# NTSB ERA23LA285: Diamond DA40, N44HH, Yorktown Heights, NY, June 29, 2023 - Type: NTSB accident investigation - Classification: Accident · Minor injuries · Class 3 · Limited · Final report - Date: June 29, 2023, 12:22 local (16:22 UTC) - Place: Yorktown Heights, NY - Coordinates: 41.269255, -73.776554 (estimated) - Nearby events: https://openairdocs.org/map.md?lat=41.2693&lon=-73.7766&mi=10 - Phase of flight: [Takeoff](https://openairdocs.org/ntsb-phases/300) (OpenAirDocs' grouping) - Defining event: [Takeoff: Loss of engine power (partial)](https://openairdocs.org/ntsb-events/342) - Highest injury: Minor injuries - Injuries: 1 minor - Status: Completed - Report: Approved by Office Director - Investigation class: Class 3 - NTSB office: Eastern Region Aviation - Parties: FAA/FSDO, Diamond Aircraft, Transportation Safety Board of Canada - NTSB case key (mKey): 192514 - NTSB case page: https://web.ntsb.gov/investigations/?ntsbnumber=ERA23LA285 - NTSB report (PDF, downloads): https://data.ntsb.gov/carol-repgen/api/Aviation/ReportMain/GenerateNewestReport/192514/pdf - NTSB docket: https://data.ntsb.gov/Docket?ProjectID=192514 - Page: https://openairdocs.org/ntsb/ERA23LA285 ## Probable cause A fatigue failure of the turbocharger housing, which resulted in a partial loss of engine power. ## Findings NTSB's coded findings; those marked are part of the probable cause. - [Turbocharging (recip only): turbocharger](https://openairdocs.org/ntsb-findings/01058120): Aircraft › Aircraft power plant · Fatigue/wear/corrosion (probable cause); cases with it: [Diamond Aircraft Ind DA 40 NG, 2 cases](https://openairdocs.org/ntsb-findings/01058120/cases.md?model=2990014), [All aircraft, 29 cases](https://openairdocs.org/ntsb-findings/01058120/cases.md) ## Sequence of events The events NTSB coded, in order, by phase of flight. The defining event best describes what happened. - [Takeoff: Loss of engine power (partial)](https://openairdocs.org/ntsb-events/342) (defining event); cases with it: [Diamond Aircraft Ind DA 40 NG, 3 cases](https://openairdocs.org/ntsb-events/342/sequence.md?model=2990014), [All aircraft, 1,858 cases](https://openairdocs.org/ntsb-events/342/sequence.md) - [Emergency descent: Off-field or emergency landing](https://openairdocs.org/ntsb-events/440); cases with it: [Diamond Aircraft Ind DA 40 NG, 3 cases](https://openairdocs.org/ntsb-events/440/sequence.md?model=2990014), [All aircraft, 3,365 cases](https://openairdocs.org/ntsb-events/440/sequence.md) - [Landing: Collision with terr/obj (non-CFIT) ](https://openairdocs.org/ntsb-events/470); cases with it: [Diamond Aircraft Ind DA 40 NG, 4 cases](https://openairdocs.org/ntsb-events/470/sequence.md?model=2990014), [All aircraft, 10,189 cases](https://openairdocs.org/ntsb-events/470/sequence.md) ## Analysis The pilot intended to fly his airplane to an airport for an annual inspection. During the flight, while climbing to cruise altitude, the engine began to lose power. The pilot subsequently attempted a forced landing to a school field. During the forced landing, the airplane was in a steep right bank when the wingtip struck the ground, resulting in substantial damage to the empennage. The postaccident examination of the engine revealed that the diesel engine’s turbocharger induction housing was fractured in half and exhibited signs of an existing fracture surface. Further metallurgical examination revealed that the turbocharger housing separated consistent with fatigue cracking. The fatigue cracking emanated from the outer surface of the housing and proceeded circumferentially. Steps on the fracture surface indicated that fatigue cracking on multiple planes had coalesced into one main fatigue crack. The remainder of the fracture surface had macro features consistent with overstress. Based on this information, it is likely that failure of the turbocharger housing resulted in a reduced quantity of intake air being available to the engine and resulted in the partial loss of engine power described by the pilot. ## Factual narrative On June 29, 2023, at 1222 eastern daylight time, a Diamond DA 40 NG, N44HH, was substantially damaged when it was involved in an accident near Yorktown Heights, New York. The pilot sustained minor injuries. The airplane was operated as a Title 14 Code of Federal Regulations Part 91 personal flight. According to the pilot, who was also the owner of the airplane, he intended to fly to Orange County Airport (MGJ), Montgomery, New York, for an annual inspection. He departed Westchester County Airport (HPN), White Plains, New York, and while climbing to cruise altitude, about 2,000 ft mean sea level (msl), the engine began to lose power. The indicated power displayed as lower than normal at 75% and the climb rate was diminishing. The pilot reported the power loss to the air traffic controller. The engine power then dropped to 68% and the airplane began to descend. The pilot looked for a field to conduct a forced landing and was “crabbing” towards West Point as the airplane descended to 1200 ft msl. He moved the throttle in an attempt to regain engine power; however, only the propeller pitch changed. The pilot subsequently attempted a forced landing to a school field. The airplane was in a steep right bank when the wingtip struck the ground. The airplane yawed right and impacted the ground with the left forward side of the nose and slid to a stop. During the accident sequence the airplane sustained substantial damage to the empennage. The airplane was equipped with a 168-hp Austro Engine E4 diesel engine. The engine was examined at a salvage facility; the engine’s turbocharger induction housing was fractured in half and exhibited signs of an existing fracture surface. The propeller blades were all fractured near the hub. The glow plugs were removed