The F/A-18E/F Super Hornet, that sentinel of naval aviation since its 2001 operational debut, is set to take to the sky for another two decades because of the Service Life Modification program. The first Super Hornet to complete depot repairs under the ambitious program was recently delivered by the Defense Contract Management Agency Boeing St. Louis.
Navy Capt. Paul Filardi, commander of DCMA Boeing St. Louis and a F/A-18 weapons system officer, spoke to the significance of this milestone. The SLM program is one of the Navy’s top priorities, expected to last more than 15 years with a program cost of approximately $7.8 billion, he said. The program functions under the “one program, two sites” philosophy, Filardi said, with activities split between St. Louis and San Antonio.
It’s just a phased approach, said Jess Overby, DCMA Boeing St. Louis F/A-18 E/F Service Life Modification program integrator. The first phase takes 18 months to extensively disassemble, inspect modify, and repair the aircraft and includes extending the service life 25 percent from 6,000 to 7,500 flight hours. This first phase which is upwards of $10 million per aircraft in comparison to 65 million dollars for a new aircraft is cost effective.
The second phase, lasting 12 months, comprises major changes to the launch system, arresting gear, and structural components. Other work includes new paint and Block III capability upgrades for crew stations, communications, and other systems. When work is done, the aircraft’s life expectancy will increase from 7,500 to 10,000 flight hours 67% boost over the original limit.
Filardi added that, together with increased tactical performance under Block III, this extended service life will ensure the Super Hornet remains the cornerstone of carrier-based naval aviation for at least the next two decades. Everything is not smooth sailing, though the biggest challenge is simply that the condition of each aircraft is currently unknown, having been in operational service for over 15 years and frequently deployed in harsh environments.
This identification, investigation, and repair of the damage requires very specialized knowledge and experience from both the industry counterparts and DCMA team members at Boeing St. Louis and Aircraft Integrated Maintenance Operations Kelly, he said. The sheer volume of the work is another challenge: 40 Super Hornets are getting the modifications during full-rate production. The program aims to process one aircraft every nine days on average.
Lt. Col. Jeremey Thomas, DCMA AIMO Kelly commander was confident in the teams at St. Louis and San Antonio. They are swift, professional, and efficient while always striving towards excellence, he said. The program has received wide support from the city of San Antonio, the state of Texas, local officials, and the Air Force community to make the program successful.
In a related development, Boeing announced that it intends to end the Super Hornet production line in 2025, after the completion of the last eight aircraft added to the fiscal 2023 budget. This decision will enable the firm to refocus its resources on other projects such as the T-7A Red Hawk, F-15EX Eagle IIs, and the MQ-25 Stingray unmanned tanker drone.
The Boeing pivot marks the end of a decade of ups and downs for the Super Hornet production line, as Congress repeatedly intervened to stretch out its life. The Navy will have taken 698 Super Hornets over 30 years. If the Indian Navy decides it wants Super Hornets, Boeing would build those aircraft, too, and then shut down the line in 2027.
Boeing spokeswoman Deborah VanNierop said that the decision to end the production line was one based on informing customers and the supply base with sufficient notice. She cited that employees associated with the Super Hornet program are well-suited for other work, such as modernization and life extension work.
The Super Hornet Service Life Modification program and the modernization of the EA-18G Growler will also continue well into the 2030s on a different production line in St. Louis. Boeing has reiterated its commitment to investing in future military aircraft programs despite recent major contracts going to competitors.
Entering into this new era, the Super Hornet will be extended in service life and improved in capability, continuing as a powerful weapon in the Navy’s arsenal for many more years.