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Air Force Global Hawk flight test evaluations are performed by the 452nd Flight Test Squadron at Edwards AFB. Operational USAF aircraft are flown by the 9th Reconnaissance Wing, 12th Reconnaissance Squadron at Beale Air Force Base.
Global Hawk ATCD prototypes have been used in the War in Afghanistan and in the Iraq War. Since April 2010, they fly the Northern Route, from Beale AFB over Canada to South-East Asia and back, reducing flight time and improving maintenance. Operators thus have a fresh plane for every sortie.While their data-collection capabilities have been praised, the aircraft did suffer a high number of accidents, with two of the aircraft, more than one quarter of the aircraft used in the wars, being lost. According to Australian press reports, the crashes were due to "technical failures or poor maintenance", with a failure rate per hour flown over 100 times higher than the F-16 fighters flown in the same wars. The manufacturer stated that it was unfair to compare the failure rates of a mature design to that of a prototype plane, and pointed to a lack of trained maintenance staff and spare parts.
The first seven aircraft were built under the Advanced Concept Technology Demonstration (ACTD) program, sponsored by DARPA, in order to evaluate the design and its capabilities. Due to world circumstances, the capabilities of the aircraft were in high demand, so the prototype aircraft were operated by the U.S. Air Force in the War in Afghanistan.
In an unusual move, the aircraft entered initial low-rate production concurrently while still in engineering and manufacturing development. Nine production Block 10 aircraft (sometimes referred to as RQ-4A configuration) were produced, two of which were sold to the US Navy. Two more were sent to Iraq to support operations there. The final Block 10 aircraft was delivered on June 26, 2006.
In order to increase the aircraft's capabilities, the airframe was redesigned, with the nose section and wings being stretched. The changes, with the designation RQ-4 Block 20, allow the aircraft to carry up to 3,000 pounds of internal payload. These changes were introduced with the first Block 20 aircraft, the 17th Global Hawk produced, which was rolled out in a ceremony on August 25, 2006. First flight of the Block 20 from the USAF Plant 42 in Palmdale, California to Edwards Air Force Base took place on March 1, 2007. Developmental testing of Block 20 took place in and 2008. Future Block 30 and 40 aircraft, similar in size to the Block 20, are scheduled for development from 2008 to 2010.
The United States Navy took delivery of two of the Block 10 aircraft to be used to evaluate maritime surveillance capabilities, designated N-1 (BuNo 166509) and N-2 (BuNo 166510). The initial example was tested in a naval configuration at Edwards Air Force Base for several months, later ferrying to NAS Patuxent River on 28 March 2006 to begin the Global Hawk Maritime Demonstration (GHMD) program. Navy squadron VX-20 was tasked with operating the GHMD system.
The GHMD aircraft flew in the Rim of the Pacific (RIMPAC) exercise for the first time in July 2006. Although RIMPAC operations were in the vicinity of Hawaii, the aircraft was operated from Edwards, requiring flights of approximately 2,500 miles (4,000 km) each way to the operations area. Four flights were performed, resulting in over 24 hours of persistent maritime surveillance coordinated with USS Abraham Lincoln and USS Bonhomme Richard. As a part of the demonstration program, Global Hawk was tasked with maintenance of maritime situational awareness, contact tracking, and imagery support of various exercise operations. The imagery obtained by Global Hawk was transmitted to NAS Patuxent River for processing before being forwarded on to the fleet operations off Hawaii, thus exercising the global nature of this aircraft's operations.
Northrop Grumman entered a version of the RQ-4B in the US Navy's Broad Area Maritime Surveillance (BAMS) UAV contract competition. On 22 April 2008 the announcement was made that the Northrop Grumman RQ-4N had won the bid, with the Navy awarding a contract worth US$1.16 billion. In September 2010, the RQ-4N was officially designated the MQ-4C.
On 11 June 2012 a U.S. Navy RQ-4A Global Hawk crashed near Salisbury, Maryland, during a training flight from Naval Air Station Patuxent River.
Program development cost overruns had put the Global Hawk system at risk of cancellation. Per-unit costs in mid-2006 were 25% over baseline estimates, caused by both the need to correct design deficiencies as well as increase the system's capabilities. This caused some concerns about a possible congressional termination of the program if its national security benefits could not be justified. However, in June 2006, the Global Hawk program was restructured. Completion of an operational assessment report by the Air Force was delayed from August 2005 to November 2007 due to manufacturing and development delays. The operational assessment report was released in March 2007 and production of the 54 air vehicles planned has been extended by two years to 2015.
In February 2011, the Air Force reduced its planned buy of RQ-4 Block 40 aircraft from 22 to 11 in a cost-cutting move.
The U.S. Defense Department's Director, Operational Test and Evaluation (DOT&E) found the RQ-4B "not operationally effective" for its mission due to aircraft reliability issues in June 2011.