Back to news

August 7, 2018 | International, Naval

The US Navy’s top acquisition priority stumbles out of the gate

By:

The U.S. Navy's $122.3 billion Columbia-class ballistic missile submarine program is off to an inauspicious start after faulty welding was discovered in several missile tubes destined for both the Columbia and Virginia-class programs, as well as the United Kingdom's follow-on SSBN program.

In all, 12 missile tubes manufactured by BWXT, Inc., are being scrutinized for substandard welds. Seven of the 12 had been delivered to prime contractor General Dynamics Electric Boatand were in various stages of outfitting, and five were still under construction. The Navy and Electric Boat have launched an investigation, according to a statement from Naval Sea Systems Command spokesman Bill Couch.

“All BWXT welding requiring volumetric inspection has been halted until the investigation is complete,” Couch said.

The bad welds came to light after discrepancies were discovered with the equipment BWXT used to test the welds before shipping them to GDEB, according to a source familiar with the issue.

The discovery of a significant quality control issue at the very outset of fabrication of Columbia injects uncertainty in a program that already has little room for delays. The issue is made even more troubling because it arises from a vendor with an excellent reputation, and raises questions about whether the Navy can deliver Columbia on time, something the Navy says is vital to ensuring continuous nuclear deterrent patrols as the Ohio class reaches the end of its service life.

Full Article: https://www.defensenews.com/breaking-news/2018/08/06/the-us-navys-top-acquisition-priority-stumbles-out-of-the-gate-after-bad-welds-discovered-in-missile-tubes/

On the same subject

  • Failure to communicate: US Navy seeks faster data transfers amid Arctic ice

    May 13, 2020 | International, Naval, C4ISR

    Failure to communicate: US Navy seeks faster data transfers amid Arctic ice

    Andrew Eversden WASHINGTON — Research in the Arctic Ocean is no small feat. The area can prove inaccessible at times, and sensors can fail to communicate data from under the ice or get crushed by slabs of ice. But with the Arctic getting warmer and ice melting at an accelerated rate, the U.S. Navy is preparing to operate in newly available waterways. To do that effectively, the service knows it will take intense research to create durable, innovative solutions that can withstand harsh conditions, while also relaying data to researchers. “If the Navy's thinking about having to run operations up there with submarines, surface vessels and aircraft, you really need to understand that operational environment,” Scott Harper, the Office of Naval Research's program manager for Arctic and global prediction, told Defense News in a May 4 interview. “Where is that sea ice and how quickly is it retreating? And what is it doing to the upper water column in the ocean? "To really understand all that, you need to have a lot of observations.” Navy and academic researchers are working together to improve the service's forecasting models in the Arctic. The Navy currently has research buoys, sensors and other technology floating in the water to track a variety of metrics: waves, atmospheric and water circulation, sea ice thickness and cover, speed at which the ice moves, and several other factors. All those metrics factor into Arctic forecasting. In order to improve its forecasting capabilities, the Navy needs to improve its numerical models, or complex equations used in predictions. But to do that, the service needs more up-to-date data. “These numerical models are kind of like balancing your checkbook,” Harper said. “You need to start with what your current checking account balances [to[ if you're going to predict what it's going to be at the end of the month. And so even if you had a perfect numerical model that you could use to make a forecast, if you don't know what the conditions are right now, you're not going to be able to forecast what the future state is going to be.” To do this, the Navy wants to more quickly collect data through an effort called the Arctic Mobile Observing System, or AMOS. The program aims to create near-real-time data transmission of the sea condition under the ice, and communicate that information to the Navy via satellite. “You have satellites that can look down at the surface of the Arctic Ocean and the sea ice conditions,” Harper said. “But what we don't have [is] the ability to look under the ice and understand what the ocean conditions are, and that's what we're really trying to enable with Arctic Mobile Observing System prototype.” The AMOS program has deployed gliders underneath the sea that are collecting and storing data about the oceanic conditions under the ice, and tracking the location of frozen water using acoustics. In a few months, Harper said, researchers will send an icebreaker to the Arctic and gather the data collected by the gliders. The Office of Naval Resarch, however, would like to bypass the multi-month delay involved in collected the data. To do so, the office plans to enable two-way communication so underwater sensors can communicate data via floating buoys in the ice that, in turn, communicate the data via satellites back to the Naval Oceanographic Office. The project is currently two years into the five-year project. According to the project website, it's slated to end in fiscal 2023 with the recovery and evaluation of the initial prototype in the late summer of 2023. Harper said the project's biggest success has been the navigation system that's currently working underneath the ocean surface. “The fact that we can put sensors out that will know where they are without having to come to the surface to get a GPS fix — because they can't come to the surface because there's sea ice there for nine months out of the year," he said. "That's a big win.” Another critical component to the real-time data collection are the buoys that ultimately must be able to survive the cruel nature of Arctic ice. The AMOS team has deployed prototypes of “ice-hardened” buoys that survived “multiple months” in the Arctic environment, Harper said, paving the way for a fully equipped communications buoy that can talk with underwater sensors. “You can go out there and you can put your sensors in the ice, but a lot of times they'll fail,” Harper said. “And they'll fail because they'll get crushed in the ice or tipped over or toppled by changing ice conditions. And so the ability to deploy a buoy that is robust enough to survive the sea ice is one of the technological hurdles to doing this.” https://www.c4isrnet.com/smr/frozen-pathways/2020/05/11/failure-to-communicate-us-navy-seeks-faster-data-transfers-amid-arctic-ice/

