Originally posted by: DLeRium
Originally posted by: EarthwormJim
Originally posted by: PingSpike
I don't really get the "designed to last" thing...assuming you have suitable replacement parts available and a solid maintenence schedule, shouldn't it be possible for any machine to last for eternity? I mean, you may eventually replace every part making it technically a different plane altogether, but if you keep fixing its not going to blow up at 4001 hours.
The issue isn't necessarily the components, but the airframe itself. You can only replace so many parts on an airframe. Some are integral and cannot be replaced.
That's why you run inspections. You use whatever inspection tools to check for cracks, deformation, stress, etc etc, and you make half-life estimates. Those 4000 hour lifespans are based on preliminary estimates. You can run a simple inspection process by inspecting at the 2000 hour mark, and then you re-estimate Is 4000 a good esimate at that point? If you can extend it, go ahead.
It wouldn't make financial sense to retire a fleet of 500 B-52s at the 4000 hour mark just because you designed for 4000 hours. You test and inspect at that point, and if they're still good, you extend the estimated lifespan. If you retired everything when it gets "old," then you would be spending billions getting new equipment all the time.
This is of course just an over simplification of the inspection process, and I'm sure they do very thorough tests to make sure that these aircraft can continue operating.
The problem is not that the planes have reached an artificial milestone and will be retired because of it, or that inspections cannot locate worn out components. The problem is that high performance aircraft which have been flown a great deal, above their initial lifespan estimates, require more and more maintenance to ensure airworthiness. The increased maintenance is a two-fold problem.
First, taking a plane down for maintenance removes it from the active inventory so you either need to have more aircraft on hand to perform the same mission (instead of two spares, you need four) or you need to modify the mission (one flight of F-15s vs. two). If you choose the first option, then you play into the second problem (see below). Compound it, actually.
Second, more intensive and frequent maintenance means that your logistical trail is longer and heavier. You need more maintenance personnel and more spare parts. An increase in logistics for maintenance means less airlift or sealift is available for munitions or combat troops. More personnel increases the footprint at a deployed location so you need more security forces to guard them, more food, more housing, etc. All of those people and resources burden logistics.
One other consideration is that even if you can keep the aircraft flying, an airframe that is 30+ years old has the inherent weakness that it was designed without the benefit of the last 30 years of aeronautical engineering. There are limitations to what you can do with the airframe in terms of upgrading the avionics and/or increasing the performance characteristics.
It's easier to illustrate with naval vessels. If you take an older missile cruiser, they had a crew of hundreds (Google...the USS California [nuclear-powered missile cruiser] had a crew of 540). The latest ship class the Navy would like to build is the Zumwalt class, which will have a crew of (Google)...140, and will be immensely more capable (it's a destroyer but with 5,000 more tons displacement than the California). It's probable that the US Navy could have kept the California going until today, but that would mean 400 extra personnel full time plus the loss of the new capabilities which the Zumwalt will employ.
The heavy bombers, especially the B-52, are called "bomb trucks" for a reason. There isn't much to them, and they don't need to be terribly sophisticated. They move a tremendous amount of weight to a point in space and release that weight. Now, with JDAM (GPS-aided bombs), the bombers don't even really need to aim, which begs the question of why we need aircrew in the bombers. I just read today that the Air Force's next generation bomber program includes both manned and unmanned aircraft.