Long-Term Performance Degradation of Polyurethane Foam Fillers in Military Aircraft Fuel Tanks

Igor Trofimov; Anna Yakovlieva; Sergii Voitenko; Oleg Dobrydenko; Yurii Tereshchenko; Vasyl Boshkov

doi:10.3849/aimt.01980

Authors

Igor Trofimov State University “Kyiv Aviation Institute”
Anna Yakovlieva Technical University of Košice
Sergii Voitenko State Research Institute of Aviation
Oleg Dobrydenko State Research Institute of Aviation
Yurii Tereshchenko State University “Kyiv Aviation Institute”
Vasyl Boshkov State University “Kyiv Aviation Institute”

DOI:

https://doi.org/10.3849/aimt.01980

Keywords:

thermal stability, degradation, foam filler, fuel tank

Abstract

Military aircraft fuel tanks are equipped with channel fillers made of elastic porous polymeric materials that are used to prevent explosions. Exposure to aviation fuel alters the morphological structure of the tank filler. To assess the behavior of the polymer material under fire conditions, three samples of polyurethane foam filler (new, exposed to fuel for 5 years, and for 10 years) for heat resistance and operational reliability were tested. The results confirmed that aging affects the reliability and heat resistance of the filler. Given the critical role of these fillers in military aircraft, ensuring their long-term performance is essential for operational safety. Based on the results, recommendations have been developed to enhance the operational performance of aircraft fuel tank fillers.

Author Biography

Anna Yakovlieva, Technical University of Košice

Researcher at the Department of avionics

References

PAPIS, M. and T. KRAWCZYK. Comparison of MiG-29 and F-16 Aircraft in the Field of Susceptibility to Destruction in Combat. Aviation, 2022, 26(3), pp. 131-137. https://doi.org/10.3846/aviation.2022.17592.

SAŁACIŃSKI, M., P. SYNASZKO, D. OLESIŃSKI and P. SAMORAJ. Approach to Evaluation of Delamination on the MiG-29’s Vertical Stabilizers Composite Skin. In: A. NIEPOKOLCZYCKI, A. and J. KOMOROWSKI (eds). ICAF 2019 – Structural Integrity in the Age of Additive Manufacturing. Cham: Springer, 2020. ISBN 978-3-030-21502-6.

KOZAKIEWICZ, A., S. JÓŹWIAK, P. JÓŹWIAK and S. KACHEL. Material Origins of the Accelerated Operational Wear of RD-33 Engine Blades. Materials, 2021, 14(2), 336. https://doi.org/10.3390/ma14020336.

LUZIŃSKI, R., P. SYNASZKO and K. DRAGAN. Application of Digital Radiography (Dr) in an Approach to Evaluate the Technical Condition of MiG-29ʼs Vertical Stabilizers. Fatigue of Aircraft Structures, 2021, 2021(13), pp. 1-7. https://doi.org/10.2478/fas-2021-0001.

OLEJNIK, A., S. KACHEL, P. ZALEWSKI, R. ROGÓLSKI, M. JĘDRAK and M. SZCZEŚNIAK. Finite Element Analysis of the Underslung Carrier Rocket Effect on Stress and Strain Distribution in a Structure of the MiG-29 Aircraft. Proceedings of the Institution of Mechanical Engineers, Part G: Journal of Aerospace Engineering, 2023, 237(14), pp. 3285-3303. https://doi.org/10.1177/09544100231189942.

JÓŹWIAK, S., A. KOZAKIEWICZ, S. KACHEL and D. ZASADA. Operational and Material Causes of High-Pressure Turbine Disc Damage in the RD-33 Engine. Materials, 2023, 16(17), 5939. https://doi.org/10.3390/ma16175939.

DOBRIDENKO, O., S. VOITENKO, Yu. TERESHCHENKO, A. YAKOVLIEVA, V. BOSHKOV and I. TROFIMOV. Statistical analysis of Aircraft Gas Turbine Engine Failures Caused by Quality of Fuel. In: 2024 New Trends in Aviation Development (NTAD). Stary Smokovec: IEEE, 2024, pp. 26-31. https://doi.org/10.1109/NTAD63796.2024.10850293.

OCHS, R.I. and C.E. POLYMEROPOULOS. Vaporization of JP-8 Jet Fuel in a Simulated Aircraft Fuel Tank Under Varying Ambient Conditions. SAE Transactions, 2006, 115, pp. 776-783.

MIL-DTL-83054C Detailed Specification: Baffle and Inerting Material, Aircraft Fuel Tank [online]. 2003 [viewed 2025-02-09]. Available from: https://1url.cz/zJTzW

MIL-PRF-87260B Performance Specification: Foam Material, Explosion Suppression, Inherently Electrostatically Conductive, for Aircraft Fuel Tanks [online]. 2006 [viewed 2025-02-11]. Available from: https://1url.cz/fJTzw

System of General Technical Requirements of the Air Force – 86. Book 1. Flying Machines. OTT 4.1.1 – 86. Part 2. Design and Systems of Flying Machines. Moscow: Voienizdat, 1987.

