With the end of the cold war, our defense policy shifted from modernization through replacement to one of weapon system sustainment. Many of our weapon systems are more than 25 years old. Plans exist to extend the service life of several of these platforms to 50 years and beyond. A summary of this projection is shown in the accompanying chart, which was developed by a recent undersecretary of defense for logistics DUSD(L).
The basic mission for many of these weapon system platforms has not changed from their initial operational capability (IOC) requirements. We have modernized and replaced most of the avionics, navigation, communication, flight control, and landing systems. But the ravages of time and mission have caused a major challenge to maintenance of the airframe structure. Corrosion continues to be the number one challenge and cost driver. While we treat corrosion with sealants and other corrosion preventive compounds (CPCs), the damage from time and environment continues to take a toll. There is no fix for corrosion. The only solution is replacement of structural parts.
Our original designs met (and often exceeded) their forecasted service lives. Now structural parts need replacement. Many of these were never provisioned. Many of the original equipment suppliers no longer exist. Most of the prime contractors have experienced extreme consolidation. Those processes that originally produced parts in quantity are generally not suited for cost-effective low-volume purchases. Many times requisitions remain unfilled for years, while creative weapon system managers cannibalize parts from stricken or bone yard aircraft. Sometimes depots locally manufacture parts using manual processes and tooling one at a time.