  • Marine Corps’ Mahlock takes reins of Cyber National Mission Force

    January 6, 2024 | International, Land

    Marine Corps’ Mahlock takes reins of Cyber National Mission Force

    Maj. Gen. Lorna Mahlock now leads a force she said is "competing daily against a threat that is very real, but which few can comprehend, quantify or see.”

  • The Pentagon has cut the number of serious F-35 technical flaws in half

    April 24, 2020 | International, Aerospace

    The Pentagon has cut the number of serious F-35 technical flaws in half

    By: Valerie Insinna WASHINGTON — The U.S. Defense Department is slowly but surely whittling down the number of F-35 technical problems, with the fighter jet program's most serious issues decreasing from 13 to seven over the past year. In June 2019, Defense News published an investigation delving into the details of 13 previously unreported category 1 deficiencies — the designation given to major flaws that impact safety or mission effectiveness. Following the report, five of those 13 category 1 problems have been “closed,” meaning they were eliminated or sufficiently corrected. Five were downgraded to a lower level of deficiency after actions were taken to help mitigate negative effects, and three issues remain open and unsolved, according to the F-35 program executive office. Four additional CAT 1 problems have also since been added to the list, raising the total CAT 1 deficiencies to seven. The program office declined to provide additional details about those issues for classification reasons, but stated that software updates should allow all of them to be closed by the end of 2020. “The F-35 Lightning II Joint Program Office is keenly aware of these existing F-35-related category 1 deficiencies and is focused on developing and implementing solutions for these issues as quickly as possible,” the program office said in response to questions from Defense News. “F-35 operator safety is the F-35 JPO's highest priority.” In a statement to Defense News, F-35 manufacturer Lockheed Martin confirmed the number of open category 1 deficiencies. However, the company declined to provide further information about the path to fix current issues or how earlier issues had been ameliorated. “We are actively addressing the deficiencies and expect all to be downgraded or closed this year,” the company said. While the overall reduction in deficiencies is a promising trend, it is also important to track how problems are solved and how quickly fixes are pushed to the rest of the fleet, said Dan Grazier, an analyst with the independent watchdog group Project on Government Oversight. “I'm not surprised that they are continuing to find issues. This is why we are supposed to be testing weapon systems before we buy a whole bunch of them. I am a little surprised that we are finding CAT 1 deficiencies at this point during operational testing,” Grazier said. “I think that speaks to the level of complexity with this program that it's taken us this long to get to this point, and even after all the testing that has been done and the time and money that has gone into this that we're still finding category 1 issues," he added. "It shows that the program wasn't born in the right place. It was way too ambitious from the very beginning.” Aside from four classified problems, there remain three open category 1 deficiencies in need of a fix. There are myriad reasons for that, the program office stated. “Reasons for delayed issue closure vary according to the complexity of the solution and the availability of test assets needed to verify the solution,” the JPO said. “The U.S. services fund the F-35 program to address a prioritized set of DRs [deficiency reports], while at the same time, develop new capabilities. It is likely that some low-priority DRs will never be resolved because of their minor impact on F-35 fleet operations does not justify the cost of resolution." The F-35 program office provided some details on the path forward for resolving these technical flaws, but noted that many details regarding those plans remain classified: Spikes in the F-35 cockpit's cabin pressure have been known to cause barotrauma, or extreme ear and sinus pain. This problem was documented when two Air Force pilots, flying older versions of the F-35A conventional-takeoff-and-landing model, experienced ear and sinus pain that they described as “excruciating, causing loss of in-flight situational awareness, with effects lasting for months,” according to documents obtained by Defense News. The physiological event is known by the medical term barotrauma. The F-35 Joint Program Office believes barotrauma in the jet is