A CCA does not necessitate a defensive system. I would argue that it is worth carrying some kind of basic defense because the aircraft are still somewhat expensive and it likely is cost ineffective to make the UAV too easy to shoot down. If an opponent can reliable shoot one down with a single AAM at extreme range, then it can rapidly negate large numbers of them (assuming it has good target information). If the CCA is able to detect missile launches (which should be quite easy with a DAS like system; I believe it serves as the missile warning sensor in F-35), then it can be aware enough to attempt evasion. It also can easily deploy expendable decoys, both ejected and towed, and time those actions with its maneuvering (in fact an AI likely could execute turns and present engagement angles with precise decoy timing in a far superior manner than a human pilot). That at least would force opponent aircraft to double tap and fire well within AAM envelope as is generally necessary with a high performance piloted aircraft. No easy trash shots.
Whether a CCA needs anything more than though I do not know - I would actually rather doubt it. The goal in my mind is to have a low enough signature such as to be able to passively detect and track a 5th generation target, and close to within the no escape zone of the AIM-120. If that goal is achieved, platform survival is not a super high priority - if I am trading a CCA for every opponent fighter, that is cost effective and sustainable. Is a more elaborate defensive system worth while? Maybe, but if I were the USAF I would definitely want to run a lot of tests and simulations to prove the case. Perhaps some kind of spoof jammer is cost effective as well; who knowns. If there is already a frequency agile electrically steerable x band emitter on the aircraft, then using it as a jammer is just a question of software. But it might not be worth installing extra hardware vs just throwing more expendable decoys on the airframe.
That is in my mind an
expendable CCA if I can basically expect to launch one, have it kill an opposing aircraft, and not return afterwards.
IIRC the "attritable" exchange rates were somewhere between 5:1 and 10:1, though I think 10:1 is going to require enough defensive systems to make the CCA very expensive. We should probably aim at exchange rates of somewhere between 3:1 and 7:1 as the definition of "attritable".
Indeed, if the companion aircraft was to have similar range and payload then removing the pilots would do almost nothing for cost, same as having a CCA equivalent of F-35. That is why the USAF is trying to calibrate exactly how much capability a CCA needs to still be effective. It may well be that Incr 1 CCAs are a move in the wrong direction - not enough capability, or even possibly too much. But the USAF has decided that they have gone as far as they can with theory and simulation and needs to start producing something now for real life testing and to provide at least some capability going forward. I suspect if anything, future CCAs actually get smaller and more numerous, but we shall see.
Which is a good thing.
Now we get to the Century Series equivalence and iterate a few times to see what size CCAs we actually need. Look at the variety of aircraft sizes that got produced in the Century series. Empty weights ranging from 14k to 51klbs. 3x 500nmi combat radius interceptors (F101, F102, F106), a 1000nmi radius interceptor or bomber escort (XF-108), a short range point defense interceptor (F104), 3x nuclear strike fighters (F100, F101A, F105), and finally the first
multirole fighter-bomber (F110/F4). At the tail end of the Century Series we even got a
very capable interdiction bomber with a variant designed for BARCAP or super long range interception (F111). No, the F-117 doesn't count as part of the Century Series.
And that's about the development path/scatter I expect to see. The current desired CCA is basically a long range interceptor, they're not expecting any dogfighting out of it. So something conceptually equivalent to an
F101 or F102 F-86(!!!! because they're subsonic) right now. So there's a couple of iterations to go before we get to the Ultimate Interceptor/F106 equivalent CCA. Gotta get one supersonic (M1.4-1.8, F-35 speed), then one as fast as the F22 or NGAD. (Two iterations, not 3-4)
As a side note, the just-supersonic CCA would be a good accompaniment to F35s so you could still get good use out of them, even if they'd struggle to keep up with an F22 or NGAD while supercruising.
But all of those are still about the size of a big cruise missile but with a few AMRAAMs internally instead of a single big warhead.
