I'm flattered that I give the impression of being an insider, however I do not work in the industry. I just like to read and have some basic technical and business knowledge. In fact, I would say you seem better informed than me.
If you still want to hear my opinion, here it is
If we are talking about overall capacity, then yes there is a need for more fab capacity. Since smartphones/IOT is a continually growing segment, you see TSMC is concentrating on the sub 7nm (also the most profitable).
However, the problems are more business than technical (sure they have been mentioned previously).
- 2024 initial production is very aggressive. How many construction projects get finished in Western countries in 2 years? One of the limitations is simply labour supply. If you need some kind of skilled construction labour, there is not enough.
- Supply location is far from customers. As mentioned, Globalfoundries is a big money loser. However, their process technology is quite advanced. One of the few foundries with FinFET and SOI capability. The issue becomes it doesn't make a lot of sense to ship chips from Western New York and Germany back to Asia for packaging. Actually Intel is doing this, but at least they are on the west coast and they had a captive market for a long time. Now that AMD's performance is competitive again, you see that their margins are threatened.
As a corollary to the above:
- Who are the customers for 5nm in the USA? 5nm by 2024 will not be the leading edge process for TSMC if things are going according to schedule. The risk is ending up with the same problem as Globalfoundries. If you are not the best, then the margin becomes lower, lower margin products are going to favor being close to Asia (To put it another way, MediaTek is not going to pay those shipping costs).
- Finally, to the best of my knowledge, the supply constraints are primarily because TSMC has been very good at supporting their customers on leading (or close to leading) edge processes in addition to actually having the best process. As a result, everyone is fighting to get their high-end chips made at TSMC (which also means TSMC has less capacity for low profit chips like 28nm)
nVidia and Qualcomm are using Samsung 8nm in addition to TSMC and there have been many reports of overheating because Samsung 8nm is simply inferior. 8nm is just the smallest feature size, if other parts of the process are not engineered well, then "Xnm" is just meaningless marketing. This was also the problem with Intel's first 10nm process (I think it was used on Cannon Lake, eventually the whole process design was thrown out). Intel is finally able to fab 10nm at volume, but only lower power chips right now (15W Laptop). Overall, Intel 10nm is probably still superior to Samsung despite the naming, which is probably why they recently announced a name change. Really, Intel is only one step behind. However, since the TSMC-AZ fab will be one step behind, then Intel and TSMC would be equals in stateside manufacturing (as long as Intel doesn't suffer further delays). As such, the issue would become less technical and more about customer support.
This was a lot to go over, so let's cut to the chase. Is the AZ Fab a Potemkin village? If you consider from a corporate standpoint, then it is really a waste of money. Is it viable? Yes, probably, but it would not be maximizing the ROI.
Ironically, Cold War ideology would favour Control economy (Communism) over Capitalism. You have empty car lots and store shelves all over the country to fight the trade war with China. It is like the old Soviet system where it was difficult to get basic consumer goods like cars, bicycles, and TVs. National champion system is inefficient and prone to corruption, otherwise everyone in Malaysia would be driving Protons.
I don't think the US is wrong to ban Huawei backend equipment domestically, USA is the expert in telecom snooping, they know what the possibilities are. Where they went wrong was their attempt to destroy the company. I get why they did it, it is like the economic version of "Shock and Awe". How well did that work out though?