Project

Explanation

Description

The $938 million F/A-18 Hornet Upgrade Air 5376 Phase 3.2 project is a structural modification project that is required to address structural deficiencies identified during the F-18 International Follow-On Structural Test Program. The project is divided into two structural refurbishment program, each providing a different amount of fatigue life to the aircraft to allow the Hornet fleet to reach its Planned Withdrawal Date as explained below:

■  A number of aircraft will have their centre barrels (the primary load bearing structure in the aircraft) replaced along with a few other discrete modifications and inspections providing continued airworthiness from 72% to 100% of the intended structural fatigue life. This program is called Structural Refurbishment Program (SRP) 2.

■  The remainder of the Hornet fleet will undergo a range of other discrete structural modifications providing continued airworthiness from 72% to 85% of the intended structural fatigue life. This program is called SRP1D.

Background

The F/A-18 Hornet was designed to reach a structural fatigue life of 6,000 hours based on a US Navy fatigue usage spectrum. However, RAAF fatigue usage is more severe than the US Navy fatigue usage meaning that RAAF Hornets would exhaust their fatigue life far earlier than the manufacturer's specified 6,000 hours. Without some further analysis and structural modification, the RAAF Hornet would not reach its Planned Withdrawal Date.

In order to address this issue the RAAF, in collaboration with Canada, initiated the F-18 International Follow-On Structural Test Program to determine the fatigue life of the aircraft and identify modifications to ensure the continued safe operation up to 6,000 flying hours. The results of the F-18 International Follow-On Structural Test Program showed that both RAAF and Canadian Forces Hornet fleets required major mid-life structural modifications to reach a structural fatigue life of 6,000 hours.

A number of the proposed modifications are being incorporated on the Hornet fleet during the Hornet Upgrade Air 5376 Phase 3.1 Project providing continued airworthiness up to 72% of the intended structural fatigue life. Phase 3.2 incorporates further structural modifications as described in the Project Description above providing sufficient fatigue life for the Hornet fleet to reach its Planned Withdrawal Date.

L-3 Communications MAS (Canada) Inc. based in Mirabel, Canada was the contractor selected for design and prototyping of the Hornet Upgrade Phase 3.2 modifications. L-3 Communications MAS (Canada) Inc. was selected due to its experience in designing, prototyping and installing almost identical modifications on the Canadian Hornet fleet.

Uniqueness

This project does not introduce any new capability to the Hornet aircraft fleet. It is a large structural modification program designed to ensure the structural fatigue life of the fleet is sufficient to meet the Planned Withdrawal Date. Therefore, the project does not have an Initial Operational Capability or Final Operational Capability.

Major Challenges

The nature of structural refurbishment of an ageing aircraft is such that unknown conditions may be revealed in the process of disassembly. This may result in more extensive refurbishment work becoming necessary and its unpredictable nature poses a challenge to the production schedule.

As a further consequence of the disassembly required during structural refurbishment, additional parts may be required to replace those that are found to be unserviceable. Obtaining these parts in time to maintain the production schedule is a major risk confronting the project.

Current Status

Cost Performance

19 aircraft have been modified to SRP1D configuration and three aircraft have been modified to SRP2 configuration. All modified aircraft have been accepted within budget.

Schedule Performance

All modified aircraft have been accepted within schedule. The remaining aircraft to be modified are scheduled for completion by December 2012 for SRP1D and June 2010 for SRP2.

Capability Performance

Modified aircraft meet the project technical specification and have been accepted back into service.