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United States Military Ospreys
FILE - Royal Australian Navy sailor Leading Seaman Keely Hagedoorn guides a U.S. Marine Corps MV-22 Osprey during take-off and landing practice on the flight deck of HMAS Adelaide in the Whitsunday Islands off the coast of Australia during Exercise Sea Raider, Aug. 7, 2023. (Sgt. Andrew Sleeman/Royal Australian Navy via AP)

Weak spots in metal may have led to fatal Osprey crash off Japan, documents obtained by AP reveal

Documents obtained by The Associated Press show that a gear crack that led to a fatal crash of a V-22 Osprey last year may have been started by weak spots in a metal used to manufacture that part

By TARA COPP and AARON KESSLER
Published - Aug 06, 2024, 07:33 PM ET
Last Updated - Aug 06, 2024, 07:33 PM EDT

WASHINGTON (AP) — A gear crack that led to a fatal crash of a V-22 Osprey last year may have been started by weak spots in a metal used to manufacture that part, according to documents obtained by The Associated Press.

The November crash killed eight Air Force Special Operations Command service members. It was the second time in less than two years that a catastrophic failure of a part of the Osprey's proprotor gearbox, which serves as its transmission, caused a fatal accident. In June of 2022, five Marines were killed when a different part of the proprotor gearbox system failed.

The crashes have led to an aggressive effort by the V-22 program office and manufacturer Bell Flight to find fixes for the critical system, which has had some components wear down earlier than the military expected. While investigators still don't know for certain what caused either crash, this latest finding might hold some clues.

There’s no other aircraft like the Osprey in the fleet. It can speed to a target like an airplane then rotate its engines to land like a helicopter. Program leaders have pointed out that the Osprey has been vital in special operations and combat missions and has flown hundreds of thousands of hours successfully.

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