What happened
On May 5, 2023, a student pilot performing solo training maneuvers at EPPO experienced a structural failure of the nose landing gear. The flight was part of a PPL(A) training syllabus involving a series of eight solo circuits. While the first two circuits were visually monitored by an instructor, the subsequent three were monitored only via radio communications as the instructor was moving around the airfield.
Upon completing the fifth touch-and-go maneuver, the pilot reported that the nose gear had likely broken. The pilot stated that the landing itself was performed correctly, touching down on the main wheels first. However, as the nose wheel made contact with the runway, the pilot increased engine power, at which point the nose gear failed, causing the aircraft to drag heavily along the runway surface. The failure resulted in damage to the nose gear strut, the propeller, and the lower engine cowlings. The pilot exited the Tecnam P2008-JC, registration SP-SMC, without injury.
The investigation
The investigation focused on the physical condition of the failed component. Examination of the nose gear strut, which is a closed-section steel construction, revealed significant corrosion on the internal surfaces and parts of the fracture surface. Because this component is a sealed unit, internal corrosion typically only occurs if the structural integrity is compromised, allowing moisture and oxygen to enter.
Investigators identified that the corrosion was extensive enough to suggest a pre-existing crack had developed along the weld edge, breaching the seal long before the final failure. The investigation also noted that the runway at EPPO features protruding centerline lights and touchdown zone lights. It was observed that aircraft of this type are subject to additional nose gear loads when striking these lights at speed, though it could not be definitively determined if these lights contributed to this specific event.
Findings
- The primary cause was excessive loading of the nose gear during training flights, which led to a fatigue crack developing near the weld.
- A contributing factor was the high volume of flight training conducted at EPPO (over 90% of flights for this aircraft type), which subjects the gear to frequent high-stress cycles.
- The potential for exceeding allowable stress limits when the nose gear strikes protruding runway lighting was identified as a contributing factor.
Safety action
Following the incident, several preventive measures were implemented:
- A technical inspection of the nose gear struts was performed on all aircraft in the fleet.
- Technical and flight personnel received training on improved methodologies for inspecting nose gear condition during pre-flight inspections.
- Instructors participated in training sessions regarding the principles of effective visual monitoring of student flights.