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April 1, 2020 | International, Aerospace

The Air Force’s KC-46 tanker has another serious technical deficiency, and Boeing is stuck paying for it

By: Valerie Insinna

WASHINGTON — The Air Force on Monday logged another critical technical flaw for the KC-46 tanker, this time revolving around excessive fuel leaks.

Under its contract with the service, KC-46 manufacturer Boeing is responsible for paying for a fix to the problem, Air Force spokeswoman Capt. Cara Bousie said in a statement.

“The Air Force and Boeing are working together to determine the root cause and implement corrective actions,” she said. “The KC-46 program office continues to monitor the entire KC-46 fleet and is enhancing acceptance testing of the fuel system to identify potential leaks at the factory where they can be repaired prior to delivery.”

The problem was first discovered in July 2019, but the Air Force did not say why the issue had been escalated to Category 1 status — the designation given to problems with a significant impact on operations or safety. The service also did not immediately comment on questions about what sort of receiver aircraft were most involved with the deficiency or the severity of the problem.

A Boeing spokesman said that the Air Force had discovered 16 aircraft in need of repair, and that seven have already been fixed.

“The KC-46 fuel system is equipped with redundant protection for fuel containment. In some cases with this issue, aircraft maintenance crews are finding fuel between the primary and secondary fuel protection barriers within the system,” the company said in a statement.

Boeing is working with “utmost urgency” to address the problem and implement a fix to the remaining aircraft, the statement said. A Boeing spokesman added it would take about 10 days to retrofit each aircraft at the rapid response depot facility in San Antonio, Texas. The fix was also being incorporated into production line in Everett, Wash., which is currently undergoing a temporary suspension due to COVID-19.

The latest Category 1 deficiency brings the total up to four:

  • The tanker's remote vision system or RVS — the camera system that allows KC-46 boom operators to steer the boom into a receiver aircraft without having to look out a window and use visual cues — provides imagery in certain lighting conditions that appears warped or misleading. Boeing has agreed to pay for potentially extensive hardware and software fixes, but the Air Force believes it will system won't be fully functional until 2023-2024.
  • The Air Force has recorded instances of the boom scraping against the airframe of receiver aircraft. Boeing and the Air Force believe this problem is a symptom of the RVS's acuity problems and will be eliminated once the camera system is fixed.
  • Boeing must redesign the boom to accommodate the A-10, which currently does not generate the thrust necessary to push into the boom for refueling. This problem is a requirements change by the Air Force, which approved Boeing's design in 2016. Last year, Boeing received a $55.5 million contract to begin work on the new boom actuator.

Boeing's fixed-priced firm contract for the development of the KC-46 has a $4.9 billion ceiling that leaves the company responsible for any expenses billed in excess of that amount. So far, the company has paid more than $3.5 billion of its own money to fund corrections to ongoing technical issues.

https://www.defensenews.com/air/2020/03/31/the-air-forces-kc-46-tanker-has-another-serious-technical-deficiency-and-boeing-is-stuck-paying-for-it/

On the same subject

  • Rebuilding it ... Better, stronger, faster.

    July 30, 2018 | International, C4ISR

    Rebuilding it ... Better, stronger, faster.

