A hidden corrosion flaw caused the dual engine failure of Hop-A-Jet Flight 823
In short: On February 9, 2024, a Bombardier Challenger 604 lost all engine power while approaching Naples, Florida. A subsequent investigation revealed that a specific type of corrosion, which had gone undetected in previous inspections, was the silent culprit behind the catastrophic loss of thrust.
The crash of Hop-A-Jet Flight 823 was traced to a non-recoverable dual-rotor compressor stall. This failure was caused by corrosion within the variable guide vane (VGV) systems of the aircraft's two General Electric CF34-3B engines. Such decay forced engine parts into incorrect positions, triggering nearly concurrent sub-idle rotating compressor stalls while the pilots transitioned to landing configuration.
The investigation by the NTSB highlighted a critical gap in maintenance. In January 2024, the engines experienced "hung-starts," where acceleration is abnormally slow. Although this should have triggered a borescope inspection—specifically Maintenance Practice 68—the engines restarted normally the following day. Consequently, the maintenance procedure was curtailed, and the hidden corrosion remained undetected for the next 25 days and 33 subsequent flights.
Evidence suggests the corrosion may have been a recurring issue. In both 2019 and 2020, borescope inspections of the aircraft's engines revealed corrosion on the compressor cases near the VGV system bushing bore holes, yet these findings were not recorded in the aircraft's logbooks. The aircraft's frequent storage in salty, marine air conditions is believed to have contributed to the degradation.
While the NTSB identified the corrosion as the probable cause, the accident has sparked legal and regulatory scrutiny. In late 2025, Hop-A-Jet filed a lawsuit against General Electric, Bombardier Aerospace, and others, seeking damages and industry-wide safety reforms. In response to the findings, GE has since issued an updated version of the engine check required after a hung-start.
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- Summary by Intellect · source: Hop-A-Jet Flight 823
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