Slashdot Mirror


Air Force Grounds $400 Billion F-35s Because of 'Peeling and Crumbling' Insulation (washingtonpost.com)

An anonymous Slashdot reader quotes the Washington Post: Less than two months after declaring the controversial F-35 Joint Strike Fighter ready for combat, the Air Force on Friday announced that it was temporarily grounding 15 of the jets after it discovered that insulation was "peeling and crumbling" inside the fuel tanks. The setback is the latest for the $400 billion system, the most expensive in the history of the Pentagon. The problem comes as the program, which for years faced billions of dollars in cost overruns and significant schedule delays, had begun to make strides.

The insulation problem affects a total of 57 aircraft, the Air Force said, 42 of which are still in production... In a statement, Lockheed Martin said that "the issue is confined to one supplier source and one batch of parts." It emphasized that "this is not a technical or design issue; it is a supply chain manufacturing quality issue..." It is unclear how long the aircraft would be grounded, how long the problem would take to fix or what the larger affect on the program would be.

âoeWhile nearing completion, the F-35 is still in development, and challenges are to be expected," said an Air Force spokeswoman, adding "The F-35 program has a proven track record of solving issues as they arise, and we're confident we'll continue to do so."

32 of 193 comments (clear)

  1. Conventional warfare is dead by barrywalker · · Score: 2, Insightful

    I want my money back. This pig isn't going to fly, and even if it does, this type of warfare is dead. Future wars will be fought with pilotless (and maybe even autonomous) vehicles. Cyber warfare will also be much more devastating than whatever damage this overpriced toy can produce. We should dock the pay of every congress critter who voted for it until it's paid back in full.

    1. Re: Conventional warfare is dead by dna_(c)(tm)(r) · · Score: 3, Insightful

      "The F-35 program has a proven track record of solving issues as they arise, and we're confident we'll continue to do so."

      That's newspeak for "this program had an abnormal amount of bad problems."

      Also good news that the total cost diminishes with time, 1 trillion to 0.4 trillion in two years time. By 2018 it will be for free.

    2. Re:Conventional warfare is dead by Opportunist · · Score: 4, Insightful

      Nobody cares if that pig flies as long as its pork fills a few barrels.

      --
      We used to have a Bill of Rights. Now, with the rights gone, all we have left is the bill.
    3. Re: Conventional warfare is dead by amiga3D · · Score: 2

      Just another new lawn dart. It's going to replace the F-16 as the worst fighter in the arsenal.

    4. Re: Conventional warfare is dead by blindseer · · Score: 4, Interesting

      I hear this often as a complaint against cost plus contracts but I believe that people do not understand why such contracts are necessary.

      The US government, or any government really, needs stuff that simply cannot be obtained on the open market. This is especially true if you want to keep things secret, companies that go bankrupt tend to not keep things secret for many reasons. If the government makes a contract at a set price then no company in their right mind would sign off, it would simply be too much risk.

      A lot of companies will sign a contract for a product knowing it will be a loss because they are gambling that the product can be sold at a profit to subsequent customers. This is often how new passenger aircraft will get built. The first person to buy such an aircraft will get a deep discount knowing that they are experimenting. They hope the costs of working out the bugs will be offset by their discount. Later customers for the aircraft will pay a higher price, and do so willingly, because they are getting an aircraft that is proven to be of value.

      This also works for passenger aircraft because there is a larger number of airframes to spread development cost over. There were about 1500 F-15 fighters built but over 9000 Boeing 737 passenger and freight airframes built.

      When building a military aircraft you have only one customer, and no means to make a profit if that customer backs out. If the government wants someone to build anything for them, and only for them, then they will have to make a promise of a profit for that company.

      I know someone is just waiting to point out that the F-35 has a dozen "customers" but that is a moot point here. Of the approximately 2000 F-35 airframes ordered the US government will buy 1800 of them, this is effectively no different than if the US was the only customer.

