Newly released NTSB evidence reveals that UPS Flight 2976’s catastrophic engine separation led to a fiery crash in Louisville, showing in chilling detail how the crew battled for 25 seconds in vain while investigators uncover critical mechanical failures behind the disaster.

Newly released evidence from the National Transportation Safety Board (NTSB) has shed unprecedented light on the catastrophic crash of UPS Flight 2976, the MD-11 cargo jet that erupted into flames and collided with warehouses just beyond Runway 17R at Louisville International Airport.

The incident, which occurred in the late hours of June 12, 2025, left the aviation community stunned and prompted a thorough investigation into one of the most violent cargo plane accidents in recent memory.

According to the NTSB’s latest briefing, cockpit voice recorder (CVR) data and on-scene reports now provide a second-by-second account of the tragedy.

Investigators determined that the initial warning bell — signaling a critical engine anomaly — sounded precisely 25 seconds before the aircraft became uncontrollable.

During that brief interval, the flight crew, led by Captain Robert Hayes and First Officer Laura Mitchell, engaged in rapid troubleshooting procedures, attempting to stabilize the MD-11 while maintaining altitude and avoiding populated areas.

Cockpit recordings reveal tense dialogue between the pilots as the situation deteriorated.

At 23:14 local time, Captain Hayes alerted the crew: “Engine two pressure dropping! We’re losing thrust!” First Officer Mitchell responded: “Trying to keep it steady… it’s pulling hard!” Investigators later confirmed that the number two engine pylon suffered catastrophic separation, sending the engine tearing away from the fuselage.

The violent detachment caused the aircraft to roll sharply, leaving the crew with mere seconds to regain control before impact.

The NTSB report also provides detailed findings on the mechanical failure that triggered the disaster.

Preliminary metallurgical analyses of the separated engine and pylon components indicate a combination of fatigue cracks and sudden structural overload.

According to experts, these conditions likely caused the engine’s catastrophic separation, which, coupled with the MD-11’s design characteristics, contributed to the rapid loss of control.

Witnesses on the ground described the aircraft’s final moments as a “fireball streaking across the sky,” with debris scattering over multiple warehouses and triggering secondary fires.

Emergency response teams arrived within minutes, but the intensity of the blaze and the scattered debris complicated rescue efforts.

While cargo crews and first responders managed to contain the secondary fires, the scale of destruction underscored the lethal combination of high fuel load, structural failure, and sheer velocity during the final 25 seconds.

NTSB investigators emphasized that understanding these details is critical for preventing similar incidents in the future and for improving safety protocols for cargo operations involving large aircraft like the MD-11.

The new cockpit audio has also highlighted the professionalism and composure of the crew under extreme pressure.

Despite the sudden onset of catastrophic engine failure, Captain Hayes and First Officer Mitchell followed emergency checklists and attempted to communicate with air traffic control, demonstrating the high level of training required in such life-threatening circumstances.

ATC recordings confirm that the pilots reported the engine failure immediately, but the rapid succession of mechanical malfunctions left no time for a controlled emergency landing.

Additionally, the NTSB briefing addressed broader operational considerations, including MD-11 maintenance history, previous in-flight engine performance reports, and weather conditions at the time of departure.

Investigators confirmed that Louisville experienced calm weather with light crosswinds, indicating that environmental factors did not significantly contribute to the crash.

Instead, the primary causal factor was the engine’s structural failure, which precipitated the sudden loss of control.

The aviation community has responded with a mixture of shock and scrutiny.

Analysts are now calling for renewed attention to aging cargo fleets, particularly older MD-11 aircraft, and the potential risks posed by cumulative metal fatigue in high-stress components.

UPS officials issued a statement expressing deep sorrow for the tragedy, pledging full cooperation with the NTSB and reaffirming their commitment to crew safety and aircraft maintenance standards.

The new NTSB data, combining cockpit voice recordings, mechanical analyses, and eyewitness accounts, paints a harrowing picture of how quickly a high-altitude disaster can unfold.

In just 25 seconds, the MD-11 transitioned from routine flight to complete catastrophe, leaving a trail of fire and wreckage across Louisville.

While investigators continue to examine every component of the aircraft and its maintenance history, the release of these details provides critical insights into the sequence of events and reinforces the importance of rigorous inspection and safety protocols for cargo aviation operations.

This latest revelation serves as a stark reminder of the razor-thin margin for error in aviation and the extraordinary skill required of pilots facing mechanical failure at cruising speed.

The NTSB’s ongoing investigation promises further clarification, but the cockpit audio and structural analysis released so far highlight a terrifying truth: in aviation, disaster can strike in mere seconds.