Finding issues during testing is normal and expected. It is why aircraft are subject to rigorous trials before being approved to enter mass-production and carry passengers. However, finding something as serious as the engines not being well attached to the wings is neither normal nor expected.
In its latest mess-up, Boeing has grounded all four of its 777X planes built for testing after finding “a component that did not perform as designed”. The component in question is the thrust link, which secures the engine to the wing of the aircraft, transferring the thrust of the engine to the airframe.
The 777X model is supposed to become the “world’s largest and most efficient twin-engine jet, unmatched in every aspect of performance, with new breakthroughs in aerodynamics and engines, (…) 10% lower fuel use and emissions and 10% lower operating costs than the competition”, according to the manufacturer.
The issue was discovered after a test flight on the third 777-9 test plane, identified as WH003, from Hawaii’s Kona Airport on 16 August. Subsequent inspections then revealed cracked thrust links on two other aircraft in the testing fleet, according to the Air Current, who first reported on the incident.
“Our team is replacing the part and capturing any learnings from the component and will resume flight testing when ready,” Boeing told the Daily Mail, adding that there are two thrust links in each of the plane’s two engines, “so there is redundancy” and they “are keeping the FAA fully informed on the issue and have shared information with our customers.”
First announced in 2013 and slated for production in 2020, the 777X has been delayed multiple times and run over budged. In July, the US Federal Aviation Administration (FAA) finally approved the beginning of testing for certification for the model, after which Boeing updated the estimated first delivery of the aircraft to next year. The latest setback however will likely push delivery even later, with Emirates, who are supposed to receive 200 of the planes, they do not see Boeing delivering before 2026.
Boeing has had a less than great year, starting in January with a plug-in door on a 737 model blowing out mid-air on an Alaska Airline flight, prompting a safety investigation in the company’s manufacturing process. Things have only gone downhill since and now the manufacturer has reported a $1.4 billion loss in the second quarter of 2024 (the months of April, May and June). With revenues 15% below last year’s second quarter, $16.9 billion compared to $19.8 billion in 2023, the company’s losses widely increased compared to the just $149 million in last year’s second quarter.
Amid the worsening financials, the company has also announced the new President and CEO, Kelly Ortberg, who took over from Dave Calhoun on 8 August. Faced with a disastrous year, Calhoun announced in March he would be leaving the company at the end of the year, but was replaced a few months ahead.