      I'm sure Lockheed just loves these "setbacks" because it makes them a profit. Forget the fact that setbacks make it that much more difficult to get future contracts. Forget the fact that setbacks distract from other potentially money making efforts. Forget the fact that even a big "evil" corporation that builds "killing machines" has people that work for them and people don't like to see other people die because the product they produced failed to protect their lives.

      I really need to stop replying to anonymous cowards but I could not let this go by for some reason.

      --
      I am armed because I am free. I am free because I am armed.
    5. Re: Conventional warfare is dead by lgw · · Score: 2

      Cruise missiles and ICBMs have their mission set before launch. The whole point of fighters (and drones) is that they don't - otherwise, just use a missile. Until SkyNet is ready, we'll be flying drones remotely, and that means jamming and EMP are issues.

      Civilian deaths are acceptable as long as they aren't ours

      This has been true for every war in history, but we've actually tried a little to minimize this recently. The fact that civilians still inevitably die in war isn't some great failing of the system - war just sucks. It's good to do what we can, but also to remember we've spend many years now fighting enemies for whom civilian casualties are the goal, so lets not compromise our effectiveness too much, as that means more total civilian casualties.

      --
      Socialism: a lie told by totalitarians and believed by fools.
    6. Re: Conventional warfare is dead by knightghost · · Score: 4, Insightful

      The Fed will never end a massive pork barrel project like this, so suggesting they "could" is unreasonable and very inaccurate. "Could" that has a very low chance effectively means 0.

    7. Re: Conventional warfare is dead by Richard_at_work · · Score: 5, Interesting

      A modern Tomahawk cruise missile has an inventory cost of around $750,000. Once you use it, you have to replace it at full cost.

      An F-35A's flight cost is around $40,000 per flight hour (google exactly what a flight hour is) and is expected to fall to around $30,000/fh in due course.

      A 5 hour mission designed to hit 5 targets means 5 Tomahawk missiles expended, at a cost of $3.75million for the mission.

      The same mission for the F-35A would cost, currently, $200,000 in flight hours, and $135,000 for 5 Mk.82 bombs with JDAM kits - a total mission cost of $335,000.

      The mission cost difference is a saving of about $3.4Million, give or take.

      So, with a current purchase cost of $98Million for a LRIP (low rate initial production) F-35A, it would only need to fly 30 or so missions to be worth while, over the cost of continually buying expendable cruise missiles to carry out the same missions.

      How does that work out in real life?

      During the second Gulf War air campaign, there were 20,753 combat sorties by coalition aircraft, during which they used 18,467 smart bombs and 9,251 dumb bombs.

      That war, if fought by using cruise missiles solely, would set you back $20.8Billion just to replace your expended ordnance.

      Take the aircraft costs out of the equation for a moment - replacing all those expended munitions with JDAMs would cost $748Million, leaving a balance of more than $20Billion to cover the operating costs of the aircraft...

      You could buy a fleet of 100 F-35s and operate them for just under half their entire projected life on the balance alone...

    8. Re: Conventional warfare is dead by amiga3D · · Score: 2

      Both.

    9. Re: Conventional warfare is dead by greenfruitsalad · · Score: 4, Funny

      10 years ago, i'd have burst your bubble with facts and combat stats. these days, i'm just gonna check if kids are asleep yet and eat a sandwich.

    10. Re: Conventional warfare is dead by LifesABeach · · Score: 3, Funny

      Technology will only get more expensive; has to be somebodies law. And why hasn't an VTOL SR-71 with a gatling laser been certified? Dam, I'm starting to fidget again.

    11. Re: Conventional warfare is dead by BarbaraHudson · · Score: 2

      Cruise missiles don't have to be guided. And when was the last time we had a war directly between two major powers?

