After 30 Years and Billions of Dollars the Missile Defense Contractors Still Cannot Solder a Wire Correctly

Notwithstanding the myriad tough technical problems that are involved, one would think that the Missile Defense Agency would at least be able to make the manufacturers make the interceptors to spec:

Two serious technical flaws have been identified in the ground-launched anti-missile interceptors that the United States would rely on to defend against a nuclear attack by North Korea.

Pentagon officials were informed of the problems as recently as last summer but decided to postpone corrective action. They told federal auditors that acting immediately to fix the defects would interfere with the production of new interceptors and slow a planned expansion of the nation's homeland missile defense system, according to a new report by the Government Accountability Office.

As a result, all 33 interceptors now deployed at Vandenberg Air Force Base in Santa Barbara County and Ft. Greely, Alaska, have one of the defects. Ten of those interceptors — plus eight being prepared for delivery this year — have both.

Summing up the effect on missile-defense readiness, the GAO report said that "the fielded interceptors are susceptible to experiencing … failure modes," resulting in "an interceptor fleet that may not work as intended."

………

One of the newly disclosed shortcomings centers on wiring harnesses embedded within the kill vehicles' dense labyrinth of electronics.

A supplier used an unsuitable soldering material to assemble harnesses in at least 10 interceptors deployed in 2009 and 2010 and still part of the fleet.

The same material was used in the eight interceptors that will be placed in silos this year, according to GAO analyst Cristina Chaplain, lead author of the report.

The soldering material is vulnerable to corrosion in the interceptors' underground silos, some of which have had damp conditions and mold. Corrosion "could have far-reaching effects" because the "defective wiring harnesses" supply power and data to the kill vehicle's on-board guidance system, said the GAO report, which is dated May 6.

………

Chaplain told The Times that based on her staff's discussions with the Missile Defense Agency, officials there have "no timeline" for repairing the wiring harnesses.

The agency encountered a similar problem with wiring harnesses years earlier, and the supplier was instructed not to use the deficient soldering material. But "the corrective actions were not passed along to other suppliers," according to the GAO report.

L. David Montague, co-chairman of a National Academy of Sciences panel that reviewed operations of the Missile Defense Agency, said officials should promptly set a schedule for fixing the harnesses.

"The older they are with that kind of a flawed soldering, the more likely they are to fail," Montague, a former president of missile systems for Lockheed Corp., said in an interview.

The second newly disclosed defect involves a component called a divert thruster, a small motor intended to help maneuver the kill vehicles in flight. Each kill vehicle has four of them.

The GAO report refers to "performance issues" with the thrusters. It offers few details, and GAO auditors declined to elaborate, citing a fear of revealing classified information. They did say that the problem is different from an earlier concern that the thruster's heavy vibrations could throw off the kill vehicle's guidance system.

The report and interviews with defense specialists make clear that problems with the divert thruster have bedeviled the interceptor fleet for years. To address deficiencies in the original version, Pentagon contractors created a redesigned "alternate divert thruster."

The government planned to install the new version in many of the currently deployed interceptors over the next few years and to retrofit newly manufactured interceptors, according to the GAO report and interviews with its authors.

That plan was scrapped after the alternate thruster, in November 2013, failed a crucial ground test to determine whether it could withstand the stresses of flight, the report said. To stay on track for expanding the fleet, senior Pentagon officials decided to keep building interceptors with the original, deficient thruster.

What sort of moron structures a multi-billion dollar multi-year defense system in such a way that there is absolutely no quality control?

To accelerate deployment, then-Defense Secretary Donald H. Rumsfeld exempted the missile agency from the Pentagon's standard procurement rules and testing standards.

(emphasis mine)

OK, that kind of moron.

Why the hell is the MDA still operating this way? 

Rumsfeld has been "spending more time with his family" for about 9 years, so one would think that the pentagon would be able to correct at least one of his f%$#-ups in the interim.


H/T the hairiest Saroff, aka Bear who Swims.
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