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Boeing Rolls Out First Production CH-47F Boeing Studies V-22 Developments Singapore Inaugurates Apache Longbow Squadron Marine CH-46s Get Lightweight Seats and Armor Sikorsky Plans Hawk Works in Upstate New York Erosion Coating Extends Engine Life In CH-53E and CH-46E China Possible Second Source for Sikorsky S-76 Airframe Australia Orders More NH90s Korea Launches New Helicopter Development Britain Locks On New Lynx Turkish Competition Delayed Singapore Inaugurates Apache Longbow Squadron The Republic of Singapore Air Force has officially inaugurated 120 Squadron operations with Boeing AH-64D Apache Longbow helicopters at Sembawang Air Base in Singapore. Singapore’s Apaches have long been based at Marana, Arizona in the United States under the Peace Vanguard training program. With their millimeter wave fire control radars and digital connectivity, the new attack helicopters are expected to enhance integrated “3rd Generation” operations between the Republic of Singapore Air force and Army. The RSAF ordered eight Apache Longbow helicopters in 1999 and 12 more in 2001. It accepted the first AH-64D at the Boeing Mesa plant in May 2002 and has since conducted training alongside Apaches of the Arizona National Guard. In 2005, the RSAF Apaches, Chinooks, and F-16s took part in Exercise Forging Sabre in the Mojave Desert. Current plans call for the helicopters to take part in Exercise Wallaby in Australia at the end of this year. Marine CH-46s Get Lightweight Seats and Armor US Marine Corps squadron HMM-165 has received the first CH-46E composite armor crewseats developed under the Lightweight Replacement Armored Seat Program (LRASP). The crashworthy, ballistically protected pilot and co-pilot seats save 200 pounds versus the 462-pound seats long used in Marine Phrogs. In conjunction with recently installed composite armor, they restore sufficient payload for the CH-46E to lift two additional Marines. Ergonomic seat cushions are also expected to reduce pilot fatigue despite the long missions and high operating tempos common in Iraq. Simula Aerospace & Defense Group received a contract in August 2005 to design and develop the CH-46 seats based on the design adopted for the Marine CH-53 and UH-1Y helicopters. Additional CH-46E fleet deliveries will begin in early August. The CH-46E Lightweight Replacement Armor System (LWARS) developed by ArmorWorks LLC meanwhile saves more than 250 lb compared with sheet meal armor and provides equal or better ballistic protection. Unlike the custom-fabricated metal armor, the LWARS is interchangeable from one aircraft to another. Deliveries of 166 sets of lightweight armor ran from October 2005 to March 2006. Installation priority is given to aircraft deploying to Operation Iraqi Freedom as part of Marine Expeditionary Units. Though the CH-46E is being replaced by the MV-22 tilt rotor, the Phrog will continue to serve with Marine Expeditionary Units and stand-alone Medium Lift squadrons until 2015. The new armor and seats, and various hydraulic, avionics, and structural improvements, are expected to reduce the empty weight of the CH-46E by more than 700 pounds over the next three years. Additional weight savings, such as removing obsolete cockpit vibration absorbers, can offset future Phrog modifications. Sikorsky Plans Hawk Works in Upstate New York Sikorsky Aircraft Corporation has plans to open a 100,000-square-foot Rapid Prototyping and Military Derivatives Completion Center (RPMDCC) at its Schweizer Aircraft subsidiary in upstate New York. The new facility will be built adjacent to the Elmira-Corning Regional Airport and is expected operational by the first quarter 2007. International Black Hawk and Naval Hawk helicopters requiring custom configurations will be manufactured at Sikorsky's Connecticut facilities and then transported to the RPMDCC for completion. The RPMDCC, will be called the Sikorsky Hawk Works @ Schweizer Aircraft. It is expected to add 100 jobs at Schweizer and will be located about a quarter-mile from the current Schweizer facility. Sikorsky expects the RPMDCC also will add capacity for additional future military work and for other special mission aircraft currently manufactured at Schweizer, such as the RQ-8Fire Scout unmanned air vehicle and fixed-wing reconnaissance aircraft. Erosion Coating Extends Engine Life In CH-53E and CH-46E A multi-layer coating of titanium nitride (TiN) and other additives has greatly extended the life of compressor gas turbine blades in General Electric T64 and T58 engines in US Marine Corps helicopters operating in Iraq and the Horn of Africa. The Naval Air Systems Command Heavy Lift Program Office initially adopted the TiN coating to remedy the loss in performance in T64 engines of Marine Corps CH-53Es operating in sandy or dusty environments. The treatment is now applied to compressor parts in the T58 engines of Marine CH-46Es. Program officials estimate the coating has more than doubled the reliability of T64 engines with operating tempos two to three times peacetime norms. High-time TiN-coated engines have exceeded 1100 hours time-on-wing. In Operation Desert Storm, T64 time-on-wing fell from 450 hours to just 100 hours due to excessive blade erosion. Titanium nitride protection was first used by Russian engine makers to prevent excessive erosion in the engines of Mil Mi-24 and Mi-28 attack helicopters. In 1997, the Navy’s Foreign Comparative Test Program successfully evaluated the TiN coating process. After development under the T64 Component Improvement Program, the first T64 TiN configuration change was approved in June 2003. The first T64 engine protected by TiN