F-35 May Never Be Ready for Combat
Dan Grazier & Mandy Smithberger. . . .9/9/2016
Testing Report Contradicts Air Force Leadership’s Rosy
Dan Grazier &
Mandy Smithberger | September 9, 2016
The F-35 Joint Strike Fighter program is the most expensive procurement
program in Pentagon history. It’s been plagued by schedule delays, gross cost
overruns, and a
slew of underwhelming performance reviews. Last month the Air Force declared
its variant “ready for combat,” and most press reports lauded this as a signal
that the program had turned a corner. But a memo issued from the Pentagon’s top
testing official, based largely upon the Air Force’s own test data, showed that
the Air Force’s declaration was wildly premature.
Dr. Michael Gilmore’s latest memorandum is damning. The F-35 program has
derailed to the point where it “is actually not on a path toward success, but
instead on a path toward failing to deliver the full Block 3F capabilities for
which the Department is paying almost $400 billion.” The
first reported by Tony Capaccio at Bloomberg and
then by others, details just how troubled this program is: years behind
schedule and failing to deliver even the most basic capabilities taxpayers, and
the men and women who will entrust their lives to it, have been told to expect.
The Pentagon’s top testing office warns that the F-35 is in no way ready for
combat since it is “not effective and not suitable across the required mission
areas and against currently fielded threats.” (Emphasis added) As it stands now,
the F-35 would need to run away from combat and have other planes come to its
rescue, since it “will need support to locate and avoid modern threats, acquire
targets, and engage formations of enemy fighter aircraft due to outstanding
performance deficiencies and limited weapons carriage available (i.e.,
two bombs and two air-to-air missiles).” In several instances, the memo
rated the F-35A
less capable than the aircraft we already have.
The memo from the Director, Operational Test & Evaluation makes very clear
that the constant stream of positive pronouncements made by the Joint Program
Office and Air Force generals have been false. Statements that General Hawk
Carlisle, the Air Force’s Air Combat Commander,
recently made to the press and that Joint Program Office chief Lt. Gen.
Christopher Bogdan has made in
testimony on Capitol Hill are directly contradicted by the facts reported in
the memorandum. “The F-35A will be the most dominant aircraft in our inventory
because it can go where our legacy aircraft cannot and provide the capabilities
our commanders need on the modern battlefield,” General Carlisle said
during the IOC announcement. According to Dr. Gilmore, however, this is not
the case and there is evidence that the Air Force knew this already. Before
declaring its variant ready for combat the Air Force conducted and presumably
read its own evaluation. The DOT&E memo clearly states that the findings
contained within are “fully
consistent” with the official report of the Air Force’s own internal IOC
Readiness Assessment Team report.
This memo is a brutally revealing assessment of the F-35’s performance
deficiencies. It’s important to note that Congress and the public know of these
severe and debilitating deficiencies only because Congress
mandated an independent testing office with broad bipartisan support in
1983—and because the present director is a person of independence and integrity.
Limited Combat Ability
The Air Force stated to Congress that its Initial Operational Capability
(“combat ready”) declaration would be
based on the ability of the current F-35A (Block 3i) to perform three basic
missions: close air support, interdiction, and limited attacks on enemy air
The services are taking delivery of new F-35s in succeeding “block” versions,
each adding increments to the previous block’s incomplete combat capabilities.
The version equipping the Air Force’s IOC squadron, the Block 3i, is an interim
version in which the earlier Block 2B’s obsolete computer has been replaced with
a new one. Meanwhile, schedule slippage continues on the F-35 program’s Block 3F
development effort, intended to incorporate all the contractually mandated
The Air Force’s current configuration can only carry two long range
air-to-air missiles (but no dogfighting short-range heat-seeking missiles) and
two bombs to attack targets on the ground. This very limited weapons load-out is
the result of ongoing software deficiencies, not of any potential (though
untested) ability of the plane
to carry more types of weapons. Larger numbers of weapons would have to be
carried externally, however, which compromises the aircraft’s range and stealth.
The next software version, Block 3F which is currently suffering
major development problems, should eventually allow the F-35 to employ the
larger variety of weapons originally specified in 2001, but these planes are
still years away from being operationally tested, much less actually reaching
the fleet. So for the time being, even if the current F-35 could perform in
combat (which DOT&E’s memorandum makes clear it can’t), the small and
non-diverse ammo load means any fight the F-35 finds itself in had better be a
The F-35’s cannon door causes the plane to
pull to one side, reducing the accuracy of the gun. (Photo by www.jsf.mil)
Another of the F-35’s basic shortcomings is the lack of a usable cannon. The
Block 3i aircraft lacks the ability to employ the cannon because the software
needed for it is a Block 3F development and has yet to be completed. This issue
has been reported
many times before. Now we learn that there are doubts that the most recent
version of the plane’s complicated helmet, which is the only way to aim the
will be accurate enough to reliably hit air-to-air or ground targets.
