F-22 a maintenance pig?

Washington Post:

The United States' top fighter jet, the Lockheed Martin F-22, has recently required more than 30 hours of maintenance for every hour in the skies, pushing its hourly cost of flying to more than $44,000, a far higher figure than for the warplane it replaces, confidential Pentagon test results show.

The aircraft's radar-absorbing metallic skin is the principal cause of its maintenance troubles, with unexpected shortcomings -- such as vulnerability to rain and other abrasion -- challenging Air Force and contractor technicians since the mid-1990s, according to Pentagon officials, internal documents and a former engineer.

While most aircraft fleets become easier and less costly to repair as they mature, key maintenance trends for the F-22 have been negative in recent years, and on average from October last year to this May, just 55 percent of the deployed F-22 fleet has been available to fulfill missions guarding U.S. airspace, the Defense Department acknowledged this week. The F-22 has never been flown over Iraq or Afghanistan.

Sensitive information about troubles with the nation's foremost air-defense fighter is emerging in the midst of a fight between the Obama administration and the Democrat-controlled Congress over whether the program should be halted next year at 187 planes, far short of what the Air Force and the F-22's contractors around the country had anticipated.

"It is a disgrace that you can fly a plane [an average of] only 1.7 hours before it gets a critical failure" that jeopardizes success of the aircraft's mission, said a Defense Department critic of the plane who is not authorized to speak on the record. Other skeptics inside the Pentagon note that the planes, designed 30 years ago to combat a Cold War adversary, have cost an average of $350 million apiece and say they are not a priority in the age of small wars and terrorist threats.

But other defense officials -- reflecting sharp divisions inside the Pentagon about the wisdom of ending one of the largest arms programs in U.S. history -- emphasize the plane's unsurpassed flying abilities, express renewed optimism that the troubles will abate and say the plane is worth the unexpected costs.

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David G. Ahern, a senior Pentagon procurement official who helps oversee the F-22 program, said in an interview that "I think we've executed very well," and attributed its troubles mostly to the challenge of meeting ambitious goals with unstable funding.

A spokeswoman for Lockheed added that the F-22 has "unmatched capabilities, sustainability and affordability" and that any problems are being resolved in close coordination with the Air Force.

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Lockheed farmed out more than 1,000 subcontracts to vendors in more than 40 states, and Sprey -- now a prominent critic of the plane -- said that by the time skeptics "could point out the failed tests, the combat flaws, and the exploding costs, most congressmen were already defending their subcontractors' " revenues.

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Skin problems -- often requiring re-gluing small surfaces that can take more than a day to dry -- helped force more frequent and time-consuming repairs, according to the confidential data drawn from tests conducted by the Pentagon's independent Office of Operational Test and Evaluation between 2004 and 2008.

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The Air Force says the F-22 cost $44,259 per flying hour in 2008; the Office of the Secretary of Defense said the figure was $49,808. The F-15, the F-22's predecessor, has a fleet average cost of $30,818.

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There is much more. Opponents of continued funding for new planes are obviously making their case.

As expensive as the maintenance is in terms of dollars, I am also concerned about the turn around time. I high intensity combat a pilot can't afford to take a couple of days off for skin repair for every hour of dog fight. What is likely to happen is that the planes will be rushed back into combat and become less stealthy as the fight goes on. This will in turn put a real premium on wiping out the enemy craft on day one.

Doing that with fewer planes will make the task even more difficult.

The down time is the most critical factor. You can usually find more money to accomplish a war objective, but you can't replace the lost time in the fight.