The US Army’s Bradley Remanufacture Program

Latest updates[?]:

The US Army has awarded LOC Performance a $49.1 million contract modification to an existing order for Bradley Fighting Vehicle modification kits and installation. Under the terms of the deal, LOC will produce and supply and additional 276 Bradley Engineering Change Proposal 1 kits and two sets of spare parts, which will be used to upgrade Bradley Fighting Vehicles weight-bearing systems and underbelly armor. Work will be conducted at Plymouth, Minn. with a completion date scheduled for April 30, 2019. The Engineering Change Proposal 1 installs heavy load-bearing tracks, torsion bars to restore ground clearance and improved underbelly armor on the Bradleys. This in turn improves the vehicle's capability to handle the stress placed on its chassis caused by the installation of armor upgrades and Bradley Urban Survivability Kits.

In the 1970s, middle eastern wars demonstrated that tanks without infantry screens were vulnerable to infantry with anti-tank missiles. Unfortunately, armored personnel carriers were easy prey for enemy tanks, and sometimes had trouble just keeping up with friendly tanks like America’s 60+ ton, 50+ mph M1 Abrams. In response, the Americans rethought the armored personnel carrier, taking a page from the Soviet book. They created a more heavily armored, faster “Infantry Fighting Vehicle” named after WW2 General Omar “the soldier’s general” Bradley, and gave it an offensive punch of its own. M2/M3 tracked, armored IFVs can carry infantry – but they also have 25mm Bushmaster cannons, networked targeting sensors, and even TOW anti-armor or Stinger anti-aircraft missiles at their disposal.

Even well-serviced vehicles must suffer the pangs of age and wear, however, and the pace of electronics breakthroughs is far faster than the Army’s vehicle replacement cycle. The US Army plans to keep its Bradley fleet for some time to come, and new technologies have made it wise to upgrade part of that fleet while renewing the vehicles. Hence the remanufacture program, which complements the restore-only RESET programs.

This free-to-view DII Spotlight article explains the differences between the Bradley variants involved, details the re-manufacture process, offers additional research sources, and covers associated contracts from FY 1999 to the present.

Timely Defenders: Keeping Patriots in Shape

The USA’s MIM-104 Phased Array Tracking Radar Intercept On Target (PATRIOT) anti-air missile system offers an advanced backbone for medium-range air defense, and short-range ballistic missile defense, to America and its allies. This article covers domestic and foreign purchase requests and contracts for Patriot systems. It also compiles information about the engineering service contracts that upgrade these systems, ensure that they continue to work, and integrate them with wider command and defense systems.

The Patriot missile franchise’s future appears assured. At present, 12 nations have chosen it as a key component of their air and missile defense systems: the USA, Germany, Greece, Japan, Israel, Kuwait, The Netherlands, Saudi Arabia, South Korea, Spain, Taiwan and the UAE. Poland, Qatar, and Turkey have all indicated varying levels of interest, and some existing customers are looking to upgrade their systems.

The C-130J: New Hercules & Old Bottlenecks

The C-130 Hercules remains one of the longest-running aerospace manufacturing programs of all time. Since 1956, over 40 models and variants have served as the tactical airlift backbone for over 50 nations. The C-130J looks similar, but the number of changes almost makes it a new aircraft. Those changes also created issues; the program has been the focus of a great deal of controversy in America – and even of a full program restructuring in 2006. Some early concerns from critics were put to rest when the C-130J demonstrated in-theater performance on the front lines that was a major improvement over its C-130E/H predecessors. A valid follow-on question might be: does it break the bottleneck limitations that have hobbled a number of multi-billion dollar US Army vehicle development programs?

C-130J customers now include Australia, Britain, Canada, Denmark, India, Israel, Iraq, Italy, Kuwait, Norway, Oman, Qatar, Saudi Arabia, South Korea, Tunisia, and the United States. American C-130J purchases are taking place under both annual budgets and supplemental wartime funding, in order to replace tactical transport and special forces fleets that are flying old aircraft and in dire need of major repairs. This DID FOCUS Article describes the C-130J, examines the bottleneck issue, covers global developments for the C-130J program, and looks at present and emerging competitors.

