract (awarded 2005) to provide AN/ALQ-211(v)6 on the MH-47E and AN/ALQ-211(v)7 on the MH-60K. The (v)6 is in production, the (v)7 system is still in testing,” said John Capeci, vice president business development, ITT Electronic Systems.
Also falling under the broad umbrella of active rotary wing survivability systems is the reduced optical signature emissions system. USSOCOM is budgeting about $3.5 million in FY09 procurement funds for this upgrade, according to the command’s FYs 2008/09 budget estimates.
In January 2007, Raytheon Company announced it was awarded a $135.4 million contract to develop the new Silent Knight tactical radar for SOF rotary and fixed-wing aircraft.
Formally signed December 12, 2006, and initially funded with $28.5 million, the system design and development contract calls for Raytheon’s Space and Airborne Division to build, test and integrate the new radar. The system will serve as a common multi-mode terrain following and terrain avoidance radar for a variety of platforms including the MH-47G, the lead aircraft for the program.
The cost-plus incentive fee contract, potentially valued at more than $164 million, contains an option for six lowrate, initial production units. Raytheon Space and Airborne Systems is performing the work in Dallas and McKinney, Texas. Principal industry partners include AIC, Crestview, Fla.; DRS Technologies, St. Louis, Mo.; and Rockwell Collins.
The Silent Knight radar will allow airborne forces safe low-level flight and safe ingress and egress in adverse environments. The system will also provide navigation support, ground mapping and weather information to air crews. The new radar will include advances in terrain following and avoidance capabilities and will be lighter and require less power than predecessors. As a common system, Silent Knight eventually will be fielded on MH-60M, MC-130H and CV-22 block 30 aircraft.
An adaptive and agile enemy in Iraq and Afghanistan has used anti-aircraft threats including massed small arms, rocketpropelled grenades and man-portable air defense systems in irregular ways against low-altitude aircraft during approach and landing events. USSOCOM is responding, in part, by budgeting about $20 million in procurement funds for an aircraft occupant ballistic protection system in FYs 2010 and 2011, stated the command’s FYs 2008/09 budget estimates.
IMPROVED WEAPONS SYSTEM
Also on USSOCOM’s horizon is a weapons modernization program for the MH-60, MH-47 and A/MH-6 fleets. The command requested funds in FY 2008 for the qualification and procurement of the Integrated Defensive Armed Penetrators (IDAP) and a modernized weapon system as a replacement for the fielded M-134 mini-gun. This capability would provide a “more reliable and maintainable system with improved suppressive fire capability,” stated the command’s FYs 2008/09 budget estimates.
NEXT GENERATION CONCEPTS
Beyond the rotary-wing upgrades and recapitalization programs in progress, USSOCOM is also eyeing the community’s next generation vertical lift requirements.
The command’s “PEO, Rotary Wing is monitoring several technologies currently in development to overcome the physical speed, payload, range and environmental limitations of traditional helicopters,” said Ticer. These innovations include: the advancing blade concept (rigid, counter-rotating, coaxial rotor blades), optimum (variable) speed tilt-rotor concept, fancraft technology, and the vectored thrust ducted propeller (VTDP).
The VTDP is a second-generation, Piasecki Aircraft Corp (PiAC) “Ring-Tail” ductedfan, compound helicopter technology that replaces the conventional helicopter tail rotor. In addition to providing anti-torque and yaw control, the VTDP also provides forward thrust and thrust vectoring control.
The program is a U.S. Army advanced technology demonstration initiative. The first flight of the PiAC X-49A VTDP Compound Helicopter Technology demonstrator occurred in June 2007.
“The government has funding in 2008 to continue the program and we expect to complete Phase One this year [2008],” said John Piasecki, vice president, PiAC. “All of the results to date are very positive. Our performance is consistent with our predictions. The vibrations and loads [main-rotor push-rod and others] are significantly below the baseline helicopter,” he added.
The demonstrator has operated up to 10,000 feet and in speeds up to 180 knots in accordance with the Phase One contract. In early January 2008, the Phase One aircraft logged 53 ground and flight hours.
“Additionally, the technology advancement of ballistic protection, aircrew and cockpit survivability, sensor arrays to enhance pilot situational awareness, and lightweight materiel hold promise for the future of SOF vertical lift,” concluded Ticer. ♦
As upgrade and recapitalization plans move forward for the fleet’s three venerable weapons platforms, USSOCOM is also eyeing innovative technologies for its next generation rotary aircraft.
ENHANCED LITTLE BIRDS
The AH-6J/MH-6J Mission-Enhanced Little Bird (MELB) program provides a significant modification to the existing A/MH-6 fleet in service with the U.S. Army’s 160th Special Operations Aviation Regiment (Airborne). A Boeing-led industry team is transforming the legacy fleet through a series of SOFspecific modifications that are changing the look and performance of the aircraft.
A refurbished MELB aircraft has a sixblade main rotor system, a four-blade tail rotor, full complement of weapon systems, digital cockpit and an increase of the maximum gross weight to 4,700 pounds (2,132 kilograms). An improved drivetrain and the Allison 250-C30R3 full authority, digitalengine control improves the MELB’s performance in harm’s way. Rolls Royce delivers the Allison engine.
