F-16 Askeri Uçağında Kullanılan Yakıt İkmal Kapağı Asamblesinin Arıza Analizi

Yıl 2026, Cilt: 8 Sayı: 1, 53 - 70, 28.02.2026

Mustafa Özgür Deveci , Özgür Balli , Tamer Saraçyakupoğlu

https://doi.org/10.51785/jar.1768779

https://izlik.org/JA75UM29CD

Öz

Bu çalışma, F-16 uçağının üst gövdesinde bulunan yakıt ikmal kapısı tertibatının menteşesinde meydana gelen kırılma arızasının ayrıntılı metalurjik analizini sunmaktadır. Bulgular, menteşenin kulakçık bölümündeki kırılmanın, uçuş sırasında yakıt ikmal işlemleri sırasında yanlış hizalama nedeniyle yakıt ikmal bomu ile kapı tertibatı arasındaki çarpışmanın neden olduğu monoton aşırı yükten kaynaklandığını ortaya koymuştur. Kırılma yüzeyini karakterize etmek için optik ve Taramalı Elektron Mikroskobu (TEM) kullanılmış ve bu sayede kırılgan yarılma özellikleri, nehir desenleri ve yorulma çizgilerinin bulunmaması tespit edilmiştir. Tüm bunlar, döngüsel yorulma yerine tek bir aşırı yük olayına işaret etmektedir. Çalışmada ayrıca, boya dökülmesi, ezikler ve çizikler gibi mekanik hasarın görünür kanıtları gözlemlenmiş ve bu da aşırı yükün neden olduğu darbe mekanizmasını doğrulamıştır. Bulgular, sıkı havacılık standartlarına göre tasarlanmış bileşenlerin bile eksen dışı yükler ve operasyonel yanlış hizalamaya maruz kaldıklarında ciddi arızalar yaşayabileceğini vurgulamaktadır. Gelecekteki çalışmalar, eksen dışı yükleme altında menteşe yeniden tasarım stratejilerini değerlendirmek için sonlu eleman modellemesini ve dayanıklılığı artırmak için alternatif malzemeler ve tasarım değişikliklerini içerebilecektir.

Anahtar Kelimeler

Yakıt ikmal kapağı , Yakıt ikmal bomesi , Metalurjik analiz , Monotonik Yük

Failure Analysis of Refueling Door Assembly used on F-16 Military Aircraft

https://izlik.org/JA75UM29CD

Öz

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.

Anahtar Kelimeler

Refueling door assembly , Refueling boom , Metallurgical analysis , Monotonic overload

Teşekkür

The authors would like to acknowledge 1. HBFM, and Turkish Aerospace Industries for their valuable supports. They also appreciate the helpful and constructive comments of the valuable reviewers.

