NTSB finds metal fatigue caused Ryanair engine failure and window breach

A preliminary report from the National Transportation Safety Board (NTSB) regarding a July 10 incident involving a Ryanair subsidiary, Malta Air, has identified metal fatigue as a factor in an engine failure. The incident occurred on a Boeing 737-800 flying from Thessaloniki, Greece, to Memmingen, Germany, when engine debris shattered a cabin window, partially ejecting a 61-year-old passenger.

Investigators found that approximately 37 percent of the fracture surface on a failed engine fan blade showed signs of fatigue caused by repeated stress. The report also noted maintenance deficiencies, including fractured fan blades due to fasteners that were not fitted with recommended enhancers. Additionally, a mandated enhancement for engine exhaust nozzle brackets was found to be overdue.

The aircraft experienced high vibrations and a loud bang before the cabin depressurized at 16,000 feet. Passengers assisted in pulling the partially ejected man back into the cabin, and the aircraft returned safely to Thessaloniki. While bird remains were found in the engine, investigators have not concluded that a bird strike caused the failure.