The F-35 stealth fighter jet suffers from hundreds of problems
and won’t be fully combat-capable before 2020, says a scathing report
from the Pentagon’s top evaluator. New issues keep cropping up, and
fixing them all may cost over $1 billion.
Dr. Michael Gilmore’s damning assessment is part of the massive
annual report for fiscal year 2016, and his
62-page dossier devoted
to the F-35 paints a grim picture of America’s much touted,futuristic
Joint Strike Fighter. The program, which began in 2001, was supposed to
deliver a fifth-generation jet serving the needs of the Air Force, the
Navy and the Marine Corps, achieving savings through a modular design.
Instead, it is 70 percent over initial cost estimates and years behind
schedule.
Dr. Gilmore, the Pentagon’s director of operational test &
evaluation (OTE) under President Barack Obama, is leaving the Department
of Defense as part of the regular change in politically appointed
officials. Though F-35 officials have continued to insist the jet is
doing just fine and that the problems found in operational testing were
being fixed rapidly, Gilmore’s final report makes it clear that he
doesn’t believe their reassurances.
“The Services have
designated 276 deficiencies in combat performance as ‘critical to
correct’ in Block 3F, but less than half of the critical deficiencies
were addressed with attempted corrections,” says Gilmore’s report, referring to problems in the F-35’s software.
“Deficiencies continue to be discovered at a rate of about 20 per month,” the report added.
“Much
more testing is needed to assess the cybersecurity structure of the air
vehicle and supporting logistics infrastructure system,” the report says,
“and to determine whether, and to what extent, vulnerabilities may have led to compromises of F-35 data.”
Worse
yet, the program is trying to skip many of the tests and declare the
systems development phase over early, shifting the testing to the
Initial Operational Test and Evaluation (IOT&E) process starting in
August 2017, the report noted. Rushing the tests means shifting the
risks onto operational testing, follow-on modernization, and to the
pilots intended to fly the planes into combat.
The F-35 program
office "has no plan to adequately fix and verify hundreds of these
deficiencies using flight testing within its currently planned schedule
and resources," Gilmore wrote.
“Multiple problems and delays
make it clear that the program will not be able to start IOT&E with
full combat capability until late CY18 or early CY19, at the soonest,”
meaning 2018 and 2019, respectively. Finalizing the systems development
phase would cost around $500 million, Gilmore noted, adding that the
Cost Assessment and Program Evaluation office’s estimate ranged up to
$1.125 billion.
A Lockheed Martin F-35 Lightning II fighter jet. © Gary Cameron / Reuters
In addition to software trouble, the jet is plagued by
structural problems. For example, the connection between the vertical
tail and the airframe is wearing out much faster than expected, while
arresting hooks are fraying after only one use. Engine nacelles are
overheating under certain flight tests, horizontal tail continues to
suffer heat damage, and the “excessive, violent” oscillations during
catapult launches of the naval F-35C version present a safety concern
for pilots.
Tests of the pilot escape system showed a risk of
serious neck injury or death for pilots weighing less than 136 pounds
(61kg), who remain restricted from flying the F-35.
On the
maintenance side, technicians are required to physically connect the
Portable Maintenance Aid (PMA) laptops to the aircraft in order to
conduct most activities. If the PMA fails to connect to the aircraft
properly and technicians unplug it prematurely, the laptop cannot
connect to another aircraft until it is reset by an Automatic Logistics
Information System (ALIS) administrator,
“which can be a lengthy process.”
Given all that, the Department of Defense should consider committing to a
“block buy” of the jets, since in their current state the F-35 does not fit the legal requirements and the Pentagon’s
“fly before you buy” approach to purchases, Gilmore’s report concluded.
The
F-35 is a single-seat, single-engine aircraft that comes in three
versions: the F-35A for the Air Force; the F-35B for the US Marine
Corps; and the F-35C for the US Navy. It is being developed by Lockheed
Martin, with additional funding from Australia, Canada, Denmark, Italy,
Norway, the United Kingdom and Turkey. Israel and Japan have also placed
orders for the jet.