^^^i think he was referring to regular overhauls. MLU involves a lot more than a overhaul.
History / The beginning
Reason for the Mid Life Update
When the F-16 entered service in 1979, it was expected that the aircraft would be replaced by a successor in 1999. Due to several reasons, both economical and political, the F-16 will not be replaced by a successor (which is not yet available right now) and will not be phased-out until 2010. In order to maintain the same level of operational capabilities and operational effectiveness of existing aircraft over the next ten to twenty years in this world of ever increasing technology, an extensive modernization program was developed, that later became known as the Mid-Life Update or MLU.
The project started in 1989 with a two year study of the possibilities to upgrade the F-16. In May 1991, the development phase started, which continued until 1997.
Aircraft structural integrity program
The F-16s airframe has been subject to more heavy loads than was predicted in 1979. This resulted in several unpredicted hair cracks in some of the airframe's bulkheads. Before an aircraft can be offered for MLU modification, the current state of the airframe is examined in the extensive Aircraft Structural Integrity Program (PACER SLIP). In this modification program, all bulkheads of the aircraft will be examined and repaired (using the so called Cold Working method) if necessary. After PACER SLIP, the aircraft will be able to last at least another 5,000 flying hours and can complete its life expectancy of 30 years.
Note that hair cracks are not uncommon in aircraft design. To predict the acceptable number and type of cracks, the aircraft manufacturer used information that reflected the exact capabilities of the aircraft. The F-16 was designed as a light and highly maneuverable aircraft that could withstand 9G and last for a minimum of 8,000 flight hours. All data is recorded in a load spectrum that specifies the use of the aircraft (i.e. type of missions), aircraft load and predicted number of landings.
Each aircraft will take up to 2,500 man hours, which is roughly equal to 5 months.
Initial work
All five Test, Verification and Installation (TVI) aircraft are stripped to the airframe and re-assembled in a later stadium in order to perform all kinds of work, including the replacement of hundreds of wiring harnesses (the cockpit alone incorporates one hundred new wiring harnesses).
When the aircraft will be completely re-assembled, they will be transported to Edwards Air Force Base in order to perform flight tests. After these flights, the Dutch and Norwegian aircraft will moved to Leeuwarden Air Base for further flight tests. One of the tests include testing of the new fire control radar system under European weather conditions. In a later stadium, the Belgian TVI aircraft follows. At that time, the software tests will commence.
Is it worth all the effort and the money?
Because of the F-16s unpredicted heavier airframe load in the Royal Netherlands Air Force, the aircraft's airframe needs to be overhauled apart from the Mid Life Update to allow the airframe to complete 3,500 flight hours. Keeping the aircraft operational until its 5,000th flight hour make the costs involved in the airframe repair / overhaul affordable and acceptable, making expensive airframe "re-inspections" unnecessary. The costs of the airframe repair / overhaul only form a quarter of the costs involved in the Mid Life Update.
The costs involved in the ASIP maintenance program result in increased operational capabilities as well as an increased life expectancy for the F-16 aircraft. These costs are lower than the price of a new aircraft. After the F-16s Mid Life Update modernization program, the F-16 can compete again with the most advanced fighters of today's world. An increase of both technical and economical life expectancy justify the cost for the Mid Life Update program.
Structure & Avionics / Avionics upgrade
Most of the avionics that will be installed during MLU is existing hardware that is modified for use in the F-16. The Modular Mission Computer however is designed especially for the F-16. This will undoubtedly be one of the most important computers of the F-16 once MLU is completed.
Modular Mission Computer
The most important item of the Mid Life Update package is the Texas Instruments Modular Mission Computer (MMC) which is the key to providing new capabilities such as sensors and weapons, improved pilot-vehicle interface and pilot aiding. Subcontractors are Terma, Nea Lindberg and Signaal. This computer consists of line-replaceable modules (LRMs) based upon several MIPSCO R3000 32-bit RISC microprocessors which will run the ADA high-order language. An object-oriented design will reduce the lead times for new software and will improve the software maintenance. Other features include multiplex bus modules, avionics display processor, display driver and power supplies. The MMC will be the key to driving towards fleetwide commonality of system modes and software.
It will replace three components, namely the computers currently in use for the Expanded Fire Control Computer (XFCC), the Head Up Display Electronics Unit (HUD EU or HUD symbol generator), and the Stores Management System's Expanded Central Interface Unit (XCIU). The MMC will take up 42% less volume in the aircraft, weights 55% less and consumes 37% less electrical power. Of the 24 slots available in the computer, ten will be used for future growth.
