Tag Archives: F-35

Trump’s focus on F-35 costs may serve US well

Donald Trump’s latest tweet on the F-35 will cause Lockheed Martin executives to have a not-so-merry Christmas, while the opposite will be true in the Boeing board room. After meeting top executives from both companies and being briefed on the F-35 this week, Trump on Thursday said he has asked Boeing to ‘price-out a comparable F-18 Super Hornet’.

Lockheed Martin’s stock immediately went down again, mirroring the effect of Trump’s earlier tweet about the F-35. However, the president-elect criticism  probably is not pointed at the F-35 itself, but at the program’s costs. Trump has made it very clear now that he will not accept such overruns after he moves into the White House in January. At the same time, Donald Trump seems to be preparing for an arms race, even stating this week that the US should expand its nuclear capabilities.

Being the businessman that he is, Trump obviously wants to keep the costs of such an arms race down. He probably realizes that his country is at a disadvantage compared to Russia and China, who are able to produce weaponry against far lower costs. China for example is developing new stealthy jets at an impressive and alarming rate. In Russia, a single new Sukhoi T-50 is many millions and millions of dollars cheaper than a single new F-35. This is indeed worrying for Trump. The signs of an arms race are already there and not to be ignored.

When it comes to the Boeing F-18 Super Hornet as an alternative for the Lockheed Martin F-35 – that shouldn’t be taken too seriously. It will definitely not be as stealthy and not as capable in the domain of  gathering and spreading data. Also, the F-35 is getting closer to being fully combat ready every day.

But Trump most likely is not interested in ditching the F-35 in favour of a cheaper Super Hornet. He is interested in costs, and that may serve the US well in the end.

© 2016 Airheadsfly.com editor Elmer van Hest
Featured image (top): A US Air Force F-35A, seen at Luke Air Force Base in Arizona. (Image © Elmer van Hest)

Exclusive: spotlight on F-35 production in Italy

In an enormous rectangular building in Cameri, Italy, a group of people swarms over the grey object that among them is known as AL-5. To others, it is known as the fifth Lockheed Martin F-35A Lightning II for the Italian Air Force. But judging by the language used, it’s not Italians who seem to turn AL-5 inside out. They are Americans, employed by Lockheed Martin and the US Department of Defense (DoD). And their job at hand is quality inspection of a factory fresh, Italian-made F-35 Lightning II.

An F-35A inflight. (Image © Lockheed Martin)
Related reading: F-35 takes a hit – from Canada. (Image © Lockheed Martin)

Airheadsfly.com’s recently paid a very exclusive visit to the rather secretive F-35’s Final Assembly and Check Out (FACO) facility in Cameri, which is run by Leonardo Aircraft and which rolled out its first F-35 in March 2015. The FACO is the result of extensive negotiations involving Italy, the US, Lockheed Martin and Leonardo Aircraft prior to 2010.

Development of the site started as soon as the ink was put on the contract. When epxloring the facility, it is hard to image that this 22-building, one million square feet complex was raised from the ground up in just three years. It is one of only three F-35 final assembly lines in the world, the others being Lockheed Martin’s production plant in Forth Worth, Texas, and Mitsubishi’s FACO in Nagoya, Japan.

Cameri sees final assembly of F-35A and B models for Italy, plus  F-35As for the Royal Netherlands Air Force (RNLAF) in the future. Other potential customers  may follow as well. “So far, we have completed delivery of four jets to the Italian Air Force, and we’re getting ready to hand over AL-5 as well. The first four were flown to the US for pilot training, but the fifth will stay in Italy. It will be delivered to the 32nd Stormo (wing) at Amendola airbase soon”, says brigadier-general Giuseppe Lupoli, F-35 FACO program manager on behalf of the Italian Ministry of Defense.

