In November 2023, a tragic crash of an Air Force CV-22 Osprey aircraft in Japan led to the deaths of eight airmen. The cause of the crash was traced to the failure of a high-speed planetary pinion gear, a critical component in the aircraft’s gearbox. This failure was later linked to previous similar incidents dating back to 2013, raising questions about the quality of the steel used in the gears. The company responsible for manufacturing these parts, Universal Stainless, has now come under intense scrutiny for its role in supplying the defective materials that contributed to the mishap.
Internal Air Force reports, reviewed by Military.com, revealed that the gear failure in the November 2023 incident was not an isolated case. Investigations showed that the metal used in the gear was found to contain non-metallic inclusions, which eventually caused a crack to form, leading to the failure. These types of flaws had been identified in previous gear failures, but no substantial corrective actions appeared to have been taken. This raised concerns about the oversight of Universal Stainless, a company that had been flagged in the past for producing faulty steel.
Universal Stainless has a troubling history, with a lawsuit filed against it in 2001 by Teledyne Technologies, a company involved in manufacturing civilian aircraft engines. The lawsuit alleged that Universal's steel was defective and caused failures in engine crankshafts, resulting in a costly recall of 200 crankshafts, nearly 92-93% of which were found to be faulty. The case accused Universal of falsifying certifications and failing to conduct proper internal audits, ensuring that defective steel made its way into critical aviation components. Despite the settlement of the lawsuit, concerns about the company’s manufacturing processes lingered.
The internal investigations into the Osprey crash revealed that Universal Stainless continued to supply a significant proportion of the metal used in the V-22’s gearbox. While other contractors, such as Carpenter Technology, took additional steps to enhance their quality control processes, Universal did not implement similar measures. For instance, Carpenter voluntarily introduced stricter testing procedures to detect material flaws, whereas Universal was found lacking in such efforts. This stark contrast in quality control procedures has fueled further doubts about Universal's commitment to ensuring the integrity of its parts.
In response to these findings, the Air Force and other agencies involved in the Osprey program, such as Bell and Boeing, have remained largely silent. While they acknowledge the internal investigations, they have not clearly stated whether Universal Stainless is still supplying parts for the Osprey or what actions have been taken to address the long-standing issues with their manufacturing processes. This lack of transparency has raised alarm among aviation experts and military personnel, who believe that better oversight is essential to prevent future accidents.
Despite the technical nature of the Osprey's complex gearbox system, which involves rapidly moving parts, many experts argue that the failure of the gear could have been avoided if the metal used in its production had been properly tested and certified. Retired aviation professionals have pointed out that when defects are identified in critical components, it is essential for the military to be transparent about the steps taken to correct the issue. The failure to address known defects in manufacturing processes is viewed as a serious oversight that could have deadly consequences, particularly for aircraft as complicated as the V-22 Osprey.
As the investigations into the Osprey crash continue, the focus remains on whether Universal Stainless will be held accountable for its past mistakes and whether it will be allowed to continue supplying parts for military aircraft. The case highlights the importance of maintaining rigorous standards in military procurement, particularly for components that are critical to the safety and reliability of aircraft. Given the stakes involved, the public and military personnel alike are demanding answers, hoping for swift corrective measures to ensure that such tragedies do not occur again.
