Test

Based on a Piaggio P.180 Avanti, the Piaggio P.1HH HammerHead is a drone prototype. Engaged in a series of test as part of the certification program, the twin engine aircraft left Trapani-Vincenzo Florio Airport at 1120LT for a local test flight. About 20 minutes later, the contact was lost with the ground station and the aircraft crashed into the sea about 8 km north of the Levanzo Island. The aircraft was lost.

The twin engine aircraft was engaged in a post-maintenance test flight out from Santiago de Querétaro Airport, carrying three engineers and two pilots. It departed runway 09 at 1421LT and the crew was cleared to climb to FL125. While approaching the altitude of 12,000 feet, the aircraft entered an uncontrolled descent and crashed on a motorway located 11 km southwest of the airport, bursting into flames. The aircraft was totally destroyed by impact forces and a post crash fire and all five occupants were killed.

The pilot departed on a postmaintenance test flight during day visual meteorological conditions. According to the operator, the purpose of the flight was to break in six recently installed engine cylinders, and the flight was expected to last 3.5 hours. Recorded automatic dependent surveillance-broadcast data showed that the airplane was operating at altitudes of less than 500 ft mean sea level for the majority of the flight. The data ended about 3 hours after takeoff with the airplane located about 23 miles from the accident site. There were no witnesses to the accident, which occurred in a remote area. When the airplane did not return, the operator reported to the Federal Aviation Administration that the airplane was overdue. Searchers subsequently discovered the fragmented wreckage submerged in a swift moving river, about 40 miles southeast of the departure/destination airport. Postmortem toxicology tests identified 21% carboxyhemoglobin (carbon monoxide) in the pilot's blood. The pilot was a nonsmoker, and nonsmokers normally have no more than 3% carboxyhemoglobin. There was no evidence of postimpact fire; therefore, it is likely that the pilot's elevated carboxyhemoglobin level was from acute exposure to carbon monoxide during the 3 hours of flight time before the accident. As the pilot did not notify air traffic control or the operator's home base of any problems during the flight, it is unlikely that he was aware that there was carbon monoxide present. Early symptoms of carbon monoxide exposure may include headache, malaise, nausea, and dizziness. Carboxyhemoglobin levels between 10% and 20% can result in confusion, impaired judgment, and difficulty concentrating. While it is not possible to determine the exact symptoms the pilot experienced, it is likely that the pilot had symptoms that may have been distracting as well as some degree of impairment in his judgment and concentration. Given the low altitudes at which he was operating the airplane, he had little margin for error. Thus, it is likely that the carbon monoxide exposure adversely affected the pilot's performance and contributed to his failure to maintain clearance from the terrain. According to the operator, the airplane had a "winter heat kit" installed, which modified the airplane's original cabin heat system. The modification incorporated an additional exhaust/heat shroud system designed to provide increased cabin heat during wintertime operations. Review of maintenance records revealed that the modification had not been installed in accordance with Federal Aviation Administration field approval procedures. Examination of the recovered wreckage did not reveal evidence of any preexisting mechanical anomalies that would have precluded normal operation of the airplane. Examination of the airplane's right side exhaust/heat exchanger did not reveal any leaks or fractures that would have led to carbon monoxide in the cabin. Because the left side exhaust/heat exchanger was
not recovered, it was not possible to determine whether it was the source of the carbon monoxide.

Brand new, the aircraft just came out from the manufacturer in Seville and was engaged in its first post assembly test flight. After take off from Seville-San Pablo Airport Runway 09 at 1254LT, the crew completed a 90° turn to the left bound to the north. Shortly later, three of the four engines (engines n°1, 2 and 3) got stuck at high power. The crew attempted to control the power setting to the normal mode but those three engines failed to respond. The crew reduced the engine power after selecting the thrust levers to idle. The regime of those three engines remained blocked in idle so the crew decided to return to the airport for an emergency landing. On approach, the aircraft collided with power lines, stalled and crashed in an open field located 1,6 km north of the airport, bursting into flames. Two crew members were rescued while four others were killed. The aircraft was totally destroyed by a post crash fire. The aircraft was following a test program prior to its delivery to the Turkish Air Force (Türk Hava Kuvvetleri).

The commercial pilot was departing on a local post-maintenance test flight in the single-engine airplane; Four aileron cables had been replaced during the maintenance. Shortly after takeoff, the airplane began to roll right. As the climb progressed, the roll became more pronounced, and the airplane entered a spiraling dive. The pilot was able to maintain partial control after losing about 700 ft of altitude; he guided the airplane away from the airport and then gradually back for a landing approach. During this period, he reported to air traffic control personnel that the airplane had a "heavy right aileron." As the airplane passed over the runway threshold, it rolled right and crashed into a river adjacent to the runway. The aircraft was destroyed and both occupants were killed.

The pilot reported that, during the postmaintenance test flight, the turboprop engine lost power. The airplane was unable to maintain altitude, and the pilot conducted a forced landing, during which the airplane was substantially damaged. The engine had about 9 total flight hours at the time of the accident. A teardown of the fuel pump revealed that the high-pressure drive gear teeth exhibited wear and that material was missing from them, whereas the driven gear exhibited little to no visible wear. A metallurgical examination of the gears revealed that the damaged drive gear was made of a material similar to 300-series stainless steel instead of the harder specified M50 steel, whereas the driven gear was made of a material similar to the specified M50 steel. Subsequent to these findings, the airplane manufacturer determined that the gear manufacturer allowed three set-up gears made from 300-series stainless steel to become part of the production inventory during the manufacturing process. One of those gears was installed in the fuel pump on the accident airplane, and the location of the two other gears could not be determined. Based on the evidence, it is likely that the nonconforming gear installed in the fuel pump failed because it was manufactured from a softer material than specified, which resulted in a loss of fuel flow to the engine and the subsequent loss of engine power. The manufacturer subsequently inspected its stock of gears and issued notices to customers that had engines with fuel pumps installed with the same part number gear set as the one installed on the accident airplane. The manufacturer also issued a service information letter and service bulletins regarding the fuel pump gear set for engines used in civilian and military applications. As of the date of this report, the two remaining gears have not been located.

The aircraft was parked on the ramp and subject to engine test run with one or two engineers on board. During the test, the aircraft jumped over the chocks then collided with obstacles and came to rest. There were no injuries while the aircraft was damaged beyond repair. It was operated by Sun-Air of Scandinavia on behalf of British Airways.

Bought in 2000 and stored since, the airplane was under restoration since August 2013. The crew (one pilot and one engineer), decided to perform a test flight in the region of Sevryukovo (Korocha District of the Belgorod region). En route, the engine failed, forcing the crew to attempt an emergency landing. The aircraft impacted ground and crashed, coming to rest upside down and bursting into flames. Both occupants escaped uninjured while the aircraft was partially destroyed by fire.

Shortly after takeoff from Shakhty Airport, Rostov oblast, the pilot encountered engine problem. He elected to make an emergency landing in an open field located 500 metres from the airport. On touchdown, the aircraft lost its undercarriage, wings and tail before coming to rest in bushes. The pilot, uninjured, fled the scene but was arrested by police few hours later. Technician by a Plant at the Shakhty Airport, he was the owner of this aircraft since seven months and was performing a local test flight despite he was not in possession of any valid pilot licence according to Russian authorities.

Two technicians were performing engine tests on apron at Chino Airport. While facing a hangar, the aircraft jumped over the chocks and collided with the metallic door of the hangar before coming to rest half inside. Both occupants escaped uninjured and the aircraft was damaged beyond repair.