Boeing AH-64 Apache
The Hughes/McDonnell Douglas/Boeing AH-64 Apache is an American twin-turboshaft attack helicopter with a tailwheel-type landing gear and a tandem cockpit for a crew of two. Nose-mounted sensors help acquire targets and provide night vision. It carries a 30 mm caliber| M230 chain gun under its forward fuselage and four hardpoints on stub-wing pylons for armament and stores, typically AGM-114 Hellfire missiles and Hydra 70 rocket pods. Redundant systems help it survive combat damage.
The Apache began as the Model 77 developed by Hughes Helicopters for the United States Army's Advanced Attack Helicopter program to replace the AH-1 Cobra. The prototype YAH-64 first flew on 30 September 1975. The U.S. Army selected the YAH-64 over the Bell YAH-63 in 1976, and later approved full production in 1982. After acquiring Hughes Helicopters in 1984, McDonnell Douglas continued AH-64 production and development. The helicopter was introduced to U.S. Army service in April 1986. The advanced AH-64D Apache Longbow was delivered to the Army in March 1997. Production has been continued by Boeing Defense, Space & Security. As of March 2024, over 2,700 Apaches have been delivered to the U.S. Army and 18 international partners and allies.
Primarily operated by the U.S. Army, the AH-64 has also become the primary attack helicopter of multiple nations, including Greece, Japan, Israel, the Netherlands, Singapore, and the United Arab Emirates. It has been built under license in the United Kingdom as the AgustaWestland Apache. American AH-64s have served in conflicts in Panama, the Persian Gulf, Kosovo, Afghanistan, and Iraq. Israel has used the Apache to fight in Lebanon and the Gaza Strip. British and Dutch Apaches were deployed to wars in Afghanistan and Iraq beginning in 2001 and 2003.
Development
Advanced Attack Helicopter
After the AH-56 Cheyenne was cancelled in 1972 in favor of projects like the U.S. Air Force A-10 Thunderbolt II and the Marine Corps AV-8A Harrier, the United States Army sought an aircraft to fill an anti-armor attack role that would still be under Army command. The 1948 Key West Agreement forbade the Army from owning combat fixed-wing aircraft. The Army wanted an aircraft better than the AH-1 Cobra in firepower, performance, and range. It would have the maneuverability for terrain following nap-of-the-earth flying. To this end, the U.S. Army issued a Request For Proposals for the Advanced Attack Helicopter program on 15 November 1972. As a sign of the importance of this project, in September 1973 the Army designated its five most important projects as the "Big Five", with the AAH included.Proposals were submitted by Bell, Boeing Vertol/Grumman team, Hughes, Lockheed, and Sikorsky. In July 1973, the U.S. Department of Defense selected finalists Bell and Hughes Aircraft's Toolco Aircraft Division. This began the phase 1 of the competition. Each company built prototype helicopters and went through a flight test program. Hughes' Model 77/YAH-64A prototype first flew on 30 September 1975, while Bell's Model 409/YAH-63A prototype first flew on 1 October 1975. After evaluating the test results, the Army selected Hughes' YAH-64A over Bell's YAH-63A in 1976. Reasons for selecting the YAH-64A included its more damage tolerant four-blade main rotor and the instability of the YAH-63's tricycle landing gear arrangement.
The AH-64A then entered phase 2 of the AAH program under which three pre-production AH-64s would be built, additionally, the two YAH-64A flight prototypes and the ground test unit were upgraded to the same standard. Weapons and sensor systems were integrated and tested during this time, including the laser-guided AGM-114 Hellfire missile. Development of the Hellfire missile had begun in 1974, originally known by the name of Helicopter Launched, Fire and Forget Missile, for the purpose of arming helicopter platforms with an effective anti-tank missile.
Into production
In 1981, three pre-production AH-64As were handed over to the U.S. Army for Operational Test II. The Army testing was successful, but afterward it was decided to upgrade to the more powerful T700-GE-701 version of engine, rated at. The AH-64 was named the Apache in late 1981, after the Apache tribe, following the tradition of naming Army helicopters after Native American tribes. It was approved for full-scale production in 1982. In 1983, the first production helicopter was rolled out at Hughes Helicopter's facility at Mesa, Arizona. Hughes Helicopters was purchased by McDonnell Douglas for $470 million in 1984. The helicopter unit later became part of The Boeing Company with the merger of Boeing and McDonnell Douglas in August 1997. In 1986, the incremental or flyaway cost for the AH-64A was $7M and the average unit cost was approximately $13.9M based on total costs.A 1985 Department of Defense engineering analysis by the inspector general's office reported that significant design deficiencies still needed to be addressed by the contractor. The Army project manager Col. William H. Forster published a list of 101 action items. In 1986, the four 22-foot-long main rotor blades, each made from steel and composite material glued together to maximize strength and minimize weight by the Composite Structures Division of Alcoa Composites, were added to the list. The steel-composite rotors could not meet the Army specification for a life of 1500 flight hours, and needed replacement after just 146 hours. After six changes to the design, the rotor blade life was extended to 1400 hours by early 1991.