F-15SG: Singapore’s RSAF Decides to Fly Like An Eagle

At the dawn of the 21st century, Singapore decided that it needed a new aircraft to replace its often-upgraded A-4SU Super Skyhawks. This was hardly surprising; John McCain had been flying an older model A-4 Skyhawk when he was shot down during the Vietnam War. The decision to require a twin-engine aircraft eliminated the JAS-39 Gripen and F-16E/F Block 60 from the competition, and the F/A-18E/F Super Hornet and Sukhoi Su-30 family were also scratched. That left just 3 finalists: Boeing’s F-15 Strike Eagle, France’s Rafale, and the Eurofighter Typhoon. Limited air-to-ground capabilities and a slow upgrade schedule splashed the Eurofighter, leaving just 2 contenders still flying.

September 2005 releases tapped Boeing as the winner, and the deal was done in December 2005. The order eventually rose to 24 planes, which was good news for Boeing: Singapore’s F-15SGs, and South Korea’s 2 F-15K orders, kept the assembly line open long enough for a huge win in Saudi Arabia, and the prospect of more orders. Singapore has legitimate grounds to argue that they currently fly the world’s most advanced version of the F-15 Strike Eagle…

EA-18G Program: The USA’s Electronic Growler

The USA’s electronic attack fighters are a unique, overworked, and nearly obsolete capability. With the retirement of the US Air Force’s long-range EF-111 Raven “Spark ‘Vark,” the aging 4-seat EA-6B Prowlers became the USA’s only remaining fighter for radar jamming, communications jamming and information operations like signals interception [1]. Despite their age and performance limits, they’ve been predictably busy on the front lines, used for everything from escorting strike aircraft against heavily defended targets, to disrupting enemy IED land mine attacks by jamming all radio signals in an area.

All airframes have lifespan limits, however, and the EA-6B is no exception. The USA’s new electronic warfare aircraft will be based on Boeing’s 2-seat F/A-18F Super Hornet multi-role fighter, and has 90% commonality with its counterpart. That will give it decent self-defense capabilities, as well as electronic attack potential. At present, however, the EA-18G is slated to be the only dedicated electronic warfare aircraft in the USA’s future force. Since the USA is currently the only western country with such aircraft, the US Navy’s EA-18G fleet would become the sole source of tactical jamming support for NATO and allied air forces as well.

DID’s FOCUS articles offer in-depth, updated looks at significant military programs of record. This article describes the EA-18G aircraft and its key systems, outlining the program, and keeping track of ongoing developments, contracts, etc. that affect the program.

CH-53K: The U.S. Marines’ HLR Helicopter Program

The U.S. Marines have a problem. They rely on their CH-53E Super Stallion medium-heavy lift helicopters to move troops, vehicles, and supplies off of their ships. But the helicopters are wearing out. Fast. The pace demanded by the Global War on Terror is relentless, and usage rates are 3 times normal. Attrition is taking its toll. Over the past few years, CH-53s have been recalled from “boneyard” storage at Davis-Monthan AFB in Tucson, AZ, in order to maintain fleet numbers in the face of recent losses and forced retirements. Now, there are no flyable spares left.

Enter the Heavy Lift Replacement (HLR) program, now known as the CH-53K. It aims to offer notable performance improvements over the CH-53E, in a similar airframe. The question is whether its service entry delay to 2018-2019 will come too late to offset a serious decline in Marine aviation.

LPD-17 San Antonio Class: The USA’s New Amphibious Ships

LPD-17 San Antonio class amphibious assault support vessels are just entering service with the US Navy, and 11 ships of this class are eventually slated to replace up to 41 previous ships. Much like their smaller predecessors, their mission is to embark, transport, land, and support elements of a US Marine Corps Landing Force. The difference is found in these ships’ size, their cost, and the capabilities and technologies used to perform those missions. Among other additions, this new ship is designed to operate the Marines’ new MV-22 Osprey tilt-rotor aircraft, alongside the standard well decks for hovercraft and amphibious armored personnel carriers.

