Technical problems experienced historically
According to the GAO, increased labor rates coupled with technical problems associated with avionics, airframe, and engines have caused 70% of the F-22 cost growth.
Avionics: overcoming avionics software instability was a key challenge that led to an extension of the EMD phase (engineering, manufacturing and development).
Airframe: Lockheed Martin experienced a number of technical challenges with the F-22 airframe, including buffeting of the vertical tail fin, a separation of materials in horizontal tail fin, and “bumps on external shape due to repackaging internal systems.”
Engine: F119 engine fuel consumption has been unsatisfactory, and problems were experienced with the engine’s core combustor, which did not demonstrate desired temperature levels. Another disappointment was manufacturing problems with fuel-air heat exchangers which reduced effectiveness.
Cockpit Canopy: The F-22 has experienced on-going challenges with the cockpit canopy, including cracking and reliability.
Maintenance and Support Requirements: The F-22 does not meet the Air Force Airlift Key Performance Parameter (KPP) of 8 C-141 equivalents to move a F-22 squadron. 8.8 C-141 equivalents are required. Further, mean time between maintenance is 3 to 5 times the Air Force requirement of ~2 flight hours between maintenance.
Although it is difficult to draw a direct correlation between technical problems and aircraft accidents (also known as mishaps), the F-22 mishap rate may be noteworthy, and may reflect on the technical challenges experienced. The F-22 program experienced three Class A mishaps (>$1 million in damage) in 14 months.” (Appendix G)
Air Force
The Air Force presentation provides evidence that the modernization of systems essential to the new mission of the F-22A has yet to be completed. The main concern is a new radar system, which is considered by the Air Force to be integral to the F-22A’s ground-attack and intelligence gathering capabilities.8 The radar system is not even scheduled to be received by the Air Force until November 2006, and the software is not scheduled to be completed until 2010. The nature of this funding establishes the case that the F-22A is still receiving, and will continue to receive, essential upgrades that are still being developed and have yet to be tested. This ultimately affects the F-22A’s ability to prove that the program complies with the “Stable Design” requirement. (Appendix B)
Requirement 5: That the estimates of both the cost of the contract and the anticipated cost avoidance through the use of a multiyear contract are realistic.
GAO
“We believe this is questionable at this time and will require the Air Force to submit a detailed and independent estimate of the cost and will require some evidence that the contractor is willing to sign up to this cost.” [Emphasis added] (Appendix A)
CRS
“The DoD has reported 10 cost over-runs in the F-22 program. (DoD is required to report cost overruns in the SAR when the cost estimate is 15% higher than past SAR.) ... Adjusting for inflation, the program unit acquisition cost (PUAC) estimate in 1991 was $114 million per aircraft ($05) and in 2006 the estimate was $354 million per aircraft ($05). In real terms, this represents a per-aircraft increase of over 200%.”(Appendix G)
DCAA
A November 9, 2005, Defense Contract Audit Agency (DCAA) presentation9 concluded there is “Moderate to high risk ... [in] Cost Estimate Development” after discovering $141 million in unsupported, inaccurate, and defective data in Air Force F-22A cost estimates. (Appendix H)
House Government Reform Subcommittee on National Security Chairman Christopher Shays
The Air Force has a history of not providing accurate cost estimates, and there is little reason to believe that it will be any more accurate for this round of procurement. For instance, five years ago, the House Government Reform Subcommittee on National Security was frustrated in getting accurate F-22A program cost estimates from the Air Force. The Subcommittee had tasked the GAO with reviewing the F-22A program’s cost reduction plans. What the GAO found was a $7 billion variance between the Air Force’s cost estimates and those made by the Office of the Secretary of Defense’s Cost Analysis Improvement Group. On August 20, 2001, Subcommittee Chairman Chris Shays wrote to House Armed Services Chairman Duncan Hunter that, “. . . as you proceed with your deliberations on the pace and scope of the F-22A program, please be advised we can have little confidence in the accuracy of production cost estimates and less confidence in the legitimacy of projected production cost savings based on those estimates.” (Appendix I)
Requirement 6: In the case of a purchase by the Department of Defense, that the use of such a contract will promote the national security of the United States.
