Issues With Weakened Metal Parts In Near-Crash Cited Again

The military is once again pausing operations of the Bell Boeing V-22 Osprey after a near-crash at Cannon Air Force Base in Clovis, New Mexico, on November 20, 2024.

Similar to a fatal accident in Japan in December 2023, contaminated metal parts failed, leading to an engine failure. In this latest incident, the crew received warnings shortly after takeoff and were quickly able to put the aircraft back on the ground without any injuries.

An initial review of the part involved in this incident showed that weakened metal may have played a role, but in a different part of the powertrain than the Japan accident.

On recommendation from Naval Air Systems Command (NAVAIR), Lt. Gen. Michael Conley, commander of the Air Force Special Operations Command, directed a pause on all Osprey training flights “to allow time and space for us to understand what happened.”

While this investigation is still under way, the metal that failed in the Japan crash, X-53 VIMVAR, had multiple inclusions, or contaminants caused by foreign material getting into the metal during the manufacturing process. The contaminants cause microscopic weak spots and can lead to fatigue cracking and eventual failure of the part.

Since the Japan accident, Bell Flight, which builds the transmission systems and assembles the Osprey at its Amarillo, Texas, facility, have been pressing for ways to make the metal stronger and more reliable.

FMI:  www.navair.navy.mil/