Originally explained on the blancolirio channel on YouTube -
The timing and manner of the break make a lot more intuitive sense when you consider that the engine is essentially a massive gyroscope. As the plane starts to rotate, the spinning engine resists changes to the direction of its spin axis, putting load on the cowling. When the cowling and mount fail, that angular momentum helps fling the engine toward the fuselage.
I think far simpler explanation is "the back part failed first and engine is making thrust so it just flipped over on now-hinge mounting
Yup. That's exactly what experts said of American Airlines flight 191 which was basically the same engine mount, same failure. Engine flipping over the wing.
American 191's engine mount failed because of improper maintenance. It remains to be seen whether this failure had the same cause or if it was something else, such as metal fatigue.
A failure due to metal fatigue would still be a failure to properly maintain the aircraft, right? I know by "improper maintenance," you're referring to actual improper things being done during maintenance, and not simply a lack of maintenance. But I'm reading things like "the next check would've occurred at X miles," and, well... it seems like the schedule for that might need to be adjusted, since this happened.
Yes, when I said "improper" I meant the American 191 maintenance crew took shortcuts. The manual basically said "When removing the engine, first remove the engine from the pylon, then remove the pylon from the wing. When reattaching, do those things in reverse order." But the crew (more likely their management) wanted to save time so they just removed the pylon while the engine was still attached to it. They used a forklift to reattach the engine/pylon assembly and its lack of precision damaged the wing.[0]
Fatigue cracking would be a maintenance issue too but that's more like passive negligence while the 191 situation was actively disregarding the manual to cut corners. The crew chief of the 191 maintenance incident died by suicide before he could testify.
[0] https://en.wikipedia.org/wiki/American_Airlines_Flight_191#E...
If the (FAA-approved) maintenance schedule says "the next check should occur at X miles" and X miles hasn't happened yet, then it's not going to be classified as improper maintenance -- it's going to be classified as an incomplete/faulty manual.
Now, of course, if that maintenance schedule was not FAA-approved or if the check was not performed at X miles, that's going to be classified as improper maintenance.
Flipping backwards is what caused the engine to fly to the right and land to the right of the takeoff runway. The stills in the NTSB preliminary report clearly show the engine flying over the aircraft, to the right, and then heading straight down.
There might be some truth in that. But the report doesn't confirm that theory.
What theory? That the mount failed? Or the rotation of the engine in the photos going up and over the fuselage?
It seems like both are true, but doesn't necessarily prove WHY the mount failed.
Not an aviation expert at all, so take this with a grain of salt, but I think "the spinning engine resists changes to the direction of its spin axis" offers two important insights:
* why it failed at rotation (the first/only sudden change of direction under full throttle) rather than as soon as it was mounted onto the plane, while taxiing, as soon as they throttled up, mid-flight, or on landing. This is important because at rotation is the worst possible time for this failure: no ability to abort take-off, no ability to land safety under no or severely limited power, little time to react at all, full fuel. Knowing these failures are likely to manifest then stresses the importance of avoiding them.
* why it failed in such a way that it damaged the rest of the plane.
Not so much what was wrong with the mounting in the first place, if that's what you're asking. Presumably it was designed to withstand the forces of this moment and clearly has done so many times before.
That the engine was flung into the fuselage due to gyroscopic forces.
Well, some force flung it inboard and above the fuselage (gods, that CCTV stills sequence.) Knowing that the engine rotates CCW, there are not many candidates.
I'm presenting it "useful not true" - not an RCA.
I assume such forces are calculated and added in when deciding hot thick to make those mounting brackets.
Yes, obviously; MD-11s aren't flinging engines off the wing every single takeoff. A 34 year old airframe may or may not actually match design strength, though.
Yep. Now do 3 decades of metal fatigue.
Did I understand the report correctly that the part was scheduled to be replaced in the future after a certain number of hours, it just hadn't hit the threshold yet ?
