Bubbles in fuselage delay FAA certification for 787

Seattle Post-Intelligencer ^ | Friday, June 9, 2006 | By JAMES WALLACE

[skeptoid]

A final composite fuselage section that was to be used in certifying The Boeing Co.'s 787 Dreamliner failed during manufacturing, sending engineers scrambling to keep the company's all-important new jetliner program on schedule.

Mike Bair, vice president and general manager of the 787 program, said in an interview Thursday that the failure will not sidetrack the program, and the first planes should still be delivered on time to All Nippon Airways of Japan in mid-2008.

But the problem -- first reported by Business Week -- shows the kinds of risks that Boeing faces at a time when the 787 program is entering a critical stage and the manufacturing and production system must work as advertised. The first flight of the new jet is expected late next year.

The 787 will have a composite airframe, including the fuselage -- a first for commercial jets. Boeing cannot afford any major snags in proving the technology to the Federal Aviation Administration and other regulatory agencies if the plane is to enter airline service on schedule.

Boeing has not been specific about the actual delivery date, but sources say All Nippon Airways is supposed to take delivery of the first planes in May 2008.

[skeptoid]

"The problem was the mandrel, Bair said. It was built some time ago and was too big. The mandrel changes size as it is heated in the autoclave and this must be taken into account when the fuselage barrel is made. Some of the material on this mandrel had been machined off to get it back to the proper size, Bair said, but as a result there were places that leaked. That's why too many bubbles formed during the curing."

The Boeing Company
A cross section of the Dreamliner's composite
fuselage, which will be made by Boeing's partners in
South Carolina, Wichita, Kan., and in Italy.
The wings will be made in Japan.

The program is healthy!

[COEXERJ145]

I'd be more surprised if they didn't have some problems.

[driftdiver]

At least Boeing admitted this problem and doesn't attempt to cover them up like the other company.

[skeptoid]

eggsackley! This was the NINTH test barrel. The first EIGHT were fine. This ninth one did not measure up to parameters that were not stated (and they may be ridiculously high),

This is, after all the testing stage.

I hope to live to see this one enter service and prove its adveritsed efficiencies.

[Paleo Conservative]

If you want on or off my aerospace ping list, please contact me by Freep mail.

[Central Scrutiniser]

Bummer, they will fix it. Stuff happens when you build a new plane.

(if this was about an Airbus jet 50 idiots would post all kinds of really stupid, uninformed xenophobic crap)

[John Valentine]

(if this was about an Airbus jet 50 idiots would post all kinds of really stupid, uninformed xenophobic crap)

How can you say such a thing!? I'm shocked and hurt.

[Einigkeit_Recht_Freiheit]

(if this was about an Airbus jet 50 idiots would post all kinds of really stupid, uninformed xenophobic crap)

You mean like: 'mericans they so dumb. Can't build composite fuselage. Too busy at Guantanomo torturing prisoners. Ha ha ha. Ummm . . . Bush's fault.

[Thinkin' Gal]

Bubbles in fuselage delay FAA certification for 787

Boeing had better quit monkeying around.

[Attention Surplus Disorder]

Great!

[Energy Alley]

This is the exact same problem Boeing had during the X-32 JSF program when they were trying to produce the composite wing.

[DB]

Something like that...

[Prodn2000]

I, for one, am amazed still at how commercial airliners work, as expected, 99% of the time.

Anyone who has ever felt that "dropping" sensation at 2500 feet knows what I am talking about.

Boeing will figure out how to satisfy even the harshest of critics when they finish the 787. And after all, at least the tail doesn't fall off (surrender) like the other manufacturer.

[PAR35]

the Dreamliner's composite fuselage, which will be made by Boeing's partners in South Carolina, Wichita, Kan., and in Italy.

Any word on which one made the part that is the subject of the story?

[brityank]

Your link goes to ADN in Alaska; the real link is:
http://seattlepi.nwsource.com/business/273302_fuselage09.html

[decimon]

Any word on which one made the part that is the subject of the story?

Made in Boeing's facilities in Oregon according to the following story.

Seattle Times.

[the crow]

carbon bump for later. thanks for the post.

[Yo-Yo]

This news doesn't seem to have affected the order book.

Continental Airlines Orders 10 More Boeing 787s and 24 More Boeing 737s


Airline Gains Flexibility to Replace Less Efficient Aircraft and Continue
Successful Growth

HOUSTON, June 6 /PRNewswire-FirstCall/ -- Continental Airlines (NYSE:
CAL) today announced that it has ordered 10 additional Boeing 787
Dreamliner aircraft, bringing to 20 the total number of 787s the company
has ordered from The Boeing Company and making Continental the largest U.S.
customer for Boeing's newest widebody aircraft.
In addition, the company will acquire 24 more Boeing Next-Generation
737 (737NG) aircraft, bringing the total number of Boeing 737NGs in its
fleet to 213 when these aircraft, and pre-existing firm order 737NG
aircraft, are delivered.
"These aircraft will give us the ability to seize long-haul market
opportunities, remove less efficient aircraft from our fleet and maintain
our role as a global network leader," said Larry Kellner, Continental's
chairman and CEO. "We continue to target 5 to 7 percent annual growth in
capacity. Our fleet plan remains flexible, permitting us to respond
appropriately to market conditions."
Working together with its valued business partners at Boeing,
Continental has been acquiring modern, fuel-efficient aircraft over the
past decade, giving the airline a natural fuel hedge and an advantage over
its competitors. Since 1998, the company has improved fuel efficiency by
nearly 25 percent per available seat mile as a result of several factors
including fleet modernization, implementation of fuel-saving technology
like winglets, and improved operating procedures.
787s Optimal for International Growth
The Boeing 787 is the optimal aircraft to support Continental's
strategy for continued international growth. With expanded range
capabilities, unmatched fuel efficiency and superior operating economics,
the 787s will allow the company to replace less efficient widebody
aircraft, such as the company's 767-200 aircraft, and target additional
long-haul markets. The 787s will also give Continental the ability to offer
more capacity on international routes that need larger aircraft to support
traffic growth.
737NGs Provide Fleet Flexibility
One of the world's most popular and reliable aircraft the Boeing 737NGs
feature advanced technology for greater operational efficiencies. The 24
additional 737NGs, along with other 737NG aircraft already on order, will
give Continental the flexibility to continue to grow while replacing older,
less efficient 737 classic aircraft, such as the company's 737-300
aircraft. Continental has arranged backstop financing for the additional
737NG aircraft.
Delivery Schedule
This new order will bring Continental's firm commitments for new
aircraft to 88 (20 Boeing 787s, two Boeing 777s and 66 Boeing 737s). The
first of the 20 Boeing 787 aircraft is scheduled for delivery in 2009, and
the first additional 737NG will be scheduled for delivery in 2008.
Well-Managed Fleet Plan
Since announcing its fleet modernization program a decade ago,
Continental has reduced the number of airplane types in its fleet from nine
to three and reached its goal of operating one of the most efficient fleets
among U.S. airlines. More than 70 percent of its fleet consists of
common-rated Boeing 737 series aircraft, which allow for greater
efficiencies in pilot training, enhanced crew flexibility, increased
savings from simplified maintenance and reduced spare parts inventory
costs. The following chart lists the type and number of aircraft in
Continental's current fleet.
Aircraft type No. in Fleet
777-200ER 18
767-400ER 16
767-200ER 10
757-300 17
757-200 41
737-900 12
737-800 99
737-700 36
737-500 63
737-300 48
Total 360

Winglets Provide Fuel Savings
Continental is installing winglets on its 757-200 and 737-700/-800
aircraft. Winglets, in combination with the company's young, fuel-efficient
fleet, provide a natural hedge against soaring fuel costs. Winglets reduce
drag on an aircraft's wings, increasing fuel efficiency by up to 5 percent.
Continental has installed winglets on 126 Boeing 737 and 24 Boeing 757
aircraft.
A Decade of International Growth
With over $3 billion invested in its hub facilities at New York,
Cleveland and Houston and a fleet plan that has been carefully managed over
the last decade, Continental has positioned itself for successful growth.
Last year, Continental completed one of the most aggressive international
expansions in the company's history, including first-ever nonstop service
between its New York hub at Newark Liberty International Airport and Delhi,
India; and Beijing, China. In May 2006, the company launched three more
international routes between New York/Newark and Cologne, Germany;
Barcelona, Spain; and Copenhagen, Denmark. The airline now serves more
international destinations than any other U.S. airline, with more nonstop
destinations to Europe from the New York area and more destinations in
Mexico from the U.S. than any other carrier.
Continental Airlines, together with Continental Express and Continental
Connection, has more than 3,200 daily departures throughout the Americas,
Europe and Asia, serving 151 domestic and 137 international destinations.
More than 400 additional points are served via SkyTeam alliance airlines.
With more than 42,000 employees, Continental has hubs serving New York,
Houston, Cleveland and Guam, and together with Continental Express, carries
approximately 61 million passengers per year. Continental consistently
earns awards and critical acclaim for both its operation and its corporate
culture.
For the third consecutive year, in 2006, FORTUNE magazine named
Continental the No. 1 Most Admired Global Airline on its annual list of
Most Admired Global Companies. Continental was also named the No. 1 airline
on the publication's 2006 America's Most Admired airline industry list.
Additionally, Continental again won major awards at the OAG Airline of the
Year Awards including "Best Airline Based in North America" for the third
year in a row, and "Best Executive/Business Class" for the fourth
consecutive year. For more company information, visit continental.com.

[N. Theknow]

Speaking of AirBus, how did the evacuation of the A380 go? I saw one thread where it had to be redone and then I had to go on a trip and missed out on the next try results.

[Yo-Yo]

The A380 evacuation test was accepted by both the FAA and the EASA. The A380 should soon be certified for 850 passengers.

Interesting reporter's view of the tests here.

[skeptoid]

My apologies for a big OOPS!

Thanks for posting the good link.