Cracked, Shorted, Broken

When a new rear wing strut was received from the manufacturer, there were two longitudinal cracks in the strut in the electrically welded seam of the seamless strut tubing one foot from the upper wing strut fitting. The defect is obviously due to the tubing manufacturing process and not by secondary operations or weldments. It is likely the entire batch of raw tubing has multiple defects and should be located and inspected. It is also likely this batch of tubing was disseminated to multiple customers in addition to the manufacturer.

Key Takeaways:

• Multiple new or recently serviced aircraft components experienced premature failures, including a wing strut with manufacturing cracks and a recently overhauled starter developing an electrical short circuit.
• Critical system malfunctions were reported across different aircraft models, such as a loose fuel shutoff cable causing an engine quit, a sheared starter drive shaft leading to a significant oil leak, and a broken magneto shaft resulting in low engine power.

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