More turbulence for USAF’s next-gen trainer

• Pentagon report details issues with T-7A Red Hawk’s ejection system. Tests revealed the system didn’t meet minimum safety requirements for the Air Force.
• T-7A was selected in 2018 to replace the USAF’s aging T-38 fleet.
• Environmental testing uncovered additional problems that need to be addressed.

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According to a new report from the Pentagon’s Office of the Director, Operational Test and Evaluation (DOT&E), there are serious issues with the emergency ejection system on the T-7A Red Hawk. Powered by a General Electric turbofan engine, the twin-tail, tandem-seat jet from Boeing was selected by the Air Force in 2018. The package came with a price tag of just over $9 billion for 351 aircraft, 46 simulators and an option to increase that total to 475 jets.

The final T-7A #RedHawk engineering and manufacturing development (EMD) jet recorded its first @USAirForce flight.

Thanks to the 416th Flight Test Squadron @EdwardsAFB for piloting this advanced trainer and its red tail legacy into the future! pic.twitter.com/iiJ1nzYtXI

— Boeing Defense (@BoeingDefense) December 13, 2024

The DOT&E report examined work across various programs for fiscal year 2024, which wrapped up in late September 2023. 

Here’s what the report found: 

“As reported in the FY22 and FY23 Annual Reports, the T-7A emergency escape system does not meet minimum safety requirements for the Air Force’s airworthiness certification and is currently operating with high-risk acceptance for airworthiness,” the report stated. “A February 2024 sled test showed improvement at medium-speed ejections for the ejection seat sequencing.”

However, it added, “The program executed a high-speed test in June 2024 where the seat sequenced correctly, but a seat hose interfered with the seat sequencer switch, which could lead to an incorrect ejection mode.”

As reported in the FY22 and FY23 Annual Reports, the T-7A emergency escape system does not meet minimum safety requirements for the Air Force’s airworthiness certification and is currently operating with high-risk acceptance for airworthiness.

Office of the Director, Operational Test and Evaluation

The new report also revealed that a redesigned canopy fracturing system pattern did not function properly in the same test. The program must complete seven more sled tests before the escape system can be certified for airworthiness. 

Researchers uncovered additional problems during environmental testing last year. They said those issues need to be addressed.

The Air Force has been working with Boeing to tackle these issues. However, the process has been challenging, resulting in significant delays. Officials have also reshuffled the program’s plans.

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The T-7A flew for the first time in 2023. As of December 2024, the Air Force had taken delivery of five pre-production test jets.