What are the structural issues with 787?

Boeing's deliveries of 787s remain halted due to quality and production issues, including those related to gaps and skin flatness between fuselage sections that fail to meet precise tolerances, Boeing has said. Shimming is one method of addressing skin-flatness problems.



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The latest issue affects a fitting assembly in horizontal stabilizers built by a Boeing facility in Salt Lake City. The fittings come from an external supplier, and each unit is assembled and installed onto stabilizers in Salt Lake, a Boeing source said.

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The problem involves a fitting for the 787's horizontal stabilizer installed by a Boeing production facility in Salt Lake City, Utah, the company said. The horizontal stabilizer, located at the base of an aircraft's tail, allows a plane to maintain longitudinal balance while flying.

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The FAA said the leaks could damage critical equipment and lead to a “loss of continued safe flight and landing.” The agency said one airline found wet carpet in the cockpit of a plane and, when it inspected its entire fleet of 787s, found “multiple” planes with leaking faucets.

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The two aircraft are the smallest variant of the Dreamliner family, being -8s, and have been in storage since May 2019. Why are they being scrapped? Norwegian placed these two aircraft into storage when Boeing 787s with Rolls-Royce Trent 1000 engines were grounded due to engine fan blade corrosion.

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The Dreamliner is a successful aircraft, still in production with more than 1600 delivered or on order. The list price for a new Boeing 787-8 is $239 million dollars. Yet even as international travel opens again for these long-range aircraft, two Dreamliners barely ten years old are waiting for the wrecker's ball.

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The typical lifespan of airliners The composite-driven Boeing 787 Dreamliner is designed for 44,000 flight cycles. These jets can theoretically last several decades with an average of two flight cycles a day. Unlike commercial airliners, fighter jets are unique due to their mission requirements.

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The Boeing 787 is known to be a more comfortable and efficient aircraft than the 747, especially for long-haul flights. There are objective differences between both planes. The 787 has newer engines, two fewer of them and more electrical (rather than hydraulic) systems, which means much less cabin noise.

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Boeing continued to build the 787 even while it was prevented from making deliveries in late 2021 and much of 2022. It was able to deliver much of that backlog once it was given clearance to resume deliveries, as it delivered 34 Dreamliners between August of last year and January of this year.

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The Dreamliner's lightweight composite structure contributes to reduced noise levels, both inside and outside the aircraft. The use of advanced soundproofing materials and quieter engines keeps the cabin environment more tranquil for passengers.

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In July 2003, a public naming competition was held for the 7E7, for which out of 500,000 votes cast online the winning title was Dreamliner. Other names included eLiner, Global Cruiser, and Stratoclimber. All Nippon Airways launched the 787 program with an order for 50 aircraft in 2004.

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While the rework of the fuselage flaws was occurring over the last year, Boeing lowered the 787 program's production rate to below five per month. The company reported 120 total undelivered 787 Dreamliners sitting in inventory during their July 27 second quarter 2022 earnings.

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The Boeing 787 has similar safety features to the 777, but also features improvements such as a wider and longer aisle space for passengers and smoother engine takeoff capability which can reduce air turbulence and improve safety during takeoffs.

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To start the Boeing 777 vs 787 comparison, we must say that the 787 is a more fuel efficient aircraft than the 777 thanks to its use of composite wings and more aerodynamically efficient design.

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The 787's simple pivot trailing edge flaps allow for much smaller flap track fairings than on conventional aircraft. This gives the airplane highly efficient lift-to-drag characteristics that reduce fuel consumption and costs.

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