If you're referring to this quote (excerpted from the AVHerald article linked elsewhere in the thread), I don't think so:
> At the time of the accident, N259UP had accumulated a total time of about 92,992 hours and 21,043 cycles [..] A special detailed inspection (SDI) of the left pylon aft mount lugs would have been due at 29,200 cycles and of the left wing clevis support would have been due at 28,000 cycles
This isn't talking about replacement, only inspection; and it wasn't going to happen in the near future: 7k cycles at four flights/day means inspection is due in 5 years.
Yes, but the point is that this moment of the takeoff is when a failure that's been waiting to happen is most likely both because of the thrust and the gyroscopic resistance.
Aluminum has limited loading cycles
I'd be very surprised to read that the aft lug that cracked (and the bearing it contained) were made of aluminum. They were almost certainly steel or Inconel.
Adding summary analysis from AVHerald [0]
"Your IP address 104.28.103.15 has been used for unauthorized accesses and is therefore blocked! Your IP address belongs to Cloudflare and is being used by many users, some of which are hackers and hide behind the cloud/proxy to avoid being tracked down. Hence the automatic defense closed access from that IP address.
"Make sure to not use a proxy/cloud service for visiting AVH (e.g. Apple Users turn off your private relay) but your native IP address, then access should be possible without a problem again."
No thank you, AV Herald.
That's a pretty nice message. Most sites that filter VPNs and proxies just kill the connection, give a generic error, or subject you to endless captchas.
I block all traffic from Cloudflare outright on my servers.
Every so often they sneak in new blocks of IP addresses though so you're playing whack-a-mole with a particularly scummy opponent.
> On the aft lug, on both the inboard and outboard fracture surfaces, a fatigue crack was observed where the aft lug bore met the aft lug forward face. For the forward lug's inboard fracture surface, fatigue cracks were observed along the lug bore. For the forward lug's outboard fracture surface, the fracture consisted entirely of overstress with no indications of fatigue cracking
If I'm parsing this correctly, they're saying that fatigue cracks should have been visible in the aft pylon mount, and that the forward mount was similarly fatigued but showed no damage on the outside?
> If I'm parsing this correctly, they're saying that fatigue cracks should have been visible in the aft pylon mount, and that the forward mount was similarly fatigued but showed no damage on the outside?
If you can get to the report, Figure 7 shows the left pylon, with the forward and aft lug enlarged in the inset. Both lugs cracked on two sides. They're saying both cracks on the aft lug as well as the inboard crack on the forward lug were observed to be fatigue cracks, but the forward lug outboard fracture was observed to be entirely a stress crack.
Outboard and inboard are just away from and towards the center of the plane. On the left pylon, that's left and right, respectively. So, it looks like the left side crack in the forward lug developed from overstress, but the other three cracks were from fatigue. My expectation is that fatigue should be apparent upon the right kind of inspection, if timely, even if the metal has yet to fracture.
It sounds like the aft lug failed first, and then the not quite as compromised forward lug failed in overload.
Link doesn't seem to be available now:
> Page not found
> The page you're looking for doesn't exist.
I found a link to the PDF that seems to work https://data.ntsb.gov/carol-repgen/api/Aviation/ReportMain/G...
Also in case that link stops working I got it from this page https://www.ntsb.gov/investigations/Pages/DCA26MA024.aspx
EDIT: nevermind immediately after posting this comment it is now giving a 403 error
Your first link is working fine
Yeah working again for me too, they're probably having some sort of server problems
If anyone saved a copy locally, it'd be great if you could share it somewhere. (I, for once, did not, and the tab is gone now :-/ ).
Appreciate the transparency in these reports. The technical breakdowns always highlight how complex aviation safety is.
Looks like it's been moved to https://www.ntsb.gov/investigations/Documents/DCA26MA024%20P...
