New Delhi. The US Department of Defence May 17 awarded Sikorsky, a Lockheed Martin company, a contract to build 12 production CH-53K King Stallion helicopters for the US Navy.
Under the $1.13 billion contract, known as Low Rate Initial Production (LRIP) Lot 2 and 3, Sikorsky will deliver the long awaited but the largest, heaviest and the most powerful helicopters ever built in America. CH-53k is designed to carry 36,000 pounds – three times the payload its earliest predecessor could carry, over a distance of up to 110 nautical miles. Made for the US Marine Corps, these advanced helicopters are part of a 200 programme of record aircraft. The contract includes spares and logistical support.
The CH-53K is the only sea-based, long range, heavy-lift helicopter in production and will immediately provide three times the lift capability of its predecessor. The CH-53K will conduct expeditionary heavy-lift transport of armoured vehicles, equipment, and personnel to support distributed operations deep inland from a sea-based centre of operations. The new CH-53K will have heavy-lift capabilities that exceed all other DoD rotary wing-platforms and it is the only heavy lifter that will remain in production through 2032 and beyond – the company press release said.
Sikorsky has designed the King Stallion to meet the future warfighting requirements for years to come qualifying for supporting special operation forces, search and rescue, HADR and troop and equipment transport.
The design features an all-digital cockpit, three General Electric GE38 5,590 kW engines, new composite rotor blades with technology similar to that currently found on the UH-60 Black Hawk helicopter, and a wider aircraft cabin than previous CH-53 variants. It will also have the “full authority fly-by-wire” flight controls. The fly-by-wire technique which is still not common in the US military rotorcraft, makes the King Stallion fleet unique and helps in reducing pilot workload without compromising on safety and situational awareness.
But the success didn’t come easy. The programme was delayed because of several design deficiencies and technical problems which further delayed the operational testing. One of the challenges faced was an exhaust gas re-ingestion problem in the three-engine design. The DoD worked with Sikorsky hand in hand to streamline the remaining test programme. Another challenge was the cost growth in Lot 1 contract which led the Navy and Marine Corps to reduce the number of the choppers to 12 compared to previous plan of buying 14 under Lots 2 and 3.
Overcoming all the challenges, the Navy and Marine Corps leadership is confident about the programme now. “I’m proud of the joint government and industry team in achieving this award,” said Col Jack Perrin, US Marine Corps programme manager for the Naval Air Systems Command’s Heavy Lift Helicopters programme, PMA-261.
In a news release, Lt Gen Steven Rudder, the deputy commandant for aviation, said, “the Marine Corps is very appreciative of the efforts by the Navy and our industry partners to be able to award the LRIP 2/3 contract. This is a win for the Marine Corps and will secure the heavy-lift capability we need to meet future operational requirements and support the National Defence Strategy. I’m very confident in the success of the CH-53K programme and look forward to fielding this critical capability.”
James Geurts, assistant secretary of the Navy for research, development and acquisition stated, “This contract award reflects close cooperation and risk sharing between the Government and industry teams to deliver critical capabilities to the Marine Corps. Working with our industry partners, the team ensured that solutions for technical challenges are incorporated into these production aircraft. This reflects the urgency to ensure we deliver capabilities necessary to support the Marine Corps and the Department of Navy’s mission, while continuing to drive affordability and accountability into the programme.”
“Sikorsky employees and our nationwide supply chain are ready to ramp up CH-53K production to support deployment of this modern, safe and reliable aircraft in 2023-2024,” said Sikorsky Programme Director Bill Falk. “This contract demonstrates the US Marine Corps’ confidence in Sikorsky to expand production of this technologically advanced heavy lift helicopter.”
Deliveries for the 12 CH-53K helicopters will begin in 2022 and the helicopters will be built at Lockheed Martin’s Connecticut Plant.
Lockheed Martin, Sikorsky, and its suppliers have made significant investments in facilities, machinery, tooling, and workforce training to ramp-up production required for the CH-53K programme. For example, more than eight new titanium machining centers have been installed, designed and implemented a new final assembly test facility with multi-floor ergonomic work platforms, installed 10-ton cranes, and now have 3D work instructions on the factory floor.
“We have transformed our factory for the future and implemented a model for all future helicopter programmes,” Falk said. “Additionally, our engineers have implemented the latest technologies such as manufacturing simulation and 3D laser inspection technology. These investments in systems, personnel, and our facilities have elevated Sikorsky’s manufacturing technology and capabilities to meet production requirements of the CH-53K for domestic and international customers.”
The all-new CH-53K, designed to be low maintenance and survivable in the most difficult conditions, has flown more than 1,400 test hours and has met all the outer reaches of the test envelope and is still in the midst of a rigorous test programme to ensure militaries can safely move troops and equipment at higher altitudes, quicker and more effectively than ever.
Sikorsky and the Marine Corps team have left no stone unturned to assess King Stallion’s success by testing it also under hot weather and brownout condition testing in Arizona, and they have certified the helicopter can be transported via C-5 and C-17 cargo planes.
Incidentally, CH-53 was the product of the US Marine Corps’ “Heavy Helicopter Experimental” (HH(X)) competition which began in 1962. The prototype YCH-53A first flew on October 14, 1964. The helicopter was designated “CH-53A Sea Stallion” and delivery of production helicopters began in 1966. It retired from service in 2012. The CH-53K is a general redesign of the CH-53E.
Sikorsky’s King Stallion has been in direct competition with Boeing’s twin-rotor CH-47 Chinook helicopter in the German military heavy transport helicopter tender and the Israeli Air Force heavy-lift helicopter race.
Over the next two decades, the Navy hopes to purchase 200 CH53K King Stallion helicopters. The total cost of the programme is expected to exceed $30 billion.
CH-53K King Stallion made its international debut at the Berlin Air Show April 2018.