This latest DOT&E report also makes public another problem with the cannon on
the Air Force’s variant of the plane, the F-35A. This is the only variant that
includes an internal cannon. The variants for the Marine Corps and Navy both use
an external belly-mounted gun pod. In order to keep the F-35A stealthy, the
internal cannon sits behind a small door that opens when the cannon is fired.
The Air Force
proudly released a video of the first time an F-35A test fired its cannon in
flight. Now we know that the simple action of opening the small door causes the
plane to turn slightly because of the door’s drag, possibly enough to cause the
cannon to miss. The DOT&E memo reports that these door-induced aiming errors “exceed
accuracy specifications” which will make it quite difficult for pilots to
hit targets. And since the Air Force’s F-35 only holds 181 rounds—as opposed to
511 for the F-16 and 1,100 for the A-10—every bullet will count.
F-35 Close Air Support Threatens Troops on the Ground
As the debate continues about the future of the close air support mission,
one thing is certain: the F-35 simply is not ready to support ground troops, and
there are plenty of reasons to doubt it ever will be.
This latest DOT&E memorandum undermines one of the fundamental arguments in
favor of the F-35 in the CAS role: that the F-35 will need to provide close air
support in places with high levels of enemy air defenses, a mission that would
require stealth capabilities. But the battles in which CAS is needed don’t
generally take place in areas where there are high levels of enemy air defenses.
The memo points out that close air support is normally conducted in
low-air defense threat environments. This is a simple acknowledgement of the
“close” in close air support. When close air support is discussed, it is
important to consider the entire military system, both air and ground forces.
These forces support each other mutually. By the time the ground troops who
engage the enemy in close combat get involved, our military has already cleared
out the heavy air defense. And the enemy ground troops will not be dragging
around bulky, lightly armored, slow-to-move, hard-to-resupply “high threat”
missile systems into the battle area because they will be too busy maneuvering
and dodging bullets in the ground fight.
U.S. Marine Corps M1A1 Abram Tanks assigned to Delta
Company, 1st Tanks Battalion, 1st Marine Division, conduct the Tank
Mechanized Assault Course during Integrated Training Exercise (ITX) 2-15
at the Delta Prospect Training Area aboard Camp Wilson, Marine Corps Air
Ground Combat Center Twentynine Palms, California, February 1, 2015.
Beyond that, the F-35’s ability to perform any CAS right now is extremely
limited. As the DOT&E memorandum says clearly, “The F-35A in the Block 3i
configuration has numerous limitations which make it less effective overall at
CAS than most currently-fielded fighter aircraft like the F-15E, F-16, F-18 and
A-10.” As mentioned earlier, the F-35A, now declared “Initially Operationally
Capable,” can only carry two bombs, both of which are too big to be safely used
near friendly troops. And even if these bombs could be used in CAS, the plane
has to immediately fly back to its base to re-load after only one pass over an
enemy formation. For F-35As that base is likely to be far from the battlefield
since the plane needs an
8,000 foot concrete runway with a massive logistical footprint, thus
seriously slowing CAS response times.
Air support for friendly troops fighting the enemy is exactly where the lack
of a usable cannon is most distinctly felt—and the F-35 won’t have a usable and
test-proven cannon until 2019 at best. Cannons are the most effective weapon in
far more CAS situations than rockets (which the F-35A currently does not carry)
or a couple of guided bombs (which it does). This is true especially when the
plane needs to engage a target in a “danger close” situation, with the enemy in
very close proximity to friendly troops. A GBU-12, the smaller of the two bombs
the F-35A can currently employ, is a 500-pound bomb. At 250 meters (820 feet), a
has a 10 percent chance of incapacitating a friendly soldier based on the
military’s risk-estimate table. That might not seem like much, but
history has proven that most firefights actually take place at considerably
less than 100 meters. If F-35As are the aircraft providing CAS, this means that
enemies closing with our troops will have plenty of room—150 meters or more—to
maneuver free of fire from above.
