Examined How FAA And EASA Assess Composite Materials In Dreamliner Fuselage And Wings

In a report released Thursday, the Government Accountability Office said that it had identified safety concerns related to the repair and maintenance of the composite materials used in the Dreamliner's wings and fuselage, but also reported that the FAA had properly followed its internal procedures in certifying the airplane.

GAO Graphic

GAO was asked to review FAA’s and EASA's certification processes and FAA's oversight of the composite airplanes once they enter service. GAO examined how FAA and EASA assessed the use of composite materials in the Boeing 787 fuselage and wings, and the extent to which FAA has addressed safety-related concerns associated with the repair and maintenance of composite airplanes. GAO reviewed certification documentation, conducted a literature search, discussed repair and maintenance issues with experts, and interviewed FAA and EASA officials and Boeing representatives. GAO is not making recommendations in this report. FAA, EASA, Boeing, and others provided technical comments, which were incorporated as appropriate.

GAO found that the FAA followed its certification process in assessing the Boeing 787 airplane's composite fuselage and wings against its own airworthiness standards. The agency applied five special conditions when it found that its airworthiness standards were not adequate to ensure that the composite structures would comply with existing safety levels. These special conditions require Boeing to take additional steps to demonstrate the 787's structures meet current performance standards. The FAA also granted Boeing an equivalent level of safety finding when the manufacturer determined it could meet the standard but prove it differently from the method specified in that standard. On the basis of a review of the FAA’s special condition requirements, Boeing submissions, and discussions with FAA and Boeing officials, GAO found that the FAA followed its process by documenting the technical issues related to the design of the composite fuselage and wings, determining the special conditions and equivalent level of safety finding, obtaining public comments on draft special conditions, and monitoring Boeing’s compliance with those conditions.

Based on expert interviews and a review of Boeing and other documents, GAO identified four key safety-related concerns with the repair and maintenance of composites in commercial airplanes:

• Limited information on the behavior of airplane composite structures.
• Technical issues related to the unique properties of composite materials.
• Standardization of repair materials and techniques.
• Training and awareness.

None of the experts believed these concerns posed extraordinary safety risks or were insurmountable. GAO says that the FAA is taking action to help address these concerns it identified related to the repair and maintenance of composite airplane structures. However, the report says, until these composite airplanes enter service, it is unclear if these actions will be sufficient.

FMI: www.gao.gov