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Elderly F-16Ds Cracking Up
by James Dunnigan
September 30, 2014
In August 2014 the U.S. Air Force grounded 82 F-16D jets after cracks were discovered in longerons (metal support beams inside the forward fuselage, which hold the cockpit in place). The D version of the F-16 is the two seater used for training. Some 16 percent of the 969 F-16s in the U.S. Air Force are the D model and these are all at least 24 years old with more than 5,500 hours in the air. The longeron design for the D model is different than that for the single seat models because the D model has a longer cockpit canopy. The air force is making repairs and replacements to put the grounded F-16Ds back in service.
There was a similar problem in 2013 with some older F-15s. In this case the longerons in question were eventually discovered to be defective, not suffering from old age. The inspections of the older F-15s found substandard parts in 182 aircraft. Boeing (the manufacturer) eventually admitted that it had built over a hundred F-15s using longerons that were not 2.5mm thick, as specified, but in some cases only one millimeter thick. That apparently worked when the F-15s were new but age was not kind to the thinner metal and it eventually broke. Thicker stuff apparently would not have failed because of age.
The U.S. F-16 fleet is rapidly aging. The average age of existing F-16s is over 25 years, and the average aircraft has over 6,000 flight hours on it. Back in 2009 the first Block 40 F-16 passed 7,000 flight hours. In 2008 the first of the earliest models (a Block 25) F-16 passed 7,000 hours in the air. The F-16C was originally designed for a service life of 4,000 hours. But advances in engineering, materials and maintenance techniques have extended that to over 8,000 hours. Because of the wars in Iraq and Afghanistan, F-16s sent to these areas will fly over a thousand hours a year more than what they would fly in peacetime.
(...SNIPPED)