      The Russians showed just how effective a cruise missile campaign can be in Syria. The Russian KH-101 stealth cruise missile (max range 5,500 km / 3,400 miles, with a rumored maximum of up to 10,000 km, nuclear variant KH-102) wasn't hampered by range constraints. The Chinese also have them. You don't need an F35 for countries like Syria, and they will be shot down on approach in wars with China and Russia, so what's the point of having the F35 again? Especially since the combat radius is only 600 miles (you can't use the ferry range, since that is one-way). An F35 taking off from Germany wouldn't even get to St. Petersburg before having to turn back, and Moscow isn't possible even as a one-way mission.

      --
      "Transparent" is a shit show that trades on every stereotype going. A man in drag is NOT a transsexual.
    12. Re: Conventional warfare is dead by Man+On+Pink+Corner · · Score: 2

      Don't worry. As soon as they find oil on Mars, they'll change their tune.

    13. Re:Conventional warfare is dead by Man+On+Pink+Corner · · Score: 2

      Drones may work well against unsophisticated opponents with minimal resources (the only place they've been used so far). But I have a hard time believing that they would be effective in a real war, one with opponents that have sophisticated jamming & vast resources.

      I used to think that way, too, and then I saw a computer beat a 9-dan Go player within an inch of his life.

      Time to change your mind.

  2. Even in light of this, we're self congratulatory! by bogaboga · · Score: 4, Interesting

    This is a piece from CBS

    Lt. Col. David Berke says there's no comparison between the F-35 and today's jet fighters.

    David Berke: I'm telling you, having flown those other airplanes it's not even close at how good this airplane is and what this airplane will do for us.

    David Martin: We have planes that are as fast as this.

    David Berke: You bet.

    David Martin: And can maneuver just as sharply as this one.

    David Berke: Sure.

    The Russians must be laughing!

    The F-35's radars, cameras and antennas would scan for 360 degrees around the plane searching for threats and projecting, for example, the altitude and speed of an enemy aircraft, onto the visor of a helmet custom-fitted to each pilot's head.

    They have had this technology in their SU-30s for at leat 4 years!

  3. Not the same by Anonymous Coward · · Score: 4, Interesting

    I worked on A-10s back in the early 80s. What a gorgeous, well-designed bird. Almost no real flaws. The old aviation companies were actually better. Republic, Fairchild, McDonnell Douglas, you name it. There is a reason why the F-16s and F-15s are still the backbone of the Air Force. Nothing else comes close. Likewise, nothing touches the A-10 for its intended role, and the Air Force cannot wait to get rid of it. Yes, the air frames are old, but the avionics packages are updated constantly, as are the engine parts and other critical pieces like stabilizers, etc., are fabricated in shops on various bases. The A-10 is the king at ground support.

    Methinks the military is trying so hard to design and develop a do-it-all bird they are not seeing the forest for the trees. The US military has the unfortunate habit of using birds designed for one thing try and fulfill other or all roles. They want this bird to DO IT ALL. This rarely, if ever, works. Hence the F-16 and F-15 are still kings of the sky.

    Case in point is the Republic F-105, likely the best light bomber the Air Force ever had. It was developed in the 1950s to quickly run nukes into and out of Europe. Had an internal bomb bay. It was the largest and fastest jet of its type when it went live in the inventory. Vietnam came around and they used it for bombing runs and dogfighting (something it was not designed to do). The F-105 carried more than a WWII B-17. They ended up using them as Wild Weasels, a role for which they excelled. Still my favorite AF bird ever.

    1. Re:Not the same by BarbaraHudson · · Score: 2

      Not to worry - once the F-35 is scrapped / sidelined, they'll re-re-refurb a bunch of B-52s as attack craft. New delta wings, new engines, new avionics, new weapons systems - see "Flight of the Old Dog",. Further variants of the EB-52 Megafortress.

      --
      "Transparent" is a shit show that trades on every stereotype going. A man in drag is NOT a transsexual.
    2. Re:Not the same by AF_Cheddar_Head · · Score: 3, Interesting

      As to drones, a significant portion of the AF is fighting them, pilots like flying and with more drones you get fewer seats for the pilots to sit in. Guess what the majority of the generals did as young officers, bingo they flew fighters.

