Static testing for the 787 Dreamliner is set to begin early next week, a key milestone on the road to first flight, Boeing has confirmed.ZY997, Boeing's static 787 test airframe, will be put through a series of grueling structural tests to validate the strength of the composite structure.
The tests are expected to continue through the fourth quarter of 2008.
The static test will begin with the "high-blow" test to validate the pressure seals inside the aircraft cabin. During the test, Boeing will raise the internal pressure of the cabin to 14.9 PSI, or about 1.5 times normal pressurization.
Because of the 787's composite one-piece barrel design, there are significantly fewer points along the fuselage where pressure seals could fail.
During the test, the aircraft will be draped in plastic wrap in the event the cabin breaks a pressure seal. If this occurs, the plastic will billow out easily identifying the source of the leak.
In a health and safety advisory sent to staff ahead of the test, "creaking and popping noises are normally noted" due to the "expansion and flexing" of the structure during static testing. The aircraft, which will never fly, was rolled on April 25 to the static test rig inside Building 40-23 where the testing will take place.
Boeing has not yet determined if it will bring the wings to ultimate load, or the point at which they break. The FAA requires all aircraft structure to withstand 150% of the maximum loads that will ever be encountered in flight.
In January 1995, wings of Boeing's 777 were brought to 154% of maximum design load in before they snapped with an explosive bang. The wings were deflected 24-feet before they succumbed to the punishing loads.
Even with the commencement of static testing next week, all 787 assembly is still frozen as the IAM strike begins its third week, though a certain portion of static testing must be completed before Dreamliner One can take to the sky.
Image credit: FlightBlogger
on September 19, 2008 9:53 PM | Reply
Great news that the Testing is moving forward
Mike
on September 20, 2008 5:32 AM | Reply
Jon,
i thought some static tests on the 787 had already taken place and were successful. I remember this being announced by Boeing.
Is this a different series?
It would be very helpful if you could clarify what steps remain in the 787 approval process. Before the strike, I thought the landing gears and wheels were being tested, propulsion was being prepared and there was talk of when the plane would taxi.
Also, is there work being done during the strike that will facilitate the process so time is not being wasted.
Thanks for any clarity you can bring to this subject
on September 20, 2008 9:26 AM | Reply
Q - so, if there are a number of places where leaks could occur/seals fail, how many pieces in a one-piece barrel design?
on September 20, 2008 1:20 PM | Reply
Q - so, if there are a number of places where leaks could occur/seals fail, how many pieces in a one-piece barrel design?
A: Someone with more technical knowledge should correct me if I'm wrong here. In a one piece barrel design there are very few (if any?) longitudinal joins, unlike a panel design which has both latitudinal and longitudinal seams. Boeing points to this as a point of cost savings as well. Typically, doors, windows and fuselage joins are most vulnerable. There are only 5 (6?) join locations. Section 41-43-44-Center Wing Box-46-47-48.
-Jon
on September 22, 2008 1:32 AM | Reply
Two points:
-- Structural components have already been tested on the 787, notably the horizontal stabilizers. The wing box test should be wrapping up soon, if it hasn't already.
-- Some work has occurred on 787 LN1 during the strike. For reasons known only to the manufacturing people, they removed the engines. Again.
on September 22, 2008 12:03 PM | Reply
High blow test delayed due to data acquisition issues.
on September 22, 2008 5:18 PM | Reply
It is nice to see that there are a few smart people are left is Seattle! When you going to work has a reward.... It's called a paycheck!
I saw a few of your IAM brothers in Kansas today and they were at work. They said it was better to get a check and feed the family than starve and have to worry about long term employment.
With trouble on the economic front it might be wise and go back to work and try to negoiate.
Texans are here working to and getting paid to take your jobs away!
Texans want to work and want BCA.
This Messaage brought to you by (Working) Texans for a new Boeing begining.
on September 22, 2008 6:51 PM | Reply
This is great stuff, and great intrigue. Of course passing the FAA requirements is import, but the intrigue is in the confirmation of the design. When real life data is available, Boeing can start tuning the design in its specifications. As soon as Air Bus "freezes" the A350 design for the 4th or 5th time, Boeing will be able to come out with its revised specifications. Great Intrigue.
on September 22, 2008 10:07 PM | Reply
Wingbender
Could be due to GE *RE*certifying the already certified combustor and other upgrades. Seems there were fuel delivery/burn/degradation problems on the GEnX. The delay is great for GE at this point.
Jon
Is RR in a similar mode? Seems we hear little news on the Trent 1000.
on September 24, 2008 4:03 AM | Reply
JE,
The engines on the first few airplanes are Rolls Royce, so the GE re-certification wouldn't be the reason. Which doesn't mean that the Trent may also not require more work.
on September 25, 2008 10:03 PM | Reply
High blow test is delayed until Saturday 9/27.