Fire Control Radar
The Westinghouse AN/APX-66(V2) Fire Control Radar (FCR) will be equipped with an completely new signal data processor. It allows a track-while-scan mode for up to ten targets as well as a six-on-six AIM-120 AMRAAM capability. Other features include a 25% improvement in detection and tracking range, an enhanced Doppler Beam Sharpening mode (DBS), enhanced air-ground and ground mapping modes, a medium resolutions DNS, an enhanced ECCM, and a color display compatibility. The MLU kit and the receiver will also have an 40% improved reliability over previous versions.
Physical parameters :
Volume : 3.43 cu. ft.
Weight : 261.5 lb
Power : 3285 V/A AC (Max), 155 Watts DC (Nominal)
Cooling : 11.3 lb/min a 27degr. C
Advanced IFF
The Hazeltine APX-111(V1) Advanced Identification Friend-or-Foe system (AIFF) with increased range performance (100 Nm) will operate via four (rather striking) antennas mounted on the upper forward fuselage in front of the canopy. These "bird slicers", more formally known as Upper Interogator Fuselage Mounted Antenna (FMA) Array, will be the most noticeable exterior change of the Mid Life Update.
The benefits of this AIFF system will be the support for BVR weapons delivery in excess of Radar/Missile limits and the enhanced situational awareness which reduces the chance of a fratricide.
Cockpit displays and indicators
Wide Angle Conventional Head Up display
The new Wide Angle Conventional Head Up Display (WAC HUD) manufactured by GEC Marconi Avionics will increase readability and pilot comfort, offers a wider field of view than the current HUD and adds a raster capability and support for night operations. This HUD is also FLIR and EEGS compatible.
Multi-Function Display
The Multi-Function Display (MFD) set, manufactured by Honeywell, include two 10cm x 10cm (4in x 4in) color active matrix liquid crystal multi-function displays, which will replace the current single monochrome Radar Electro/Optical Indicator Unit (REO-IU) and the Stores Control Panel (SCP) - the Stores Management System display. Both displays will increase the pilot's Situational Awareness drastically and will therefore contribute to increased flight safety.
Enhanced Upgraded Programmable Display Generator
An Enhanced Upgraded Programmable Display Generator (EUPDG), manufactured by Honeywell and Nea Lindberg in Denmark, will support the two color MFD's, allowing the pilot to set up to twelve display programs. One of them includes a color Horizontal Situation Display, which will be, provide the pilot with a God's eye view of the tactical situation. Inside is a 20MHz, 32-bit Intel 80960 Display Processor and a 256K battery-backed RAM system memory. The color graphics controller is based on the T.I. TMS34020 Raster Graphics Chipset.
Audio/Video Recorder
Also new is the Cockpit Television System manufactured by Telemetrics. The current Airborne Video Tape Recorder (AVTR) will be replaced by a TEAC color audio visual tape recorder. Head Up Display images as well as the images of the Multi Function Displays will be selectable for recording which is great for the debriefing of missions.
A helmet-mounted display (HMD) is not part of the present configuration, but program director Philip Schwab believes that most operators may decide to incorporate it if the program continues to progress well. Lockheed Martin and Honeywell have demonstrated the use of the HMD, combined with DTS, to allow the pilot to designate targets of opportunity simply by placing an HMD pipper on the target. EPAF and USAF are to pursue a five-nation HMD program, related to the introduction of the ASRAAM, the Advanced Short Range Air-to-Air Missile, somewhere in the next century. Software and hardware modifications are already being studied by a cockpit review team and both space and wiring is already being accounted for in the current MLU.
On Eglin AFB, Honeywell and GEC Marconi experiment with a Helmet Mounted Cueing System (HMCS), combined with Raytheon's Box-Office agile missile. Honeywell and GEC-Marconi will start with the development and promotion of a Look-And-Shoot Helmet Mounted Cueing System for the F-16. This year, flight tests will take place in one of Lockheed-Martin's F-16B duals.
Side stick controller and throttle grip
The side stick controller (manufactured by Lear Astronics Corporation) and throttle grip are block 50 unit models and will replace the current Block-10/15 stick grips. Both throttle and stick will be equipped with various controls, for an increased variety of functions, including VHF and UHF communications, IFF interrogation, Improved Data Modem operation, secondary flight controls (speed brakes), night vision cockpit blackout selection (NVIS Switch) and boresighting as well as slaving of missiles (now only selectable via the cues of the Stores Control Panel, which requires hands-off-throttle, head-down operation).
