Tag Archives: HH-60W Jolly Green II

Climatic Lab

An HH-60W Jolly Green II, the Air Force’s new combat search and rescue helicopter, completed a month-long trial of extremes inside the McKinley Climatic Lab April 2.

An HH-60W Jolly Green II sits under bright lights used to create heat in the McKinley Climatic Lab at Eglin Air Force Base, Florida, March 19, 2020. The Air Force’s newest combat search and rescue helicopter and crews experienced temperature extremes from 120 to minus 60 degrees Fahrenheit/from 49 degrees to minus 51 degrees Celsius as well as torrential rain during the month of testing. The tests evaluate how the aircraft and its instrumentation, electronics and crew fare under the extreme conditions it will face in the operational Air Force (U.S. Air Force photo by Samuel King Jr.)

The Sikorsky test aircraft endured real temperatures ranging from 120 degrees to minus 60 degrees Fahrenheit/from 49 degrees to minus 51 degrees Celsius as well as 45 mph/72 km/h winds coupled with heavy rainfall. All of those scenarios were created within the lab’s 55,000-square-foot/5,110-square-meter test chamber.

The goal of these punishing tests was to prove the new aircraft’s sustainability in any operational environment.

«Operating the HH-60W in the extreme conditions was a truly unique experience as a pilot and a tester», said Lieutenant Colonel Ryan Coates, 88th Test and Evaluation Squadron pilot, who also performed most of the testing. «Checking system performance under the stress of heat, cold, heavy wind and rain will give us real-world data regarding the helicopter’s capability to perform the rescue mission worldwide in various environments, which is exactly what the operator needs to make solid employment decisions».

Once the lab technicians created extreme environments, the aircrew would enter the aircraft and perform various test procedures. The crew would execute their preflight checklists and perform tasks to see if the extreme conditions affected any of the avionics, electronics, engine and other systems.

The aircrew performing the procedures were also test subjects themselves. Their own reactions and movements were evaluated in the harsh environments. For example, the cold-weather gear worn by the aircrew is much bulkier than a standard flight suit. One of the evaluations was to ensure the pilots could easily reach all of the aircraft controls in the thicker cold-weather gear.

A significant amount of the test schedule was dedicated to preparing the chamber for extreme conditions. McKinley’s lab professionals create, break-down, and recreate again for each new test environment. Technicians worked continuously to go from a superheated 100-degree desert condition to a below-freezing icebox in only three days.

«McKinley Climatic Laboratory maintains quickness and technical proficiency by retaining our own staff of highly experienced welders, machinists, electricians, instrumentation experts, test assembly personnel and refrigeration operators», said William Higdon, the lab’s technical advisor. «Our main mission is to support the warfighter and to ensure any environment they encounter in the field; their equipment has already been proven in those extremes».

The Jolly Green II created some unique challenges for McKinley Lab personnel. The lab technicians created a system specifically for the HH-60W to remove the aircraft’s exhaust. Thorough exhaust removal is a critical part of maintaining the controlled temperature conditions needed for chamber testing, according to lab technicians working on the test.

The design of the ventilation system meant the aircraft’s blades were removed for the duration of the testing. The lab’s in-house fabrication shop also specially designed brackets for the aircraft’s weapons among other items.

«Successful completion of this test is absolutely shared with the Sikorsky and McKinley teams», said Ben Walker, 413th Flight Test Squadron lead test engineer for the effort and Air Force PALACE Acquire journeyman. «Everyone worked together extremely well and we completed on time and on budget. I am very thankful for this opportunity to perform exciting engineering work, while also supporting the warfighter».

After testing in the climatic lab, the HH-60W will return to Sikorsky’s test facility in West Palm Beach for further evaluation. The HH-60W developmental test program is a joint effort between Sikorsky, the 413th FLTS, the 88th TES and Air Force Operational Test and Evaluation Center. Test aircraft are primarily split between Duke Field here and Sikorsky’s West Palm Beach facility.

