Aviation incident CHI03IA153

Failure of the aileron sprocket assembly at the sprocket-to-shaft braze joint. Contributing factors were the improper braze procedure used by the part manufacturer at the time of fabrication which resulted in an inferior quality joint and the inadequate quality control (inspection) criteria which failed to identify the improperly brazed joint. An additional factor was the improper inspection procedure utilized by the operator's maintenance personnel, during which excessive force was applied to the control wheel in order to obtain acceptable flight data recorder readings during the functional check.