Innovating Naval Aviation: The Rise of the MQ-25 Stingray Unmanned Refueler –

The evolution of military aviation continually demands innovation and adaptation to maintain operational efficiency. In the world of unmanned aerial refuelers, the US Navy’s MQ-25 Stingray program stands at the forefront of technological advancement.

However, the challenges posed by component obsolescence have prompted a strategic response from experts within the Naval Air Systems Command (NAVAIR) at Patuxent River Naval Air Station, Maryland.

Let’s take a closer look.

Background on the MQ-25 Stingray Program

The MQ-25 Stingray program, spearheaded by Boeing Defense, Space & Security, was initiated to address the critical need for an operational carrier-based unmanned aircraft.

The MQ-25, designed to provide crucial refueling capabilities, aims to extend the combat range of deployed F/A-18 Super Hornets, EA-18G Growlers, and Lockheed Martin F-35C combat aircraft.

With the integration of a persistent, sea-based tanker, the Carrier Air Wings (CVW) gains an unprecedented enhancement in deploying combat strike fighters, effectively extending the operational range of aircraft carriers.

Furthermore, the Navy set the MQ-25 to play a pivotal role in pioneering the manned-unmanned teaming (MUM-T) operational concept, serving as the foundational element for future carrier-based unmanned systems.

The service also envisions all Nimitz– and Ford-class carriers ultimately being MQ-25 capable.

The MQ-25 system consists of two major segments: the MQ-25 Air System, the unmanned aircraft itself, and the Unmanned Carrier Aviation Mission Control System (UMCS), which is crucial for carrier integration and commanding the MQ-25 air vehicle and its payload.

Oversight of these segments falls under PMA-268, serving as the government Lead Systems Integrator (LSI).

Boeing secured a $805 million development contract in August 2018, winning the bid over competing designs from General Atomics and Northrop Grumman.

Notably, the MQ-25 successfully took its inaugural flight in 2021, marking a significant milestone in unmanned aviation technology.

NAVAIR’s recent announcement of a $36 million order to Boeing underscores the urgency of mitigating parts obsolescence in the MQ-25 subsystems.

This non-recurring engineering effort aims to address challenges posed by aging components and ensure sustained operational capability.

Moreover, this proactive approach reflects the Navy’s commitment to declare MQ-25’s initial operational capability by 2024.

It highlights the importance of overcoming component obsolescence issues without compromising the aircraft’s performance or reliability.

Features and Capabilities of the MQ-25 Aircraft

The MQ-25 plays a pivotal role in augmenting carrier-based refueling capabilities.

Its integration into the Navy’s fleet is poised to enhance the combat range of various aircraft significantly, providing extended mission durations and operational flexibility.

One notable technological feature integrated into the MQ-25 is the advanced remote I/O interface controller developed by Aitech Defense Systems Inc., a company based in Chatsworth, California.

This system, known as the Aitech Ai-RIO avionics remote interface, boasts expandability and a myriad of capabilities crucial for modern aviation requirements.

Aitech Ai-RIO: Unveiling Key Components and Functions

The Ai-RIO serves as a high-density, low-power, rugged subsystem capable of controlling various critical functions.

Its versatility spans across vehicle platform flight control, navigation, servo-valve and thrust vector control, data telemetry, communications, and more.

Notably, its expandability allows networking of up to eight units together, offering extensive I/O (input/output) capabilities.

This sophisticated subsystem employs a radiation-qualified dual-core PowerPC processor along with rad-tolerant Field Programmable Gate Arrays (FPGAs), ensuring robust performance in demanding environments.

Furthermore, its conduction-cooled internal electronics, housed within a sealed EMI/EMC (electromagnetic interference/electromagnetic compatibility) Faraday cage, maximize thermal transfer, enhancing reliability.

Pentagon Watchdog’s Concerns: Evaluation of MQ-25 Stingray Program

Recent revelations from the Department of Defense’s Office of Inspector General (DODIG) have highlighted the US Navy’s ambitious progress in advancing the MQ-25 Stingray tanker drone program.

The DODIG released a partially redacted audit, raising concerns regarding the Navy’s fast-tracked approach and its potential risks.

The audit’s executive summary expresses apprehensions about the Navy’s intent to greenlight critical production decisions for the MQ-25 program before conducting essential tests and evaluations to validate its operational capability.

Unmanned MQ-25 aircraft on the flight deck aboard the aircraft carrier USS George H.W. Bush (CVN 77), December 2021 (Image source: DVIDS)

By advancing production decisions without undergoing developmental and initial operational tests and evaluation (DT&E and IOT&E), the review underscores the heightened risk that the MQ-25 might fall short of operational requirements.

This could lead to delays in deployment to the aircraft carriers, escalating program costs and potentially compromising its effectiveness.

“The MQ‑25 program is an acquisition category 1B Major Defense Acquisition Program with an estimated cost of $16.5 billion, including $3.1 billion for research, development, test, and evaluation, $12.6 billion for procurement, and $747.5 million for military construction,” the DODIG’s review read.

Navy budget estimates peg the average unit cost for each MQ-25 at approximately $150 million, exclusive of various ancillary items.

“The Deputy Secretary of Defense designated the MQ‑25 program as a Key Performance Parameter Reduction Pilot Program, which allows the Navy to focus on fewer primary operational capability requirements than the six that were required at program designation,” DODIG’s report adds.

This allows the Navy to focus on fewer primary operational capability requirements than originally stipulated at program inception.

Notably, the MQ-25 program initially outlined only two operational requirements, with the first requirement pertaining to the drone’s capability to operate from both Nimitz– and Ford-class aircraft carriers.

However, the DODIG’s report redacts details regarding the second operational requirement, adding an element of mystery or sensitivity to the specifics of this aspect.

Collaborations and Subcontractors Involved

Boeing’s collaboration with an extensive array of subcontractors is instrumental in elevating the MQ-25’s capabilities.

Companies like BAE Systems, Collins Aerospace, Raytheon, and others contribute expertise in various domains, including avionics, propulsion, and system integration, ensuring a comprehensive and robust final product.

Work related to the recent $36 million order will be distributed across several locations, including Endicott, New York; St. Louis; Cedar Rapids, Iowa; Clearwater and Melbourne, Florida; and San Diego.

The targeted completion by April 2024 underlines the focused efforts to tackle component obsolescence efficiently.

Conclusion: Paving the Way Forward in Naval Aviation

The MQ-25 Stingray program signifies a pioneering leap in unmanned aerial refueling within naval aviation.

Despite challenges like component obsolescence, recent concerns highlight the importance of a balanced approach between rapid progress and thorough evaluation.

Collaborative endeavors between the Navy, Boeing, and subcontractors remain pivotal in advancing unmanned aerial systems.

As the program navigates challenges, it propels carrier-based operations toward agility and resilience, ensuring preparedness for future strategic needs.