Accident Details
On May 29, 2022, at approximately 1527 mountain daylight time, a Piper PA-28RT-201T (registration N2148J) was substantially damaged during a forced landing near Morgan, Texas. The pilot, who was the sole occupant, was not injured. The flight was conducted under Part 91 of the Code of Federal Regulations as a personal flight.
Sequence of Events
According to the pilot, while cruising at 9,500 ft mean sea level (msl), the throttle lever gradually moved backward, accompanied by a drop in manifold pressure. The pilot descended to about 5,500 ft msl, after which a loud rattling noise and strong vibrations emanated from the engine. The pilot shut down the engine and identified a nearby airport, W4 Ranch Airport in Morgan, Texas, for a forced landing on runway 17. Initially believing the aircraft was too high on the downwind leg, the pilot later realized after turning final that a headwind would prevent reaching the runway. The airplane touched down short of the runway in rough terrain, causing substantial damage to the right wing.
Engine Examination
The No. 3 cylinder was examined at the National Transportation Safety Board Materials Laboratory. The cylinder barrel had fractured in the smooth-walled region between the cooling fins and the threaded section where the cylinder head mounts. Stereomicroscopic examination revealed features consistent with a fatigue crack that originated along the outer diameter surface at a corrosion pit. The fracture surface exhibited radial lines and flat feathery features indicative of crack initiation and progression due to cyclic fatigue. Additionally, the inboard-facing side of the first cylinder cooling fin and adjoining material displayed black tinting over about a 180° arc, with the fatigue crack aligned with the center of the tinted area.
Maintenance History
The Continental Engine Standard Maintenance Practice Manual specifies visual inspection criteria for cylinder components, including checks for cracks, leaks, and signs of structural integrity breaches. Maintenance records indicated that compression checks of the No. 3 cylinder had been lower than those of other cylinders during the last three annual inspections. The engine had accumulated approximately 30 hours of operation since its most recent annual inspection on July 19, 2021. The mechanic responsible for the maintenance did not respond to requests for an interview.