Tornado IDS (Interdiction Strike) - Upgrade (2024)

Lessons learned from the missions in NATO´s Combined Air Operations lead now to further mid-life modular upgrade programs concerning “Combat Efficiency Enhancement” under the software cycle ASSTA 3.1. The integration of a tactical data link hardware and initial functionality (MIDS Link 16), the 500 lbs dual mode weapon LJDAM, SATURN secure radio and a Digital Video Data Recording were completed in 2012 and have since been rolled out into the fleet. This plays a key role in providing increased situational awareness resulting in optimised flexible response in the modern air-to-ground scenario.

On top of this in 2016 integration of new coloured, multifunction navigator LCDs (replacing the former TV/TAB CRTs) together with a significant increase in MIDS functionality was completed and the first aircraft were modified to that standard. Furthermore, increased MIDS functionality is being developed for release to service. In addition a digitalized emitter locator system (ELS) is being implemented; a Future Dispenser System (FDS) equipped with a Missile Approach Warner and the intergration of the AARGM into the German fleet are under development. This continuous modernisation program would allow the Luftwaffe to maintain its Tornado fleet in service until at least 2030.

Load hours are electronically recorded for many areas of the machine and result from the time in which they are really used during the flight. Therefore, the number of load hours is always lower than the number of flight hours actually flown. The basis for when a component has to be replaced is based on the results of a structural fatigue test at IABG in Ottobrunn. Here a new tornado completed around 21,000 simulated flight hours and 5,247 hours of stress. Once a component has reached its maximum load hours, it must be replaced or modified so that the machine can continue to fly.

The tornado with the identification 43 + 42 of the Tactical Air Force Wing 33 from Büchel, which had been in Holloman in the USA for a long timeUnited States of America was used in pilot training and was accordingly intensively stressed. Because he had almost reached the limit of his exercise hours, he flew to Manching on May 24, 2017. Here, in the huge jet hall on the Airbus Defense and Space site with space for 20 tornadoes, all attachments such as tanks and carriers of the 43 + 42 were first removed. The machine was then stripped of paint and checked for external damage. Subsequently, six Luftwaffe soldiers and 14 Airbus employees dismantled almost the entire plane. The goal: "To give new life to the aircraft or the worn components involved," explains Sergeant Major König. The employees of the cooperation between the Bundeswehr and Airbus checked the condition of the affected structural parts in order to replace or replace them if necessary.

The first overhauled machine took off with new structural packages for the acceptance flight: the Tornado of the German Air Force with the serial number 43+42 successfully completed its first factory flight after extensive structural measures on February 8, 2021 at Airbus Manching. On behalf of the The Federal Office of Bundeswehr Equipment, Information Technology and In-Service Support (BAAINBw), the necessary measures for a structural lifespan of up to 8,000 flight hours are currently being developed and implemented. This German Service Life Enhancement Program (SLE) is a Panavia contract in a trinational context, including the two System Design Responsibilities Airbus and BAE Systems.

The airworthiness of the tornadoes depends on the operational strength of the components of the aircraft, for which, according to structural fatigue tests, upper limits are set in the load hours. When this limit is reached, the component must be replaced so that the aircraft can continue to fly. The 43-42 had been subjected to particularly intense loads in the training company in Holloman / USA and therefore had to be largely dismantled in order to reach all parts to be replaced. Since the machines have to be kept in use much longer than originally expected, components also had to be replaced that were not planned for this (e.g. the ring bulkhead that connects the front and middle part of the fuselage). Some parts had to be re-produced, although the production lines have been closed for a long time.

By scaffolding extensive structural packages and thanks to numerous inspection measures, the first Tornado after its successful acceptance flight was extended to up to 8000 flight hours. This will ensure that the German Tornado fleet will be fully operationally also in the future. Even after more than 45 years in use, the Tornado continues to be brought up to date with the latest technology. Whether measures to extend the life of its structure, updates to avionics, new head-up displays in the co*ckpit, modernized air defence systems or the integration of new weapons: Panavia Aircraft GmbH is tasked to keep the Tornado operational. This includes also important innovations that are a prerequisite for interoperability with other weapon systems within the NATO alliance, for example a digital communication system with improved cryptography capabilities. The Tornado is prepared for the years to come and perfectly fit for the future.