NTSB: Engine Corrosion Caused Fatal Naples Challenger Crash

National Transportation Safety Board has determined that corrosion in both engines caused the fatal crash of a Bombardier Challenger 604 in Naples, Florida, on February 9, 2024.

In its final report, the NTSB identified corrosion in the variable geometry (VG) systems of the aircraft’s GE CF34-3B engines as the probable cause. The VG system regulates airflow through the high-pressure compressor by adjusting inlet guide vanes and multiple stator vane stages, which are critical for stable engine performance.

Following the accident, both engines were sent to GE Aerospace for detailed evaluation. Testing revealed extensive corrosion within the high-pressure compressor case, particularly in the VG stage 5 area. Investigators found significant corrosion in the stator vane spindle bores, which impaired the movement of key components.

As a result, the VG system could not operate across its full range. The stator vanes failed to move from fully open to fully closed positions during testing and required higher-than-normal pressure to function. The system also responded more slowly than expected, indicating degraded performance.

According to the NTSB, these conditions became critical during the aircraft’s approach. At low power settings, the restricted VG movement likely caused near-simultaneous compressor stalls in both engines. This led to a sudden and unrecoverable loss of thrust at low altitude, leaving the flight crew with no opportunity to regain control before the aircraft impacted the ground.

The crash resulted in the deaths of both pilots. A flight attendant and two passengers were able to escape the aircraft before it was engulfed in flames.

The NTSB also cited contributing factors, including inadequate fault isolation guidance from the engine manufacturer. Investigators noted that earlier signs of trouble—specifically “hung start” events reported about a month before the accident—did not lead to the identification of corrosion within the VG system during maintenance troubleshooting.

The findings highlight the critical importance of early detection of internal engine corrosion and the need for more effective diagnostic procedures, particularly for components that directly affect airflow and engine stability.

Sources: AirGuide Business airguide.info, bing.com, ainonline.com