Boeing discloses new flaw with 787 Dreamliner jet as problems mount

[Section28- BE]

ex CNN/9: https://www.9news.com.au/world/boeing-announces-further-flaws-in-dreamliner-787-jet-aviation-news/965220ba-58ab-4be9-bc37-2be96ceed58d

[717tech]

“the 787 Dreamliner until recently had been a problem free aircraft”

Didn’t they have the odd issue with Batteries early days?

[capngrog]

Yes, the early problem was with the lithium ion (I think I have that terminology right) batteries, but not the airframe. The most recent airframe problems could be due to the rigid quality control requirements required of composite manufacturing. There is little margin for error when producing a composite structure, it all has to be spot on.

Cheers,
Grog

[MrPeabody]

Some news reporting is referring to incorrectly sized spacing strips being used at horizontal stabilizer and fuselage production joins.

[Wizofoz]

I wonder if those were some of the many out-sourced structures...

[megan]

Boeing patent re shimming.Aerodynamic, also known as “wetted”, exterior surfaces of aircraft can experience significant manufacturing tolerance variations during component fit-up. If gaps at faying edges (i.e. fastening joints) are fixed and/or locked in place with contoured fillers or shims, resulting variations can create turbulent air flows which may create erosion of aft joint surfaces. When the components are formed of composite materials, the erosion may actually produce delamination. As a result, special care must be taken in the manufacture of faying edges of wetted aircraft components at risk for erosion damage.Such risks may be somewhat greater for certain thin-walled curvilinear aircraft components, including engine nacelle lipskins, leading edges of wings, and wetted areas aft of fuselage joints. To avoid critical damage, such thin-walled structures including the noted nacelle lipskins, for example, have been fitted with shims for assuring desired positioning of the thin-walled structures on underlying support structures such as bulkheads.

Methods of applying the shims, generally referred to as “shimming”, have traditionally required relatively tedious efforts to achieve desired levels of precision. Generally, custom contoured shims have been employed, even though applications of the latter have tended to be expensive and time-consuming.

Thus, there has been a continuing need to develop less expensive and more time-saving shimming methods and systems.


https://patents.justia.com/patent/20200271016

Aviation Week article of 787 issues.

https://aviationweek.com/air-transport/safety-ops-regulation/new-787-problems-spotlight-boeings-quality-issues?elq2=adc91fbbf2fa453c988dcedb9065e3aa

[Sunfish]

What’s wrong with using a few tins of bog? Keeps most commodores going!.

[Senior Pilot]

Let’s keep it to the one thread, https://www.pprune.org/rumours-news/635106-eight-b787-pulled-service-over-structural-issues.html