The discovery was made over the weekend and the grounding of the test aircraft announced on Monday.

According to Boeing, the thrust link is a structural component between the engine and the airplane structure. The thrust link is designed to transfer thrust between the engines and pylons that attach the engine to the airframe.

• READ MORE: Report: Boeing Grounds 777X Test Fleet

“This part is custom to the 777-9, and each 777-9 engine includes two of this component so there is redundancy,” the company told FLYING in a statement. “We are keeping the FAA fully informed on the issue and have shared information with our customers.”

The FAA confirmed that Boeing had notified the agency about the situation and was taking steps to assess the issue.

A thrust link is described as a “heavy titanium component” that is not part of the engine itself. The 777X is powered by the General Electric GE9X, which has a 134-inch front fan, sitting in a cowling measuring 11 feet across. According to GE, it is the largest and most powerful engine in the world and also has more fuel efficiency than its predecessors.

Boeing told FLYING that no near-term flight tests were planned on the other flight test airplanes, which have scheduled maintenance and layup activities.

There are three 777X aircraft being used for test flights. One a is located in Hawaii, and the other two are at King County International Airport-Boeing Field (KBFI) in Seattle and Snohomish County Airport-Paine Field (KPAE) in Everett, Washington.

According to the Seattle Times, maintenance technicians discovered cracks in the thrust link after a 777X landed in Hawaii on Friday. Boeing immediately inspected the other two test aircraft and discovered cracks in them as well.

The Boeing 777X was unveiled in 2013 and took its first flight in 2020. Deliveries of the aircraft, which have not yet been certified by the FAA, are slated to begin in 2026.

The post Boeing Responds After Suspending 777X Test Flights appeared first on FLYING Magazine.

The publication said a thrust link that helps secure the engine to its mounting structure was discovered to be broken after a flight from Kona, Hawaii, to Seattle.

Cracks in the thrust links on the other two aircraft were also discovered, prompting the grounding of the fleet.

The Air Current said Boeing confirmed the testing pause, saying it “identified a component that did not perform as designed” and that after replacement the company “will resume flight testing when ready.”

After a series of manufacturing and quality control issues, the announcement of certification flight testing of the new 777 variant was viewed as a boon for the troubled company. It’s not clear how long it will take to fix.

Thrust links help distribute loads within the mounting structure of the engine.

Editor’s Note: This article first appeared on AVweb.

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“We are reviewing a technical issue that occurred during GE9X post-certification engineering testing, and we are closely coordinating with Boeing on our findings to support their return to flight testing,” GE Aerospace [NYSE: GE] said.

The potential issue was discovered during a borescope inspection of a flight test engine. Both GE and Boeing agreed to remove the powerplant in question, pending further testing. The engine was sent to GE’s facility in Peebles, Ohio, for further engineering test runs. The engine manufacturer noted that during the test runs there was a temperature alert, and the operator shut the engine down. The GE9X engine involved in the test run is GE’s highest-time engine in the program, with more than 1,700 hours and 2,600 cycles.

• READ MORE: Boeing Lands Qatar Airways as First Customer for 777X Freighter

“We are supporting GE Aerospace as they assess a recent GE9X engine issue and will resume airplane testing once their thorough process and appropriate actions are complete,” Boeing officials said. “Safety is our top priority, and our supplier and technical teams will take the time necessary to support the review as we work transparently with our customers and regulators.”

About the 777X

Boeing’s 777X is the latest generation of the 777 model series. According to Boeing, the 777X is designed using advanced technologies from the Boeing 787 Dreamliner, and it will be the largest and most fuel efficient twin-engine jet in the world.

The 777X features composite wings and folding wingtips. Unveiled in 2013, the aircraft has two variants: the 777-8, which provides seating for 384 passengers, and the 777-9, with seating for 426 passengers. The 777X is also available in a freighter version.

The first flight of the 777-9 took place on January 25, 2020, and by June of that year there were more than 300 orders on the books for the aircraft then described by the company as “the most sophisticated airliner on the market.” 

Boeing predicted the first deliveries of the 777X would take place in 2023, but that date has been pushed back to 2025.

The post Boeing 777X Test Flights Suspended Over Engine Issue appeared first on FLYING Magazine.