Kaynakça

• Ament, J., Lachmann, J., Schmelz, J., & Wandrey, L. (2024). Design and assessment of fighter pilot assistance systems for air-to-air refuelling with probe-and-drogue-equipment. CEAS Aeronautical Journal, 15, 1091–1110. https://doi.org/10.1007/s13272-024-00756-4
• Akman, H., Turgut, A. E., & Çalışkan, H. (2022). Optimal design of an in-flight refueling door mechanism. Hittite Journal of Science and Engineering, 35(1), 27–36. https://doi.org/10.17350/HJSE19030000252
• Armendáriz, I., Olarrea, J., & García-Martínez, J. (2015). Parametric analysis of a highly dynamical phenomena caused by a propeller blade loss. Engineering Failure Analysis, 57, 528–543. https://doi.org/10.1016/j.engfailanal.2015.03.007
• Balli, O. (2020). Failure analysis of inlet guide vane (IGV) actuator and bellcrank assembly used on J85 turbojet engines. Engineering Failure Analysis, 115, 104700. https://doi.org/10.1016/j.engfailanal.2020.104700
• Balli, O. (2021). Turbine wheel fracture analysis of Jet Fuel Starter (JFS) engine used on F16 military aircraft. Engineering Failure Analysis, 128, 105616. https://doi.org/10.1016/j.engfailanal.2021.105616
• Bardis, K., Avdelidis, N. P., Ibarra-Castanedo, C., Maldague, X. P. V., & Fernandes, H. (2025). Advanced diagnostics of aircraft structures using automated non-invasive imaging techniques: A comprehensive review. Applied Sciences, 15(7), 3584. https://doi.org/10.3390/app15073584
• Dally, M., & Guston, B. (2008). Jane’s aero-engines. Jane’s Information Group Limited. ISBN: 1478-2534
• Hou, J., Wescott, R., & Attia, M. (2014). Prediction of fatigue crack propagation lives of turbine discs with forging-induced initial cracks. Engineering Fracture Mechanics, 131, 406–418. https://doi.org/10.1016/j.engfracmech.2014.06.001
• Khalifeh, A. (2024). Fatigue failure in aircraft materials. In Sustainable Aviation (Vol. 283, pp. 63–79). Springer. https://doi.org/10.1007/978-3-031-65850-1_4
• Lee, D., & Achenbach, J. D. (2016). Analysis of the reliability of a jet engine compressor rotor blade containing a fatigue crack. Journal of Applied Mechanics, Transactions ASME, 83(4), 041004. https://doi.org/10.1115/1.4032376
• Ma, F., Cao, W., Luo, Y., & Qiu, Y. (2016). The review of manufacturing technology for aircraft structural part. Procedia CIRP, 56, 594–598. https://doi.org/10.1016/j.procir.2016.10.117
• Ma, M., Wang, Z., Gao, Z., & Jiang, M. (2025). Ultrasonic phased array testing and identification of multiple-type internal defects in carbon fiber reinforced plastics based on convolutional neural network. Materials, 18(2), 318. https://doi.org/10.3390/ma18020318
• Mishra, R. K., Srinivasan, K., Nandi, V., & Bhat, R. R. (2017). Failure analysis of an uncooled turbine blade in an aero gas turbine engine. Engineering Failure Analysis, 79, 836–844. https://doi.org/10.1016/j.engfailanal.2017.05.024
• Mueller, E. (2024). Failure analysis and fracture. The Minerals, Metals & Materials Society (TMS). https://www.tms.org/portal/downloads/profdev/pe_course_notes/Unit-17-Failure-Analysis-Fatigue-Fracture-Mueller_2024.pdf. Last Entered: 28 August 2025.
• Noh, H. M., Benito, A., & Alonso, G. (2016). Study of the current incentive rules and mechanisms to promote biofuel use in the EU and their possible application to the civil aviation sector. Transportation Research Part D: Transport and Environment, 46, 298–316. https://doi.org/10.1016/j.trd.2016.04.007
• Pantazopoulos, G. A. (2019). A short review on fracture mechanisms of mechanical components operated under industrial process conditions: Fractographic analysis and selected prevention strategies. Metals, 9(2), 148. https://doi.org/10.3390/met9020148
• Park, M., Hwang, Y.-H., Choi, Y.-S., & Kim, T.-G. (2002). Analysis of a J69-T-5 engine turbine blade fracture. Engineering Failure Analysis, 9(5), 593–601. https://doi.org/10.1016/S1350-6307(01)00019-1
• Purton, L., & Kourousis, K. (2014). Military airworthiness management frameworks: A critical review. Procedia Engineering, 80, 545–564. https://doi.org/10.1016/j.proeng.2014.09.111
• Saptarshi, S. M., & Zhou, C. (2019). Basics of 3D printing: Engineering aspects. In M. Dipaola (Ed.), 3D printing in orthopaedic surgery (pp. 17–19). Amsterdam, Netherlands: Elsevier.
• Schwarz, K. A. (2015). The design for manufacturing and assembly analysis and redesign of an aircraft refueling door hinge utilizing additive manufacturing (Master’s thesis, Embry-Riddle Aeronautical University). https://commons.erau.edu/edt/283
• Terzioğlu, M. (2024). The effects of crew resource management on flight safety culture: Corporate crew resource management (CRM 7.0). The Aeronautical Journal, 128(1326), 1743–1766. https://doi.org/10.1017/aer.2023.113
• Torbali, M. E., Zolotas, A., Avdelidis, N. P., Alhammad, M., Ibarra-Castanedo, C., & Maldague, X. P. (2024). A complementary fusion-based multimodal non-destructive testing and evaluation using phased-array ultrasonic and pulsed thermography on a composite structure. Materials, 17(14), 3435. https://doi.org/10.3390/ma17143435
• Tyagi, A., Tripathi, R., & Bouarfa, S. (2023). Safety management system and hazards in the aircraft maintenance industry: A systematic literature review. Aviation, 27(3), 212–224. https://doi.org/10.3846/aviation.2023.19851 United States Air Force. (2016). Technical order of engine (T.O. 2J-J85-113-1). USAF.
• Young, T. M. (2017). International standard atmosphere (ISA) table. In Performance of the jet transport airplane: Analysis methods, flight operations and regulations (pp. 583–590). Wiley. https://doi.org/10.1002/9781118534786.app1
• 1st Air Maintenance Factory Directorate (1 HBFM). (2023). Eskisehir, Turkey