Modifications & Upgrades / Other features
Improved Data Modem
The Improved Data Modem (IDM), developed by the U.S. Naval Research Laboratory and built by Symetrics Inc., will be used to exchange data of various systems and targets with other aircraft (e.g. F-16, A-10, AH-64 or E-8 JSTARS) or with a ground station. Provisions have been made for the Link 16 Joint Tactical Information Distribution System (JTIDS).
Electronic Warfare Management System
An Electronic Warfare Management System (EWMS) developed by Terma Elektronik AS in Denmark provides centralized EW control for entire EW suite : management of threats (RWR), ANQ pods and advanced chaff/flare systems.
Miniaturized Airborne GPS Receiver
MAGR, Miniaturized Airborne GPS Receiver built by Rockwell-Collins Avionics & Communications Division, operating via an E-Systems antenna. It provides accurate position, velocity and time to support navigation, steering and weapon delivery. This system is smaller and lighter than the Block 40/50 receiver (RCVR 3A), consumes less power but delivers the same performance.
Digital Terrain System
A Digital Terrain System (DTS), which uses the British Aerospace Systems & Equipments (BASE) Terprom system hosted on a Fairchild Defense memory module (128kb). The DTS provides precise navigation (in conjunction with the Rockwell/E-Systems GPS) and performs a number of safety and situational-awareness functions in low-level flight. This does not imply however, that the F-16 will be capable of automatic terrain following. The (former Block-10/-15) F-16 aircraft does not have a digital flight control system, so the system cannot be linked directly to the aircraft's Flight Control System. The pilot will be following the DTS advice manually by flying on the Flight Path Marker in the HUD. The system is as accurate as the accuracy of the maps being used, so this requires extremely accurate maps of the area.
Cockpit Layout
The cockpit layout will be the one of the F-16C Block-40/50. However, unlike the Block-40/50 aircraft, the MLU F-16s will be equipped with color displays. The cockpit lighing will be compatible with Night Vision Imaging System (NVIS) and all visible surfaces will be painted black. The Night Vision goggles are deactivated in the HUD field-of-view to allow inhibited HUD viewing.
Provisions for recce pods
Up to now, if the F-16 were to carry reconnaissance pods, it had to be specially equipped for that purpose. A number of Dutch F-16s has been equipped to carry the Oudedelft pod. The MLU will see a standard recce interface installed for a number of reconnaissance pods.
Provisions for the Microwave Landing System
This system will be incorporated in the F-16 structure. The system will not be standard equipment on the F-16 and the particular countries have to by it seperately. Although not standard, the system will enhance flight safety by adding an MLS, which can guide the pilot through adverse weather conditions.
Following the DT&E phase
FTT-1 tape
Radar performance evaluation
FTT-2 tape
Weapon modes Air-Air and Air-Ground testing
Navigation (INS and GPS)
Basic MMC core functions integration
FTT-3 tape
Datalink
IFF interrogation
Horizontal Situation Display
DTS integration
Cockpit color screen implementation
FTT-4 tape
"Clean-up" tape (intended as correction to imperfections found in earlier phases)
After the M1 tape, the M2 tape followed in 2000, M3 tape in 2003, M4 tape in 2005 and M5 tape in 2009. All these tapes incorporate other features, including:
M2 tape
Automatic Target Hand-off System (ATHS)
Integration of anti radiation missile capability
Integration of target designator system
Further implementation of the Digital Terrain System
M3 tape
Integration of the Link-16 system
Integration of capability for GPS controlled weapons (GBU30/32)
Introduction of Helmet Mounted/Cueing Sight
Introduction of NVG compatible helmets
M4 tape
Introduction of advanced short-range missile, as a replacement for the current Sidewinder (AIM-9X, IRIS-T)
Integration of advanced Link-16 functions
Integration of SNIPER targeting pods
M5 tape
Integration of capability for stand-off weapons (AGM-154)
Introduction of more advanced A/G weapons (EGBU-12)
Introduction of advanced Stores Management System
Specifications
Engine: One Pratt & Whitney F100-PW-220 turbofan, rated at 14,590 lb.s.t. dry and 23,770 lb.s.t. with afterburning.
Maximum speed: Mach 2.05 at 40,000 feet. Service ceiling 55,000 feet. Maximum range 2400 miles. Initial climb rate 62,000 feet per minute.
Dimensions: wingspan 32 feet 9 1/2 inches, length 49 feet 3 1/2 inches, height 16 feet 8 1/2 inches, wing area 300 square feet.
Weights: 16,285 pounds empty, 25,281 pounds combat, 37,500 pounds maximum takeoff.
