·E905

Li-ion Thermal Runaway

August 19

1h 8m

View Transcript

Episode Description

Li-ion thermal runaways in aircraft cabins, Ryanair engine blade-out accident, two planes with the same flight number at the same airport at the same time, Marine One and commercial operations at DCA, Air India crash report update, Boeing 737 Max crack inspections, hiring gamers to become air traffic controllers, and the Heart Aerospace X1 battery-electric demonstrator first flight.

Aviation News

Li-ion Thermal Runaways on the Rise in Aircraft Cabins

UL Standards & Engagement (ULSE) issued a 2025 Data Review, Lithium-ion Battery Incidents in Aviation [PDF, 13 pages]. The study reports a 15% increase in Lithium-ion battery thermal runaway incidents on passenger flights in 2025, compared to the year prior. Portable charger incidents increased 42%, ahead of e-cigarettes, with cell phones the third most common device involved in thermal runaways.

The data comes from the voluntary ULSE Thermal Runaway Incident Program (TRIP). More than 40 passenger and cargo airlines participate in the program. These incidents cost the industry an average of $1.8 million a year, or $96,000 per incident, “in damage, disruption, and associated losses.”

To mitigate the risk of thermal runaway incidents, ULSE recommends cabin crew training, standards for onboard safety equipment to help manage thermal runaways, and more passenger education.

Bird strike suspected in Ryanair engine blade-out accident

In July, a Malta Air Boeing 737-800, doing business as Ryanair flight 1879, experienced a No 2 fan-blade-out failure as it climbed out of Thessaloniki International Airport in Greece. Engine fragments breached the fuselage and the cabin depressurized. A passenger was partially sucked out through a window that blew out.

In its Aviation Investigation Preliminary Report [PDF, 13 pages], the NTSB reports:

“Examination of the airplane revealed that the No. 2 engine, an CFM International (a joint company between Safran Aircraft Engines and GE Aerospace) model CFM56-7B26, experienced a fan blade separation that resulted in engine fragments striking the fuselage and the right horizontal stabilizer. The pressurized section of the fuselage was penetrated 1) through the passenger cabin window located at row 11, as well as 2) lower lobe fuselage skin behind the right wing-to-body fairing… Additional impact damage was found on the right wing-to-body fairing, a dent with paint smearing on the fuselage window belt skin, a dent on a stringer common to the dented fuselage window belt skin, a gouge on the right horizontal stabilizer upper skin and a dent on the right horizontal stabilizer leading edge.”

View of the No.2 (right) engine inlet. View is looking aft..Courtesy NTSB.

“Examination of the engine and nacelle revealed that one fan blade (No.10) had fractured and separated below the blade platform. The outer blade tips were fractured and separated on two additional fan blades (Nos. 16 and 21). All remaining blades were full length but exhibited varying levels of impact deformation. Three loose fan blade fragments were recovered from the engine. A visual examination of the core was performed and there was no evidence of radial uncontainment though the engine cases, or any undercowl fire. The engine inlet cowl, which is forward of the fan case, exhibited evidence of punctures…”

Bird remains were recovered and hand-carried to the Smithsonian Institution Feather Identification Lab in Washington. The Greece Hellenic Air and Railway Safety Investigation Authority (HARSIA) delegated the investigation in full to the NTSB.

See: Ryanair Uncontained Engine Failure followed by Cabin Depressurization and Passenger Window Injury),

2 planes with the same flight number avoid possible disaster thanks to quick-thinking controller

Recently, American Airlines flight 2482 was departing Phoenix International Airport (PHX) while another American Airlines flight 2482 was arriving at the same airport from Chicago. A Phoenix air traffic controller with 25 years on the job quickly recognized the problem and referred to the flights as “American 2482 on the arrival” and “American 2482 on the departure.”

See: ‘It Could Have Been Disastrous’: Air Traffic Controller Carefully Handles Two American Airlines Planes With the Same Callsign as They Flew Towards One Another

Passenger plane taking off got too close to Trump’s Marine One helicopter, NTSB and FAA to investigate

Ronald Reagan Washington National Airport is located about three miles from the White House. When the president departs the Ellipse in Marine One, airport traffic is typically halted. This time, airport traffic continued for a few minutes. The FAA said, “…there was momentary loss of separation after which the aircraft continued to move away from one another.”

Ahmedabad tragedy: Supreme Court accepts pilot dad’s plea not to make Air India crash report public

The Supreme Court of India granted a request from the 91-year-old father of one of the pilots killed in the June 2025 Air India Ahmedabad crash (Flight AI171, 260 dead) that the final crash investigation report from the Aircraft Accident Investigation Bureau (AAIB) be submitted to the court in a sealed cover rather than made public.

The AAIB had told the court its final report would be ready by October, and the government agreed to submit it in a sealed cover out of respect for the father’s wishes, even though the Solicitor General had initially opposed keeping it confidential, citing international investigation norms under ICAO.

FAA orders crack inspections for hundreds of Boeing 737 Max jets

The final rule applies to certain Boeing 737-8, -9, and -8200 Max models, estimated to be 471 planes. While no cracks have been found in these Max models, the FAA received reports of cracks in a forward “bear strap” for several older 737 NG planes.