Flying any aircraft through or in the vicinity of thunderstorms WHERE IT CAN BE AVOIDED is contra to all and any SOP's (standard operating procedures) I have ever read. Hail is a very real risk to aircraft safety and numerous fatal accidents have occured as a direct result of hail encounters. The risk to aviation from Windshear resulting from Microburst is well documented and is now well managed, (sadly however it took fatalities, particularly the losses of a Delta airlines L1011 on approach to Dallas? and a Boeing 727 on departure from Moisant to awaken the aviation world to the dangers of shear associated with microbursts.)
With the recent advances in weather radar technology, hail encounters are now majoritively avoided, but in the 70's when the Bendix monochromatic displays were forefront technology, and our understanding and eduction relating to inclement weather encounters was average at best, it was a different story altogether and accidents DID happen.
One that springs to mind readily, in fact an accident I researched quite thoroughly, is the loss of Southern Airways flight 242, from Muscle Shoales to Atlanta, via Huntsville. The date was April the 4th 1977. In short, without the aid of sophisticated radar the aircraft entered an area of exceptionally high precipitation and hail of up to 75mm diameter! The ingestion of this hail caused the engine rpm to decrease below that required to sustain operation of the generators, the throttle levers were advanced in an attempt to obtain power, and the resulting engine surging and stalling at low rpm produced overpressures in the low pressure compressors, sufficient to result in compressor blades clashing against the stator vanes and thus causing critical damage resulting in both engines failing. Despite the efforts of the crew to glide to Dobbins AFB, the aircraft was lost when the flight crew attempted as a last resort an emegency landing on a single lane highway, resulting in the deaths of most on board.
The crew knew to expect inclement weather as the latest met they had received was:- Ceilings btwn 1000 to 2000 feet broken to overcast. with layered clouds to 15000 feet. Visibility 5 to 8km in haze and moderate precip. There were scattered Thunderstorms with tops to 35000 feet and a few of these stated as severe along the leading edge of the cold front. Moderate to severe icing existed within the thunderstorm above freezing level at 12 to 14000 feet. Gusts in excess of 50 knots and hail of 18mm or larger was a possibility with the passage of the cold front. On top of the area forecast, SIGMET's (Significant Meteorological Information, is a weather advisory that contains meteorological information concerning the safety of all aircraft in the area as desribed within the advisory) issued by met officeswere in force as well as Tornado watches issued by the National Severe Storms Forecast Centre. These predicted tornadoes E of Huntsville, with a few severe Thunderstorms reaching 58000 feet, extreme turbulence, severe windgusts to 70 knots and hail to 75mm in diameter. - NOT a good day to be flying, especially given the standard of instrumentation (typical for the period) that was on-board
Regards
Kris