Helicopter Model Grey Wolf Continues to Display Defects Ahead of Trials for Deployment
Air Force's New MH-139A Grey Wolf Helicopter Faces Operational Challenges
The United States Air Force is on the brink of initiating the initial operational test and evaluation (IOT&E) of its new MH-139A Grey Wolf helicopter, a crucial step before full-production deployment. However, the Pentagon's test director has warned of significant issues that could prevent the helicopter from meeting operational requirements.
According to the Director of Operational Test and Evaluation's 2024 annual report, the MH-139A, Boeing's adaptation of the Leonardo AW-139, is struggling with several deficiencies. These include dust ingestion during landings, software problems, a redesigned gun mount, spent shell casing management, seating restraints, and seating layout, among others. Moreover, an electromagnetic pulse test, a prerequisite for IOT&E, remains untested.
Although testing is scheduled for this quarter, the report admitted that the assessment could be delayed if the Air Force and Boeing cannot rectify the problems. The Air Force has largely concluded developmental testing and made progress in resolving previously mentioned deficiencies, such as the automatic flight control system, sensor displays, and crosswind takeoffs. Nevertheless, the report highlights ongoing performance concerns that pose a risk to the MH-139A meeting operational effectiveness requirements.
The engine's propensity to ingest dust and debris, particularly during landings in austere regions, has caused engine performance degradation. This issue is supposedly the primary concern threatening the MH-139A's suitability. In addition, concerns remain about engine maintenance due to aircraft flight envelope expansion and higher power requirements, as well as a buildup of carbon on several engine parts.
Other outstanding issues involve cabin seating limitations and commercially derived mission planning software. The helicopter's M240 machine gun also faces previously reported challenges, such as weapon malfunctions, spent-brass casing management, and ammunition feed system concerns. A gun mount redesign is underway but will not be completed before IOT&E.
Moreover, the helicopter's intercom system will likely require a redesign, again not to be finished before IOT&E. The original fuel cell design failed to meet self-sealing military requirements, and there are survivability concerns.
The Air Force has extended developmental testing to incorporate equipment changes, like an additional radio for Global Strike Command missions and integration with the system. The MH-139 is also reportedly delayed in integrating contractor maintenance data into the Air Force Integrated Maintenance Data System, a requirement for IOT&E and regular operations.
To enter IOT&E, Boeing must deliver operationally representative aircraft, complete flight and maintenance technical orders with the new radio and environmental control system, and provide fully trained flight crews and maintenance personnel.
The first phase of cyber testing has been conducted by the Air Force Operational Test and Evaluation Center, and plans for further cyber testing have been submitted.
The MH-139A program has experienced substantial fluctuations in its planned fleet size in recent years, initially targeting a fleet of 84 aircraft to replace the aged UH-1N fleet. However, budget constraints have led to a reduced buy of 36 aircraft in the 2025 fiscal budget, eliminating the VIP transport mission. Six developmental aircraft will join the fleet, making the new inventory objective 42 aircraft. The Air Force has contracted with Boeing for 26 aircraft so far, fully equipping all ICBM bases with planned MH-139s.
The Director of Operational Test and Evaluation's report advised the Air Force to develop corrective action plans for all known deficiencies in the Grey Wolf, ensuring that enough operationally representative aircraft, trained flight and maintenance crews, maintenance support, and supporting equipment are available for IOT&E.
- The military's Air Force is cautioned about the potential implications of deficiencies in their new MH-139A Grey Wolf helicopter, particularly the engine's susceptibility to dust ingestion and software problems, which could hinder it from meeting operational requirements and pose a risk to space operations due to the helicopter's expanded flight envelope.
- The ongoing challenges with the MH-139A's intercom system, commercial mission planning software, M240 machine gun malfunctions, spent-brass casing management, and ammunition feed system concerns may necessitate technology upgrades before the initial operational test and evaluation (IOT&E) can commence.
- Despite progress made in resolving previous issues with the automatic flight control system, sensor displays, and crosswind takeoffs, the Air Force's sports programs may face operational challenges if the MH-139A fails to meet operational effectiveness requirements, as originally planned aircraft numbers have been reduced due to budget constraints, impacting the replacement of aged UH-1N aircraft.
