U.S. Army's Future Recon Helicopter Delayed By GE Engine Development
/ Aviation Week
DATE: April 1, 2022
BYLINE: Brian Everstine
The U.S. Army is increasing its funding requests for the Future Vertical
Lift program as the government-mandated engine for one of the helicopters
has slowed progress on the Future Attack Reconnaissance Aircraft ahead of
first flights next year.
In the fiscal 2023 budget request released in late March, the Army called
for $468.7 million for the Future Attack Reconnaissance Aircraft (FARA) to
replace its Boeing AH-64 Apache, and $693.6 million for the Future-Long
Range Assault Aircraft (FLRAA) as part of an overall request of $1.5 billion
for Future Vertical Lift (FVL). The remaining $369.7 million will go toward
technology development, advance munitions and a future unmanned aircraft
system. The funding will go for hardware and software development, assembly
of component subsystems and government-furnished equipment planning and
development of the Modular Open Systems Architecture-an approach to updating
the aircraft's systems and armaments from any manufacturer.
The Army is planning a flight demonstration from the two competitors in the
fourth quarter of fiscal 2023. The entrants-Bell and Sikorsky-are working
briskly toward that goal, but the government-required engine is slowing them
down.
The service is requiring that the FARA winner be powered with the GE
Aviation T901 engine, developed under the Improved Turbine Engine Program
(ITEP) contest. However, after a protest by the Honeywell/Pratt & Whitney
team, followed by issues caused by the COVID-19 pandemic, delivery of the
engine has slowed and forced the companies to push back their schedules for
first flight.
Army Undersecretary Gabe Camarillo says the service is planning to make the
same milestones for competition, though in the 2023 budget request it needed
to "realign" funding from procurement to development and shift scheduled
spending to account for ITEP delays.
"You'll see these kinds of puts and takes . . . fact-of-life changes within
the current budget submission," he says.
Bell is more than 85% complete in assembling its FARA entrant, the Model 360
Invictus. Chris Gehler, Bell vice president and FARA program director, says
the company was hoping for delivery of the engine earlier in 2022 so that it
could start ground runs in late spring or early summer in anticipation of
flights by year-end. Bell now expects the flights to be in late fiscal 2023.
Because of the delay, Bell is taking more time to work through its build and
develop the second helicopter, assembly of which is expected to be completed
in early 2023, Gehler says. This follow-on aircraft, called Increment 1,
would be outfitted with Army mission systems. As an example of this extended
work, Bell is looking at ways to reduce the aircraft's weight, which in turn
could provide better performance for Army operators. Specifically, the
company is looking at a redesign of the helicopter's landing gear for
Increment 1 as an initial step to cut weight.
During Aviation Week's recent visit to Bell's Amarillo, Texas, facility, the
company outlined the specific progress on the first aircraft. It recently
finished stress testing, and some components such as the forward fuselage
and the open-tail rotor are fully assembled. The company expects assembly to
be held at just more than 90% complete until the ITEP engine is ready. In
addition to the T901, the 360 also uses a supplemental power unit based on
Pratt & Whitney Canada's PW207D1 turboshaft.
Bell expects the FARA program to start with eight aircraft under
engineering, manufacturing and development, with 8-16 aircraft in each early
production lot and a ramp-up to 24-48 aircraft for later production lots.
The Model 360 Invictus is produced at the same assembly center as the
company's V-22 tiltrotor, UH-1Y and AH-1Z helicopters, and the company says
it has the capacity to ramp up for both FVL aircraft if it receives the
contracts.
Sikorsky says its Raider X prototype for FARA is also more than 85%
complete, and it recently conducted its first landing gear retraction tests
as it awaits the ITEP engine.
"We're nearly complete on the build for that aircraft and are waiting for
the ITEP engine, to get that in and install that," Sikorsky President Paul
Lemmo says. "Then [we will] go flying that aircraft, hopefully later next
year."
GE Aviation has delivered the first T901 to the Army for testing, and the
service on March 22 conducted the first "light-off" test, during which fuel
was ignited to produce power. The Army expects the engine to complete more
than 100 hr. of run time over two months, with more than 700 sensors
tracking its performance data.