TU 6-55-53-91. Polyurethane Foam, Elastic, Open-Cell, PPU-EO-130 Brand [online]. 1991. [viewed 2025-02-09]. Available from: https://www.russiangost.com/p-340433-tu-6-55-53-91.aspx

BAKIR, M. and R. ASMATULU. Enhancing Aviation Safety: Multifunctional Graphene Nanostructured Foams for Lightweight Fire Suppression Materials. Journal of Materials Research and Technology, 2024, 33, pp. 6914-6924. https://doi.org/10.1016/j.jmrt.2024.11.009.

PRUSKI D. and M. SPRYNSKYY. Jet Fuel Contamination: Forms, Impact, Control, and Prevention. Energies, 2024, 17(17), 4267. https://doi.org/10.3390/en17174267.

YAKOVLIEVA A., S. BOICHENKO and J. ZAREMBA. Improvement of Air Transport Environmental Safety by Implementing Alternative Jet Fuels. In: 2019 Modern Safety Technologies in Transportation (MOSATT). Kosice: IEEE, 2019, pp. 146-151. https://doi.org/10.1109/MOSATT48908.2019.8944122.

IAKOVLEVA, A., S. BOICHENKO and A. GAY. Cause-Effect Analysis of the Modern State in Production of Jet Fuels. Chemistry and Chemical Technology, 2014, 8(1), pp. 107-116. https://doi.org/10.23939/chcht08.01.107.

TROFIMOV, I., A. ZUBCHENKO, A. SULIMAN and S. MAXYMOV. Development of Plant for Treatment of Working Liquids used for Process Purposes. Transport, 2008, 23(2), pp. 129-134. https://doi.org/10.3846/1648-4142.2008.23.129-134.

YEUNG, P., A. ROGERS and B. DAVIES. Safe Working in Aircraft Fuel Tanks: An Australian Experience. Applied Occupational and Environmental Hygiene, 1997, 12(9), pp. 587-594. https://doi.org/10.1080/1047322X.1997.10387726.

MURAD, M.S., E. ASMATULU, A. NURAJE, Ö. ER, M. GÜRSOY, E. BAHÇECI, M. BAKIR and R. ASMATULU. Improved Mechanical and Fire-Retardant Properties of Fiber-Reinforced Composites Manufactured via Modified Resins and Metallic Thin Films. International Journal of Advanced Manufacturing Technology, 2024, 133, pp. 4715-4730. https://doi.org/10.1007/s00170-024-13965-2.

ZALOSH, R. Deflagration Suppression Using Expanded Metal Mesh and Polymer Foams. Journal of Loss Prevention in the Process Industries, 2007, 20(4-6), pp. 659-663. https://doi.org/10.1016/j.jlp.2007.04.039.

MA, Z., J. ZHANG, L. LIU, H. ZHENG, J. DAI, L.-C. TANG and P. SONG. A Highly Fire-Retardant Rigid Polyurethane Foam Capable of Fire-Warning. Composites Communications, 2022, 29, 101046. https://doi.org/10.1016/j.coco.2021.101046.

TSABULIS, U.A., V.Ya. ZELTIN'SH, I.V. GRUZIN'SH, N.P. ZHMUD' and A.F. ALKSNIS. Effect of a Fireproofing Compound, Trichloroethyl Phosphate, on the Physical-Mechanical Properties of Isocyanurate-Urethane Foam Plastics. Mechanics of Composite Materials, 1991, 27(3), pp. 355-358. https://doi.org/10.1007/BF00616887.

CHEN, X., L. HUO, J. LIU, C. JIAO, S. LI and Y. QIAN. Combustion Properties and Pyrolysis Kinetics of Flame-Retardant Polyurethane Elastomers. Journal of Thermoplastic Composite Materials, 2017, 30(2), pp. 255-272. https://doi.org/10.1177/0892705715598361.

SIHAROVA, N.V., P. PĄCZKOWSKI, Y.I. SEMENTSOV, S.V. ZHURAVSKY, M.V. BORYSENKO, A.D. TERETS, O.V. MISCHANCHUK, M.I. TERETS, Y.V. HREBELNA and B. GAWDZIK. Thermal Degradation of Polymer Composites Based on Unsaturated-Polyester-Resin- and Vinyl-Ester-Resin-Filled Kraft Lignin. Materials, 2025, 18(3), 524. https://doi.org/10.3390/ma18030524.

GONTSOV, A.A., N.I. SLAVGORODSKII and E.G. AMARSKII. Application of Thermal Methods of Analysis to the Investigation of Combustible Shales. Solid Fuel Chemistry, 1982, 17(4), 6594198.