An effective cannon on the plane closes that gap. The F-35 is supposed to
eventually use a 25-millimeter cannon. The risk-estimate factor for that weapon
is 100 meters. Of course the safe distance depends on how accurate the aircraft
platform and aiming system is. As noted in the DOT&E memo, the simple act of
opening the cannon door on the Air Force’s variant pulls the plane to one
side—which could shift the bullet impacts either closer towards friendly troops
or away from the enemy’s (thereby rendering the attack dangerous or useless).
The F-35 relies heavily on aerial
refueling. (Photo by www.luke.af.mil)
But that presupposes the F-35 will actually be able to stay over the
battlefield long enough to be on hand to drop its bombs or fire its cannon
exactly when needed. The F-35 is a notorious gas-guzzler that relies heavily on
aerial tankers to stay on station for any length of time to be useful for the
ground troops. According to the memorandum, “the F-35 has high fuel burn rates
and slow air refueling rates that extend air refueling times and decreases
overall on-station time.” Unfortunately, the troops on the ground can’t call a
time-out when their air support has to leave the battle to re-fuel or reload.
The high fuel burn rate and high drag of the F-35 creates a plane that has
“short legs” and inadequate on-station times. All variants and versions of the
F-35 share this problem. Current short-legged fighters mitigate this deficiency
by rotating flights of planes back to the tanker while another remains over the
battlefield. But with the well-documented problems the services’ maintainers
keeping the F-35 flightworthy, it is doubtful there will be enough flyable
planes to make such a rotation practical any time soon. Actual current F-35
sortie rates reveal the severity of the problem: today’s F-35s are flying one
sortie every 5 days. In other words, a squadron deployment of 12 F-35s to
Afghanistan or Syria—such as is typical for F-16s or A-10s—would only be able to
put up slightly more than one two-ship mission a day to cover the whole country.
Data Fusion Causes Pilots to See Double
Publicists and “experts” sent out to
try to convince the
American people their money isn’t being wasted on the F-35 frequently tout
the system’s capability to combine data derived from onboard sensors, sensors on
other aircraft, and ground sensors. This is called sensor fusion. Each F-35,
like other current fighters, has radars, video cameras, infrared seekers, and
passive electronic warfare receivers to locate targets and threats in the air or
on the ground. One of the main selling points for the F-35 has been that its
computer system is intended to merge the information from all these onboard and
offboard sensors to create a simple combined-sensor display (instead of the
current approach of a separate display for every sensor) of each target and each
threat for the pilot. This single display is shared instantly with every other
plane in the formation. This is supposed to provide everyone with a more
accurate, less confusing picture of the target and threat environment
surrounding the formation—and to do so quickly without the need for
time-consuming radio voice exchanges.
That’s what it’s supposed to do anyway. As it turns out, the F-35s have
difficulty managing and fusing their own data, let alone that of their wingmen
or surveillance assets further away.
Test pilots have reported their F-35s are
creating false multiple tracks when all of their sensors are turned on. For
example, when a radar and an infrared sensor detects the same enemy plane, the
two sensors display it on the helmet-mounted sight as two enemy planes. The same
thing happens when two or more sensors detect the same ground target.
Test pilots have worked around this problem by turning off all but one of
their sensors to eliminate the multiple tracks. DOT&E says this is “unacceptable
for combat and violates the basic principle of fusing contributions from
multiple sensors into an accurate track and clear display to gain situational
awareness and to identify and engage enemy tracks.”
It is bad enough that each individual F-35 computer struggles to create a
clear picture of what is going on in the battlespace for the pilot. But the
false target problem
is compounded when multiple F-35s try to share data through what is called
the Multi-Aircraft Data Link.
What has been described as one of the F-35’s greatest advantages has yet to
live up to expectations—and, to the contrary, has been increasing the pilot’s
Logistics Software Falling Behind
Another major and expensive component of the F-35 program, the Autonomic
Logistics Information System (ALIS), is a massive computer system intended to
automate mission operations, maintenance diagnosis, maintenance scheduling, and
parts ordering. But the cumbersome ALIS continues to be a major headache for the
program. An updated version, ALIS 2.0.2,
was supposed to be delivered in time for the Air Force’s Initial Operational
Capability announcement. Yet IOC was declared without the new version, which
remains seriously delayed because Lockheed has been unable to integrate Pratt
and Whitney’s separate engine computer data system into ALIS.