As of 2024, the AH-64E is being produced at an economical rate of 82 aircraft a year. Boeing states that the minimum sustainment rate for the aircraft is 48 per year while current tooling and space allows for up to 98 aircraft to be manufactured per year. The U.S. Army states that with additional investment and labor, production could be raised to 144 aircraft per year.
Further development
During the 1980s, McDonnell Douglas studied an AH-64B, featuring an updated cockpit, new fire control system and other upgrades. In 1988, funding was approved for a multi-stage upgrade program to improve sensor and weapon systems. Technological advance led to the program's cancellation in favor of more ambitious changes. In August 1990, development of the AH-64D Apache Longbow was approved by the Defense Acquisition Board. The first AH-64D prototype flew on 15 April 1992. Prototype testing ended in April 1995. During testing, six AH-64D helicopters were pitted against a bigger group of AH-64As. The results demonstrated the AH-64D to have a sevenfold increase in survivability and fourfold increase in lethality compared to the AH-64A. On 13 October 1995, full-scale production was approved; a $1.9-billion five-year contract was signed in August 1996 to upgrade 232 AH-64As into AH-64Ds. On 17 March 1997, the first production AH-64D flew. It was delivered on 31 March.Portions of the Apache are produced by other aerospace firms. AgustaWestland has produced a number of components for the Apache both for the international market and for the British Army's AgustaWestland Apache. Since 2004, Korea Aerospace Industries has been the sole manufacturer of the Apache's fuselage. Fuselage production had previously been performed by Teledyne Ryan Aeronautical. The transfer of fuselage production led to a prolonged legal dispute between Teledyne Ryan and Boeing.
The AH-64D program cost a total of $11 billion through 2007. In April 2006, Boeing was awarded a $67.6 million fixed-price contract for the remanufacture of several existing U.S. AH-64As to the AH-64D configuration. Between May 2009 and July 2011, a further five contracts were issued to remanufacture batches of AH-64As into AH-64Ds. Since 2008, nations operating the older Apaches have been urged to undertake modernization programs as support for the AH-64A is withdrawn.
By May 2019, Boeing tested in a wind tunnel a compound Apache scale model with a pusher propeller, a small wing to increase range and speed, and a counter-torque tail rotor like the cancelled Lockheed AH-56 Cheyenne of the 1960s. It competed for the U.S. Army's Future Long Range Assault Aircraft unveiled in April, developed from the Future Vertical Lift Capability Set 3 without the attack requirement, while the U.S. Army's FARA should replace the retired Bell OH-58 Kiowa scout and up to half of the AH-64 fleet.
Indian fuselage manufacturing facility
On 9 November 2015, Boeing and Tata Advanced Systems announced a joint venture to co-produce the fuselage of AH-64 in India for the global market. This was after the Indian Air Force ordered the helicopters. On 18 June 2016, the companies laid the foundation of the facility in the outskirts of Hyderabad. The joint venture was named Tata–Boeing Aerospace. In March 2018, the facility was inaugurated by Nirmala Sitharaman, the then Indian Defence Minister. On 1 June 2018, TBAL delivered the first Made-in-India fuselage to Boeing ahead of schedule. The fuselage would be then transported Boeing's AH-64 Apache manufacturing facility in Mesa, Arizona for final assembly. The facility will also deliver secondary structure and vertical spar boxes for the combat helicopter. On 23 July 2021, TBAL delivered the 100th Indian-made fuselage. By then, the facility also started delivering secondary structure and vertical spar boxes to Boeing. On 19 January 2023, TBAL delivered the first fuselage for the Indian Army's 6-chopper contract. Overall, over 190 fuselages were supplied by TBAL. The facility also became the sole manufacturer of Apache fuselage globally, in addition to supplying parts for Boeing 737, 777 and 787 aircraft. On 10 February 2025, TBAL delivered the 300th fuselage.As of 2018, the facility spans over an area of and is staffed by 350 workers at full production. The workforce, by 2023, grew to 900. As for the fuselages delivered, 90% of the components are being manufactured in India through more than 100 MSME suppliers.