What happened
On 30 June 2025, a Bellanca (American Champion) Decathlon, registration G-TALX, was conducting a training flight at Tatenhill Aerodrome in Staffordshire. The flight, an introduction to aerobatics led by a flight instructor, was proceeding normally until the landing phase.
As the aircraft touched down on Runway 2/4, the left landing gear leg fractured at the top of the leg. The pilot attempted to maintain control by applying aileron to keep the left wing elevated as the airspeed decreased; however, the wing subsequently dropped to the runway surface. The aircraft veered off the runway into a grassy area, where the propeller also struck the ground. There were no injuries to the two occupants, who were able to exit the aircraft without assistance.
The investigation
The AAIB examined the fractured component and conducted metallurgical testing. The investigation focused on the condition of the steel landing gear legs, which had been installed during a major maintenance event in 2018.
Investigators found that the fracture occurred near the attachment point to the fuselage. While the lower part of the leg showed damage from contact with the runway, the upper section exhibited clear evidence of corrosion. Scanning electron microscopy revealed thumbnail-shaped features measuring up to 1.66 mm in depth, which were characteristic of fatigue crack propagation. The final failure was identified as an overload failure in the high-strength steel.
Maintenance records showed that a 100-hour inspection had been completed in March 2025, which included a check for corrosion; at that time, no issues were noted. The investigation also reviewed a manufacturer service letter, SL-449, which provides guidance on inspecting for corrosion in these components. While this service letter suggests more frequent inspections for aircraft in moderate operating environments like the UK, these specific checks were not mandatory under the aircraft's approved maintenance program.