I'm not sure we will see a point defense interceptor CCA (F104 equivalent). That role has really been taken over by capable SAMs. The only real advantage a CCA would have is being able to be redeployed a lot faster than a Patriot battery. The physics of trying to intercept any hypersonics makes it so that any defense has to basically be sitting on top of the target to be able to get the intercepting missile in front of the hypersonic. So a plane that can scoot 200km or so (2min from launch to altitude and 3min at ~Mach 2.9) in the time between "hypersonic launch detected" and "interceptor needs to launch" may prove a viable option to cover enough ground versus how many SAM sites you'd need.
A BARCAP or Air Policing CCA is an interesting idea, but I expect that to remain a manned aircraft role for the forseeable future. Partly because it's going to be a big airframe to fly 500nmi and then orbit for 2 hours, and partly because someone is going to want to have eyes on scene for Air Policing. Just flat better situational awareness with a pilot on scene.
Then we get into questions about weapons load. Most of the Century Series assumed one engagement and one or two kills per mission, 2-4 missiles carried. That lasted up till the F110/F4 and F111. F110/F4 carried 4x Radar guided and 4x IR missiles, so could arguably intercept 4 enemy planes per mission. Then the F111B was set up to have 6x Phoenix missiles which would be launched in a volley but guided to individual targets and a pair of Sidewinders for cleanup, so arguably intercepting 7 enemy planes/AShMs per mission. The F110 and F111 conceptual equivalents are also getting into
"CCAs the size of the plane they're escorting", though, so are unlikely to be built due to expense.
One of the biggest limits on the CCAs is "small" afterburning engines for supersonic flight. The only relatively recent engine is the F125 used in the F-CK-01, but that was designed in 1979! The other option is the RR Adour, but that first ran in 1968... USAF really needs to pony up some development funds for a "~10klb-in-afterburner" class engine for CCAs. Or they end up buying F404/F414s
designed for the Navy, ewwwwwwww... Plus, F404/F414 are about twice the power you need. Might be good for the 104-equivalent CCA, though.
And the bigger problem is that there's only 2 engines designed for supercruise currently available and they're both huge. F119 and F135. No small engine is designed with the low pressure ratio needed for supercruise. So that's going to need some help as well if we want CCAs that can supercruise along with their controller.
EDIT: I think you're being pretty fast and loose with payload numbers. B-21 is credited with at least 20,000 lbs, and in at least one USAF slide I saw stated 30,000. And it must minimally be able to drop the GBU-57, possibly with reduced fuel load. You can load a lot of crap onto an F-15, but not nearly that much, and it will not travel super far with those kind of load outs. Payload is definitely a big driver of size, and one of the sacrifices the CCAs seem to make is minimizing their payload to 2-4 AAMs and nothing more to keep the thrust and fuel requirements (and thus size and cost) down.
As far as the B21 payload goes, carrying the GBU-57 means they drop the rotary launcher out of the bay, which gives them several thousand pounds of load back. I wouldn't be surprised if one of the B2 guys tells me that the rotary launcher weighs 8000lbs, or that the Bomb Rack Assembly weighs 10,000lbs! So yes the B21 can carry a 30,000lb bomb with a payload of 24,000lbs, but it doesn't change the gross weight of the plane or impact the fuel load as much as it sounds like it should.
So bombers have to be manned but not fighters it seems.
There isn't any cost advantage to making a
long range high capacity aircraft unmanned, no.
The question is, "at what capacity-at-range point does unmanned get a cost advantage over manned for a strike aircraft?"
Obviously not at 24klbs over 3000nmi radius (B-21).
What about 24klbs over 1100nmi (F111 capacity)? Or what about 24klbs over 700nmi (Strike Eagle capacity)? 6000lbs over 700nmi (F-35 internal capacity)? ~17,000lbs over 300nmi (F-16 capacity)? 16,000lbs over 250nmi (A-10 capacity)? 12,000lbs over ~250nmi* (AH-56 capacity)?
* I'm not sure about that range, I'm not seeing a combat radius for the Cheyenne so I used the Apache's. Cheyenne stated range is the same as Apache ferry range, and the Cheyenne was originally supposed to be able to self-deploy from the US to UK, which means a ~2000nmi ferry range from Gander to Heathrow.
Because if you can get a cheaper CAS plane out of a drone, you'd better believe that both Army and USAF will jump all over it.