Sikorsky CH-53K
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The Sikorsky CH-53K King Stallion (Sikorsky S-95) is a
heavy-lift An airlift is the organized delivery of supplies or personnel primarily via military transport aircraft. Airlifting consists of two distinct types: strategic and tactical. Typically, strategic airlifting involves moving material long distanc ...
cargo helicopter designed and produced by Sikorsky Aircraft. The King Stallion is an evolution of the long running CH-53 series of helicopters which have been in continuous service since 1966, and features three uprated engines, new
composite Composite or compositing may refer to: Materials * Composite material, a material that is made from several different substances ** Metal matrix composite, composed of metal and other parts ** Cermet, a composite of ceramic and metallic materials ...
rotor blades, and a wider
aircraft cabin An aircraft cabin is the section of an aircraft in which passengers travel. Most modern commercial aircraft are pressurized, as cruising altitudes are high enough such that the surrounding atmosphere is too thin for passengers and crew to bre ...
than its predecessors. It is the largest and heaviest helicopter in the U.S. military. The
United States Marine Corps The United States Marine Corps (USMC), also referred to as the United States Marines, is the maritime land force service branch of the United States Armed Forces responsible for conducting expeditionary and amphibious operations through combi ...
plans to receive 200 helicopters at a total cost of $25 billion. Ground Test Vehicle (GTV) testing started in April 2014; flight testing began with the maiden flight on 27 October 2015. In May 2018, the first CH-53K was delivered to the Marine Corps. On 22 April 2022, it was declared to have passed
initial operational capability Initial operating capability or initial operational capability (IOC) is the state achieved when a capability is available in its minimum usefully deployable form. The term is often used in government or military procurement. The United States D ...
. Israel has also reportedly ordered the type; other potential export customers include Japan and Germany.


