Chafed, Corroded, Failed

Out of concerns about chafing or corrosion, a technician was motivated to closely inspect the right fuel-flow pressure gauge line where it crosses the defrost duct. He was right, finding extensive corrosion at the point of contact. After the line was removed, slight bending pressure cracked the area wide open and it was seen that the corrosion had actually penetrated to the inside of the line, yet the line was not leaking. If a leak started, the only way to stop it would be to shut down the right engine.

Key Takeaways:

• Corrosion and chafing were identified as potential causes for critical fuel pressure line failure, even when not actively leaking.
• Failures in other systems included a separated fuel injection intake tube and cracked hydraulic lines due to stress at bends and tool marks.
• Critical engine components, such as a crankshaft connecting rod and a magneto impulse coupling, also failed, leading to engine malfunction or inoperability.
• These incidents underscore the importance of meticulous and proactive inspections to detect hidden damage and prevent in-flight component failures.

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