(Image © Airheadsfly.com)
Work in progress on an F-35A for the Italian Air Force. Visible in the background is the first F-35B to be produced in Cameri. (Image © Airheadsfly.com)
An F-35A takes shape in one of 11 assembly docks in the Cameri FACO. (Image © Airheadsfly.com)
An F-35A takes shape in one of 11 assembly docks in the Cameri FACO. (Image © Airheadsfly.com)

Assembly

Situated in the center of the FACO is the assembly hall. It covers eleven assembly bays, in one of which Leonardo Aircraft employees now crawl under and over AL-8, the final aircraft of an initial order of eight F-35s from Italy. The same hall also covers five bays for future maintenace, repair and overhaul works on the Lightning II.

Whereas in Fort Worth the hugely expensive 5th generation fighter jets are manufactured on a moving production line, in Cameri an F-35 stays in a specific assembly bay for the whole build process, with parts being brought to the jet. “Our bay approach is certified by Lockheed Martin and elements of it have even been introduced in Fort Worth”, says Lupoli. At full speed, the Cameri FACO is said to be capable of delivering two new jets per month.

The first F-35 Lightning II from the assembly line in Italy (Image © Larry Bramblett / Lockheed Martin)
The first Cameri-built F-35 Lightning II was rolled out in March 2015.  (Image © Larry Bramblett / Lockheed Martin)

First F-35B

For now, production rate is not anywhere remotely near that. Most assembly bays remain unused and empty while awaiting a formal procurement decision from Rome. The exact numbers are debated for a considerable time already in Italy, but the country  currently is eyeing 52 more F-35As for its air force, plus 30 F-35B short takeoff/vertical landing (STOVL) variants to be used by both navy and air force.  Meanwhile, the FACO understandably needs to keep the production flow going. Lupoli: “Because of long lead times, we are indeed moving ahead with production of parts for the next batch of jets.” Indeed, during Airheadsfly.com’s visit the first Italian F-35B was seen in final assembly, along with more A-models for the air force.

Dutch jets

Also, 2019 will see production of the first F-35s for the Royal Netherlands Air Force. The RNLAF has for several years been performing operational test and evaluation (OT&E) with its first two Lightnings in the US and should initially see delivery of six more from Fort Worth. The remaining 29 out of 37 aircraft ordered are to be assembled in Cameri.

(Image © Airheadsfly.com)
In Cameri, F-35s also receive their stealthy coating. Here, a full scale mock up is used to test the FACO’s associated installation. (Image © Airheadsfly.com)

Quality

In the Netherlands some concerns were raised over the fact that a 90 million USD aircraft designed and ordered in the US, is to be manufactured in an Italian factory. Those concerns were mainly about quality control…. and that’s were those Americans swarming over AL-5 come in. Not one F-35 leaves this FACO without a US pilot test flying it and without personnel from both Lockheed Martin and US DoD performing an inspection that easily lasts a couple of days. Pieces of blue tape on AL-5’s stealthy coating mark the spots that apparently are not up to standard.

Although their number has been greatly reduced since production got underway, the presence of US personnel in Italy comes as no surprise given the sensitive nature of the F-35. Lupoli: “Even with an aircraft destined for the Italian Air Force, we first hand it over to US DoD personnel for inspection and acceptance. Only then does US DoD hand it back  to our own air force. By doing so, quality control here in Cameri is totally in line with the US standard.”

(Image © Airheadsfly.com)
US personnel inspects AL-5 before acceptance. Only then will US DoD hand the aircraft over to its customer, being the Italian Air Force. (Image © Airheadsfly.com)

Wings

Apart from complete jets, the FACO also produces full wing sets for use in Fort Worth, with a maximum capacity of 72 sets per year. Quality control is equally strict here. Experts check each wing before it is ‘closed’, which means the upper skin is joined with the lower skin, making components inside unreachable without extensive repair jobs. Recently, faulty insulation on piping inside the wing forced Lockheed Martin to do exactly that kind of work on dozens of F-35s. According to the Italians, the problem was not found on Cameri-made wings.