Uploading data into Autonomic Logistics Information
System can take up to 24 hours. (Photo by www.jsf.mil)
ALIS combines aircraft onboard and ground-based computers and software to
create a world-wide network that, for each F-35 flight, uploads and downloads
flight path/target/threat data (at beyond top secret level), diagnoses
maintenance problems, assigns corrective maintenance actions to mechanics,
orders parts, tracks their installation, tracks aircraft modifications, and
orders mechanics to perform preventative maintenance actions. It is a massively
complex system, with
24 million lines of computer code. It also requires a large, heavy footprint
of hardware wherever the F-35 is based. The latest hardware version is smaller
than the original bulky and undeployable ALIS units, but it still takes several
days to set up whenever it is moved. This impedes the F-35’s ability to deploy
quickly and raises questions about the entire program’s operational suitability.
For example, when it is working,
it takes 24 hours to upload data from each plane into a new ALIS ground
computer. So when an F-35 deploys to a new base, an entire day is lost as the
data is passed to the new ALIS. And only one plane at a time can upload. So if
the 12 F-35’s of Hill Air Force Base’s first “operational” squadron deploy to
combat, it will take nearly two weeks to start maintaining the full squadron
Because ALIS uploads and downloads top secret mission data, the ALIS
computers have to be housed in a secure compound called a Special Access Program
Facility, made up of one or more modified large shipping containers called
Deployable Debrief Facilities.
Furthermore, forward-deploying units not only need to lug bulky equipment and
facilities to foreign battlefields, they also need to
drag around civilian contractors to help set up and operate the equipment.
Contractors from Lockheed Martin are essential to transfer data from the plane’s
home station to the deployed ALIS unit. Field service representatives from Pratt
and Whitney are also needed to download engine data for the post-flight
maintenance process. This is fine during development, but in combat, such
arrangements hamper rapid deployment and limit basing options to locations safe
for civilians. That means basing farther from combat zones, slower emergency
response times, and increased reliance on scarce aerial tankers.
Future Development in Jeopardy
The program is supposed to have truly combat-capable F-35s—Block 3F—ready for
operational testing at the end of the System Development and Demonstration
process, which is now scheduled to be at the end of 2018. Dr. Gilmore reports
that while some progress is being made in the simpler developmental
flight-testing process, the pace has fallen far behind that which is necessary
to complete the Block 3F testing within the remaining schedule and budget. And
this is the point in the developmental flight test plan where the most complex
capabilities are added to the plane. He estimates developmental flight testing
will need to
continue at full capacity for at least another year to “complete the planned
testing of the new capabilities and attempted fixes for the hundreds of
remaining deficiencies.” It will simply be impossible to complete operational
testing by the 2018 deadline.
There is still a long way to go to complete the development
phase of the JSF program, but rather than budgeting to resource that adequately,
program officials seem to be focused more on expanding future procurement
To complicate matters even further, the program is losing testing personnel
right at this critical juncture. The test centers have a turnover rate of
approximately 20 percent on a normal basis.
DOT&E reported that the recent departures are not being replaced. Dr.
Gilmore also reports the program has started laying off people including
maintenance staff, engineers, and analysts. The layoffs have started a cascading
effect where many of those left are now looking for other jobs before they can
be laid off.
Dr. Gilmore pointed out that how “the program will be able to complete the
volume of work remaining at the integrated test centers while the staffing
begins to ramp down is not known.”
This is all further evidence of program mismanagement. There is still a long
way to go to complete the development phase of the JSF program, but rather than
budgeting to resource that adequately, program officials seem to be focused more
on expanding future procurement budgets. JSF Program officials
both inside the government and at
Lockheed Martin have repeatedly expressed their desire to ramp up from low
rate initial production. They want Congress to authorize a block buy of 465
planes—with commensurate large pre-payments—for the United States and foreign
military partners beginning in 2018. But not one official has expressed the need
for funding the extra people and extra flight hours essential to keeping the
development program from sliding further behind.
Ramping up production means we will be buying more airplanes that will
require ever more fixes in order to be deployable. The GAO has already
estimated it will cost $1.7 billion to upgrade planes bought early in the
program just to fix the deficiencies so far identified in development testing.
These fix-costs will certainly rise as the
services continue buying new F-35s and as the more stressful operational
testing gets started in the next few years.
There are 175 F-35s operational worldwide. In 2017 the DoD will get 80 new
F-35s plus 100 more in 2018. That's 355 F-35s being delivered that can't go into
combat and will have to go back to the depot for major rebuilds when
developmental and operational testing has discovered and then designed all the
fixes required (and then confirmation-tested those fixes to make sure they
actually fix the problem). Operational testing and evaluation likely can't be
completed any sooner than fall 2021, and that means those 355 F-35s will be
non-combat-capable until at least 2023 and more likely 2024 or 2025. In other
words, those 355 (plus lots more delivered after 2018) can't go to war for
another seven to nine years.
