Incident Overview

Date: Thursday 10 May 2001
Aircraft Type: McDonnell Douglas DC-9-83 (MD-83)
Owner/operator: Spanair
Registration Number: EC-FXI
Location: Liverpool International Airport (LPL) – ÿ United Kingdom
Phase of Flight: Landing
Status: Substantial, repaired
Casualties: Fatalities: 0 / Occupants: 51
Component Affected: Right Main Gear Strut CylinderRight Main Gear Strut Cylinder
Investigating Agency: AAIBAAIB
Category: Accident
An automatic landing on runway 27 was initiated by the first officer, piloting the aircraft. Immediately upon touchdown, the right main landing gear failed, causing the aircraft to slide 1,600 meters and come to rest on its right flaps, slats, and wingtip. An emergency evacuation was immediately conducted. Examination of the aircraft revealed a fractured right main gear strut cylinder below the trunnions, releasing the wheels/axle assembly. A fatigue crack, measuring approximately 3.5 mm long and 1.1 mm deep, was found on the cylinder fracture, which was subsequently identified as a fatigue crack. The incident was likely caused by spin-up drag loading combined with surface irregularities introduced during a grit-blasting process, potentially leading to a mode of ‘gear walking’ that propagated the cracks.An automatic landing on runway 27 was initiated by the first officer, piloting the aircraft. Immediately upon touchdown, the right main landing gear failed, causing the aircraft to slide 1,600 meters and come to rest on its right flaps, slats, and wingtip. An emergency evacuation was immediately conducted. Examination of the aircraft revealed a fractured right main gear strut cylinder below the trunnions, releasing the wheels/axle assembly. A fatigue crack, measuring approximately 3.5 mm long and 1.1 mm deep, was found on the cylinder fracture, which was subsequently identified as a fatigue crack. The incident was likely caused by spin-up drag loading combined with surface irregularities introduced during a grit-blasting process, potentially leading to a mode of ‘gear walking’ that propagated the cracks.

Description

An automatic landing on runway 27 was carried out with the first officer being the pilot flying. The right main landing gear failed immediately upon touchdown. The aircraft slid along the runway and came to a halt some 1,600 metres further on, resting on its right flaps, slats and wingtip. An emergency evacuation was carried out. Examination of the aircraft showed that the right main gear strut cylinder had fractured below the attachment trunnions, releasing the wheels/axle assembly back into the flaps and wing/fuselage fairing. The lower portion of the failed cylinder remained attached only by the sidestay. A closer inspection revealed the presence of an anomaly on the forward outer surface of the cylinder fracture, which subsequent examination identified as a fatigue crack measuring approximately 3.5 mm long and 1.1 mm deep. CAUSAL FACTORS: 1. The right main landing gear cylinder failed immediately upon touchdown due to the application of spin-up drag loads on a section of the cylinder containing a major fatigue crack 3.2 mm long and 1.0 mm deep and several other smaller cracks associated with it. 2. The origins of these fatigue cracks could not be identified but other embryonic cracks were found which were associated with surface irregularities arising from a grit-blasting process during manufacture. Abnormal loading, possibly due to an occurrence of a mode of fore-and-aft vibration known as ‘gear walking’ is thought to have been responsible, at some time in the aircraft’s history, for propagating the cracks to a depth at which continued growth was possible under normal loading. Alternatively, some abnormal loading may have relaxed the beneficial compressive surface stresses induced by shot-peening at the critical section and allowed propagation from the same surface defects. 3. Inspection and other mandatory preventive measures taken following two similar accidents did not prevent the occurrence of this third accident. This was probably due to the small size of cracks which are required to be detected before reaching a critical dimension.

Primary Cause

Spin-up drag loading and surface irregularities induced by grit-blasting during manufacture, potentially resulting in a ‘gear walking’ mode of vibration.Spin-up drag loading and surface irregularities induced by grit-blasting during manufacture, potentially resulting in a ‘gear walking’ mode of vibration.

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