The work done is testimony of the skills acquired by Leonardo Aircraft employees in just a few years’ time. In total, F-35 works in Cameri should generate an estimated 6,000 Italian jobs and add 15.8 billion USD to the Italian economy.

Lifespan
The Cameri site is projected to be in operation for at least forty years, during which focus will shift more and more to maintance, repair and overhaul of European. Lupoli: “Over the next 15 years, we expect to reduce the number of assembly bays and turn those into additional bays for F-35 maintenance.”

That’s no surpise, given the fact that Cameri back in 2014 was appointed as  the sole provider of heavy F-35 airframe maintenance in Europe. But to maintain one of the world’s most advanced and expensive military jets, this facility will first have to build them. To a passing visitor such as Airheadsfly.com, it seems the FACO is ready to fill those empty assembly bays and do exactly that. It seems ready to fulfill its projected contribution to the Italian economy as well as European defense needs. All it needs, are more actual F-35s to build.

© 2016 Airheadsfly.com editor Elmer van Hest
Featured image (top): A view of F-35 production in Cameri. (Image © Airheadsfly.com)

The first F-35A for the Italian Air Force takes off from Cameri FACO (Image © Todd McQueen, Lockheed Martin
The first F-35A for the Italian Air Force took off from Cameri  in September 2015. (Image © Todd McQueen, Lockheed Martin)

The F-35 takes a hit – from Canada

The Lockheed Martin F-35A Lightning II on Tuesday 22 November took a major hit. Not in any mock 1 vs 1 dog fight or any large scale military exercise, but in the political arena. By choosing the F/A-18E/F Super Hornet as an interim solution to its immediate fighter jet needs, Canada is signalling that the F-35’s development takes to long and its price tag is to high.

Canada is looking to buy 18 Boeing F/A-18E/F Super Hornets as  immediate replacements of ageing ‘legacy’ model F-18 Hornets. If a deal with Boeing is finalized, delivery of new jets should take no more than two or three years.

With the F-35, that would take considerably longer, not to mention the fact that development and testing of this 5th generation fighter jet – and its software along with it – may not even be finished by then. Recent progress in the program still doesn’t mean the jet is capable of firing its internal gun, for example.

Later purchase

Canada has pondered and postponed an F-35 purchase for many years. Today’s selection of the Super Hornet does not exclude the possibility that the Canadian government in Ottawa may still purchase the F-35 at a later stage. However, the 400 billion USD weapons program has been the subject of much criticism in Canada, especially its 100 million USD per piece price tag.

A RAAF F-18 in flight (Image © Commonwealth of Australia, Department of Defence)
An F/A-18F Super Hornet.

Partner nation

Nevertheless, Canada’s choice is remarkable and concerning for Lockheed Martin and the F-35’s Joint Program Office (JPO) in Washington, since the country is a level 3 partner in the program. Other level 3 partners are Australia, Norway, Denmark, Turkey, all of which have selected the F-35 as their new fighter jet.

Unique

In fact, Canada now is unique in being the only partner nation in the program not to actually buy the F-35 – for now. By doing so, it’s industry will benefit from taking part in the program, without tax payers having to cough up billions of dollars to actually buy the jets. For other nations however, it means that their jets will have higher price tags, since fewer jets sold means that development and production costs per aircraft remain higher than anticipated. That will cause some sour faces in other partner nations.

A CF-188 is preparing for flight at Bagotville in Quebec (Image © Corporal Marc-André Gaudreault, Canadian Forces Combat Camera / DND-MDN)
One of Canada’s ageing ‘legacy’ Hornets. (Image © Corporal Marc-André Gaudreault, Canadian Forces Combat Camera / DND-MDN)

Reputation

Yes, both Lockheed Martin and Ottawa will downplay this and probably point to a possible Canadian fighter jet competition still to be held. But the truth is, it is a major hit for the JPO’s promise of lower unit costs and the F-35’s reputation – which saw a change for the better in 2016, partly due to appearances in the Netherlands and the UK.

