What happened
On 5 February 2003, an RAF 2000 gyroplane, registration G-BWAE, was performing a training flight near Hall Farm landing strip, Lichfield, Staffordshire. Following a successful morning inspection and several successful flights, the aircraft was prepared for a second flight of the day.
During the takeoff roll, the aircraft lifted into a level attitude. As the pilot attempted to increase airspeed by easing the stick forward, the aircraft suddenly developed a significant nose-down attitude and a slight right roll at approximately 10 feet of altitude. Despite the instructor's attempt to correct the movement by pulling the stick fully aft, the controls failed to respond. The aircraft struck the ground heavily, resulting in the breakage of the nosewheel and damage to the rotor blades and cockpit underside. There were no injuries to the two crew members on board.
The investigation
The investigation focused on the loss of control and the lack of response to control inputs. Post-accident inspections of the rotor blades revealed gross delamination, though testing eventually determined this damage was caused by the ground impact rather than being a pre-existing condition.
Investigators identified a fracture in one control rod eye end within the rotor control system. Metallurgical analysis of this component revealed that the eye end had failed due to bending overload. While the part appeared to be of high quality, it was manufactured from a low-carbon, free-machining steel with a relatively low tensile strength. The material also contained high concentrations of manganese sulphide 'stringers', which further compromised its bending strength and stiffness.
Furthermore, the aircraft's history included a previous rollover accident. The manufacturer noted that following such an event, the entire control system should be inspected and parts like rod ends replaced, yet there was no record of such replacements for this specific aircraft.