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Aviation safety reports, made easier to study

NTSB Reports is an independent research and search tool for public aviation accident and incident records. It brings NTSB aviation reports, structured fields, docket files, extracted figures, photos, videos, and update history into one searchable interface.

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December 28, 1985 · Boeing 727-232 · N519DA

Fort Lauderdale, FL

Overview

Report Status
Preliminary report
Event Type
Incident
Date
December 28, 1985
Injury Outcomes
No injuries (131 uninjured)
Location
Fort Lauderdale, FL
Aircraft
Boeing 727-232
Tail Number
N519DA
Injuries
None
Aircraft Damage
Minor
NTSB Number
MIA86MA048

After gear retraction during takeoff, at approximately 150' AGL, the aircrew heard a loud noise and noted the #2 engine had failed. They secured the engine, dumped fuel, and landed without further incident. An exam of the #2 engine revealed the combustion chamber outer case, PN 616315, had failed from high stress, low-cycle fatigue. The failure originated at a 4.6 inch crack at the rear drain boss to case weld. At the last shop inspection, a suspected crack was visually observed in this area. The case was prepared for non-destructive testing by grit blasting it with aluminum oxide beads to strip off nickel-cadmium plating. However, the testing did not reveal a crack. Therefore, the case was recoated with nickel-cadmium and returned to service. After the failure, an exam of the fracture area revealed the presence of nickel and cadmium (0.5 to 0.75 inch, centered on the fracture origin area). There was evidence that grit blasting (prior to non-destructive testing) had mechanically closed the previous crack, thus preventing detection. The operator revised the shop procedure to a shell blasting method.

Full Narrative

AFTER GEAR RETRACTION DRG TAKEOFF, AT APRX 150' AGL, THE AIRCREW HEARD A LOUD NOISE & NOTED THE #2 ENG HAD FAILED. THEY SECURED THE ENG, DUMPED FUEL & LANDED WITHOUT FURTHER INCIDENT. AN EXAM OF THE #2 ENG REVEALED THE COMBUSTION CHAMBER OUTER CASE, PN 616315, HAD FAILED FROM HI STRESS, LOW-CYCLE FATIGUE. THE FAILURE ORIGINATED AT A 4.6 INCH CRACK AT THE REAR DRAIN BOSS TO CASE WELD. AT THE LAST SHOP INSPN, A SUSPECTED CRACK WAS VISUALLY OBSVD IN THIS AREA. THE CASE WAS PREPARED FOR NON-DESTRUCTIVE TESTING BY GRIT BLASTING IT WITH ALUMINUM OXIDE BEADS TO STRIP OFF NICKEL-CADMIUM PLATING. HOWEVER, THE TESTING DID NOT REVEAL A CRACK. THEREFORE, THE CASE WAS RECOATED WITH NICKEL-CADMIUM & RETURNED TO SVC. AFTER THE FAILURE, AN EXAM OF THE FRACTURE AREA REVEALED THE PRESENCE OF NICKEL & CADMIUM (0.5 TO 0.75 INCH, CENTERED ON THE FRACTURE ORIGIN AREA). THERE WAS EVIDENCE THAT GRIT BLASTING (PRIOR TO NON-DESTRUCTIVE TESTING) HAD MECHANICALLY CLOSED THE PREV CRACK, THUS PREVENTING DETECTION. THE OPERATOR REVISED THE SHOP PROCEDURE TO A SHELL BLASTING METHOD.

Flight

Event TypeIncident
Event Time13:33 EST
Nearest AirportFt Lauderdale Int'L (0nm N)
Runway9L
Runway Length8018 ft
Runway Width150 ft
Flight Plan FiledIFR
Aircraft FireNo
Aircraft ExplosionIflt

Aircraft

AircraftBoeing 727-232
Tail NumberN519DA
Aircraft CategoryAir
DamageMinor
Operating RulePart 121
Engines3
Engine TypeTurbofan
Engine DetailsP&W · JT8D-15A · Turbofan · 15500
Seats157

People & Injuries

Injury SummaryNo injuries (131 uninjured)
Fatal0
Serious0
Minor0
Uninjured131
Total131
Crew 1Age 55 · First Class

Conditions

ConditionsVMC
LightDaylight
Wind130° @ 9 kt
Visibility5 sm
CeilingBroken clouds 8000 ft
Temperature / Dew Point64 F
Altimeter30.00 inHg
Observation Time17:49
Weather SourceWFAC

Appendix: Source Data