    By: Mike Gruss   The long-held thinking in Washington is that if the Department of Defense wants to stay ahead of its adversaries, it will need improved capabilities, many of which are being developed outside of the Beltway. To that end, Pentagon leaders launched the Defense Innovation Unit Experimental, commonly referred to in defense circles as DIUx, as a way to attract new companies into the fold and accelerate the pace of acquisition. In fall 2017, Secretary of Defense Jim Mattis visited the organization's headquarters and said its influence would grow. A few months later, DIUx's director, Raj Shah, left the organization for the private sector. Capt. Sean Heritage has served as the acting managing partner since then. Heritage spoke recently with C4ISRNET's Mike Gruss. C4ISRNET: What's the status of the DIUx reboot? CAPT. SEAN HERITAGE: The last two years have been largely focused on fielding capability across the department. We like to say we can solve problems faster, better, cheaper using commercial technologies with nontraditional companies that are out there. We've learned that we have some amazing talents on our team and rather than just defaulting to fielding capability, we are creating tailored solutions using organic expertise. We've been able to do this primarily in a suborganization we refer to as the Rogue Squadron — it works in the UAF, counter-unmanned aerial system world. We're sharing our lessons learned across the department. We're coaching people on how we do things so that they can emulate us. So, we'd like to think that if we are the only ones doing CSOs [commercial solutions openings] and OTAs [other transaction authorities], in our image a year or two from now, then we failed. C4ISRNET: How do you know this is working? HERITAGE: We know all our prototypes aren't going to transfer to production. Our target goal is between 40 to 60 percent success rate. The feeling is that if we are more successful than that, then we probably aren't being innovative or creative enough and assuming enough risk on behalf of the department. With regard to our creating line of effort, we're very proud of the [Air Operations Center] Pathfinder project. Kessel Run was a great example of fielding capability and then leveraging organic talent to create tailored solutions and transition to a program of record. Then the coaching effort, we're defining success by creating somebody in other organizations in our image every six months. C4ISRNET: On talent development, is part of that asking leaders to rethink how they're using their people or is it something else? HERITAGE: The best example would go back to Kessel Run. That really started with the Defense Innovation Board. We were able to help the Air Force explore the art of the possible, which made a compelling case for the DIB's original recommendation: you guys need software developers as a core skill at the unit level to solve these problems in real time. They like to use the example that Home Depot has 6,000 software developers to sell you hammers. You can say the same for any service. How many software developers do you have? Well, the answer is we don't know, because we don't have a specialty for software developers, but no doubt once you know people across your team, there are many very capable people who do software development on the side. How do you leverage that? How do you more deliberately recruit to that? And how do you develop them? C4ISRNET: What's one area where you guys have been able to say, “Without us, we're not sure this would've happened as fast?” HERITAGE: We are very proud of the work we are doing in the artificial intelligence world. So, we are doing some projects on predictive maintenance. Again, for the Air Force, focusing on the [E-3 Sentry airborne warning and control system] out of the gate. But it's scaling across other platforms. We're already able to deliver value by solving that problem, reducing unplanned maintenance. Another contract was let out that's scaling to the Army with their Bradley Fighting Vehicles. We are going to be doing predictive maintenance with them. Something that may be lost on many people is our involvement in the formulation of the JAIC, the Joint AI Center. That would not have happened without us, but, more specifically, that would not have happened if we weren't here in the Valley and had access to create relationships with some significant talent in the civilian world. C4ISRNET: I wanted to reframe what you were saying. If DIUx wasn't in existence, do you think that there wouldn't be the same level of talent? HERITAGE: The talent we are able to attract to our team, to work through any problems and inform strategic thinking, wouldn't have happened. What we have is very open-minded senior leaders who are yearning for diverse thinking. And, as a career military guy, it's not all that diverse. What we're able to do is reach into a talent pool that has lots of credibility and expertise that isn't resident in the department. C4ISRNET: What's something DIUx is doing now, that it wouldn't have done three years ago? HERITAGE: The biggest difference is the deliberate embracing of our role in creating solutions and scaling ... coaching. Those were things that DIUx didn't do in the past. We have much more support from across the department. We no longer need that direct cover of the Dep. Sec. Def as a direct report. The percentage of our team that is military is higher than at the beginning. That's not necessarily by design. We are attempting to recruit more individuals, commercial executives, to help coach us. We don't want to be a military organization that happens to be in Silicon Valley, Boston and Austin. We want to truly be representatives of the culture. C4ISRNET: You talked about that 40 to 60 percent goal. What are the other ways you measure success? HERITAGE: The first one is the number of customers within the department that are coming our way to ask us to help them solve problems using our relationships, authorities and methodologies. That's one metric and that number continues to go up. The other is the number of nontraditional companies who want to help solve problems. A commercial solutions opening is a honey-pot for all these creative companies to say, ‘Can I contribute?' The number of companies continues to go up. It was 40-plus on the last CSO. The record to date is over 70. Now we're in a position where we have to say no to projects. We're a little more selective. C4ISRNET: What is DIUx's role with AI? HERITAGE: A lot of folks claim to be able to contribute to the AI mission area. There are 593 initiatives across the department that claim to be AI. It's our ability and our connections with Project Maven that have afforded us the opportunity to influence the way ahead for the department and facilitate some conversions. Some of the work that we're able to do with these nontraditional companies is not only shaping understanding of the power of AI across the department, but it's focusing everybody as well. We're able to help make them a bigger part of the conversation or maybe inspire them to a bigger part of the conversation. C4ISRNET: How do you convince a company that working with the Pentagon is the right path, and it's not a quagmire like it has been at Google? HERITAGE: We don't spend time trying to convince companies to do or think anything. There are plenty of folks out here and elsewhere, who are passionate about contributing to the cause, and appreciate what they are learning just through having access to the data that we're able to provide them. But it's a challenging conversation to be a part of because we don't want to turn people off. We're here to provide people with opportunity. C4ISRNET: Where can you help the most in IT? HERITAGE: [Information technology] is an example of how a DoD organization can leverage technology and access to a network that is still secure, yet different than what the rest of the department is using. It's things that you probably take for granted. We have people come to our team for a short period of time, after a career within the department going, “Wow, look at how my productivity has changed since I've been here.” I have access to Slack and the G Suite and a whole host of other tools that are not allowed, and for good reason, on DoD networks. C4ISRNET: One concern is whether new vendors can provide overmatch. Is that the case? HERITAGE: We look at the companies to make sure they're going to be around long enough to provide this capability. When we talk about our responsibility to help navigate the “Valley of Death,” and make sure that these prototypes don't just die, these companies have to have legs underneath them and investors behind them to be viable down the road so that we don't spend our time developing a prototype that they won't be around to deliver. https://www.c4isrnet.com/thought-leadership/2018/07/27/rebuilding-it-better-stronger-faster/

