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00719 CATASTROPHIC UNCOMMANDED CLOSURES OF ENGINE FEEDLINE FUEL VALVE FROM CORRODED ELECTRICAL CONNECTORS

Picture for 00719 CATASTROPHIC UNCOMMANDED CLOSURES OF ENGINE
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Product Number: 51300-00719-SG
ISBN: 00719 2000 CP
Author: David H. Home, ChE, P.E.
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The F-16 Fighter is a spectacular combat aircraft that has proven its value, but corrosion problems plague its maintainability, safety, and reliability. One problem discovered by a Kelly AFB Engineer trained in corrosion control was corrosion of tin- plated electrical connector pins mated with gold-plated sockets. Frettin corrosion between these contacts (so subtle that it's not even visible) appears to have been implicated in at least five F-16 crashes when their main fuel shutoff valves closed uncommanded. The prime contractor believed the tin to gold was astute design and incorporated the dissimilar metal combination in connector sets all over the aircraft. However, application of "MIL-L-87177A Grade B; Corrosion Preventive" into the fuel valve's dissimilar metal electrical contacts appeared to stop the uncommanded fuel valve closures for about a year, suggesting corrosion was the cause. In a MIL-L-87177A corrosion test application to all F-16 aircraft electrical connectors increased the Mission Capable (MC) rate 16%. In addition, many millions of dollars saved were documented even in the flight test program by treating aircraft and AGE electrical connectors with the corrosion preventive spray. Keywords: Dissimilar metals, gold contacts, tin contacts, sea water, fretting corrosion, galvanic corrosion, electrical connectors, short circuits, irthibitors, military equipment, aerospace, humidity, F-Ill, F-16, moisture intrusion, MIL-L- 87177A, lubricants, corrosion inhibiting lubricants, corrosion specialist, corrosion costs, corrosion control training.
The F-16 Fighter is a spectacular combat aircraft that has proven its value, but corrosion problems plague its maintainability, safety, and reliability. One problem discovered by a Kelly AFB Engineer trained in corrosion control was corrosion of tin- plated electrical connector pins mated with gold-plated sockets. Frettin corrosion between these contacts (so subtle that it's not even visible) appears to have been implicated in at least five F-16 crashes when their main fuel shutoff valves closed uncommanded. The prime contractor believed the tin to gold was astute design and incorporated the dissimilar metal combination in connector sets all over the aircraft. However, application of "MIL-L-87177A Grade B; Corrosion Preventive" into the fuel valve's dissimilar metal electrical contacts appeared to stop the uncommanded fuel valve closures for about a year, suggesting corrosion was the cause. In a MIL-L-87177A corrosion test application to all F-16 aircraft electrical connectors increased the Mission Capable (MC) rate 16%. In addition, many millions of dollars saved were documented even in the flight test program by treating aircraft and AGE electrical connectors with the corrosion preventive spray. Keywords: Dissimilar metals, gold contacts, tin contacts, sea water, fretting corrosion, galvanic corrosion, electrical connectors, short circuits, irthibitors, military equipment, aerospace, humidity, F-Ill, F-16, moisture intrusion, MIL-L- 87177A, lubricants, corrosion inhibiting lubricants, corrosion specialist, corrosion costs, corrosion control training.
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