      Once you get to be a Colonel you rarely fly but the ex-flyers are the ones that get promoted most often. Hell even a couple of the Cyber commanders were fighter pilots. You read that right not Computer guys but fighter pilots.

  4. Golden Rule by jargonburn · · Score: 2

    "The F-35 program has a proven track record of solving issues as they arise, and we're confident we'll continue to do so."

    Funny, isn't it? If you throw enough money at most problems, they go seem to go away! From almost start to finish, this "program" has been an exercise in "work richer, not smarter".

  5. One Plane by Ann+Coulter · · Score: 4, Funny

    We are getting close to having a one plane military.

    Law Number XVI: In the year 2054, the entire defense budget will purchase just one aircraft. This aircraft will have to be shared by the Air Force and Navy 3-1/2 days each per week except for leap year, when it will be made available to the Marines for the extra day.

    https://en.wikipedia.org/wiki/...

  6. Something I saw 1st hand there... apk by Anonymous Coward · · Score: 4, Interesting

    See subject: While working @ Lockheed Martin coding. Each day I had to pass thru a hangar (accompanied by a Colonel, who by now must be retired) where they were working on all types of planes (some in 'clean room' type settings) - he noticed I'd look over @ the far end of the hangar each time we passed. He inquired why. I told him I was looking @ a sign there that said:

    "Do your best work: Our young men & women's lives ride on it".

    This affected me personally since my brother is an officer in the military (about to retire though). I don't want him to die, let alone due to shoddy workmanship!

    He then said "Look kid, get used to one thing - the ONLY reason we got this contract was because we're the lowest bidder & build crap - that's how the REAL WORLD really works - so do NOT believe that sign!"

    To which I was astounded (especially considering how much money they had available considering it's nigh limitless from taxpayers - you'd think they'd have Quality Control assuring that wouldn't happen... they don't).

    So he took me into a troop carrier type plane & showed me the stud metal frames that were supposed to have iirc, 16 rivets each & instead, only used like 8. This was how they were able to do it, pinching pennies cutting corners.

    * I was NEVER the same after that & it was in 1996 - very VERY early in my career professionally in computers.

    I took off after that job was done & instead decided to work for things other than the military industrial complex (i.e. - I jumped to Bell South to work on the 1996 Atlanta Olympics project to allow their workers to do what is common place now via remote desktop (except we used Windows NT & Citrix (Pentium I 133mhz laptops & 32mb of RAM each, powerful machine then) via IBM Thinkpads into an Ascend Gateway via 56k dialup modems (they said it couldn't be done but myself & some DEC engineers made it work so they could work from home during the traffic jams to go into downtown Atlanta to work) - this was a better more noble effort than building war machines imo, especially ones built VERY subpar)...

    APK

    P.S.=> Money truly is the root of evil in this world - so much so, they don't give a flying "f" (pun intended) if our soldiers ride on junk... apk

  7. Re:Even in light of this, we're self congratulator by Anonymous Coward · · Score: 5, Insightful

    I hate the f-35, waste of money. But... that's a little bit disingenuous.

    Modern fighter jets are not rated solely on speed and manoeuvrability. Range, ceiling, avionics, weapons and all the rest are what make it a proper piece of kit. Dogfighting is low on the list of priorities in 2016.

    The Russians are laughing all right, but this is way down the list. I bet invading the Ukraine with almost no repercussions has them grinning widely. Trump expressing his willingness to ditch NATO probably has probably garnered a few giggles as well.

  8. On the Inside? by Sir+Holo · · Score: 3, Interesting

    Insulation on the inside of the fuel tanks? Who puts insulation on the inside of a fuel tank?

    Reading between the lines, it is probably an anti-corrosion coating, not some foam or fiberglass.

    There's really only one product on the market for this, from ATFI, and the company relies upon knowingly upon falsified data-analysis to make the sale. ATFI bragged about their contract as a subcontractor to the F-35 in a press release a year or two ago . . .

