Engine failures and malfunctions in light aeroplanes



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Jabiru


  • Nearly half (45%) of the safety factors associated with Jabiru engine failure or malfunctions (where the safety factor was known) were classified as fractures, leading to a rate of 1.11 fractures per 10,000 hours flown.

  • Mechanical discontinuities were the next most common failure mechanism for Jabiru engines (38%, rate 0.94/10,000 hours).

  • These were followed by electrical discontinuities (5%, rate 0.12/10,000 hours) and wear (2%, 0.05/10,000 hours).

  • Non-technical issues accounted for 11%.

Rotax


  • Safety factors relating to Rotax engine failure or malfunctions were predominantly due to mechanical discontinuities (46%, rate 0.39/10,000 hours).

  • Fractures then made up 13 per cent (0.11/10,000 hours) followed by electrical discontinuities (6%, rate 0.05/10,000 hours) and corrosion issues (4%, rate 0.04/10,000 hours).

  • Non-technical issues accounted for 19 per cent of the known Rotax safety factors.

Lycoming


  • Electrical discontinuities where the most common technical failure mechanism for Lycoming engines with 33 per cent of the known safety factors, leading to a rate of 0.29 per 10,000 hours.

Continental


  • At a rate of 0.17 per 10,000 hours and accounting for 20 per cent of known safety factors, fractures where the most common technical failure mechanism for Continental engines.

  • However, engine failure or malfunction occurrences with Continental engines had by far the highest proportion of non-technical contributing factors (65%, rate 0.56/10,000 hours).

Figure 7: Technical failure mechanism safety factors for engine failure or malfunctions, as a rate per 10,000 hours flown, for the four primary engine manufacturers in the light aeroplane set, between 2009 and 2014. Error bars show rates extrapolated to occurrences without safety factor information.9 Jabiru had by far the highest rate of fractures, which also exceed all other rates considerably. Jabiru also had the highest rate of mechanical discontinuities, while Lycoming had the highest rate of electrical discontinuities.

The most striking observation to be made from Figure 7 is the rate of Jabiru fractures in comparison to both other Jabiru failure mechanisms as well as fractures involving other manufacturers. With a rate of 1.11 per 10,000 flight hours, components in Jabiru engines appear to be fracturing at a rate significantly higher (more than six times) than any other engine manufacturer in the study.




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