«Testing on the combat rescue helicopter continued amidst the chaos of COVID-19», said Lieutenant Colonel Wayne Dirkes, 413th FLTS operations officer. «While the situation could change at any moment, we have not lost any test schedule thus far. That is a testament to the entire team’s attitude and willingness to work through challenges».

Jolly Green II

Sikorsky, a Lockheed Martin Company, will build 12 additional HH-60W Jolly Green II Combat Rescue Helicopters (CRH) following a second Low Rate Initial Production (LRIP) contract award by the U.S. Air Force, known as Lot 2, and valued at over $500 million. The award follows a string of significant program milestones in 2019, including first flight, a Milestone C decision by the Air Force, and award of the first Low Rate Initial Production (LRIP) contract for 10 aircraft. The HH-60W Jolly Green II is an all-new helicopter based on the proven UH-60M Black Hawk and customized for the U.S. Air Force’s rescue mission.

Barbara M. Barrett, Secretary of the Air Force, assigned Jolly Green II as the name of the new HH-60W Combat Rescue Helicopter during the annual Air Force Association (AFA) Air Warfare Symposium (Photo courtesy Sikorsky, a Lockheed Martin company)

«This second contract award demonstrates the confidence the U.S. Air Force has in Sikorsky’s proven ability to deliver and support the next generation combat search and rescue helicopter», said Greg Hames, Sikorsky’s CRH Program Director. «Our team works daily – and in close collaboration with our customer – to ensure we build and deliver this highly capable and much-needed helicopter to the warfighter».

Since achieving the Milestone C decision from the Air Force in September 2019, which moved the CRH program into low rate initial production, the program continues to progress, reaching key milestones and executing an aggressive flight test schedule. Currently seven CRH aircraft are in flight, two of which are with the Air Force at Duke Field, Eglin Air Force Base in Florida, with all aircraft engaging in expanded flight tests to support the path forward to Required Assets Available (RAA). Low rate initial production of CRH Lot 1 aircraft major assembly is underway, with Lot 2 assembly to follow. The program remains on track to meet contract delivery of RAA in 2020.

The HH-60W Jolly Green II arrived on February 27, 2020 at the Rosen Shingle Creek resort in Orlando, the site of the annual Air Force Association (AFA) Air Warfare Symposium, offering a first-hand look of the much-anticipated aircraft to service members who perform critical search and rescue operations. The Air Force also assigned the new helicopter its proper name – Jolly Green II – in a name reveal event hosted by Barbara M. Barrett, Secretary of the Air Force.

«We respect the long tradition of assigning a moniker that communicates the Combat Search and Rescue (CSAR) mission. Jolly Green II is a fitting tribute to its history and to airmen and women worldwide», said Dana Fiatarone, Sikorsky’s Vice President, Army and Air Force Systems. «The name is greatly respected by our workforce – past and present – and it’s an honor to build this critical aircraft for the Air Force and bring it to the symposium today to provide our customer with the opportunity to view the Jolly Green II in person. We look forward to continued production and executing on the recent Lot 2 contract award».

The HH-60W Jolly Green II Combat Rescue Helicopter is significantly more capable and reliable than its predecessor, the HH-60G Pave Hawk. The aircraft hosts a new fuel system that nearly doubles the capacity of the main fuel tank on a UH-60M Black Hawk, giving the Air Force crew extended range and more capability to rescue those injured in the battle space. The HH-60W Jolly Green II specification drives more capable defensive systems, vulnerability reduction, weapons, cyber-security, environmental, expanded adverse weather sensor capabilities, and more comprehensive net-centric requirements than currently held by the HH-60G.

The U.S. Air Force program of record calls for 113 helicopters to replace the Pave Hawks, which perform critical combat search and rescue and personnel recovery operations for all U.S. military services. A total of nine aircraft will be built at Sikorsky’s Stratford, Connecticut, facility during the Engineering & Manufacturing Development (EMD) phase of the program – four EMD aircraft and five System Demonstration Test Articles (SDTA).