What happened
On March 1, 2025, at 0800 EST, a Boeing 767-300F operated by Federal Express Corp was performing a domestic cargo flight from Newark Liberty International Airport (EWR) to Indianapolis International Airport (IND). During the initial climb, approximately 500 feet above the ground, the flight crew observed three white birds to the left and below the aircraft. Immediately following this observation, the crew heard an abrupt bang and experienced moderate to severe vibrations.
The first officer, acting as the flying pilot, initiated a right turn back toward Newark and declared an emergency. The captain observed engine indications signaling damage and fire on the right engine, including a fire bell, warning lights, and an "R ENGINE FIRE" message on the EICAS display. Following the quick reference checklist (QRC) for engine fire or severe damage, the crew shut down the No. 2 engine and discharged the first fire bottle. Despite discharging a second fire bottle, fire indications persisted throughout the flight.
The crew requested the assistance of a passenger, who was type rated in the aircraft, to help with monitoring and checklists. During the landing approach, Air Traffic Control (ATC) notified the crew that fire was visible on the right engine. After landing, the captain stopped the aircraft on the runway and shut down the left engine. Aircraft Rescue and Fire Fighting (ARFF) responders arrived and applied water to the engine. All fire indications eventually ceased, and the crew exited the aircraft via the stairs.
There were no injuries to the two crew members or the single passenger on board the N178FE.
The investigation
Post-accident examination of the aircraft revealed bird remains on the No. 1 engine nacelle, including the inlet, spinner, fan blades, and vanes. While the fan blades on the No. 1 engine remained intact, they showed soft-body impact marks and tip bending.
The No. 2 engine sustained much more severe damage. Bird remnants were found on the spinner and fan blades, which exhibited hard-body impacts, missing material, gouging, and bending. One fan blade was fractured just outboard of the mid-span shroud. The inlet inner barrel liner showed multiple holes and embedded metallic material, and several through-hole penetrations were found in the inlet outer barrel. Additionally, the outer skin of the turbine exhaust sleeve detached from the engine and was recovered in a field near Interstate 95.
The No. 2 engine showed extensive fire damage, including 360-degree sooting and thermal distress from the aft fan case to the combustion case. Fire consumed electrical wire sheathing, isolator grommets, and portions of air, oil, and fuel tubes. Small impact marks from engine debris were also found on the horizontal stabilizer, fuselage, and wing control surfaces on the right side of the aircraft.
Qualified parties participating in the investigation include the FAA, Federal Express, Boeing Commercial Airplanes, and General Electric Aerospace. An Accredited Representative from the Swiss Transportation Safety Investigation Board was also appointed to support the investigation.