Su-57's unusual fuselage screws caught on camera in China

Just yesterday, the Russian Su-57 fighter jet touched down in China for the Zhuhai Air Show, quickly drawing attention once again—but not for the reasons its creators might have hoped. This aircraft’s latest appearance only further tarnishes its reputation, as it has been all but confirmed that this jet is anything but stealthy. Regardless of its sleek design or radar-absorbent coatings, the Su-57’s capabilities seem to falter under scrutiny.

As one observer at the airshow pulled out their phone to capture the aircraft up close, little did they know they would inadvertently reveal critical details that could go viral. These shots provided an unprecedented glimpse at the Su-57, showcasing its construction in a way rarely seen before. What stands out is the surprising number of screws adorning the fuselage and wings—hundreds, in fact—rather than the rivets typically used in stealth aircraft design.

The use of screws instead of rivets raises serious concerns about the aircraft’s radar stealth capabilities. Rivets create a tighter, smoother bond between panels, while screws protrude slightly, reflecting radar waves. This distinction is crucial, as even the smallest surface irregularities can increase the likelihood of radar detection. Each imperfection compromises the aircraft’s stealth profile, making it more susceptible to enemy radar systems.

Moreover, riveted connections ensure structural integrity under the intense forces experienced during high-speed maneuvers. Unlike screws, which can loosen due to vibrations, riveted joints remain secure and stable, a vital requirement for aircraft operating in combat scenarios.

The aerodynamic properties of stealth aircraft also benefit from riveting; the smooth surface it provides minimizes drag, enabling more efficient and agile flight. At the speeds involved, particularly those nearing or exceeding the sound barrier, even minor surface irregularities can significantly impact aerodynamic performance.

Additionally, the precision required for applying radar-absorbent coatings demands a smooth substrate. Rivets allow for more uniform application of these specialized coatings compared to screws, which may require adjustments and could introduce micro-cracks. Any flaws in this coating not only increase the risk of detection but also diminish the effectiveness of the stealth technology itself.

This issue of screws on the Su-57’s wings first garnered attention a few years back, when footage released by the Russian Air Force showed the aircraft up close. The video clearly displayed screws on the outer wings and other fuselage panels, igniting a flurry of questions among military experts and aviation enthusiasts alike. Stealth technology necessitates a seamless surface and meticulous attention to detail in every component to minimize radar visibility; thus, the choice to use screws instead of rivets raised eyebrows and doubts.

Experts speculated that screws might represent a temporary fix used during the prototyping phase or for pre-production aircraft to facilitate possible modifications or repairs. However, it seemed incongruous for an aircraft touted as cutting-edge technology meant for operational missions and demonstrating stealth capabilities.

Another theory suggested that screws were utilized to secure easily replaceable panels or components that required faster access during maintenance. These panels are typically located in areas deemed less critical for radar visibility. Yet, such explanations did little to assuage skeptics who argued that screws disrupt the aircraft’s sleek aerodynamic shape and jeopardize its radar-absorbing qualities, which are vital for maintaining stealth.

The ongoing saga of the Su-57, especially its visible screws, highlights the technological hurdles and production challenges that Russia faces in developing modern stealth aircraft. While the Su-57 aims to compete with other fifth-generation fighters like the F-22 and F-35, such details cast doubt on the quality of its manufacturing standards and the robustness of its design.

Comparing the stealth characteristics of the F-22, F-35, and Su-57 reveals not just technological innovations but also strategic differences in the approach to invisibility. The F-22 Raptor, with its astonishing radar cross-section [RCS] of just 0.0005 square meters, epitomizes the pinnacle of stealth technology. Its sophisticated geometry and flat surfaces are specifically designed to minimize radar wave reflection, rendering it virtually invisible to enemy detection systems.

In contrast, the F-35 Lightning II, a multirole fighter, employs a different approach to stealth, achieving an RCS of around 0.005 square meters. While its radar signature is higher than that of the F-22, the F-35 combines good stealth with advanced sensor and communication systems. Its versatility makes it a preferred choice for contemporary military operations, even if it lacks the ultra-low visibility of its predecessor.

However, the Su-57 struggles to match the stealth levels of its American counterparts. With an RCS ranging from 0.1 to 0.5 square meters, the Su-57 remains detectable by radar, casting doubts on the effectiveness of the stealth technologies employed in its design. Despite its impressive maneuverability and array of weaponry, the compromises made in its stealth capabilities underscore the challenges Russia faces in producing modern fighters.

This dynamic among the three aircraft illustrates the divergent strategic priorities and technological capabilities of the United States and Russia. The F-22 remains the undisputed leader with its minimal RCS, followed closely by the F-35, while the Su-57, despite its ambitious aspirations, lingers in the shadows of its American rivals. Ultimately, these disparities not only highlight the innovations within the aviation industry but also reveal the fundamental challenges confronting the future of military aviation.

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