Development


H-53 background

The
Sikorsky CH-53 Sea Stallion The CH-53 Sea Stallion (Sikorsky S-65) is an American family of heavy-lift transport helicopters designed and built by the American manufacturer Sikorsky Aircraft. It was originally developed in response to a request from the United States ...
came out of the US Marine Corps' (USMC) "Heavy Helicopter Experimental" (HH(X)) competition begun in 1962. Sikorsky's S-65 was selected over
Boeing Vertol Boeing Rotorcraft Systems (formerly Boeing Helicopters and before that Boeing Vertol) is the former name of an American aircraft manufacturer, now known as Vertical Lift division of Boeing Defense, Space & Security. The headquarters and main r ...
's modified
CH-47 Chinook The Boeing CH-47 Chinook is a tandem rotor helicopter developed by American rotorcraft company Vertol and manufactured by Boeing Vertol. The Chinook is a heavy-lift helicopter that is among the heaviest lifting Western helicopters. Its name, C ...
version. The prototype YCH-53A first flew on 14 October 1964.Sikorsky Giant Helicopters: S-64, S-65, & S-80
Vectorsite.net, 1 May 2006.
It was designated ''CH-53A Sea Stallion'', delivery of production helicopters began in 1966.Frawley, Gerard: ''The International Directory of Military Aircraft'', p. 148. Aerospace Publications Pty Ltd, 2002. . The CH-53A was equipped with two T64-GE-6
turboshaft A turboshaft engine is a form of gas turbine that is optimized to produce shaftpower rather than jet thrust. In concept, turboshaft engines are very similar to turbojets, with additional turbine expansion to extract heat energy from the exhaust ...
engines, and had a maximum gross weight of . Variants of the original CH-53A Sea Stallion include the RH-53A/D, HH-53B/C, CH-53D, CH-53G, and MH-53H /J/M. The RH-53A and RH-53D were used by the
United States Navy The United States Navy (USN) is the maritime service branch of the United States Armed Forces and one of the eight uniformed services of the United States. It is the largest and most powerful navy in the world, with the estimated tonnage ...
for
minesweeping Minesweeping is the practice of the removal of explosive naval mines, usually by a specially designed ship called a minesweeper using various measures to either capture or detonate the mines, but sometimes also with an aircraft made for that ...
. The CH-53D had a more powerful version of the
General Electric T64 The General Electric T64 is a free-turbine turboshaft engine that was originally developed for use on helicopters, but which was later used on fixed-wing aircraft as well. General Electric introduced the engine in 1964. The original engine desig ...
engine, used in all H-53 variants, and external fuel tanks. The
US Air Force The United States Air Force (USAF) is the air service branch of the United States Armed Forces, and is one of the eight uniformed services of the United States. Originally created on 1 August 1907, as a part of the United States Army Sig ...
's ''HH-53B/C Super Jolly Green Giant'' were for special operations and combat rescue. The Air Force's ''MH-53H/J/M Pave Low'' were the final twin-engined H-53s, and had extensive avionics upgrades for all-weather operation. In October 1967, the USMC issued a requirement for a helicopter with a lifting capacity 1.8 times that of the CH-53D, that could fit on
amphibious assault ship An amphibious assault ship is a type of amphibious warfare ship employed to land and support ground forces on enemy territory by an amphibious assault. The design evolved from aircraft carriers converted for use as helicopter carriers (and, a ...
s. Before this, Sikorsky had been working on an enhancement to the CH-53D, under the company designation "S-80", featuring a third turboshaft engine and a more powerful rotor system. Sikorsky proposed the S-80 design to the Marines in 1968. The Marines considered this a good, quick solution, and funded development of a testbed helicopter.S-80 Origins / US Marine & Navy Service / Japanese Service
Vectorsite.net, 1 May 2006.
Changes on the CH-53E also included a stronger transmission and a fuselage stretched . The main rotor blades' material was changed to a
titanium Titanium is a chemical element with the Symbol (chemistry), symbol Ti and atomic number 22. Found in nature only as an oxide, it can be reduced to produce a lustrous transition metal with a silver color, low density, and high strength, resista ...
-
fiberglass Fiberglass (American English) or fibreglass ( Commonwealth English) is a common type of fiber-reinforced plastic using glass fiber. The fibers may be randomly arranged, flattened into a sheet called a chopped strand mat, or woven into glass clo ...
composite Composite or compositing may refer to: Materials * Composite material, a material that is made from several different substances ** Metal matrix composite, composed of metal and other parts ** Cermet, a composite of ceramic and metallic materials ...
. A new automatic flight control system was added. The vertical tail was also enlarged, with the tail rotor tilted upwards slightly to provide some lift in hover.CH-53A/D/E Sea Stallion and MH-53E Sea Dragon
US Navy, 15 November 2000.
The initial YCH-53E first flew in 1974. Following successful testing, the initial production contract was awarded in 1978, and service introduction followed in February 1981. The US Navy acquired the CH-53E in small numbers for shipboard resupply. The Marines and Navy acquired a total of 177. For the airborne mine countermeasures role, the Navy obtained a CH-53E variant, designated ''MH-53E Sea Dragon'', with enlarged
sponson Sponsons are projections extending from the sides of land vehicles, aircraft or watercraft to provide protection, stability, storage locations, mounting points for weapons or other devices, or equipment housing. Watercraft On watercraft, a spon ...
s and fuel tanks for greater fuel storage, in the 1980s. The Navy obtained 46 Sea Dragons.


