Casualties unknown

Propeller Blade Failure During Takeoff Leads to Engine Separation (N4735D)

Menomonee Falls, WI, US

On July 5, 1991, a Cessna 182A (registration N4735D) operated by Robert D. Blanchard was involved in an aviation accident near Menomonee Falls, WI. Investigators recorded the probable cause as: Fatigue failure of the propeller blade originating at the first thread of the threaded hub. This summary draws on records from the U.S. National Transportation Safety Board (NTSB) historical archive.

Sourcesthe U.S. National Transportation Safety Board (NTSB) historical archivePrimary reportUpdated 2026-07-04Data APIEditorial standards

During takeoff ground roll, a propeller blade failed due to fatigue, separating from the hub and causing the engine to break free of its mounts. The blade's threaded hub was the origin of the fatigue crack.

Incident Overview

During the takeoff ground roll, shortly after the pilot applied full power, one propeller blade failed and separated from the hub assembly. The engine subsequently broke free of its engine mounts.

Metallurgical Findings

Post-accident metallurgical examination of the propeller blade and hub assembly revealed that the failure was due to fatigue. The point of origin of the fatigue crack was identified as the first thread of the threaded hub.

Propeller Maintenance History

The propeller had been installed on July 11, 1975, and had accumulated 1,227.57 hours of operation at the time of the incident. It had not been overhauled. The manufacturer recommends propeller overhaul at intervals not to exceed five calendar years.

Subsequent Airworthiness Directive

An airworthiness directive, effective 33 days after the accident, requires a penetrant inspection of the propeller blade threaded retention area and a modification of the propeller assembly to enable early detection of failure.

Probable cause

Fatigue failure of the propeller blade originating at the first thread of the threaded hub.

Frequently asked questions

What happened in the 5 Jul 1991 Cessna 182A accident near Menomonee Falls, WI?

During takeoff ground roll, a propeller blade failed due to fatigue, separating from the hub and causing the engine to break free of its mounts. The blade's threaded hub was the origin of the fatigue crack.

What aircraft was involved and where did it happen?

The accident on 5 Jul 1991 involved a Cessna 182A, registration N4735D, operated by Robert D. Blanchard, at Menomonee Falls, WI.

What was the probable cause of the accident?

Fatigue failure of the propeller blade originating at the first thread of the threaded hub.

Investigation report by the U.S. National Transportation Safety Board (NTSB) historical archive. Original record: https://carol.ntsb.gov/event/20001212X17497. This page is a structured re-presentation; facts and quotes are in the National Transportation Safety Board (NTSB), United States.