Big Hurdle Cleared For Composite Airliner

For all the reports of late about all that's gone wrong with Boeing's 787 Dreamliner -- namely, mounting delivery delays stemming from a shortage of fasteners, and various other supplier woes -- Boeing would like everyone to note some things are going right, too.

On Thursday, the American planemaker announced the 787's composite technology, design and construction was proven to be up to the rigors of regular scheduled airline service, during a series of testing scenarios conducted beginning in late 2007 and concluding this week. The tests were performed on a composite fuselage test section, and are part of Boeing's certification efforts for the 787.

"The tests were very successful -- they couldn't have gone any better," said Kevin Davis, 787 fuselage authorized representative and leader of the testing.

Boeing says its engineers proved the composite barrel design through a series of incremental tests that first took the barrel to limit load, a test condition that simulates the most extreme conditions expected to be experienced in the life of the airplane.

Next, the test article was taken to 150 percent of limit load -- a condition called "ultimate load," the level required for certification. Finally, the team pushed the composite section past ultimate load well beyond ultimate load to a destruct-condition maneuver beyond two and a half times the force of gravity.

Testers observed audible indications of damage as the test progressed, but the piece did not reach the level of destruction that had been anticipated. Boeing engineers now are performing an extensive inspection of the barrel and analysis of test results.

The robust test program is key to clearing the Dreamliner for first flight. Some testing on the composite barrel section will continue, Boeing says, but it is at the company's discretion for additional learning, and not an FAA requirement.

Additional static testing is required, and will be conducted, on a full airplane structure prior to first flight.

FMI: www.boeing.com