Boeing Grounds Test Fleet, Critical Component Fails

Boeing has grounded its 777X test fleet after the failure of a “thrust link mounting component” attached to one of the engines on a test aircraft.

“The discovery was made during post-flight inspections of the third test aircraft, WH003, following its return to Kailua-Kona, Hawaii, from a 5 hr. 31 min. certification test flight over the Pacific,” Aviation Week reports.

NEW – Boeing grounds 777X test fleet after “the failure of a crucial piece of structure that mounts the engine to the aircraft.”https://t.co/vKP74vvDY0

— Disclose.tv (@disclosetv) August 20, 2024

Boeing grounded the three other 777-9 airplanes in its test fleet and has no other flight testing scheduled.

“Our team is replacing the part and capturing any learnings from the component and will resume flight testing when ready,” Boeing said in a statement, according to CNBC.

Boeing grounds B777X test fleet over structural issues: Boeing (BOE, Washington National) has grounded its B777-9 testbed fleet after a routine post-flight inspection revealed the failure of a piece of the structure that mounts the engine to the… https://t.co/SPpNJpkUd7 pic.twitter.com/KwgPYonTnQ

— ch-aviation (@chaviation) August 20, 2024

Aviation Week reports:

The failure of the component, which was first reported by The Air Current, comes just as Boeing was accelerating into the first phase of 777-9 type inspection authorization (TIA), FAA-required testing for certification. Formal TIA tests began July 12 after a delay of almost three years and represent the last major milestone before anticipated FAA approval and initial deliveries—still currently scheduled for late 2025.

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There are two fail-safe thrust links on each engine for redundancy and are designed to transfer vertical and lateral mechanical stresses between the engine and the aircraft. The Boeing-designed thrust links attach to the fan frame and carry mechanical loads—as well as engine torque about the engine axis and thrust—to the aft engine mount at the rear.

Company sources confirm the accuracy of reports that one of the links was severed, and that subsequent inspections on the other two active test aircraft, WH001 and WH002, have revealed cracks. Both of these aircraft are currently in lay-up undergoing scheduled maintenance at Boeing sites in Everett and Boeing Field, Seattle, respectively.

WATCH:

Boeing has suffered a further setback in its development of the widebody 777X aircraft, with the grounding of its entire test fleet.

The grounding decision came after a critical engine mounting structure failure was discovered on one of the aircraft. Subsequent inspections… pic.twitter.com/GKfOfWhZQZ

— AviationSource (@AvSourceNews) August 20, 2024

“We are inspecting the flight test fleet for this condition. No near-term flight tests were planned on the other flight test airplanes, which have scheduled maintenance and layup activities. We are keeping the FAA fully informed on the issue and have shared information with our customers,” the company stated, according to Aviation Week. 

From the New York Post:

The 777X is Boeing’s latest and largest aircraft. It was initially set to start commercial service in 2020. Increased regulatory scrutiny following a series of safety faults pushed the date back to 2025.

Now, the discovery of a faulty engine part threatens to push the date back even further.

The cracks were found on an integral part called the thrust link that connects the plane to its engines. The link – which is made of heavy-duty titanium – is manufactured by Boeing and unique to the 777X fleet.

The new Boeing plane features GE9X engines manufactured by General Electric, new composite wings, a larger cabin and increased seating.

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General Electric became the planemaker’s engine maker in 2014, partnering with Boeing on large jets like the 777X.

This is a Guest Post from our friends over at 100 Percent Fed Up.

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