CH-53K

The USMC had planned upgrades to retain most CH-53Es, but this effort stalled. Sikorsky proposed a new model, originally designated "CH-53X"; in April 2006, the USMC signed a $18.8 billion contract for 156 "CH-53K" helicopters, with deliveries to be completed by 2021.Whittle, Richard
USMC CH-53E Costs Rise With Op Tempo
''Rotor & Wing, Aviation Today'', January 2007.
The USMC was to begin retiring CH-53Es in 2009, and needed replacements as rotorcraft reached their structural life limits in 2011–12. CH-53K flight testing was expected to begin in 2011.
. Vectorsite.net, 1 March 2008.
In August 2007, the USMC increased the order from 156 to 227. By that time, the first flight was planned for November 2011 with
initial operating capability Initial operating capability or initial operational capability (IOC) is the state achieved when a capability is available in its minimum usefully deployable form. The term is often used in government or military procurement. The United States D ...
(IOC) by 2015. The CH-53K will be the USMC's heavy lift helicopter with the MV-22 (medium lift) and
UH-1Y The Bell UH-1Y VenomDoD 4120-15L, ''Model Desi ...
(light lift). A 2007
RAND The RAND Corporation (from the phrase "research and development") is an American nonprofit global policy think tank created in 1948 by Douglas Aircraft Company to offer research and analysis to the United States Armed Forces. It is finan ...
report on seabasing found that a higher ratio of CH-53Ks to MV-22s would reduce ship-based deployment times. In 2008, design work was well underway, along with weight reduction efforts to meet operational requirements; increased engine performance and rotor blade improvements are options to help meet requirements if needed. The rotor mast tilt was decreased and components shifted to ensure the center of gravity does not shift too far rearward as fuel is burned. Design requirements were frozen in 2009–10. On 22 January 2010, Sikorsky opened a $20 million Precision Components Technology Center in Stratford, Connecticut, for producing CH-53K parts, such as the rotating and stationary swashplates, main and tail rotor hubs, and main rotor sleeves. On 3 August 2010, the CH-53K passed its Critical Design Review, reading it for test production."CH-53K helicopter program achieves successful Critical Design review"
''Rotorhub'', 3 August 2010.
"CH-53K Helicopter Program Achieves Successful Critical Design Review"
Sikorsky Aircraft, 3 August 2010. Retrieved: 16 August 2010.
However, the IOC fielding date was deferred to 2018. Sikorsky proposed building four pre-production aircraft for evaluation. On 4 December 2012, Sikorsky delivered the first CH-53K, a Ground Test Vehicle (GTV) airframe. Early tests included fuel system calibration and attaching test sensors across the airframe to record temperature, aerodynamic load, pressure, and vibration. Two additional static GTVs underwent structural testing at the firm's Stratford manufacturing plant. In January 2013, the program had an estimated cost of US$23.17 billion after procurement of the planned 200 CH-53Ks. In April 2013, the U.S. Navy program manager stated that work had gone well and it may become operational ahead of schedule. On 31 May 2013, the Navy awarded Sikorsky a $435 million contract to deliver four prototype CH-53Ks for evaluation and mission testing; The first two prototypes focused on structural flight loads while the third and fourth validated general performance, propulsion and avionics. Major subcontractors include
Aurora Flight Sciences Aurora Flight Sciences is an American aviation and aeronautics research subsidiary of Boeing which primarily specializes in the design and construction of special-purpose Unmanned aerial vehicles. Aurora has been established for 20+ years and th ...
(main rotor pylon),"Sikorsky Selects CH-53K Fuselage Supplier Team"
Sikorsky Aircraft, 9 May 2007.
Exelis Aerostructures (tail rotor pylon and sponsons),
GKN Aerospace GKN Ltd is a British multinational automotive and aerospace components business headquartered in Redditch, England. It is a long-running business known for many decades as Guest, Keen and Nettlefolds. It can trace its origins back to 1759 an ...
(aft transition), Onboard Systems International (external cargo hook),
Rockwell Collins Rockwell Collins was a multinational corporation headquartered in Cedar Rapids, Iowa, providing avionics and information technology systems and services to government agencies and aircraft manufacturers. It was formed when the Collins Radio Comp ...
(avionics management system),"Sikorsky Aircraft Selects Rockwell Collins to Provide CH-53K Avionics Management System"
Sikorsky Aircraft, 29 June 2006.
Sanmina-SCI Corporation (communications), and Spirit AeroSystems (cockpit and cabin). In October 2013, Sikorsky gave
Kratos Defense & Security Solutions Kratos Defense & Security Solutions, Inc, (), headquartered in San Diego, California, is an American technology company specializing in directed-energy weapons, unmanned systems, satellite communications, cyber security/warfare, microwave electro ...
a $8.5 million contract for CH-53K maintenance training aids, such as the Maintenance Training Device Suite (MTDS) and Helicopter Emulation Maintenance Trainer (HEMT). The MTDS is a realistic training and evaluation environment for various avionics, electrical, and hydraulic subsystems. The HEMT is a 3D simulation of multiple scenarios, such as functional test, troubleshoot, fault isolation, removal and installation of 27 subsystems. On 24 January 2014, the CH-53K GTV ignited its engines, spinning the rotor head without rotors attached. Low-rate production is planned to proceed from 2015 to 2017. Initial operating capability (IOC) was set to occur in 2019, with full-rate production commencing between then and 2022. The USMC intends to have eight active squadrons, one training squadron, and one reserve squadron. In April 2014, testing with blades attached began, system integration followed. Flight testing was set to start in late 2014, each test aircraft flying approximately 500 hours over three years. The
maiden flight The maiden flight, also known as first flight, of an aircraft is the first occasion on which it leaves the ground under its own power. The same term is also used for the first launch of rockets. The maiden flight of a new aircraft type is alw ...
was delayed,Drwiega, Andrew.
King Stallion Trots Toward Flight Test Program
" '' Aviation Today'', 2 October 2014.
due to issues with the titanium quill shafts in the transmission and gear box. On 5 May 2014, General James F. Amos announced during the official rollout that it will be called the "King Stallion". On 27 October 2015, the CH-53K took its first flight. On 7 March 2018, one lifted a payload of , the maximum weight on the single center point cargo hook. The first CH-53K was delivered to the USMC on 16 May 2018; at the time, 18 additional helicopters were in production, and the second was planned for delivery in early 2019. In December 2018, the CH-53K was projected to not be combat ready as expected in late 2019, due to delivery delays caused by technical flaws found in testing, which resulted in a major program restructuring. Flaws included the engine re-ingesting exhaust gas, limited service life for the rotor gear boxes, late deliveries of redesigned parts, and deficiencies with the tail rotor and driveshaft. It is estimated that the delay will push back delivery of combat-ready CH-53Ks until May 2020.


