Villa struck first in the 14th minute when Tammy Abraham controlled Douglas Luiz's free-kick on his chest and turned smartly to beat Aaron Ramsdale, though the striker appeared marginally offside - a moment that stood given VAR is not in use until the fifth round.
The contest hung on a knife edge thereafter, with Villa enjoying the better chances, but tempers escalated when there was more drama just before the break.
Left-back Lucas Digne escaped a red card for a late challenge on Jacob Murphy, only for the tension to ramp up moments later when goalkeeper Marco Bizot raced from his area and took down Murphy as well, receiving a straight red for a last-man foul.
Reduced to ten men and forced into a reshuffle, Villa could not withstand the pressure after the interval.
Sandro Tonali broke their resistance on 63 minutes with a long-range free-kick that took a telling deflection, before producing a second moment of quality with a precise low drive from outside the box to complete the turnaround.
Newcastle wrapped up the tie late on when Nick Woltemade pounced after Pau Torres inadvertently teed him up, sealing a dramatic result.
Newcastle United staged a thrilling turnaround to defeat 10-man Aston Villa 3-1 and secure their place in the fifth round of the FA Cup, with Sandro Tonali's double proving decisive.
Arsenal captain Martin Odegaard wants his team to do better in the FA Cup this season ahead of the fourth-round tie against Wigan Athletic at Emirates Stadium on Sunday.
Manchester City boss Pep Guardiola was happy to progress to the next round of the FA Cup after beating Salford City 2-0 but admitted his team's performance was 'flat'.
Liverpool advanced to the next round of the FA Cup after defeating Brighton and Hove Albion 3-0 in their fourth-round clash at Anfield on Saturday evening.