was installed in a CH-53E in April 2004. As of May 2006, General Electric and Canadian coating supplier MDS-PRAD had delivered 366 sets of T64 engine components for installation at Naval Aviation Depot Cherry Point and the H-53 Marine Aviation Logistics Squadrons. More than 250 T64 engines with TiN compressor airfoils have accumulated over 48,000 engine flight hours. About 180 TiN-coated T64-416/416A engines are flying in Marine Corps CH-53E heavy lift helicopters. The CH-46 subsequently adopted TiN technology. As of June 2006, 52 TiN coated T58 engines were in service with CH-46Es as part of the T58 Engine Reliability Improvement Program. Eight engines are installed in Phrogs deployed to Iraq, and every forward-deployed spare T58 engine features TiN-coated parts. China Possible Second Source for Sikorsky S-76 Airframe Sikorsky and China Aviation Industry Corporation II (AVIC II) have announced a Memorandum of Understanding (MOU) to collaborate on the development and manufacture of light, intermediate, and medium civil helicopters. Under the MOU, Sikorsky and AVIC II will also explore establishing Changhe Aircraft Industry Corporation under AVIC II as a second source for the S-76 helicopter airframe. Aero Vodochody in the Czech Republic currently supplies S-76 airframes for final assembly in the US. "We look forward to exploring many potential projects with AVIC II for both the Chinese and international marketplace,” said Carey Bond, Sikorsky vice president for corporate strategy and advanced programs. Changhe, an AVIC II subsidiary, already manufactures the tail pylon of the Sikorsky S-92A. The Australian government has approved an acquisition plan for 34 MRH90 helicopters to replace its Navy Sea Kings and Air Force Black Hawks. The second batch of multi-role MRH-90s is in addition to 12 aircraft ordered in June 2005. The follow-on order from Eurocopter subsidiary Australian Aerospace buy is expected to give Australia efficiencies for joint fleet management and industrial participation. The twin-engine, medium-lift MRH90 is the Australian version of the NHIndustries NH90 helicopter and has an integrated cockpit, Fly-by-Wire control system, and advanced Automatic Flight Control. Korea Launches New Helicopter Development The government Republic of Korea has given final approval to launch the KHP military transport helicopter development. Korea Aerospace Industry (KAI) will be the main contractor with Eurocopter providing technical assistance during development and certain sub-assemblies during production. The $6-8 billion program is expected to produce 245 aircraft. The agreement between KAI and Eurocopter includes export marketing through a joint company. The British government has awarded AgustaWestland a $1.82 billion contract for at least 70 Future Lynx helicopters for the British Army and Royal Navy with deliveries starting in 2014. Powered by the Honeywell/Rolls Royce T800 turboshaft developed for the RAH-66 Comanche, the Future Lynx is expected to integrate “configurable” cockpit displays, networked-enabled capability, better defensive aids, and a new tail rotor system. The agreement includes an option for 10 additional aircraft. The UK Ministry of Defense says the deal is a “major step forward” for its Defense Industrial Strategy meant to sustain critical helicopter design and engineering skills in the UK, and to help ensure cost-effective support of the UK helicopter fleet. According to the official news release, “Not withstanding the Partnering Arrangements, the MoD will continue to look to the vibrant and competitive global market place to satisfy our future helicopter requirements with AgustaWestland's role neither predefined nor guaranteed, but dependent upon their performance and the value for money of their propositions.” Italian-owned Agusta Westland is currently assembling the first VH-71A US Presidential helicopter in Yeovil, England and has entered its AW139 in the competition for a US Army Light Utility Helicopter. The Turkish Daily News reports Turkey's defense procurement officials have once again postponed the deadline to respond to a request for proposals for 32 utility helicopters to be built in Turkey. The new bidding deadline is now September 15, previously delayed from March 15 to June 15. The report quotes procurement officials saying Sikorsky Aircraft sought to postpone the bidding deadline. Turkey wants US companies to obtain a preliminary US government consent letter for the sale. US export laws and regulations require the State Department and Department of Defense ask Congressional approval for defense sales only after contracts have been signed. Turkey denies discriminating against American companies but instead blames overly strict US export rules. Winner-take-all plans give the Turkish Land Forces 20 helicopters while the Turkish Air Force and the Navy will each get six. The program also calls for the purchase of 20 civil firefighting helicopters. Potential contenders for the military aircraft include the Sikorsky S-70, the NH Industries NH90, Rosoboronexport Mi-17-1V Kamov Ka-62; and Ulan-Ude Aviation Plant Mi-8T. Boeing Rolls Out First Production CH-47F The first production CH-47F Chinook cargo helicopter for the US Army was rolled out in a ceremony at the Boeing plant south of Philadelphia on June 15. The new-build helicopter is one of 452 new and “renewed” CH-47Fs planned to re-equip General Aviation Support battalions. It will undergo final equipment installations, inspections, and flight testing before formal DD250 delivery in September. A mix of six to eight new and renewed CH-47Fs will complete Development Testing this year in preparation for Operational Testing