MALTA AIR FR1879: EVIDENCE OF BIRDS AND FAN-BLADE FATIGUE

The NTSB’s preliminary report into the July 9 Malta Air/Ryanair FR1879 engine failure has revealed significant details.

The Boeing 737-800 (9H-QEU) suffered a No. 2 CFM56-7B26 fan-blade-out during climb from Thessaloniki. Fan fragments penetrated the fuselage, including the cabin window at row 11, causing a rapid decompression. One passenger was seriously injured after being partially pulled through the damaged window.

The crew first received a HIGH VIBRATION warning at about 16,000 ft. Vibration initially decreased after power was reduced, but then increased significantly. A loud bang followed, the autopilot disconnected and the cabin altitude warning activated.

The crew donned oxygen masks, declared an emergency and initiated an immediate descent. The No. 2 engine was later shut down below 10,000 ft and the aircraft returned safely to Thessaloniki.

Investigators found that fan blade No. 10 had fractured below the blade platform and separated. The tips of two additional blades, Nos. 16 and 21, were also fractured. Three loose fan-blade fragments were recovered.

There was no evidence of radial core uncontainment or an under-cowl fire.

However, the engine inlet cowl and fan cowling sustained extensive damage. Fasteners around the inlet cowl and exhaust nozzle had failed, while several components had not yet received enhancements mandated by three FAA airworthiness directives.

Those ADs — 2025-04-01, 2025-04-02 and 2025-04-03 — have a compliance deadline of July 2028, meaning the modifications were not yet required at the time of the accident.

Bird remains were also recovered from several areas of the engine. The aircraft had reported four suspected bird strikes involving the No. 2 engine during the previous 12 months, although no damage was found during the subsequent maintenance inspections.

Importantly, the fan blades had undergone ultrasonic inspections in accordance with CFM SB 72-1033 Rev. 3 on November 11, 2025, and again on May 24, 2026 — just 253 cycles before the accident — with no findings.

That service bulletin was originally introduced after a previous CFM56 fan-blade-out event in which a passenger was fatally injured.

The investigation is examining the fan-blade fracture, previous FBO events involving similar engines, the role of bird strikes, and the damage to the inlet/cowling and fuselage.

The NTSB investigation remains ongoing, so the cause of the blade failure has not yet been determined.