and the propeller was rotated by hand; air pressure was heard exiting the glow plug holes. The engine rotated smoothly and did not exhibit evidence of any preimpact mechanical anomalies. The turbocharger was sent to the National Transportation Safety Board Materials Laboratory for further examination. The examination revealed that the turbocharger housing separated consistent with fatigue cracking. The fatigue cracking emanated from the outer surface of the housing and proceeded circumferentially. Steps on the fracture surface indicated fatigue cracking on multiple planes had coalesced into one main fatigue crack. The remainder of the fracture surface had macro features consistent with overstress (for further information, see the Materials Laboratory Factual Report in the public docket for this investigation). According to the pilot, and the airplane’s maintenance records, at the time of the airplane’s most recent annual inspection in June 2022, the airframe and engine had accumulated 740 total hours of operation since the airplane was manufactured in 2017. The maintenance log entry describing the annual inspection of the engine noted, “Visually inspected turbo charger and lubricated as required.” No othermaintenance had been performed on the turbocharger since it was new. Review of the engine’s maintenance manual noted that every 100 and 300 hours the turbocharger should be inspected for oil leakage, mechanical wear and damage at the compressor blades, significant wear and grooves at the air intake, and damage concerning the functionality of the turbocharger and sealing. A review of Federal Aviation Administration service difficulty reports did not reveal a history of any other similar turbocharger failures. ## Aircraft - Registration: [N44HH](https://openairdocs.org/aircraft/N44HH), registered now, S/N 40.NC001, built 2017 (OpenAirDocs) - Reported make and model: DIAMOND DA40 (NG) - Registry model: [Diamond Aircraft Ind DA 40 NG](https://openairdocs.org/model/diamond-aircraft-ind-da-40-ng) (registry code 2990014) (OpenAirDocs) - Registry engine: [Austro E4 series](https://openairdocs.org/engine/austro-e4-series) (registry code 06400, reciprocating) (OpenAirDocs) - Category: Airplane - Serial number: 40.NC001 - Year built: 2017 - Airframe hours: 740 - Engines: Austro Engines E4 168 horsepower reciprocating - Damage: Substantial damage - Flight: Personal, Part 91 - Airworthiness certificate: Standard, Normal - Last inspection: Annual, June 11, 2022 - Departed: HPN, White Plains, NY - Destination: MGJ, Montgomery, NY - Flight plan: VFR - Equipment: ADS-B ## Flight crew As NTSB recorded them. NTSB leaves out names. - Pilot; age 66; injuries: none; private; airplane ratings: single-engine land; medical: class 3, with waivers/limitations; last flight review October 22, 2021; seat: left; restraint: 3-point; flight hours: 2,206 total, 2,206 as pilot in command, 8 in the last 30 days ## Weather - Conditions: Visual (VMC), Day - Wind: 310° at 7 knots - Visibility: 10 statute miles - Lowest ceiling: 6,000 ft broken - Temperature: 75 °F, dew point 61 °F - Altimeter: 30.02 inHg - Observed at: HPN ## FAA reports on this event (1) The FAA's own accident and incident reports, matched to the aircraft by N-number and date (OpenAirDocs). - [Accident 20230629017899A](https://openairdocs.org/incident/20230629017899A), Jun 29, 2023: Diamond Aircraft Ind Inc DA 40 NG, Mohegan Lake, NY, Substantial damage. 06/29/2023 1624Z DA40, declared an emergency due to a engine issue and crashed into a field near a school aproximately 15 km north of the airport . No injuries… ## Docket (9 files) The files NTSB released with the investigation on July 5, 2024, on NTSB's docket system: https://data.ntsb.gov/Docket?ProjectID=192514. 12.4 MB in all. - Pilot/operator aircraft accident report, NTSB form 6120.1 (item 1, PDF, 11 pages, 2.0 MB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=16581988&FileExtension=pdf&FileName=6120_Redacted-Rel.pdf - Memorandum for record a�� pilot (item 2, PDF, 1 page, 91 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=16581998&FileExtension=pdf&FileName=Memo%20for%20record-Rel.pdf - Maintenance records (item 3, PDF, 3 pages, 1.0 MB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=16599798&FileExtension=pdf&FileName=Maintenance%20Records_Redacted-Rel.pdf - Maintenance manual excerpt (turbocharger inspection checks 100/300 hr.) (item 4, PDF, 2 pages, 130 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=17273303&FileExtension=pdf&FileName=Turbocharger%20insp%20Ch%205-Rel.pdf - Investigative photographs (item 5, PDF, 4 pages, 931 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=16600530&FileExtension=pdf&FileName=Investigative%20Photo-Rel.pdf - Wreckage examination summary (item 6, PDF, 6 pages, 918 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=16582295&FileExtension=pdf&FileName=Wreckage%20Examination%20Summry-Rel.pdf - Materials laboratory factual report (item 7, PDF, 12 pages, 6.2 MB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=16582285&FileExtension=pdf&FileName=23-104%20Materials%20Laboratory%20Factual%20Report-Rel.pdf - Release of aircraft wreckage, NTSB form 6120.15 (item 8, PDF, 1 page, 1.1 MB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=16588263&FileExtension=pdf&FileName=WRF_Redacted-Rel.pdf - Evidence control form (item 9, PDF, 1 page, 28 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=17263329&FileExtension=pdf&FileName=Evidence-Control-Form-Rel.pdf From the NTSB's public API. Aircraft are matched to registry aircraft by N-number and event date, checked against the reported serial number, make and model; the registry's history has gaps, so older matches can be wrong. Compare the reported make and model. --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain.