More Air Force drones are crashing than ever as mysterious new problems emerge
By Craig Whitlock, Washington Post, January 20, 2016
A record number of Air Force drones crashed in major accidents last year, documents show, straining the U.S. military’s fleet of robotic aircraft when it is in more demand than ever for counterterrorism missions in an expanding array of war zones.
Driving the increase was a mysterious surge in mishaps involving the Air Force’s newest and most advanced “hunter-killer” drone, the Reaper, which has become the Pentagon’s favored weapon for conducting surveillance and airstrikes against the Islamic State, al-Qaeda and other militant groups.
The Reaper has been bedeviled by a rash of sudden electrical failures that have caused the 2 1/2-ton drone to lose power and drop from the sky, according to accident-investigation documents obtained under the Freedom of Information Act. Investigators have traced the problem to a faulty starter-generator, but have been unable to pinpoint why it goes haywire or devise a permanent fix.
All told, 20 large Air Force drones were destroyed or sustained at least $2 million in damage in accidents last year, the worst annual toll ever, according to a Washington Post investigation. The Pentagon has shrouded the extent of the problem and kept details of most of the crashes a secret.
The aircraft losses pose another challenge for the Air Force as it struggles to provide sufficient drone coverage for counterterrorism operations in Iraq, Syria, Afghanistan, Somalia, Yemen, Libya, Mali and Cameroon, among other countries.
Despite a surge in requests from field commanders, the Air Force last year had to curtail its drone combat missions by 8 percent because of an acute shortage of pilots for the remote-controlled aircraft. Things have gotten so bad that the Air Force is offering retention bonuses of up to $125,000 to its drone pilots, who have long complained of overwork.
The Air Force also has contracted out more drone missions to private companies to meet what one general called “a virtually insatiable appetite” from military commanders for airborne surveillance.
While Air Force leaders have publicly bemoaned a lack of personnel and resources, they have said little about the high number of drone crashes, a long-standing vulnerability that worsened substantially last year.
Ten Reapers were badly damaged or destroyed in 2015, at least twice as many as in any previous year, according to Air Force safety data.
The Reaper’s mishap rate--the number of major crashes per 100,000 hours flown--more than doubled compared with 2014. The aircraft, when fully equipped, cost about $14 million each to replace.
The Air Force’s other primary drone model, the Predator, also suffered heavy casualties.
An older and less capable version of the Reaper, the Predator was involved in 10 major accidents last year. That’s the most since 2011, when the U.S. military was simultaneously surging troops into Afghanistan and withdrawing ground forces from Iraq.
Although the Defense Department has a policy to disclose all major aircraft mishaps, it did not publicly report half of the 20 Reaper and Predator accidents last year.
In five other cases, U.S. military officials provided confirmation only after local authorities reported the crashes or enemy fighters posted photos of the wreckage on social media.
According to the military, only one drone was downed by hostile forces: a Predator that was hit by Syrian air defenses near Latakia on March 17.
All but one of the 20 Air Force drone accidents last year occurred overseas. Six drones crashed in Afghanistan. Four crashed in the Horn of Africa, near a U.S. military base in Djibouti. Three crashed in Iraq. There were also crashes in Kuwait, Turkey, Syria and Libya.
In two cases, Air Force officials would not identify the country where the mishaps occurred.
Military drones have been dogged by persistent safety and reliability problems since the first Predator was deployed to the Balkans on a combat mission two decades ago.
Of the 269 Predators purchased by the Air Force since then, about half have been destroyed or badly damaged in accidents, records show.
Air Force officials describe the Predator as an experimental aircraft that was rushed into war zones, particularly after the U.S.-led invasion of Afghanistan in 2001. They say it has lasted much longer than expected and that, at a cost of $4 million apiece, is relatively expendable in the event of a crash.
The Air Force has about 140 Predators left and plans to retire them all by 2018. They are gradually being replaced by the Reaper.
Introduced in 2007, the Reaper can fly twice as far as the Predator and carry more bombs and missiles. Until recently, it also had a much better safety record.
Over the past three years, however, some production models of the Reaper have been hobbled by an outbreak of electrical failures.
Investigators and engineers have traced the problem to the starter-generator. It powers the drone but is prone to conking out, for reasons that remain unclear.
The Reaper carries an emergency battery backup system. But the batteries last only for about one hour. If a malfunctioning drone needs more time than that to reach an airfield, it is in trouble.
In such emergencies, the drone pilot usually has no choice but to intentionally crash the aircraft in a remote area, such as a mountainside or a waterway, to avoid striking people on the ground. No one has died in a military drone accident, though many catastrophes have been narrowly averted, documents show.
“Once the battery’s gone, the airplane goes stupid and you lose it,” said Col. Brandon Baker, chief of the Air Force’s remotely piloted aircraft capabilities division. “Quite frankly, we don’t have the root cause ironed out just yet.”
On Dec. 12, 2014, a Reaper armed with missiles and bombs experienced a starter-generator failure about 90 minutes after it took off from Kandahar Air Base in Afghanistan.
As the batteries drained, the crew intentionally flew the drone into a mountain.
“I thought it was a very prudent place to ditch it, onto a high mountain top,” the unidentified mission crew commander told Air Force investigators, according to the accident-investigation report. “Our deal is we try to do it into high mountain tops.”
Less than two months later, on Feb. 4, 2015, an Air Force Reaper had to cut short a surveillance mission over Somalia when its starter-generator died.
The flight crew tried to rush the drone back to its base in Djibouti. But with about 30 miles to go, the battery ran out and the Reaper was ditched in the sea, according to the Air Force’s accident investigation report.