While its design incorporates notable advances, the number of serious issues encountered in this ship class have been much higher than usual, and more extensive. The New Orleans shipyard to which most of this contract was assigned appears to be part of the problem. Initial ships have been criticized, often, for sub-standard workmanship, and it took 2 1/2 years after the initial ship of class was delivered before any of them could be sent on an operational cruise. Whereupon the USS San Antonio promptly found itself laid up Bahrain, due to oil leaks. It hasn’t been the only ship of its class hurt by serious mechanical issues. Meanwhile, costs are almost twice the originally promised amounts, reaching over $1.6 billion per ship – 2 to 3 times as much as many foreign LPDs like the Rotterdam Class, and more than 10 times as much as Singapore’s 6,600 ton Endurance Class LPD. This article covers the LPD-17 San Antonio Class program, including its technologies, its problems, and ongoing contracts and events.

LCS: The USA’s Littoral Combat Ships

Exploit simplicity, numbers, the pace of technology development in electronics and robotics, and fast reconfiguration. That was the US Navy’s idea for the low-end backbone of its future surface combatant fleet. Inspired by successful experiments like Denmark’s Standard Flex ships, the US Navy’s $35+ billion “Littoral Combat Ship” program was intended to create a new generation of affordable surface combatants that could operate in dangerous shallow and near-shore environments, while remaining affordable and capable throughout their lifetimes.

It hasn’t worked that way. In practice, the Navy hasn’t been able to reconcile what they wanted with the capabilities needed to perform primary naval missions, or with what could be delivered for the sums available. The LCS program has changed its fundamental acquisition plan 4 times since 2005, and canceled contracts with both competing teams during this period, without escaping any of its fundamental issues. Now, the program looks set to end early. This public-access FOCUS article offer a wealth of research material, alongside looks at the LCS program’s designs, industry teams procurement plans, military controversies, budgets and contracts.

P-8 Poseidon MMA: Long-Range Maritime Patrol, and More

Maritime surveillance and patrol is becoming more and more important, but the USA’s P-3 Orion turboprop fleet is falling apart. The P-7 Long Range Air ASW (Anti-Submarine Warfare) Capable Aircraft program to create an improved P-3 began in 1988, but cost overruns, slow progress, and interest in opening the competition to commercial designs led to the P-7’s cancellation for default in 1990. The successor MMA program was begun in March 2000, and Boeing beat Lockheed’s “Orion 21” with a P-8 design based on their ubiquitous 737 passenger jet. US Navy squadrons finally began taking P-8A Poseidon deliveries in 2012, but the long delays haven’t done their existing P-3 fleet any favors.

Filling the P-3 Orion’s shoes is no easy task. What missions will the new P-8A Poseidon face? What do we know about the platform, the project team, and ongoing developments? Will the P-3’s wide global adoption give its successor a comparable level of export opportunities? Australia and India have already signed on, but has the larger market shifted in the interim?

EMALS/ AAG: Electro-Magnetic Launch & Recovery for Carriers

As the US Navy continues to build its new CVN-21 Gerald R. Ford Class carriers, few technologies are as important to their success as the next-generation EMALS (Electro-MAgnetic Launch System) catapult. The question is whether that technology will be ready in time, in order to avoid either costly delays to the program – or an even more costly redesign of the first ship of class.

Current steam catapult technology is very entertaining when it launches cars more than 100 feet off of a ship, or gives naval fighters the extra boost they need to achieve flight speed within a launch footprint of a few hundred feet. It’s also stressful for the aircraft involved, very maintenance intensive, and not really compatible with modern gas turbine propulsion systems. At present, however, steam is the only option for launching supersonic jet fighters from carrier decks. EMALS aims to leap beyond steam’s limitations, delivering significant efficiency savings, a more survivable system, and improved effectiveness. This free-to-view spotlight article covers the technology, the program, and its progress to date.