As new problems are identified, the schedule and cost will be affected. And
most certainly no funds have been programmed for fixing the far larger number of
deficiencies that will be uncovered in the growing backlog of remaining
developmental tests—not to mention the additional deficiencies sure to be
uncovered in the subsequent operational tests. Ramping up production instead of
funding adequate development and testing may stick the services and the
taxpayers with hundreds of unusable F-35s because the DoD budget
can’t afford the fixes necessary to make them combat capable. These planes
would then become little more than very expensive sources of spare parts on the
Future Testing on Shaky Ground
The most worrisome news in this report is that officials in the Air Force and
the Joint Program Office seem to be ramping up production and simultaneously
slow-rolling future testing of the F-35. Dr. Gilmore reports that “plans and
support for preparing for adequate IOT&E have stagnated.”
Not only has the Joint Program Office failed to create an
adequate operational testing plan, it has failed to fund and test the equipment
essential to conduct the tests.
The Air Force identified 7 "Must Fix"
deficiencies during Block 2B testing for the current version to meet IOC
standards. Only 4 of 7 were corrected before the announcement. (Source:
As evidence, he reports that the Joint Program Office has not created a
realistic plan to provide production representative aircraft for combat testing.
Dr. Gilmore says the program will not be able to produce enough F-35s in the
necessary final configuration to proceed with operational testing. “Due to the
lengthy program delays and discoveries during developmental testing, extensive
modifications are required to bring the OT aircraft, which were wired during
assembly to accommodate flight test instrumentation,…into the production
representative configuration required,”
the report states. It goes on to say that more than 155 modifications have
to made to the 23 planes needed for the upcoming combat (“operational”) testing
and that some of these have not even been contracted yet, meaning that the start
of IOT&E will be further delayed.
Not only has the Joint Program Office failed to create an adequate
operational testing plan, it has failed to fund and test the equipment essential
to conduct the tests. This includes no funding for flight-testing the Data
Acquisition Recording and Telemetry pod, an instrument mounted to the F-35 that
is used to simulate the aircraft’s weapons. This is essential for reporting and
analyzing the results of each simulated weapons firing. There can be no such
tests until the pod is cleared for function and safety in conditions that the
plane will fly during the engagement and weapons testing.
The report also states that the simulation facility needed for the most
complex and combat-realistic of the operational test scenarios is still
not on track to be delivered on time, despite 15 years of Joint Program
Office promises that it would be. This is the Verification Simulator, which is
supposed to provide multiple ultra-realistic, thoroughly test-validated pilot
cockpit simulators operating together to enable operational testing of
multi-ship tactical scenarios with large numbers of advanced threats. It’s the
only way to test many of the F-35’s capabilities because the test ranges cannot
realistically replicate the full spectrum and quantity of targets and threats
the F-35 combat formations would confront. Beginning in 2001 Lockheed Martin
engineers were under contract to create this complex simulator facility, but the
project had fallen so far behind that DOT&E questioned whether it would be ready
in time for operational testing. Rather than reinvigorating that project,
the JPO moved the entire simulator development to a Navy lab. That lab is
now in the throes of trying to take over this monumental design, fabrication,
and verification testing task. According to the DOT&E memorandum, the
Verification Simulator will not be ready for the currently planned IOT&E start
date in 2018—and perhaps not until two or more years later.
The Last Honest Assessment of the F-35 Program?
This DOT&E memo clearly exposes the Air Force’s F-35 IOC announcement as
nothing more than a publicity stunt.
Unfortunately, Dr. Gilmore’s memo may prove to be one of the last honest
assessments of the F-35 program the Congress, White House, DoD, or American
people receive. Dr. Gilmore’s position as Director, Operational Test &
Evaluation is an appointed one, made by the President. He has proven himself to
be an independent, principled actor. He has resisted the temptation that
several, though certainly not all, of his predecessors failed to resist: to act
on behalf of their future employers in the defense industry by signing off on
ineffective operational test plans or watering down reports of operational test
failures to make it appear as though all is well for continued program funding.
And so it may be again in a few months. With a new Administration, there may
well be a new head of operational testing. Unless a competent and courageous
operational tester, one not beholden to industry, occupies that office, the men
and women who have to take these weapons into combat will be in danger of
receiving flawed tools that could cost them victory and their lives. With all
the evident foot-dragging that has taken place so far, a skeptical observer
could be forgiven for believing that those in charge of the F-35 program may be
attempting to run out the clock on Dr. Gilmore’s tenure.
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