caused when sensors on the outer mold line of the aircraft detect “rapidly changing static pressures” that, in turn, drive very quick changes of the cockpit pressure regulator valve. Lockheed Martin has tested a fix that proved to be successful in a laboratory setting, Lockheed program head Greg Ulmer said last year. But flight testing of that improvement has not occurred, slowing the pace of a solution. The F-35 program office now says flight testing of a new cockpit pressure regulation system is planned for mid-2020. If all goes well, the deficiency should be completely eliminated in 2021. On nights with little starlight, the night vision camera sometimes displays green striations that make it difficult for all F-35 variants to see the horizon or to land on ships. On nights where there is little ambient light, horizontal green lines sometimes appear on the night vision camera feed, obscuring the horizon and making landing on a ship more dangerous. The problem is different than the notorious “green glow” issue, caused when the F-35 helmet-mounted display's LED lights produce a greenish luminescence that inhibits a pilot's ability to land on an aircraft carrier on nights with very little light. At one point, both Lockheed and the government's program office believed both problems could be solved by the F-35 Generation III helmet that the U.S. military began fielding last year. Although the program office no longer considers the “green glow” problem a deficiency, it appears that the new helmet did not completely solve the night vision camera issue. The program office told Defense News that it intends to develop software improvements and test them in flight later this year, but the deficiency will not be considered “closed” until at least 2021. The sea search mode of the F-35's radar only illuminates a small slice of the sea's surface. Unlike the other problems, which are the result of the contractor not meeting technical specifications or the jet not working as planned, this deficiency is on the books even though the jet's Northrop Grumman-made AN/APG-81 active electronically scanned array radar fulfills its requirements. Currently, the radar can only illuminate what is directly in front of it when in sea search mode. That performance is not good enough for the Navy, which wants to be able to search a wider area than is currently possible. Although this problem can be fixed with software modifications and an upgrade to the radar's processing power, it will continue to be on the books for some time. According to the program office, “[the] U.S. services agreed to plan for an improved radar mode, which will require the Technology Refresh-1 avionics update, for software release in [calendar year] 2024.” ‘A line in the sand' Although Defense Department and military leaders have criticized the F-35 program for high operations and sustainment costs, the operational community has rallied around the performance of the jet, praising its advanced computing capability that allows the aircraft to mesh together data from different sensors and provide a more complete picture of enemy threats. Brig. Gen. David Abba, who leads the Air Force's F-35 integration office, said in March that he was comfortable with the path forward to correct open deficiencies, downplaying the impact of those issues on daily operations. “Is it important to hold folks' feet to the fire and make sure that we're delivering on the capabilities that we need? Yes,” he said. But, he added, it's also difficult to balance the need to meet a stated technical requirement against the reality of a fielded technology that may already be performing well in daily operations. “That's the crux of the acquisition and the delivery problem that we have,” Abba said. “When we say ‘I need this to work exactly like this,' I'm drawing a line in the sand. If I'm a half degree on one side of that line versus the other, is it really that different? That's where the art comes in.” “We've got to kind of get over ourselves a little bit and acknowledge that we never field perfect weapon systems,” he continued. “I don't want to diminish the fact that it's critical that we get after open DRs, but every weapon system in the United States Air Force — and frankly around the planet — has open deficiencies. What matters is the severity of those deficiencies and ensuring that we have a robust process between government and industry to triage those and deal with them appropriately.” Aaron Mehta and David B. Larter contributed to this report. https://www.defensenews.com/smr/hidden-troubles-f35/2020/04/24/the-pentagon-has-cut-the-number-of-serious-f-35-technical-flaws-in-half/

All news