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-35 Lightning: The Joint Strike Fighter Program

The $382 billion F-35 Joint Strike fighter program may well be the largest single global defense program in history. This major multinational program is intended to produce an “affordably stealthy” multi-role fighter that will have 3 variants: the F-35A conventional version for the US Air Force et. al.; the F-35B Short Take-Off, Vertical Landing for the US Marines, British Royal Navy, et. al.; and the F-35C conventional carrier-launched version for the US Navy. The aircraft is named after Lockheed’s famous WW2 P-38 Lightning, and the Mach 2, stacked-engine English Electric (now BAE) Lightning jet. Lightning II system development partners included The USA & Britain (Tier 1), Italy and the Netherlands (Tier 2), and Australia, Canada, Denmark, Norway and Turkey (Tier 3), with Singapore and Israel as “Security Cooperation Partners,” and Japan as the 1st export customer.

The big question for Lockheed Martin is whether, and when, many of these partner countries will begin placing purchase orders. This updated article has expanded to feature more detail regarding the F-35 program, including contracts, sub-contracts, and notable events and reports during 2012-2013.

APKWS II: Laser-Guided Hydra Rockets in Production At Last

The versatile Hydra 70mm rocket family is primed for a new lease on life, thanks to widespread programs aimed at converting these ubiquitous rockets into cheap laser-guided precision weapons. Conversion benefits include cost, use on both helicopters and fighters, more precision weapons per platform, low collateral damage, and the activation of large weapon stockpiles that couldn’t be used under strict rules of engagement.

Firms all over the world have grasped this opportunity, which explains why strong competition has emerged from all points of the compass. America’s “Advanced Precision-Kill Weapon System (APKWS)” is one of those efforts, but the road from obvious premise to working weapon has been slow. After numerous delays and false starts since its inception in 1996, an “APKWS-II” program finally entered System Design and Development (SDD) in 2006. In 2010, it entered low-rate production, and it was fielded to the front lines in 2012. That date will still put APKWS on the cutting edge of battlefield technology, as a leading player in a larger trend toward guided air-to-ground rockets.

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.

Airbus’ A400M Aerial Transport: Delays, Development, and Deployment

Airbus’ A400M is a EUR 20+ billion program that aims to repeat Airbus’ civilian successes in the full size military transport market. A series of smart design decisions were made around capacity (35-37 tonnes/ 38-40 US tons, large enough for survivable armored vehicles), extensive use of modern materials, multi-role capability as a refueling tanker, and a multinational industrial program; all of which leave the aircraft well positioned to take overall market share from Lockheed Martin’s C-130 Hercules. If the USA’s C-17 is allowed to go out of production, the A400M would also have a strong position in the strategic transport market, with only Russian AN-70, IL-76 and AN-124 aircraft as competition.

Airbus’ biggest program issue, by far, has been funding for a project that is more than EUR 7 billion over budget. The next biggest issue is timing, as a combination of A400M delays and Lockheed’s strong push for its C-130J Super Hercules narrow the field for future exports. This DID Spotlight article covers the latest developments, as the A400M Atlas moves into the delivery phase. Will Airbus’ 3rd big issue become its own customers?

The USA’s DDG-1000 Zumwalt Class Program: Dead Aim, Or Dead End?

DID’s FOCUS Article for the DDG-1000 Zumwalt Class “destroyer” program covers the new ships’ capabilities and technologies, key controversies, associated contracts and costs, and related background resources.

The ship’s prime missions are to provide naval gunfire support, and next-generation air defense, in near-shore areas where other large ships hesitate to tread. There has even been talk of using it as an anchor for action groups of stealthy Littoral Combat Ships and submarines, owing to its design for very low radar, infrared, and acoustic signatures. The estimated 14,500t (battlecruiser size) Zumwalt Class will be fully multi-role, however, with undersea warfare, anti-ship, and long-range attack roles. That makes the DDG-1000 suitable for another role – as a “hidden ace card,” using its overall stealth to create uncertainty for enemy forces.