Design

The CH-53K King Stallion is a heavy lift helicopter, being a general redesign of the preceding CH-53E, the main improvements being the new engines and cockpit layout. It has over twice the lift capacity and radius of action of the CH-53E, and a wider cargo hold to allow it to carry a
Humvee The High Mobility Multipurpose Wheeled Vehicle (HMMWV; colloquial: Humvee) is a family of light, four-wheel drive, military trucks and utility vehicles produced by AM General. It has largely supplanted the roles previously performed by the ...
internally. A new composite rotor blade system is also used, featuring technology similar to that of the
UH-60 Black Hawk The Sikorsky UH-60 Black Hawk is a four-blade, twin-engine, medium-lift utility military helicopter manufactured by Sikorsky Aircraft. Sikorsky submitted the S-70 design for the United States Army's Utility Tactical Transport Aircraft System ( ...
helicopter. The CH-53K is powered by the General Electric GE38-1B engine, which was selected over the Pratt and Whitney Canada PW150 and a variant of the Rolls-Royce AE 1107C-Liberty used on the V-22 Osprey. Each of the three T408 engines is rated at , and gives the CH-53K the ability to fly faster than its CH-53E predecessor.CH-53K brochure
Sikorsky.
The CH-53K features a new digital glass cockpit with fly-by-wire controls and haptic feedback, HUMS, a new elastomeric hub system, and
composite Composite or compositing may refer to: Materials * Composite material, a material that is made from several different substances ** Metal matrix composite, composed of metal and other parts ** Cermet, a composite of ceramic and metallic materials ...
rotor blades to improve "
hot and high In aviation, hot and high is a condition of low air density due to high ambient temperature and high airport elevation. Air density decreases with increasing temperature and altitude. The lower air density reduces the power output from the airc ...
" performance."Prototype Assembly Looms As First Production Parts Arrive for CH-53K Heavy Lift Helicopter"
. Sikorsky Aircraft, 6 August 2009.
The split torque gearbox with quill shafts started development around 2007.He, S., Gmirya, Y., Mowka, F., Leigh, L
"Trade Study on Different Design Configurations of the CH-53K Main Gearbox"
''
NASA The National Aeronautics and Space Administration (NASA ) is an independent agencies of the United States government, independent agency of the US federal government responsible for the civil List of government space agencies, space program ...
'', 2008
The gearbox assembly including rotor hub and rotating control system weighs around .Parker, Andrew.
CH-53K King Stallion Inches Closer to Sunrise
''Aviation Today'', 6 May 2014. Accessed: 7 May 2014.
The split torque gearbox weighs . For comparison, the twin-engine
Mil Mi-26 The Mil Mi-26 (russian: link=no, Миль Ми-26, NATO reporting name: Halo) is a Soviet/Russian heavy transport helicopter. Its product code is ''Izdeliye 90''. Operated by both military and civilian operators, it is the largest and most po ...
's split torque gearbox weighs . The CH-53K has an improved external cargo handling system, survivability enhancements, and improvements to extend service life. The cabin will be long by wide by tall.CH-53K Helicopter (click on Attributes tab)
Sikorsky.
Its cabin will be wider and 15% larger, but will have new shorter composite sponsons. The CH-53K can carry two 463L master pallets, eliminating the need to break apart pallets between airlifter and helicopter. The CH-53K is to surpass the capability of its predecessor by carrying nearly 30% more than the CH-53E's external payload of over the same radius of . The CH-53K's payload reaches a maximum of . The CH-53K's maximum gross weight will be , which is increased over the CH-53E's . The CH-53K will keep approximately the same footprint as the CH-53E. To this end, it has redesigned composite sponsons that cut overall width for a narrower footprint, which is better for shipboard service.