  • Despite some opposition, US on course to deliver F-35s to Turkey on June 21

    June 14, 2018 | International, Aerospace

    Despite some opposition, US on course to deliver F-35s to Turkey on June 21

    WASHINGTON — The U.S. government is proceeding with plans to deliver the first F-35 to Turkey, with the country set to accept its first jet on June 21 despite opposition from some in Congress. A Lockheed Martin spokesman confirmed to Defense News that it's still gearing up for a rollout ceremony at its production facilities in Fort Worth next week. “The F-35 program traditionally hosts a ceremony to recognize every U.S. and international customer's first aircraft. The rollout ceremony for Turkey's first F-35 aircraft is scheduled for June 21,” the spokesman said in a written statement to Defense News. “The aircraft will then ferry to Luke Air Force Base, Arizona, where Turkish pilots will join the F-35A training pool.” The Senate is set to vote this week on the annual defense policy bill, which includes language that would prohibit the U.S. government from “transfer of title” to Turkey until the time that the Defense Department submits a report to Congress on removal of Turkey from the F-35 program. But even if that language succeeds in the Senate, the defense policy bill will proceed to conference, where a group of armed services committee members will hammer out differences between the House and Senate versions to emerge with a single, final piece of legislation. That process could take months. Congress's opposition to allowing Turkey to purchase the F-35 hovers around two points: the country's detainment of American pastor Andrew Brunson and a deal to purchase the Russian S-400 air defense system. But for now, it appears that the Defense Department has no plans to keep Turkey from getting its first F-35 or to put restrictions on its use at Luke AFB. Thomas Goffus, the Defense Department's deputy assistant secretary of defense for Europe and NATO, acknowledged during an Atlantic Council event Wednesday that Turkey's acquistion of the S-400 could present the U.S. military and NATO alliance with added technical risks. But he would not go as far to spell out what actions the Defense Department is considering or could consider later down the road — perhaps a sign that the Pentagon is waiting to see how this legislation shakes out. “We have a process to evaluate the risks to Western technology that that [procurement] would present. Our preference is that they do not acquire the S-400,” Goffus said. “Given that, they are a sovereign nation, and they are trying to take care of their defense needs,” he added. “What restrictions are placed on them and what Congress will eventually pass, I can't even speculate on it on this point.” By the time Congress passes legislation that could curb Anakara's F-35 ownership, the country will likely have already started building up its first squadron at Luke AFB. There, Turkish pilots and maintainers will train alongside U.S. ones, moving from academic courseware to live flights. NATO and U.S. Defense Department officials have warned Turkey that if it continues down the path of purchasing the S-400, it will not be able to plug it in with NATO technologies like the F-35. SASC, in its policy bill, echoed those concerns, saying that Turkey's purchase of Russian hardware would “degrade the general security of the NATO alliance [...] and degrade interoperability of the alliance.” After a meeting in Washington with U.S. Secretary of State Mike Pompeo earlier this month, Turkish Foreign Minister Mevlüt Çavuşoğlu expressed confidence that the United States would not only deliver the first F-35 to Turkey as planned, but that it would ultimately decide to continue F-35 sales to Turkey. “Turkey rejects threatening language from the U.S. on the issue, it is not constructive,” Çavuşoğlu said on June 4, according to a report from the Turkish newsgroup Anadolu Agency. Turkey plans to buy 100 F-35As. As a partner of the program, its domestic defense industry helps build the Joint Strike Fighter. Most notably, Turkish Aerospace Industries' serves as a manufacturer of the aircraft's center fuselage. It has also been chosen as a sustainment hub for the international F-35 community. https://www.defensenews.com/smr/nato-priorities/2018/06/13/despite-some-opposition-us-on-course-to-deliver-f-35s-to-turkey-on-june-21/