At over $3 billion per ship for construction alone, however, the program faced significant obstacles if it wanted to avoid fulfilling former Secretary of the Navy Donald Winter’s fears for the fleet. From the outset, DID has noted that the Zumwalt Class might face the same fate as the ultra-sophisticated, ultra-expensive SSN-21 Seawolf Class submarines. That appears to have come true, with news of the program’s truncation to just 3 ships. Meanwhile, production continues.

Saving the Galaxy: The C-5 AMP/RERP Program

When it was introduced, back in 1970, the C-5 Galaxy was the largest plane in the world. It also has the highest operating cost of any US Air Force weapon system, owing to extremely high maintenance demands as well as poor fuel economy. Worse, availability rates routinely hover near 50%. To add insult to injury, the Russians not only built a bigger plane (the AN-124), they sold it off at the end of the Cold War to semi-private operators, turning it into a commercial success whose customer list now includes… NATO.

Meanwhile, the USA still needs long-range, heavy load airlift. The AN-124’s commercial success may get its production line restarted, but the C-5 has no such hope. Boeing’s smaller C-17s cost more than $200 million per plane. That’s about the cost of a 747-8 freighter, for much higher availability rates than the C-5, and a longer lifespan.

What’s the right balance between new C-17s and existing C-5s? The US Air Force believes that the right balance involves keeping some of the larger C-5s, and thought they could save money by upgrading and renewing their avionics (AMP) and engines (RERP). Their hope was that this would eliminate the problems that keep so many C-5s in the hangar, cut down on future maintenance costs, and grow airlift capacity, without adding new planes. Unfortunately, the program experienced major cost growth. In response, the C-5M program wound up being both cut in size, and cut in 2. The C-5A and C-5B/C fleets are now slated for different treatment, which will deliver fewer of the hoped-for benefits, in exchange for lower costs and lower risk.

The Rockets’ Red Ink: from EELV to a Competitive Space Launch Future

The EELV program was designed to reduce the cost of government space launches through greater contractor competition, and modifiable rocket families whose system requirements emphasized simplicity, commonality, standardization, new applications of existing technology, streamlined manufacturing capabilities, and more efficient launch-site processing. Result: the Delta IV (Boeing) and Atlas V (Lockheed Martin) heavy rockets.

Paradoxically, that very program may have forced the October 2006 merger of Boeing & Lockheed Martin’s rocket divisions. Crosslink Magazine’s Winter 2004 article “EELV: The Next Stage of Space Launch” offers an excellent briefing that covers EELV’s program innovations and results, while a detailed National Taxpayer’s Union letter to Congress takes a much less positive view. This DID Spotlight article looks at the Delta IV and Atlas V rockets, emerging challengers like SpaceX and the new competition framework, and the US government contracts placed since the merger that formed the United Launch Alliance.

Turkey Finally Lands Its Attack Helicopters

Turkey has been looking to modernize its attack helicopter fleet since the mid-1990s, but the process has mostly served as an object lesson in how not to buy defense equipment. This competition faced many difficulties; after numerous snafus, technology transfer and production issues, and canceled competitions, all 3 invited American manufacturers had abandoned the competition entirely.

Even the “final” round seemed imperiled, following reports of the Turkish military’s deep dissatisfaction with the choices. Nevertheless, the competition survived long enough to pick a winner, and signed contracts with AgustaWestland. But Turkey didn’t just buy helicopters. They bought the A129 model – lock, stock, and rotor.

Adir Who? Israel’s F-35i Stealth Fighters

In an exclusive June 2006 interview, Israeli Air Force (IAF) chief procurement officer Brigadier-General Ze’ev Snir told Israeli media that the F-35 Joint Strike Fighter was a key part of their IAF recapitalization plans, and that Israel intended to buy over 100 of the fighters to replace their fleet of over 300 F-16s.

Since then, however, the expected cost of that purchase has more than doubled. Israel’s F-35 contract had to deal with that sticker shock, with issues like the incorporation of Israeli technologies and industrial work, and with major schedule slips in the core F-35 program. Israel was even contemplating delaying its purchase, which would have removed an important early adopter for the Lightning II. In the end, however, Israel decided to forego other fighter options, and became the first foreign buyer of operational F-35s. So, how is the “F-35i Adir” shaping up?