in January and February 2007. The 6th Battalion of the 101st Aviation Brigade, 101st Airborne Division (Air Assault) is due to become the First Unit Equipped with the CH-47F in May 2007. The current commander of the 101st Combat Aviation Brigade, Colonel Warren E. Phipps, Jr. told the rollout audience that 12 of his CH-47Ds have so far transported 40,000 troops and 4,000 tons of cargo in 10 months of Operation Iraqi Freedom. The Brigade is one of the US Army’s first Transformational Aviation Units of Action. Each General Support Aviation Battalion within the Army’s Combat Aviation Brigades will be fielded with 12 CH-47Fs, one “float” aircraft, 24 pilots, and 24 non-rated crewmembers. The first CH-47F unit commander will determine when Initial Operational Capability is achieved with all equipment and trained personnel. The CH-47F replaces the 40 year-old Chinook airframe with new monolithic machined structures to reduce vibration and structural repairs. It enhances situational awareness and reduces workload for the crew with a five-screen Rockwell Collins Common Avionics Architecture System. The CAAS hover display facilitates safe approaches and landings in brown-out or white-out conditions, and messaging capability allows the CH-47F crew to send and receive information on a network-centric battlefield. The CAAS flight director also has a coupling feature that reduces pilot workload in a variety of flight profiles. A BAE Digital Automatic Flight Control System meanwhile improves AFCS reliability and remedies component obsolescence issues. Honeywell T55-L-714A engines enhance the high-and-hot performance of the CH-47F. The production at rollout wore Engine Air Particle Separators and a new greenish-tan paint scheme for desert operations. The Army is currently testing infrared engine suppressors from Rolls Royce and Davis Engineering to field a suppressor in 2007. CH-47F production will stretch through 2020 to include 55 totally new CH-47Fs built from scratch plus 395 Chinooks “renewed” with all-new airframes and refurbished dynamics. (Two CH-47Fs remanufactured from CH-47Ds remain in testing.). Boeing Philadelphia is currently producing MH-47G Special Operations Aircraft and CH-47F cargo helicopters at the rate of two aircraft per month and will deliver 12 G-model and 12 F-model Chinooks in 2006. The rate picks up to 2.5 aircraft per month in 2007 with a ratio of three Fs to two Gs for the next four years to complete delivery of 61 Special Operations Aircraft. Boeing Studies V-22 Developments Boeing Philadelphia is studying additional missions for the Bell Boeing V-22 tilt rotor and hopes to receive a reclaimed V-22 fuselage later this year to model and demonstrate new equipment. Current studies focus on the present production V-22 air vehicle without rotor, transmission, or major airframe changes. “We’ve always had a desire to extend the number of missions the aircraft can conduct,” says Jim Butts, manager of new product development. Potential roles include Medevac, Combat Search And Rescue, Command And Control, Air Refueling Tanker, Surveillance, and Fleet Logistics Support. The MV-22 already has provisions for 12 casualty litters, but Boeing engineers are looking at adding utility connections and attachments for more medical equipment and additional storage provisions. Though the Air Force CV-22 was withdrawn from the current Combat Search And Rescue competition (CSAR-X), studies continue on cabin weapons, armor, command-and-control provisions for cabin “We’re deriving that directly from the requirements that came out of CSAR-X,” says Mr. Butts. The V-22 has long been suggested as an air refueling tanker, and program officials are considering formation flights with the tilt rotor simulating tanker and receiver in 2007. “Air refueling is actually a very viable mission at this point,” says Mr. Butts. Boeing engineers are studying three different hose-and-reel arrangements mounted inside and outside the cabin. Stub wings suggested early in the JVX program for torpedoes and other external stores could carry refueling equipment or Unmanned Air Vehicles (UAVs). With its wide speed range, the tilt rotor with launch provisions could extend UAV endurance by releasing vehicles closer to their operating areas and controlling or relaying sensors through cabin consoles. Much of the advanced development work has focused on data communications including how to exploit Link XVI connectivity in non-strike aircraft. The MV-22 has potential application in reconnaissance/surveillance and homeland security/homeland defense. The US Navy is also conducting an Analysis of Alternatives for a fleet logistics support platform to replace the C-2 Greyhound and some MH-53E Sea Stallions. The Block B MV-22 now in production already has flip-over cargo floor rails, barrier nets, and cargo tie-downs. MV-22 Block C plans introduce weather radar. Mr. Butt says, “We are looking at virtually no modification to the aircraft to support the Navy’s requirements.” The advanced development studies are separate from routine Engineering Change Proposals discussed with V-22 customers and ongoing weight/cost reduction initiatives. Boeing Philadelphia has, for example, implemented more efficient production techniques for small composite detail parts. The composite shop has also introduced pre-cut, pre-shaped reusable covers in place of disposable vacuum bags. In addition, a new gimbaled tool transports the tow-placed V-22 composite aft fuselage through de-flashing operations. Together, the three manufacturing changes are expected to save $50,000 to $60,000 per aircraft and generate savings around $25 million over the life of the V-22 program. |