The fleet is also undergoing a Block 1.0 upgrade to reduce operational weight, add an additional ARC-231 radio, and improve forward-looking infrared radar.
The ARC-231 radio is supplied by Raytheon. The radio is an airborne VHF/UHF/ line-of-sight (LOS) and Demand-Assigned Multiple Access (DAMA) satellite communications communication system.
“Future modifications to the Little Bird include upgrades to the mission processor, an infrared exhaust suppression system, lightweight Hellfire missile, and minor modifications to the assault version to better support the customer,” noted Air Force Captain Wes Ticer, USSOCOM public affairs spokesman.
The infrared exhaust suppression system will supply passive countermeasures compatible with the high-performance Allison engine. The effort to field the lightweight Hellfire launcher and control system is programmed to start in fiscal year (FY) 2009 according to the USSOCOM’s FYs 2008/2009 budget estimates for the Procurement, Defense Wide (P, DW) account document distributed in February 2007.
While these improvements are made, the sun continues to set on the A/MH-6J fleet. In FY 2013, $6.3 million in procurement funds is set aside to modify and qualify an Armyprovided Armed Reconnaissance Helicopter as a potential replacement platform for the A/MH-6 fleet.
MODERNIZED BLACK HAWKS
The MH-60M modernization program will receive 70 UH-60M aircraft from the program manager, Utility Helicopter, Program Executive Office Aviation, through FY 2013. This is a huge program for industry, with about $792 million in procurement funds programmed in FYs 2008-13, noted the command’s FYs 2008/09 budget estimates.
These Sikorsky-built aircraft will be modified to the SOF-unique MH-60M configuration to replace MH-60K Black Hawk and MH-60L Direct Action Penetrator rotary aircraft, which have experienced accelerated aging due to the global war on terror’s operations tempo and associated harsh flight regimes.
“The UH-60M aircraft will be delivered equipped with a dual digital automatic flight control system, wide-chord blades, a digital intercom system, rotor brakes, ARC-201D SATCOM-capable radios, the common missile warning system, and the AN/AVR-2B laser detecting set,” indicated Ticer. “Program Executive Office–Rotary Wing (PEORW) and Technical Application Program Office (TAPO) will add GE YT706-GE-700 engines with greater horsepower (2,500 shaft horsepower) than the standard UH-60 in order to provide a more capable assault platform for high altitude/hot (10,500 feet (3,200 meters))/(68.5 degrees Fahrenheit (20.3 Celsius)) environments,” he added.
An August 13, 2007, press release from GE Aviation, the provider of the engine, stated, “The YT706 is based on the Federal Aviation Administration-certified CT7-8A engine. Compared with the T700 currently powering H-60 helicopters, the YT706 has a larger compressor, hot section improvements and a full authority digital engine control.” The release continued, “The YT706 provides up to 30 percent more power than the current T700-701C and will increase the hot-and-high mission capability of the MH- 60M Black Hawk.”
The SOCOM procurement is part of a U.S. government and Sikorsky five-year, multi-service contract signed on December 12, 2007, for 537 H-60 helicopters to be delivered to the U.S. Army and U.S. Navy.
“The UH-60M and HH-60M helicopters will give the U.S. Army survivable, supportable Black Hawk helicopters with the latest rotor, propulsion and cockpit technologies to enhance performance,” said Sikorsky President Jeffrey Pino, in a company press release dated December 12, 2007.
Initial production deliveries of the baseline UH-60Ms are scheduled to start this year. PEO-RW and TAPO will further modify the UH-60M airframes with aerial refuel probes, external rescue hoists, electro-optical sensor systems, advanced aircraft survivability equipment, multi-mode radar and other SOF-unique equipment.
MH-47G SLEP
The MH-47G service life extension program (SLEP) provides for airframe improvement by reducing vibration, changing the design of high-crack propagation areas, reducing susceptibility to corrosion and meeting other objectives. The SLEP is expected to extend the average life of the aircraft for an additional 20 years.
This is a another significant industry program, with about $163 million in procurement funds programmed for the contract’s remaining years (FYs 2008-11), stated the command’s FYs 2008/2009 budget estimates.
A Boeing-led team is converting legacy AFSOC MH-47D and E, and U.S. Army CH-47 rotary aircraft, into a fleet-common MH-47G Chinook rated at a maximum gross weight of 54,000 lbs. The remanufactured aircraft is provided with post-production modifications, which include the new common avionics architecture system cockpit, long-range (2,000 gallon) fuel tanks, aerial refueling probe, expanded gunner’s window, multi-mode radar and other advanced systems to ensure the aircraft’s relevance in current and future operations.
The MH-47G has successfully completed operational testing, has received a full air worthiness release, and fielding and deployment release, and deployed to combat in February 2007.
Boeing will complete delivery of 61 MH-47G aircraft in FY 2011.