Operational history


United States Marine Corps

The U.S. Marine Corps received its first CH-53K simulator at
Marine Corps Air Station New River Marine Corps Air Station New River is a United States Marine Corps helicopter and tilt-rotor base in Jacksonville, North Carolina, in the eastern part of the state. In 1972, the airfield was named McCutcheon Field for General Keith B. McCutcheo ...
in
Jacksonville, North Carolina Jacksonville is a city in Onslow County, North Carolina, United States. As of the 2020 census, the population was 72,723, which makes Jacksonville the 14th-largest city in North Carolina. Jacksonville is the county seat and most populous commu ...
on 1 May 2020. It is a Containerized Flight Training Device (CFTD) built by Lockheed Martin, Sikorsky's parent company. On 22 April 2022, Lt. General
Mark R. Wise Mark R. Wise is a retired United States Marine Corps lieutenant general who last served as the Deputy Commandant for Aviation of the United States Marine Corps. Previously, he was the Assistant Deputy Commandant for Combat Development and Integ ...
, Deputy Commandant for Aviation, declared
initial operational capability Initial operating capability or initial operational capability (IOC) is the state achieved when a capability is available in its minimum usefully deployable form. The term is often used in government or military procurement. The United States D ...
for the CH-53K.Eckstein, Megan
"Marine Corps declares its heavy lift helicopter operational"
Defense News, 26 April 2022.


Israel

In 2009, the
Israeli Air Force The Israeli Air Force (IAF; he, זְרוֹעַ הָאֲוִיר וְהֶחָלָל, Zroa HaAvir VeHahalal, tl, "Air and Space Arm", commonly known as , ''Kheil HaAvir'', "Air Corps") operates as the aerial warfare branch of the Israel Defens ...
(IAF) said it would evaluate the new variant after it flies. In August 2015, it formalized a requirement for the CH-53K, listing the type as a "very high priority" item to enable the service to perform missions only the platform is capable of. Israel's current CH-53 "Yasur" fleet is to remain operational until 2025. The CH-53K competed with the Boeing CH-47F Chinook for an order of approximately 20 helicopters to replace the CH-53 Yasur. In February 2021, the Israeli Ministry of Defense announced the CH-53K's selection. On 31 December 2021, it was announced that Israel had signed a deal to buy 12 CH-53Ks.


Potential operators


Germany

In February 2018, Sikorsky signed an agreement valued at around €4 billion with Rheinmetall to team up for the German Air Force's CH-53G heavy lift helicopter replacement program, in which the CH-53K competed against the Boeing CH-47 Chinook. The German
Federal Ministry of Defence The Federal Ministry of Defence (german: Bundesministerium der Verteidigung, ), abbreviated BMVg, is a top-level federal agency, headed by the Federal Minister of Defence as a member of the Cabinet of Germany. The ministry is headquartered at ...
was expected to issue an official request for information in late 2018, to award a contract in 2020, and for deliveries to begin in 2023 for an expected order of around 40 helicopters. On 29 September 2020, the German Ministry of Defense cancelled the "Schwerer Transporthubschrauber" (STH) heavy-lifting helicopter program, it having been judged to be too expensive; instead, the CH-53Gs are still to be replaced after reexamining the project. In 2022, Germany decided to procure the CH-47F Chinook instead, citing interoperability advantages with other European NATO countries - especially the Netherlands - as well as the lower unit cost compared to the CH-53K which would allow the purchase of more helicopters for the same budget.


Japan

Japan has reportedly shown interest in the CH-53K.


Operators

; *
United States Marine Corps The United States Marine Corps (USMC), also referred to as the United States Marines, is the maritime land force service branch of the United States Armed Forces responsible for conducting expeditionary and amphibious operations through combi ...


Specifications (CH-53K)


See also


References


External links


Sikorsky CH-53K page on Sikorsky.com

Department of the Navy CH-53K acquisition page


an


CH-53K information on DefenseIndustryDaily.com

Assessment of Existing Rotorcraft Technology/Cost


Flightglobal.com, 12 February 2008. {{US helicopters Aircraft first flown in 2015 Military transport helicopters H-053K H-53K King Stallion Three-turbine helicopters 2010s United States helicopters United States military helicopters