Alternators

The alternator cooling fan came apart after takeoff, and parts punched a hole in the induction air box downstream of the air filter. Also, the alternator belt became loose in the engine compartment. Loss of power from engine FOD damage resulted in an uneventful landing back to the airport. The cooling fan had fractured at one of the fins spot welds.

Key Takeaways:

• The incidents reveal a variety of alternator system failures in different aircraft models, including component fatigue (cooling fan, brush holder), internal shorts causing power spikes, and manufacturing defects.
• These failures resulted in a range of consequences, from engine foreign object damage (FOD) and loss of electrical power to complete electrical system failure during flight.
• Despite the malfunctions, pilots were consistently able to land their aircraft safely, often utilizing emergency procedures like manual gear extension.
• Several alternators and associated components exhibited short service lives before failure, with some new units found defective or failing after minimal operational hours.

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