Grounding all MD-11s and DC-10s is a major move. I guess it makes sense as a big factor was the fatigue cracks on the pylon (lugs), despite the pylon not being behind on inspections. I am wondering what the inspections of pylons in other planes will yield, likely that will determine whether the grounding will continue.
But beyond figuring out why the engine mount failed, I am very interested in what caused the actual crash. "Just" losing thrust in a single engine is usually not enough to cause a crash, the remaining engine(s) have enough margin to get the plane airborne. Of course this was a major structural failure and might have caused additional damage.
EDIT: It seems there was damage to the engine in the tail, even though this was not specified in the preliminary report, likely because it has not been sufficiently confirmed yet.
And if the failure of a wing engine can cause the rear engine to fail, that would raise concerns about all "two in front one in back" trijets. Similar to how putting the Space Shuttle orbiter's heat shield directly in the line of fire for debris that comes off he rocket during launch turned out to be a bit of a problem.
At this point there aren’t any trijet designs like that being built, and it’s unlikely we’ll ever see a new trijet design. It served a role in the transition from four engines to two, but now with ETOPS-370 there’s no commercially viable route that can’t be served with an appropriate twinjet.
And the failure of an inboard wing mounted engine can cause the failure of an outboard wing mounted engine on the same side, as in the case of El Al 1862. https://www.faa.gov/lessons_learned/transport_airplane/accid...
And the failure of an engine mounted on the left wing can cause debris to cross through the fuselage structure and cause a failure of the engine mounted on the right wing, or to fly thousands of feet in any particular direction, as happened to American Airlines in both a ground run incident, and in their Flight 883 accident.
https://www.dauntless-soft.com/PRODUCTS/Freebies/AAEngine/
https://aerossurance.com/safety-management/uncontained-cf6-a...
The industry also responded to those crashes. For example, the El Al 1862 incident prompted a redesign of the engine strut that was subsequently mandated as a retrofit for all 747s.
And here's a more detailed description of that ground run incident. It also found that the failure was related to a design flaw, and mandated that aircraft be grounded for inspection and rework. https://skybrary.aero/accidents-and-incidents/b762-los-angel...
I'm not a regulator or aerospace engineer or anything like that so I can't really say which actions are or are not appropriate. But I do want to observe that these are all unique failures with unique risk profiles that can't all be painted with a single broad brush. All I was trying to do in the previous post was speculate on why a MD-11 failure could result in a grounding of the DC-10 and KC-10A as well. The first thing that came to mind is that I think those are the only remaining trijets of that general shape that are still around. Though I suppose another possibility is that they all share an identical pylon design or something like that.
Yeah, the trijet design seems failed in general. Unless you can design it to tolerate any wing+tail dual engine failure -- in which case, why have the tail engine at all?
It wasn’t failed. It was designed for a very specific reason and served that purpose well.
Once the reason went away, better designs took over.
They were designed to allow smaller jets to fly over the ocean further than a two engine jet was allowed (at the time). Airlines didn’t want to waste all the fuel and expense of a huge 4 engine jet, but 2 wouldn’t do. Thus: the trijet.
The rules eventually changed and two engine jets were determined to be safe enough for the routes the trijets were flying.
Using two engines that were rated safe enough used less fuel, so that’s what airlines preferred.
It was never designed to be used anywhere else as a general design. Two engines did that better.
You've framed this as disagreeing with me, but I don't think you are. I agree the design made sense in the 1960s, when we didn't know any better and requirements were different.
In the case of the quad jets, Boeing tried the 747-SP and had minimal marketing success.
In the case of the trijets the MD-11 lived on as a freighter because it had a much higher capacity than anything else smaller than a 747.
Not quite. Dassault still makes a three engined bizjet and in theory the Chinese fly a three engined stealth jet.It was never designed to be used anywhere else as a general design. Two engines did that better.
> in which case, why have the tail engine at all?
"you know what this motorized piece of anything needs, less power"
-nobody, ever
You know you can just make the wing engines 50% more powerful, right?