It will be interesting to see what comes out of other fighter jet competitions that see the F-35 and Super Hornet go head to head, such as the current ones in Belgium and Finland. The former beat the latter earlier this year in Denmark. Following today’s decision in Canada, that makes the score even.

© 2016 Airheadsfly.com editor Elmer van Hest

 

First Japanese F-35 rolled out is amongst grounded jets

The first pictures leaked out several weeks ago  and the aircraft already took to the skies since, but Friday 23 September saw the official roll out ceremony for the very first Lockheed Martin F-35A Lightning II for the Japan Air Self Defense Force (JASDF).

The unveiled aircraft is one of four to be built by Lockheed Martin in Fort Worth, Texas. The remaining 38 JASDF Lightnings will be build in a brand new Final Assembly and Check-Out  (FACO) in Nagoya, Japan. Assembly of the first aircraft at this location is very much underway.

Irronically, the jet rolled out on Friday is amongst those suffering from a recently found problem, causing insulation to disolve in the aircraft’s fuel tanks. Dozens of F-35s have been grounded over this.

The introduction of the stealthy jet will mean the beginning of the end for the F-4 Phantom in Japanese service. The remaining F-4 fighters and RF-4 recconaissance jets are now centred at Hyakuri airbase, close to Tokyo. The F-35 will operate in the JASDF alongside Boeing F-15 Eagles and Mitsubishi F-2 jets, all produced locally.

The first Japanese jet, seen during its first flight in the US. (Image © Elmer van Hest)
The first Japanese jet, seen during its first flight in the US. (Image © Elmer van Hest)

The Japanese are known to paint jets in spectacular colors every now and then, but not so with this new F-35.  Even the traditional red Japanese markings have been subdued to grey.  Earlier this year, the Israelis – while not afraid to adorn their F-15s and F-16s with nice paint jobs – also refrained so from doing this with the F-35.

It begs the question: which air force will be the first to do some nice color blocking on an F-35?

© 2016 Airheadsfly.com editor Elmer van Hest

 

Norway spills the beans: dozens of F-35s affected by bad wiring

Faulty wiring has caused 15 Lockheed Martin F-35A’s to be grounded in the US, while 42 aircraft currently in production in Fort Worth are affected by the same problem. The news was  made public solely by the Royal Norwegian Air Force, which saw two of its four F-35s stationed at Luke Air Force Base in Arizona, affected by the problem.

The state-of-the-art and highly expensive F-35 uses its fuel tanks as part of its on-board cooling system. Several cooling lines have been installed inside the tanks to allow cooling liquid for the aircraft’s avionics and other systems to pass through. The lines are covered in insulating materials that in some cases have been found to decompose, leaving residue in the fuel.

The issue first came to light during inspection of a US aircraft at Luke, following which 14 more F-35s were found to be affected by the same problem. Among those are two jets that Norway received from Lockheed Martin earlier in 2016, leading to a decision by Norwegian authorities to temporarily suspend flight operations with these aircraft pending corrective measures.

According to the Norwegians the problem is not a design flaw, but instead is caused by a supplier using improper materials and improper sealing techniques for these specific parts. “I expect Lockheed Martin to identify the appropriate measures to correct this issue, and that they implement these as quickly as possible, says Major General Morten Klever, the director of the Norwegian F-35 Program Office.”

Lockheed Martin appears to have no choice, since an additional 42 jets currently on the production line have received parts from the same provider, including three Norwegian aircraft scheduled for delivery early next year.

Norway plans to procure up to 52 F-35A, and has so far received four aircraft. Beginning in 2017, Norway plans to receive six aircraft annually, and the F-35 will begin taking over missions from the current F-16-fleet in 2019. As of September 2016 more than 200 F-35s have been delivered, including test aircraft, which have completed more than 68 000 flight hours, including roughly four hundred hours with Norwegian F-35s.

© 2016 Airheadsfly.com editor Elmer van Hest