At the end of the day, perhaps the most important question remains - why are we continuing to fund a Cold War-era weapon that was designed to counter the next-generation Soviet fighters that were never constructed? In fact, the GAO stated, “Based on our review, in our opinion, the DOD has not demonstrated the need or value for making further investments in the F-22A program.” (Appendix A) While the final requirement of the law that it promotes the national security of the United States is a matter of judgment and is not quantifiable, the ballooning costs of this aircraft render it impossible to meet the Air Force's own stated requirements for 381 F-22A’s “in order to meet the needs of the warfighter.” If it is too expensive to buy enough aircraft to meet our national security needs, this certainly challenges the assumption that the final requirement has been met.
![]()
... the FY 2006 President's Budget did not include sufficient funds to terminate the Air Force C-130J aircraft procurement and accelerate the Marine Corps KC-130J aircraft procurement if the unsupported cost estimate was valid.21
Of course, requesting the cancellation costs from Congress would require an accurate, publicly available figure subject to review and debate. So far, the Air Force has not provided such a figure for its proposed F-22A multiyear procurement, which could lead to the same exaggerated cancellation estimates as the C-130J if the F-22A program faces trouble.
Indeed, as recently as February 2006, a Power Point presentation from the Air Force showed that its plan was to get a special waiver from the Office of the Secretary of Defense that would allow the Air Force to fund cancellation costs outside the contract: “Termination liability and contract cancellation covered by Air Force outside F-22 budget authority. ... Need OSD(C) waiver to allow termination liability/cancellation ceiling to be an unfunded contingent liability.” (Appendix B, page 18)
In March 2006 Congressional testimony, the CBO described how cancellation of a multiyear procurement would put the government and the taxpayer at greater risk if funds were not set aside:
But with no funds set aside specifically for cancellation costs, the Air Force would have to terminate orders for some or all of the aircraft that had already entered production if a decision was made to cancel subsequent orders. Thus, if it canceled the remaining years of the multiyear contract at the end of the first year, the government would not only forgo the aircraft to be produced in later years but also would not receive all of the planes it had ordered in the first year and the taxpayers’ investment in those aircraft would be lost. In particular, at the end of the first year, the Air Force would have ordered 20 aircraft. If the government decided to cancel the contract at that point but had not set aside funds specifically for cancellation costs, it would not only forgo the 40 aircraft that had not entered production, but, to free up funds for cancellation costs, it would have to stop work on some of the 20 aircraft that had already been ordered. The Air Force’s proposal differs from the practice of full up-front funding in two ways: it seeks incremental funding for acquiring capital assets, and it provides for a multiyear procurement without funding for possible cancellation costs.22
The CBO further stated, “On the basis of cancellation liabilities for other multiyear programs, that amount could be between 5 percent and 15 percent of contract costs. ... According to the Air Force, the 60 airplanes would cost about $10.5 billion in total.” As a result, cancellation costs could reach as much as $1.6 billion if it follows the pattern set by other multiyear procurements.23
![]()
1. POGO recommends that the language authorizing multiyear procurement of the F-22A be struck immediately, to be reconsidered only when the program can more thoroughly justify its capabilities to fulfill the requirements of an MYP contractual agreement.
2. Define “substantial savings” in Requirement 1 of Title 10 U.S.C. Section 2306(b). POGO further recommends that substantial savings be defined as 10%, as has been done in the past. Establishing 10% as a permanent definition for substantial savings will provide a reasonable measure of accountability rather than leaving the standard open to interpretation.
3. Require an independent analysis of cancellation costs for the F-22A and all proposed multiyear procurements, and that those analyses be provided to Congress before it approves an MYP. Furthermore, the Pentagon should be required to request funding to cover those cancellation costs in the event the program is terminated.
4. Apply federal conflict of interest laws to federally funded research and development centers. These organizations are fully funded by the federal government and should be required to meet the same ethics standards as federal agencies.
![]()
![]()
Home I Archives I Expose I Search I Donations I Investigations I About Us I Contact Us I Press Room
Site Map I Web Overseer I Site Policies
---
© The Project On Government Oversight 2006
updated: