May 2010 Archives

If ever there was a route that the 787 was designed for, this is it.

A new 777 is making its way down the moving line inside Boeing's Everett factory. That aircraft, with a painted Union Jack rudder, will be the first -300ER (G-STB_) for British Airways. The aircraft, set for a July handover, will be the first new wide-body type (variant) in the carrier's fleet since they added their first 777-200ER (G-VIIA) in July 1997. It will be the first of six the carrier has on order. Two of the six are directly purchased from Boeing, while the balance will be leased from GECAS. British Airways holds options for a further four more. A source at the airframer says that the aircraft left final body join earlier this week and is heading to the front door at a breakneck pace of 1.6 in/min.

In the last two weeks, the world has seen air major accidents in North Africa and South Asia involving brand new airframes from both Boeing and Airbus. While the final verdict on the probable causes of these accidents are months, if not years away, the close proximity of both tragedies, prompts a distinct train of thought.
 
Afriqiyah Airways Flight 771, an Airbus A330-200 built in late 2009, crashed on approach to Tripoli following a flight from Johannesburg, killing all but one of the 104 passengers on 12 May. Ten days later on May 22, Air India Express Flight 812, a Boeing 737-800 delivered in 2008, overran a runway in Mangalore after a flight from Dubai, killing 158 of 166 on board.

While very different airlines, with very different fleets, in very different regions, these two accidents have an important link tied to each region's common aviation future.
 
Boeing and Airbus estimate Africa will require 620-929 new aircraft over the next 20 years, a more than doubling the current continental fleet of 660, while India will require 1,032-1,093 aircraft, with the Indian passenger fleet growing four-fold.
 
Grouping an entire continent such as Africa is a common fallacy, pockets of well developed airlines and airports have expanded safety in important ways over the last half century. The same goes for India where highly developed airports in Mumbai and Delhi account for half of the air traffic in South Asia.
 
Staggering economic growth, which will outpace mature markets in the US and Europe will drive unprecedented demand for new aircraft and new routes to airports that had limited or no previous commercial service whatsoever.
 
While technology in the aircraft is further enhancing safety, such as runway overrun protection and precision navigation capability, technology on the ground has to keep pace. In developed regions, approach radar aids a pilot on descent to the runway threshold, analyzing the aircraft's position in relation to the instrument landing system.
 
Additionally, the EMAS, or Engineered Materials Arresting System, has proven itself to be far superior than other types of runway arresting measures such as sand bed, like that available in Mangalore.
 
Though as the massive influx of new aircraft continues over the next two decades into the emerging markets, aircraft large and small will continue to put strain on an limited and often outdated airport infrastructure.
 
Flight 771 is believed to have been flying a non-precision NDB approach into the rising morning sun at the end of Runway 9 when it crashed, while early reports indicate Flight 812 approached high on the glideslope to Mangalore, resulting in a long touchdown by the 737.

Just as the airframers manage the unprecedented demand from these regions, particular focus needs to be paid by governments, international regulatory authorities and airframers, on both sides of the aircraft/airport equation.
 
The introduction of high technology cannot be limited to flying hardware. Unprecedented growth cannot be successfully accomplished without expansion of not only pavement and terminals, but the modern safety technologies that make emerging markets into developed markets.

Photos Credit Rick Schlamp & Christophe Ramos

Videos Courtesy Liz Matzelle

787 Flight Test Updates: Month One, Month Two & Month Three

It has been five months since ZA001 made its maiden flight on December 15, 2009 has surpassed 747 flight hours with its four Rolls-Royce powered 787s through May 18.

With five months of testing now under its belt, only Boeing knows if it is truly on track for first delivery and certification by the end of 2010, though with about 750 of the 2400 planned flight test hours (for Rolls-Royce certification) accumulated through a five months worth of testing, the goal looks tighter and tighter. While Boeing has not swayed from its projection of a year-end first delivery, ANA - launch customer for the 787 - is quietly making preparations for a further delay into 2011, with other industry sources saying the airline's preparations angle closer to a springtime entry into service for the new composite jetliner.

On May 10, tracking by UBS Investment Research estimated that the 787 was only 20% through type certification and was as much as a month behind to a mid-September completion "due to extended downtime for both planned and unplanned maintenance on its four test aircraft."

The most significant program milestone in the last two months was the granting of the expanded Type Inspection Authorization on April 21 which cleared the way for the certification operations with the Federal Aviation Administration. Earlier in the month, on April 7, Boeing declared the static structural tests successful following the high-blow and wing flex tests of late March. Additionally, on April 8, the 787's Hamilton Sundstrand APS5000 APU completed ETOPS testing after logging 10,000 operating hours.

Sometimes you're in the right place at exactly the right time to capture an image that makes you question its authenticity. This, my friends, is the crowded airspace in Seattle. The United Express CRJ700 on final to Sea-Tac as a US Air Force C-17 passes directly overhead.

Photos Credit Liz Matzelle

Boeing ended its deliberations today on whether or not it would increase the 737 production rate in the coming years. The verdict: Yes. Renton will increase its output from 31.5 aircraft per month to 34 aircraft per month at the beginning of 2012. The increase follows planned rate hikes on the 777, 747, and 787 lines, which is intended to position the airframer to overtake Airbus as the world's largest planemaker. Here's my story on the production rate increase.

Fixing a previously undisclosed 787 design flaw has now emerged as a contributor to Boeing's decision to freeze shipments from suppliers until early June.

Shear ties, which affix the fuselage frames to the skin of the aircraft, now require replacement or rework, after the initial design failed to take into account thermal fatigue loading of the parts.

The parts in question are located in the aft most part of the fuselage, inside sections 48 and 48 aft, which is the tail cone of the 787.

The problem, which was discovered in December, found that repeated cooling and warming of the unpressurized Section 48 and 48 Aft, the shear ties, those of which are made of aluminum, can pull away from the skin of the fuselage, potentially compromising the structural integrity of the aircraft.

Boeing says the solution, which will be incorporated on all deliverable aircraft, is a combination of new thicker shear ties, while an additional program source adds that radius fillers will be employed along side some existing shear ties.

The airframer says that the changes to the shear ties will not impact the current flight test or delivery schedules, and does not present an immediate safety of flight issue to the four flying 787s.

"It is a structural issue in that we are modifying the airplanes but once complete, the structure has full integrity and will meet all FAA requirements," says Boeing.

Rework on Airplane 23, say program sources, has already begun in Charleston and will be completed in Everett, as will Airplane 24. The same changes are required for Airplanes four through 22 as well, including three of the six flight test aircraft, which will eventually be delievered. A permanent design solution is planned for introduction beginning with Airplane 55.

Section 47 and 48 are both fabricated by Boeing Charleston, formerly Vought Aircraft Industries, while Section 48 Aft is made by Korean Aerospace in South Korea.

Starting with Airplane 25, shear tie modification of the Section 48 and 48 Aft will be done in Charleston and Korea, respectively.

The 24-manufacturing day hold does not represent a new production schedule as the 787 ramp up continues, rather, the pace of deliveries will quicken as the time between rate breaks is reduced.

One program source says the shear tie issue was an important driver for the 24-manufacturing day hold, while Boeing downplayed the shear tie issue as being on a long list of contributing factors.

Continued part shortages and design changes were identified by Boeing as the cause of the 24-manufacturing day hold announced on April 27 will keep structures for Airplane 23 at suppliers until early June.

While accurate, program sources say that the stoppage can be ultimately traced to the aft fuselage shear tie replacement and rework. Holding structural sections at suppliers, particularly the aft fuselage, allows for the completion of required engineering along with significantly easier access by crews to address the rework.

Once in Everett at Final Assembly & Delivery, the horizontal stabilizer is installed and access to the frames and shear ties in the aft fuselage becomes "extremely limited," they add.

Compared to a year ago, says vice president of airplane programs Pat Shanahan, design changes to the aircraft have declined by a factor of ten or greater, though he acknowledges changes, even small ones, continue to be disruptive to the manufacturing process.

During manufacturing in Charleston, Sections 47, which is the pressurized aft passenger cabin, and Section 48 which houses the aft pressure bulkhead and horizontal stabilizer, are joined, stuffed with systems, wiring, insulation and ducting before being shipped to Everett for final assembly.

Who is ultimately responsible for the design oversight remains an open question, while Boeing and Vought, which still provides engineering support to Boeing, says the other is where blame lies, says one program source.

Shear ties have been a source of supply chain disruption before. A 2007 and 2008 shortage of shear ties built by Boeing Winnipeg prevented structural frames from being installed, prompting a limited structural completion of assembly at the time of delivery.

A report by Flightglobal partner Commercial Aviation Online (CAO) identifies Irish aircraft lessor AWAS  as having cancelled its order for six 787 aircraft. The cancellation brings the net 2010 787 order total to 9, following the cancellation of 10 aircraft by Air Berlin and the finalization of United's order for 25. The AWAS order was formerly held by the Pegasus Aviation Finance Company and before that originated as a four aircraft 2004 order by Italian charter operator Blue Panorama for the 7E7. Pegasus increased its order in 2006 to six aircraft.

Lufthansa is set to take delivery of its first A380 - MSN038 (D-AIMA) on May 19. Final preparations are underway for the arrival of the first of four superjumbos to join the German flag carrier this year. The first, arriving next week, will be followed by additions in June, July and September.

Last of eights flights over the last two week will take me back home
to DC. It's been a heck of a whirlwind with six countries visited.
Today's flight is onboard United Airlines 777-200ER flight 919. Anyone
have a reg?

The volcano has added about an hour to our flight taking us a bit
farther north than usual with an estimated blocktime of 08+40.

Looking forward to about 10 days at home before another (shorter) trip
out west then a light June before heading into Farnborough & Oshkosh
madness in July. Been a fun swing with Bombardier, EBACE, Boeing and
Airbus, but this blogger is ready for home.

BROUGHTON -- Airbus today outlined the key concepts for its next generation narrowbody replacement for its A320 family aircraft due for entry into service in the middle of the next decade.

UPDATE: While these two concepts have been seen before, what makes this slide notable is the detail that comes along with it. Airbus had always made a point when showing these renderings that they were merely artistic interpretations of possible configurations, however at the technical briefings, they began to discuss these designs with a bit more conviction as potential options for A30X. 

Additionally, the detail of technologies that would be leveraged for the new platform is also new information. It represents the first time Airbus has opened up about not just their vision for a configuration, but also establishing technological goals for getting to a 30% fuel burn improvement over today's A320 family.

BROUGHTON -- I'm here in the UK visiting Airbus for its annual Innovation Days technical briefing and I'll be sending updates from the 15 briefings we have planned for our two days here. Follow me on Twitter for the latest on Airbus.

HAMBURG -- Lufthansa has just unveiled a new special livery for a
Boeing 747-400 celebrating 50 years in partnership with the American
Airframer. D-ABVH is adorned with. custom logo reading "50 years /
Innovation Partnership Boeing and Lufthansa" while listing all the
Boeing models operated over the years from the 707 to the upcoming
747-8.

BERLIN -- I write this morning from a Starbucks asking myself how this is any different from being in DC. It's not really, aside from the fact that there's a delightful "to stay" option to enjoy your caffeine fix out of a mug instead of a paper cup, but I digress. 

BERLIN -- In what could be its first overseas trip, indications point to the 747-8F heading to Hamburg on Friday to celebrate the 50th anniversary of the partnership between Lufthansa and Boeing.

While the trip is not officially confirmed, once source says the 747-8 is set for arrival and parking at the Lufthansa Technik ramp, with ramp four on the ramp reserved for the jumbo. Lufthansa 747-400 (D-ABVK) is also set to attend the celebration. Lufthansa is the launch customer for the passenger variant of the 747-8.

I currently find myself in Berlin for a few days to breathe before heading to Northern UK for technical briefings with Airbus. I'll keep this updated as more information becomes available, though it is possible the -8's first trans-Atlantic journey may wait until Farnborough.

UPDATE 8:55 AM 5/7: Unfortunately, the 747-8 will be remaining stateside for the time being. Boeing confirmed that the new jumbo will NOT be visiting Hamburg on Friday. D-ABVK still plans to attend the celebration adorned with custom stickers for the event.

GENEVA -- Our first issue of interactive Flight Daily News is now released! Go inside Day One of EBACE here in Geneva with interviews, photos and videos around the show. Also, make sure to visit our show landing page for all the latest news, blogs and twitter updates at Europe's biggest business aviation event.

A FlightBlogger Exclusive:

The short answer: Hard to tell.