Boeing Dreamliner 'coming to life' (Part 1 of 3)

Seattle PI ^ | 27 June 2006 | James Wallace

[TalonDJ]

Sounds to me like the first couple of 787s made should be used to freight 787 parts

It is really hard to fit something inside something else when they are both the same diameter.

[pepperdog]

They better have very strong configuration control and integration managers. (Who speaka the language too!)

[ccmay]

The other day I was coming off a drop when my $4000 composite mountain bike cracked.

Composites are stronger and better than metals in many ways, but they do have a rather catastrophic mode of failure. Metals bend; composites break. With good engineering and thorough testing, this should not be a problem.

-ccm

[sam_paine]

Aloha Air 243

Metals break catastrophically, too!!

[SunkenCiv]

alas...

http://www.freerepublic.com/focus/f-news/1656488/posts

[Prophet in the wilderness]

Is composites like fiber glass ? and does it fray like fiberglass ? or is it more of a solid consistency ?
I am sure Boeing will insure and take steps to make sure those airframe do not crack like that mountain bike did.

[Prophet in the wilderness]

So with composites, if it is designed to a certain stress limit, and as long as that limit is not surpassed, it won't break ?
And, composites don't " fatigue " as does metals.
At a certain point metals bend, it begins to fatigue, and eventually cracks, breaks, or give out.

[phoenix0468]

I think it would depend on the type of composite. Yet, most composites, such as carbon fiber, are fiberous similar to fiberglass and may fray at the break point. I have yet to see carbon fiber fail. It is extremely strong, like kevlar. But much much lighter. Not being an engineer, I can't really give any definite answer on how it would break.

The thing about composites is the fact that even if they do crack, they will retain their regidity and strength, in most cases. Where metal would shear, if it were to crack and continue under pressure, as the picture in one of the earlier posts, composite would most likely keep it's integrity. Much safer, much lighter, and most likely cheaper in the long run.

[Prophet in the wilderness]

You said " much cheaper " in the long run, as in maintenance ( because planes won't have to go under the required inspection as soon as aluminum as does with composites ) and the production process can be simplified and less money for labor because most of it can be automated by robots and machines ?

[monkeyshine]

Well it better be good. But it's part of the business strategy. These countries are large plane buyers, and often own large stakes in the national airlines. By being involved in the project they are more likely to buy the finished product and other Boeign products like the new 747-800.

[Energy Alley]

The biggest problem Boeing is having with the 787 is a high defect rate on the composite fuselage sections.

It isn't a serious problem at this stage, but it could be a very expensive and time consuming one when production is ramped if it isn't resolved or dramatically reduced by then.

[Yo-Yo]

One test barrel out of the first nine ever made is not what I would call a high failure rate. The full reason why that one barrel failed is here but the short answer is one mandrel was used that had been made too big then machined down to size, which allowed too many air leaks during the autoclaving process.

The problem has already been diagnosed and solved.

[Energy Alley]

I am not talking about failure in testing, I am talking about straight from the autoclave to the garbage.

[DesScorp]

This is idiotic. They've largely outsourced the building of the plane. They're basically just slapping their name on it after assembly. First the eat McDonnell-Douglas and ruing that company, now they can't even build their own airplanes. I really wish Lockheed and Northrop-Grumman would get into the airliner business. Boeing sucks.

[Yo-Yo]

Boeing outsorces major subassemblies for their 737, 767, and 777 now.

[looscnnn]

Ok, if the majority of the parts are built in SC or sent to SC, why not just assemble the whole thing in SC? Wouldn't it save money, reduce delay's, reduce damage, shorten the construction time, etc.?