N86SD

THE FATIGUE CRACKING AND FRACTURE OF THE PROPELLER HUB ARM. THE RESULTANT SEPARATION OF THE HUB ARM AND THE PROPELLER BLADE DAMAGED THE ENGINE, NACELLE, WING, AND FUSELAGE, THEREBY CAUSING SIGNIFICANT DEGRADATION TO AIRCRAFT PERFORMANCE AND CONTROL THAT MADE A SUCCESSFUL LANDING PROBLEMATIC. THE CAUSE OF THE PROPELLER HUB ARM FRACTURE WAS A REDUCTION IN THE FATIGUE STRENGTH OF THE MATERIAL BECAUSE OF MANUFACTURING AND TIME-RELATED FACTORS (DECARBURIZATION, RESIDUAL STRESS, CORROSION, MIXED MICROSTRUCTURE, AND MACHINING/SCORING MARKS) THAT REDUCED THE FATIGUE RESISTANCE OF THE MATERIAL, PROBABLY COMBINED WITH EXPOSURE TO HIGHER-THAN-NORMAL CYCLIC LOADS DURING OPERATION OF THE PROPELLER AT A CRITICAL VIBRATION FREQUENCY (REACTIONLESS MODE), WHICH WAS NOT APPROPRIATELY CONSIDERED DURING THE AIRPLANE/PROPELLER CERTIFICATION PROCESS.