IRIA News

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The U.S. Air Force has awarded a three-year contract worth up to $1.5 billion to Pratt & Whitney, a subsidiary of RTX, to continue sustaining the F119 engine, which powers the F-22 Raptor stealth fighter.

The contract will cover the maintenance of more than 400 powerplants, ensuring the continued operational effectiveness of the Air Force’s premier air superiority fighter.

The F-22 Raptor, a single-seat stealth fighter developed by Lockheed Martin, is renowned for its ability to “supercruise”—a capability that allows it to sustain supersonic speeds without engaging afterburners. The twin F119 engines produced by Pratt & Whitney are critical to this performance.

Jill Albertelli, president of Pratt & Whitney’s military engines division, emphasized the importance of maintaining the Raptor’s readiness and reliability while keeping costs down.

“The F119’s readiness and reliability rates have never been more important, and we are improving both while lowering lifecycle costs,” Albertelli said. “We are committed to helping our U.S. Air Force customer maintain the F-22’s combat edge.”

This latest contract reflects the Air Force’s continued reliance on the F-22 while broader discussions about its eventual replacement under the Next Generation Air Dominance (NGAD) program remain unresolved.

Data-driven maintenance

Pratt & Whitney has been implementing a Usage-Based Lifing (UBL) program since 2022, which uses flight data and engineering algorithms to determine precisely when maintenance is necessary, rather than performing scheduled overhauls at fixed intervals.

According to Caroline Cooper, executive director for the F119 program, this approach is projected to save over $800 million over the engine’s lifespan. The company acknowledged concerns about how long the F-22 will remain in service, especially given discussions about its replacement. However, a Pratt & Whitney statement emphasized that real-time flight data continuously refines the maintenance strategy, ensuring both cost savings and operational effectiveness.

“The constant flow of data collected from ongoing flight operations is continuously re-analyzed and allows the customer to take advantage of the full life of the engine parts while reducing risk to the fleet,” the statement read.

This data-driven approach could allow the Air Force to either extend the lifespan of existing parts or enhance engine performance, whichever best aligns with the service’s evolving needs.

3D-printed engine parts

In addition to refining its maintenance strategies, Pratt & Whitney is exploring the use of additively manufactured (3D-printed) parts in the F119 engine. While specifics were not disclosed, Cooper confirmed that the company is actively evaluating the technology.

“I can say with certainty that we’re looking at leveraging additive across Pratt,” she said.

The use of 3D printing in military aviation is becoming more common, as it can reduce production costs, speed up manufacturing, and enhance the durability of engine components. However, the company did not provide a timeline for when these components might be integrated into the F-22’s engines.

The F-22 program was conceived in the late stages of the Cold War, but with the decline of superpower competition in the 1990s, production was capped at 187 aircraft—far below original projections. As a result, sustaining and upgrading the existing fleet remains a critical priority for the Air Force.

The service initially planned for the Next Generation Air Dominance (NGAD) fighter to replace the F-22. However, the program is now in limbo as policymakers debate its direction. The Trump administration is expected to weigh in on the program’s future, with options ranging from a direct F-22 replacement to a multirole fighter concept that could operate alongside drone wingmen.

The uncertainty surrounding NGAD means that sustaining the F-22 fleet remains a top priority. As a result, the $1.5 billion contract with Pratt & Whitney is a crucial step in ensuring that the Raptor remains combat-ready until a clear path forward emerges for its replacement.

The Air Force’s new $1.5 billion sustainment contract with Pratt & Whitney underscores the ongoing importance of the F-22 Raptor in America’s air superiority strategy. With data-driven maintenance, potential 3D-printed engine components, and continued investment, the F-22 is set to remain a dominant force in the skies for the foreseeable future. However, with NGAD’s future uncertain, how long the Raptor will remain the backbone of the Air Force’s air superiority remains an open question.