| | Type of aircraft | Issues |
| | 1 | C/KC 135 (Tanker aircraft) | Corrosion between fuselage lap joints and spot welded double layers, around fasteners in the 7178-T6 aluminum upper wing skins, between wing skins and spars, between bottom wing skin and main landing gear trunnions, between fuselage skin and steel doublers around pilot windows,
Stress Corrosion Cracking (SCC) of large 7075-T6 aluminum forging (fuselage station 620, 820, and 960), corrosion and SCC of fuselage station 880 and 890 floor beams, wing station 733 closure rib, and corrosion in the E model engine struts. | | 2 | C-141B (Transport aircraft) | Widespread Fatigue Damage (WFD) in the fuel drain holes in the lower surfaces of the wings, corrosion and SCC in the upper surface of the center wing, fatigue cracking and SCC around the wind shield, fatigue cracking in the stiffeners in the aft pressure door, SCC in the fuselage main frames, and corrosion in the empennage. | | 3 | C-5 (Airlifter) | SCC of the 7075-T6 aluminum mainframes, keel beam, and fittings in the fuselage, 7079-T6 fuselage lower lobe and aft upper crown. | | 4 | B-52H (Bomber) | Cracking in the bulkhead at body station 694, fatigue cracking in flap tracks and in the thrust brace lug of the forward engine support bulkhead, cracking in the side skin of the pressure cabin, aft body skins, and upper surface of the wing. | | 5 | F-15 (Fighter aircraft) | Low-cycle fatigue cracking in the upper wing surface runouts, upper wing spar cap seal grooves, front wing spar conduit hole, upper in-board longeron splice plate holes, corrosion in nonhoneycomb structure including fuselage fuel tank, the outboard leading-edge structure of the wings, and the flap hinge beam. | | 6 | F-16 (Fighter aircraft) | Cracking of the vertical tail attachment bulkhead at fuselage station 479, fuel vent holes of the lower wing skin, the wing attach bulkhead at fuselage station 341, the upper wing skin, fastener problems on the horizontal tail support box beam, and the ventral fin. | | 7 | A-10 (Attack aircraft) | Fatigue cracking in the wing auxiliary spar cutout of the center section rib at wing station 90, outer panel front spar web at wing station 118 to 126, outer panel upper skin at leading edge. Fatigue cracking in the center fuselage forward fuel cell floor at the boost pump, forward fuselage gun bay compartment, forward fuselage lower longeron and skin at fuselage station 254, and center fuselage overwing lower floor panel stiffeners. Fatigue cracking in the aft nacelle hanger frame, thrust fitting and the engine inlet ring assembly skin/frame. Fatigue cracking in the main landing gear shock strut outer cylinder. Exfoliation corrosion in the 2024-T351 aluminum lower wing skin, 7075-T6 aluminum upper wing at the leading edge, 2024-T3511 aluminum lower front spar cap, 7075-T6 aluminum fuselage bottom skin 2024-T3/7075-T6 aluminum fuselage side skin and beaded pan, and 2024-T3511 aluminum horizontal stabilizer upper spar caps. Pitting corrosion in the 9Ni-4Co-0.3C steel wing attach fitting bushing and lug bore, main landing gear fitting attach bolts, 7075-T6 aluminum aft fuel cell aft bulkhead, and 2024-T351 center fuselage upper longeron. SCC in the wing attach bushing flange, and the main landing gear attach bolts. | | 8 | E-3A (Airborne Warning and Control System) | Fatigue and corrosion in the 7178-T6 rudder skins and spoiler actuator clevis. Exfoliation corrosion in the 7178-T6 upper wing skin, leading edge slats, main landing gear door, fillet flap, fuselage stringer 23, and magnesium parts. Delamination and disbonds in the windows, floor panels, and nose radome core. Wear in the antenna pedestal turntable bearings. | | 9 | E-8 (Joint Surveillance and Attack Radar System) | “Small” fatigue cracks in fastener holes in the 7075-T6 aluminum stringers, in the 2024-T3 aluminum skins. | | 10 | T-38 (Air training command aircraft) | Fatigue cracking in the lower surface of the wing, lower wing skin fastener holes, wing skin access panel holes, milled pockets on the lower wing skin, and the fuselage upper cockpit longerons. SCC in the fuselage cockpit upper and lower longerons, fuselage forgings.
Honeycomb corrosion in the horizontal stabilizer (due to water intrusion), and the landing gear strut door. |
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