Ospreys had safety issues long before they were grounded. A look at the aircraft’s history

The grounding of the U.S. military’s V-22 Osprey fleet has brought to light longstanding safety issues that have plagued this aircraft throughout its history. This action was not solely prompted by the recent tragic crash off the coast of Japan but rather the culmination of a series of problems that have raised concerns.

The V-22 Osprey is a remarkable aircraft that combines the capabilities of a helicopter and an airplane, allowing for vertical takeoff and landing as well as horizontal flight. This unique design has been instrumental in rapidly deploying troops to the battlefield and has been heralded as a game-changing asset by the U.S. Marine Corps, which predominantly operates these aircraft.

However, the decision to ground the Ospreys by the Air Force, Navy, and Marine Corps was driven by a preliminary investigation into the recent crash, indicating a material failure within the aircraft itself rather than human error. This incident is sadly not an isolated case. Over the years, questions have persisted about a mechanical issue involving the clutch, which has plagued the program for more than a decade. Additionally, concerns have arisen regarding the manufacturing quality of various Osprey components and whether they maintain their structural integrity as they age, given the unique structural and dynamic demands of tiltrotor flight.

Japan, the only international partner operating the Osprey, had already grounded its fleet after the November 29 crash that claimed the lives of all eight Air Force Special Operations Command personnel on board.

Rex Rivolo, a retired Air Force pilot and analyst, expressed his support for grounding the fleet, emphasizing that it was a necessary step. The Osprey has become a vital asset for the Marine Corps and Air Force Special Operations Command and was in the process of replacing the Navy’s C-2 Greyhound propeller planes for personnel transport on aircraft carriers.

The safety concerns extend to the clutch system in the Osprey. Hard clutch engagement (HCE) has been identified as a persistent issue, resulting in power surges that can lead to uncontrolled rolls or slides and even catastrophic mechanical failures. The interconnected drive shaft linking the two engines is integral to the Osprey’s balance and safety, making clutch problems a critical concern.

Despite efforts to address these issues, the root cause remains elusive. The recent crash in Japan, if eyewitness accounts are accurate, may further implicate clutch failure and the interconnected drive shaft in the accident. Recommendations have been made to design a new quill assembly and strengthen drivetrain components, but this work is still in progress.

A whistleblower lawsuit related to materiel strength has also drawn attention to the manufacturing standards of the Osprey. Boeing settled this lawsuit with the Justice Department for $8.1 million, addressing allegations of falsified records concerning composite parts’ temperature requirements. While Boeing maintains that the non-critical parts in question did not affect flight safety, concerns linger about the overall manufacturing standards during the period from 2007 to 2018.

In the absence of a definitive root cause, significant efforts are being made to understand and mitigate hard clutch engagement issues. This complex challenge requires a collaborative approach between government and industry to ensure the safety and reliability of the V-22 Osprey.

As investigations continue and safety measures are refined, the future of the Osprey program remains uncertain. It is imperative that thorough and transparent efforts are undertaken to address these safety concerns and protect the lives of those who operate and depend on this aircraft.

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More about Osprey Safety Issues

• V-22 Osprey
• Hard Clutch Engagement (HCE) in Osprey
• Boeing Whistleblower Lawsuit