@article{article_1768779, title={Failure Analysis of Refueling Door Assembly used on F-16 Military Aircraft}, journal={Journal of Aviation Research}, volume={8}, pages={53–70}, year={2026}, DOI={10.51785/jar.1768779}, url={https://izlik.org/JA75UM29CD}, author={Deveci, Mustafa Özgür and Balli, Özgür and Saraçyakupoğlu, Tamer}, keywords={Yakıt ikmal kapağı, Yakıt ikmal bomesi, Metalurjik analiz, Monotonik Yük}, abstract={This study presents a detailed metallurgical analysis of the fracture failure that occurred at the hinge of the refueling door assembly located on the upper fuselage of the F-16 aircraft. The findings revealed that the fracture of the hinge’s auricle section resulted from a monotonic overload caused by an impact between the refueling boom and the door assembly due to improper alignment during in-flight refueling operations. Optical and Scanning Electron Microscopy (SEM) were used to characterize the fracture surface, enabling the identification of brittle cleavage features, river patterns, and the absence of fatigue striations, all indicative of a single overload event rather than cyclic fatigue. The study further observed visible evidence of mechanical distress, such as paint removal, dents, and scratches, corroborating the overload-induced impact mechanism. The findings underscore that even components designed to stringent aerospace standards may experience catastrophic failure when subjected to off axis loads and operational misalignment. Future studies may include finite element modeling to assess hinge redesign strategies under off-axis loading, as well as investigations into alternative materials and design modifications to enhance durability.}, number={1}