    Looking today, I see that ATFI has disabled their RSS scroller, and has disabled their previously-functioning link NEWS menu-link at the top of their website.

    Huh. No better way to show that they are the guilty party, eh?

    1. Re:On the Inside? by Anonymous Coward · · Score: 2, Interesting

      I don't think its really intended for insulation, though it probably has some insulating properties. From what I can gather it is some kind of foam that is intended to prevent tank fires, fuel sloshing and as part of the aircraft leak prevention measures.

      https://en.wikipedia.org/wiki/Self-sealing_fuel_tank

  9. Times change by AF_Cheddar_Head · · Score: 4, Interesting

    All the base level Fab shops are shutdown, manpower cuts. Fab work is done at depot or outsourced to contractor facilities. Sucks when you are in-country.

    The A-10 is a simple, single purpose bird. Really good at one job, destroying ground vehicles. The Army tries to tell us that the choppers are just as good until you tell them they aren't getting any A-10 air support. The USAF has never been fond of the close air support mission, not very glamorous.

    The bean counters always think a multi-purpose bird makes fiscal sense, that is until you actually try to build one. It works better to build a single purpose aircraft, the F-15 comes to mind then modify the basic airframe for other missions. AKA the F-15E.

    Worked at the 682 ASOC supporting ROMAD/TACP and ALOs.

    1. Re:Times change by JustAnotherOldGuy · · Score: 2, Funny

      Agreed.

      The A-10 and the F-15 are arguably the two greatest airborne weapons platforms ever built. They have long, well-proven track records showing that pound-for-pound no other pair of aircraft can match, period. They worked so well that we had to dream up some ridiculous bullshit reasons to replace them.

      Time and time again the A-10 has shown that it is the single most effective ground support plane ever built, and the F-15 is still patrolling the skies shooting down everything that's dumb enough to fly up to challenge it. The Israeli version of the F-15 rivals both the F-22 and the F-35, and in a protracted fight would probably wipe them from the skies while the F-35 pilot was busy rebooting his flight computer.

      -------------

      Thank you for calling ITI Advanced Combat Systems

      Please press 1 if you are in a combat situation other wise please hold for the next technician...
      beep
      Please in put your mission number...
      beep boop beep booop beeep boop beep boop beep beeep boop boop beep boop beep
      Mission verification complete we will now transfer you to a support technician... (...hold music...)

      Thank you for calling ITI my name is nahmeed how may I be helping you?

      Look buddy my radar is froze up and I'm dodging a couple of MIGs at the moment how about you fix this thing so I can take these suckers out.

      I'm sorry to hear about that sir what ITI system are you calling about?
      The radar!!
      I understand sir but we have a lot of radar systems do you know the model number?
      No! ... its the radar in the f-35.

      Ok very good sir I can look that up. please hold ... (...more hold music...)

      Sir you still there ??
      Yes I am I don't know how much longer I'm going to be able to shake these MIGs.
      Thats fine sir, can you tell me what firmware revision of the radar you are using?

      What?? I don't know all I know is that its stuck with the same blips thats been on the screen for the last 15 minutes and nothing has changed. Look just log in and fix it.

      I would be happy to be helping you sir. Let me know when you have landed the plane and come to a full stop and all weapon systems are in their safe position.

      Are you kidding me?? I can't land this plane right now this MIG will make mince meat of me once I stop evasive maneuvers!

      Ah I see sir unfortunately I can not help you until the planes is at a full stop and all weapons are safe.

      Is there any thing else I can be doing for you?

      Yeah how about you.... BOOM*&@*shzzzzttzzzzzzztzzzztzssssssstssssss

      Sir hello are you there?
      Hello sir??
      Thank you for calling ITI I hope you found this session helpful please reply to the survey at the end of this call. have a good day

      --
      Just cruising through this digital world at 33 1/3 rpm...
  10. Future warfare by sjbe · · Score: 3, Informative

    Future wars will be fought with pilotless (and maybe even autonomous) vehicles.

