Accident Overview
On June 18, 2023, about 0843 central daytime, a Piper PA46-350P airplane, registration N463HP, was substantially damaged during a forced landing near College Station, Texas. The pilot, the sole occupant, was not injured. The flight was conducted under Title 14 Code of Federal Regulations Part 91 as a personal flight.
Flight History
The pilot reported that while climbing through 4,000 ft mean sea level (msl), the oil temperature began increasing, reaching 215°F, which exceeded the normal range of 190-200°F. Despite reducing the climb rate, the oil temperature continued to rise to 230°F. The pilot then requested an instrument clearance to return to Easterwood Field Airport (CLL). While receiving vectors for the RNAV 11 approach, the pilot descended to about 2,000 ft msl when smoke was noted in the cabin and engine power was lost. Unable to glide to a runway, the pilot selected a field for a forced landing. The airplane sustained substantial damage to the wings and fuselage during the landing.
Maintenance History
Eleven days before the accident, on June 7, 2023, the pilot experienced decreased manifold pressure and a partial loss of engine power during a cross-country flight. After diverting to CLL, an aviation mechanic determined the turbocharger required replacement. Following turbocharger replacement, an engine test run was completed uneventfully. An engine logbook entry dated June 16, 2023, documented that in addition to the turbocharger replacement, the mechanic drained the engine oil, opened the oil filter, and cleaned the oil pickup screen, where a small amount of metal was observed. The oil sump was flushed, and 11 quarts of new oil were added. The logbook noted the engine ran normally at 42 inches of manifold pressure after maintenance.
Postaccident Examination
A postaccident engine examination was conducted with assistance from a Lycoming Engines technical representative. The engine oil sump contained about 2 quarts of oil, and the recovered oil displayed evidence of metal contamination. The oil filter was saturated with metallic particles. No loose or disconnected oil lines were found. Engine crankshaft continuity was established, with compression noted on all cylinders except cylinder No. 6. Spark plugs exhibited normal operation signatures. The oil suction screen plug located in the oil sump was found not secured with safety wire as required per the manufacturer's maintenance manual. There was no evidence that the plug or its required safety wire were damaged by other objects. The plug was loose, with engine oil observed below it. The crush washer behind the plug was intact and undamaged.
Metallurgical examination of a portion of the oil dipstick port and fractured crankcase revealed no material defects; fracture features were consistent with overload. Analysis of metallic debris from the oil suction screen was consistent with connecting rod material and steel from fittings, fasteners, and brackets.