  • GA-ASI and SENER Aeroespacial Team to Develop New NATO Pod for MQ-9

    September 1, 2020 | International, Aerospace

    GA-ASI and SENER Aeroespacial Team to Develop New NATO Pod for MQ-9

    SAN DIEGO, Sept. 1, 2020 /CNW/ -- Since General Atomics Aeronautical Systems, Inc. (GA-ASI) and the engineering and technology firm SENER began collaborating in 2008, the international partnership has resulted in significant agreements regarding the MQ-9A Remotely Piloted Aircraft (RPA) for Spain and its adaptation to the requirements of the Spanish Armed Forces. The latest joint development effort is a NATO Pod, designed and built by SENER Aeroespacial, part of the SENER Group. GA-ASI will integrate the NATO Pod onto the MQ-9 aircraft line to increase its configuration and payload options. NATO Pod development is driven by GA-ASI's initiative to provide customers with a customizable pod for carriage of sovereign, cross-domain Intelligence, and Surveillance and Reconnaissance (ISR) sensors that can be integrated onto GA-ASI-built MQ-9A and MQ-9B RPA Systems. GA-ASI is working with European suppliers to add sensor capabilities to the new European-built payload pod that meets NATO airworthiness standards. The NATO Pod is a flexible, scalable, certifiable, aerodynamic, and low-cost enclosure that enables customers to add sovereign sensor capabilities developed in their respective countries using a common set of interfaces to the aircraft system. This approach reduces integration time and cost. "With the NATO Pod, European sensor suppliers will be provided a standard Size, Weight and Power (SWAP) and Interface Control Document (ICD) to the aircraft system to efficiently integrate their payloads. This offers our customers a broader range of ISR capabilities and makes ISR-system upgrades faster," said Linden Blue, CEO, GA-ASI. "Interface standardization also allows sovereign containment of payload hardware and data by customers, when required." Andrés Sendagorta, president of the SENER Group, said: "Since the beginning in 2008, the relationship between GA-ASI and SENER has been based on the existence of a common corporate philosophy where the technological component represents a fundamental link. This has led to an alliance in which the development of value-added products and technology by SENER has been applied to meet the demanding needs of GA-ASI over the years and, particularly, now with the NATO Pod that will be integrated onto the MQ-9 line. As we have stated on previous occasions, and once the first system of this type has come into operation in Spain, SENER reiterates its commitment to make available to the Spanish Ministry of Defense its capabilities and strengths in support of national industry through alliances, industrial cooperation and the development of an increasingly wide range of products." Having successfully completed the system definition and specification phase, the conceptual and preliminary design phases, as well as the Critical Design Review at the beginning of the summer, SENER Aeroespacial is currently working for GA-ASI on the detailed design phase of the NATO Pod. SENER Aeroespacial is designing the NATO Pod from the ground up to be certifiable, having established a wide set of certification base requirements that will fulfill the vast majority of demands from European certification agencies. About GA-ASI General Atomics Aeronautical Systems, Inc. (GA-ASI), an affiliate of General Atomics, is a leading designer and manufacturer of proven, reliable Remotely Piloted Aircraft (RPA) systems, radars, and electro-optic and related mission systems, including the Predator® RPA series and the Lynx® Multi-mode Radar. With more than six million flight hours, GA-ASI provides long-endurance, mission-capable aircraft with integrated sensor and data link systems required to deliver persistent flight that enables situational awareness and rapid strike. The company also produces a variety of ground control stations and sensor control/image analysis software, offers pilot training and support services, and develops meta-material antennas. For more information, visit www.ga-asi.com. SkyGuardian, SeaGuardian, Predator and Lynx are registered trademarks of General Atomics Aeronautical Systems, Inc. About SENER Aeroespacial SENER Aeroespacial has been a leading supplier of high-performance aerospace systems for Defense, Space and Science for more than 50 years, with high added-value technological developments. In Defence, it develops electromechanical systems, COMINT (communications intelligence), and communications links (D-Link), as well as helicopter modernization services. In Astronomy and Science, it produces precision mechanical equipment for terrestrial telescopes and engineering services. And, finally, its ATC & Broadcast division is a supplier of antennas and passive units. In Space, SENER Aeroespacial is participating in the main programs of ESA and in the Space commercial market, as a key supplier for the leading international manufacturers of communications satellites. SENER Aeroespacial is part of the SENER engineering and technology group, founded in 1956. The SENER Group has 2,300 professionals in offices in four continents and the group's operating revenue exceeded 589 million Euros (2018 data). CONTACT: GA-ASI Media Relations General Atomics Aeronautical Systems, Inc. +1 (858) 524-8101 ASI-MediaRelations@ga-asi.com Related Images ga-asis-mq-9a-remotely-piloted.jpg GA-ASI's MQ-9A Remotely Piloted Aircraft GA-ASI and SENER's international partnership has resulted in significant agreements regarding the MQ-9A Remotely Piloted Aircraft (RPA) for Spain and its adaptation to the requirements of the Spanish Armed Forces. The latest joint development effort is a NATO Pod. SOURCE General Atomics Aeronautical Systems, Inc. Related Links http://www.ga-asi.com https://www.newswire.ca/news-releases/ga-asi-and-sener-aeroespacial-team-to-develop-new-nato-pod-for-mq-9-866418525.html

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