    Some will, some won't. You won't see large scale remote operated vehicles between major powers because they have one huge weakness - namely they can be jammed. They're useful against third world countries with limited military resources. I wouldn't have nearly so much faith in them against a major power like Russia or China. Autonomous fighting vehicles are not only not ready for combat yet, it's not clear that they are a good idea at all for a host of both practical and ethical reasons. Even if they manage to deal with those concerns adequately (and I doubt they will) we're still quite a long ways from having practical autonomous weapons platforms. (If the phrase "autonomous weapons platform" doesn't scare you there is something wrong with you)

    Cyber warfare will also be much more devastating than whatever damage this overpriced toy can produce.

    Not any time soon. Maybe someday but that day is a ways off. Right now bombs and missiles have a lot more power to shut down the infrastucture of a country than any hacker. Go to Syria and tell me how much damage has been done there with just conventional weapons versus hacking. The difference isn't even close and it's likely to remain that way for quite some time to come. Cyber warfare can cause some serious problems but it's a rather awkward way to kill them in any meaningful numbers.

    We should dock the pay of every congress critter who voted for it until it's paid back in full.

    Good luck with that.

  11. MF'ing Lockheed... by irving47 · · Score: 2

    https://en.wikipedia.org/wiki/Space_Shuttle_external_tank

    Who you NOT gonna call when getting your fuel insulated. (internal OR external)

    --
    I had a sucky sig.
  12. Re:"proven track record of solving issues.." by hey! · · Score: 2

    As an engineer I understand how a "track record of solving issues" works. You only get competency points for resolving an unexpected issue when you deliver the project on time.

    --
    Post may contain irony: discontinue use if experiencing mood swings, nausea or elevated blood pressure.
  13. Re:So not combat ready then. by hey! · · Score: 2

    "Combat Ready" is being used in a highly contrived way. It does NOT mean any of the following things:

    (1) That the system works like it is supposed to.
    (2) That the system in its current state is ready to provide a valuable set of capabilities in any real situation.
    (3) That you would even remotely consider operating the system in its current state in a hostile environment.

    What "Combat Ready" means is that it meets a set of criteria designed, Texas Sharpshooter style, around the system's current progress. You could theoretically fly one of these things into a hostile environment and have it release a weapon, but you'd have no reason to except to make a political point.

    I think it's a fair bet that if we get into any conflicts in the next three or four years any use of F35s will be carefully scripted. The dangerous work will be done by more mature, actually "combat ready" aircraft.

    --
    Post may contain irony: discontinue use if experiencing mood swings, nausea or elevated blood pressure.
  14. Funny definition of autonomous by AF_Cheddar_Head · · Score: 4, Insightful

    By your definition a bullet is autonomous. once an ICBM is launched or a JDAM is released you cannot change its target. Just like a bullet.

    A truly autonomous weapon is capable of evaluating the on-going/changing situation and selecting the best target and attacking it, none of your examples is capable of this.

  15. F16 was the only fighter to fight the trend by rbrander · · Score: 2

    Col. Jim Burton's "The Pentagon Wars" is back in print. While the Kelsey Grammer/Carey Elwes comedy movie is focused on their reluctance to test the Bradley Fighting Vehicle, much of the book is about the development of the F-16 by the "Fighter Mafia" - Col. John Boyd, Pierre Sprey, Chuck Finney, and designer Harry Hilliker - and how how hard they had to fight to get the F-16 built and accepted.
    The F-16 hate in this forum could be coming from the 3- and 4-stars that wanted another standard Pentagon product: twice the weight and twice the price of the aircraft that came before it. But the F-16 was lighter and cheaper than the F-15 and focused laserlike on the job of dogfighting.
    The F-35 has finally gone as far as you can go in the other direction: multi-multi-purpose, does everything, but the weight and especially the cost are almost comically bloated.

    The question is not whether an F-35 could beat an F-16: it's whether a billion dollars of F-35 could beat a billion dollars of F-16s. And that's not even up for discussion.