Over the summer, the Army will test against Army Military Airworthiness
Certification Criteria standards with more than 1,500 hr. of full-scale
ground testing for the engine to achieve a Preliminary Flight Rating and
about 5,000 hr. for full engine qualification. The 3,000-shp ITEP engine
will also replace the powerplants in the Boeing AH-64 and Sikorsky UH-60s,
in addition to the FARA aircraft.
If there is a severe delay in ITEP development, both Bell and Sikorsky
expect to use the 2,000-shp T701 engine for the prototype fly-off, though
the T901 will still be used in the eventual FARA winning aircraft. In the
meantime, the companies have fit-checked a mockup of the T901 in their
helicopters.
GE says it is working closely with the Army to deliver the first flight-test
engines late this year for the competitors' aircraft.
For the FLRAA, the planned replacement for the UH-60, the Army is requesting
$693.6 million in funding for fiscal 2023. This would go toward completing
preliminary design efforts, weapon system and virtual prototyping, and
weapon system development contract options later this year. Additionally,
the Army is doing preliminary analysis of how the FLRAA would also support
additional utility missions for medical evacuation and special operations,
says Brig. Gen. Michael McCurry, director of force development in the office
of the Army deputy chief of staff for programs.
For the FLRAA competition, Bell is offering the tiltrotor V-280 Valor, and
the team of Sikorsky and Boeing is offering the coaxial Defiant X.
In February, the Sikorsky/Boeing team announced it had selected Honeywell's
HTS7500 turboshaft engine to power the Defiant X. In January, the Defiant
prototype, the SB-1 Defiant, flew its first mission profile test flight,
during which the aircraft flew low-level operations and landings in a
confined area.
"We fully demonstrated Defiant's ability to execute the FLRAA mission
profile by flying 236 kt. in level flight, then reducing thrust on the
propulsor to rapidly decelerate as we approached the confined, and
unimproved, landing zone," Bill Fell, Defiant chief flight test pilot at
Sikorsky, said in an announcement.
Bell's V-280 completed more than 215 flight hours before ending its
prototype test flights last year.
The Army expects to select a FLRAA winner this year, with FARA to follow
after a fly-off in 2023, ahead of fielding in 2030. Army officials say they
expect costs for each program to rise as selections are made and the winners
move into development and testing.
"As you get into sort of the midterm period, the costs for those programs
get pretty big," Army Secretary Christine Wormuth said March 9. "So I think
what we're going to have to do again is see what we learn technically over
the next of couple years as we go to the prototypes and do flight tests . .
. and then continuously evaluate and assess how we're going to balance,
because the bills do get big for those programs in the out years."
To meet these cost requirements, the Army expects to continue to
"ruthlessly" modernize by cutting more of its older aircraft and other
systems. At the same time, Congress has shown a willingness to continue to
raise the Pentagon's top line by adding funding for the 2022 budget, and
many lawmakers are already saying the administration's 2023 request of $773
billion is not enough.
"At this point, I feel pretty comfortable that we're going to be able to
maintain our momentum with modernization," Wormuth says.
Army Chief of Staff Gen. James McConville noted that doing FARA and FLRAA at
the same time will take much effort and time. "And we're going through the
acquisition and the development process. We're committed to making that
happen," he added.
The Army is also looking for international support. In February, Maj. Gen.
Walter Rugen, Army Futures Command's FVL Cross-Functional Team director,
signed an agreement with Maj. Gen. James Bowder, the British Army's director
of futures, to share information about rotorcraft requirements and programs.
The agreement specifically calls on the two services to find ways to reduce
helicopter cost, schedule and performance risk as well as increase
integration and cooperation in testing, sustainment and follow-on
development. It also specifically states that the UK will cooperate in
future phases of the FVL program.
"As you would expect, the British Army has an extremely close and productive
relationship with the U.S. Army," Bowder said in an announcement. "Together
we are stronger. Our deep science and technology collaboration is an
important element of this and makes us both more competitive. Today's
agreement formalizes our cooperation to help determine the future direction
of aviation in competition and conflict.