“The MH-47G SLEP is on cost, on schedule and meeting performance criteria,” reported Ticer.
OTHER FLEET UPGRADES
Other enhancements are also planned for avionics, weapons and other systems across multiple platforms.
A key survivability upgrade in USSOCOM’s budget is the AN/ALQ-211 suite of integrated radio frequency countermeasures (SIRFC). The command programmed about $104 million in FYs 2008-2010 for SIRFC procurement and installation, stated its FYs 2008/09 budget estimates.
ITT Electronics Systems has delivered the family of SIRFC suites for DoD aircraft.
The system provides state-of-the-art warning receivers and technologicallyadvanced radar jamming capabilities for increased threat detection, enhanced situational awareness and defensive countermeasures on a variety of the services’ and USSOCOM’s rotary platforms.
“We’re on a contract (awarded 2005) to provide AN/ALQ-211(v)6 on the MH-47E and AN/ALQ-211(v)7 on the MH-60K. The (v)6 is in production, the (v)7 system is still in testing,” said John Capeci, vice president business development, ITT Electronic Systems.
Also falling under the broad umbrella of active rotary wing survivability systems is the reduced optical signature emissions system. USSOCOM is budgeting about $3.5 million in FY09 procurement funds for this upgrade, according to the command’s FYs 2008/09 budget estimates.
In January 2007, Raytheon Company announced it was awarded a $135.4 million contract to develop the new Silent Knight tactical radar for SOF rotary and fixed-wing aircraft.
Formally signed December 12, 2006, and initially funded with $28.5 million, the system design and development contract calls for Raytheon’s Space and Airborne Division to build, test and integrate the new radar. The system will serve as a common multi-mode terrain following and terrain avoidance radar for a variety of platforms including the MH-47G, the lead aircraft for the program.
The cost-plus incentive fee contract, potentially valued at more than $164 million, contains an option for six lowrate, initial production units. Raytheon Space and Airborne Systems is performing the work in Dallas and McKinney, Texas. Principal industry partners include AIC, Crestview, Fla.; DRS Technologies, St. Louis, Mo.; and Rockwell Collins.
The Silent Knight radar will allow airborne forces safe low-level flight and safe ingress and egress in adverse environments. The system will also provide navigation support, ground mapping and weather information to air crews. The new radar will include advances in terrain following and avoidance capabilities and will be lighter and require less power than predecessors. As a common system, Silent Knight eventually will be fielded on MH-60M, MC-130H and CV-22 block 30 aircraft.
An adaptive and agile enemy in Iraq and Afghanistan has used anti-aircraft threats including massed small arms, rocketpropelled grenades and man-portable air defense systems in irregular ways against low-altitude aircraft during approach and landing events. USSOCOM is responding, in part, by budgeting about $20 million in procurement funds for an aircraft occupant ballistic protection system in FYs 2010 and 2011, stated the command’s FYs 2008/09 budget estimates.
IMPROVED WEAPONS SYSTEM
Also on USSOCOM’s horizon is a weapons modernization program for the MH-60, MH-47 and A/MH-6 fleets. The command requested funds in FY 2008 for the qualification and procurement of the Integrated Defensive Armed Penetrators (IDAP) and a modernized weapon system as a replacement for the fielded M-134 mini-gun. This capability would provide a “more reliable and maintainable system with improved suppressive fire capability,” stated the command’s FYs 2008/09 budget estimates.
NEXT GENERATION CONCEPTS
Beyond the rotary-wing upgrades and recapitalization programs in progress, USSOCOM is also eyeing the community’s next generation vertical lift requirements.
The command’s “PEO, Rotary Wing is monitoring several technologies currently in development to overcome the physical speed, payload, range and environmental limitations of traditional helicopters,” said Ticer. These innovations include: the advancing blade concept (rigid, counter-rotating, coaxial rotor blades), optimum (variable) speed tilt-rotor concept, fancraft technology, and the vectored thrust ducted propeller (VTDP).
The VTDP is a second-generation, Piasecki Aircraft Corp (PiAC) “Ring-Tail” ductedfan, compound helicopter technology that replaces the conventional helicopter tail rotor. In addition to providing anti-torque and yaw control, the VTDP also provides forward thrust and thrust vectoring control.
The program is a U.S. Army advanced technology demonstration initiative. The first flight of the PiAC X-49A VTDP Compound Helicopter Technology demonstrator occurred in June 2007.
“The government has funding in 2008 to continue the program and we expect to complete Phase One this year [2008],” said John Piasecki, vice president, PiAC. “All of the results to date are very positive. Our performance is consistent with our predictions. The vibrations and loads [main-rotor push-rod and others] are significantly below the baseline helicopter,” he added.
The demonstrator has operated up to 10,000 feet and in speeds up to 180 knots in accordance with the Phase One contract. In early January 2008, the Phase One aircraft logged 53 ground and flight hours.
“Additionally, the technology advancement of ballistic protection, aircrew and cockpit survivability, sensor arrays to enhance pilot situational awareness, and lightweight materiel hold promise for the future of SOF vertical lift,” concluded Ticer. ♦