For the quarter, the company lost $1.24 billion, twice as much as the company lost during the first quarter of 2021. Revenue also decreased to $13.9 billion, an 8.1 percent year-over-year drop, despite analysts’ expectation of $16.02 billion.   

Today, we report our first-quarter results.

Details here: https://t.co/l2HrFQ04UR pic.twitter.com/muXTDqZCQE

— The Boeing Company (@Boeing) April 27, 2022

What may have been the most disappointing news for stockholders was the announcement that the company has paused its 777-9 jetliner production until 2025 instead of 2023, the timeframe the company had initially told customers. The company estimates the delay will cost Boeing $1.5 billion in extra costs.

Boeing’s president and CEO, Dave Calhoun, remained optimistic about the company’s path forward while acknowledging the challenging march it will take to return to normal for the company.

“We increased 737 Max production and deliveries and made important progress on the 787 by submitting our certification plan to the FAA,” Calhoun said. “Despite the pressures on our defense and commercial development programs, we remain on track to generate positive cash flow for 2022. We’re focused on our performance as we work through certification requirements and mature several key programs to production.”

Segment Breakdown

On the commercial side, revenue fell 2.5 percent from the first quarter of 2021 to $4.16 billion, which Boeing attributed to the timing of wide-body deliveries, partially offset by higher 737 deliveries. The company also said that some of its operating margins were affected by abnormal changes caused by the war in Ukraine and higher R&D expenses. 

With the 737 Max almost entirely back in service, the company expects to increase production to 31 airplanes per month in the second quarter. Meanwhile, 787 productions have slowed to five per month until deliveries resume. The penalty for this will be abnormal costs of approximately $2 billion, with most being incurred by the end of 2023, including $312 million recorded in Q1.

Boeing delivered 95 commercial airplanes for the quarter and ended with a 4,200 airplane backlog valued at $291 billion.

Compared to the same period last year, its defense, space, and security segment also faced headwinds, recording a 24 percent loss in revenue to $5.5 billion. This was driven by lower volume and charges on fixed-price development programs, including VC-25B and T-7A Red Hawk. The VC-25B program recorded a $660 million charge from higher supplier costs and higher costs to finalize technical requirements and schedule delays. 

An additional $367 million in charges were recorded by the T-7A Red Hawk program due to ongoing supplier negotiations impacted by supply chain constraints, COVID-19, and inflationary pressures.

Ending the quarter, the backlog at defense, space, and security was $60 billion, of which 33 percent percent represents orders from customers outside the U.S.

All was not lost, as the global service segment recorded $4.3 billion in first-quarter revenue, a 15 percent jump over last year due to higher commercial volume. The company said it secured a fuel-saving digital solutions contract for Etihad Airways’ 787 fleet and was awarded a contract for KC-135 horizontal stabilizers from the U.S. Air Force. 

The division also captured a 767 converted freighter order from Air Transport Services Group and announced plans to create additional capacity for 767 converted freighters.

Analysts Question Company Direction 

Analysts on the call were perturbed at the company’s losses. Ron Epstein of Bank of America asked if it was time for the company to consider restructuring the engineering organization.

“I struggled to think of a program that you guys aren’t or haven’t taken charge on,” Epstein charged. “The vast number of issues you’ve had, compared to some of your peer companies, both in defense and commercial, it’s just the more troublesome for Boeing—what can you do to prevent that for future programs?”

Calhoun rebuffed the charge, saying the company was making progress amid a strict regulatory environment.

“I don’t attribute our certification issues and timelines to engineering shortfalls in any way,” Calhoun put forward. “Our airplanes are flying incredibly well. Our 777X made it to Dubai, made it to Singapore in a gangbuster show—the discovery process between ourselves and our certification or our regulators around the world—it’s got to be thorough, and it’s got to be good. So, I don’t accept the premise entirely.”

The market doesn’t appear to share Calhoun’s optimism. Pre-trading, shares dropped to a 17-month low and were down 8 percent for the day Wednesday afternoon, trading at $152.

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Qatar Airways has signed to be the launch customer for Boeing’s next-generation 777X freighter still in development, agreeing Monday to buy 34 of the widebody aircraft in a deal that seemed inevitable given recent bad blood between the airline and European manufacturer Airbus.

The Middle East carrier also announced that it has options for 16 additional cargo aircraft beyond its firm commitment and signed an agreement for up to 50 737-10s, the largest 737 Max single-aisle passenger jet. As part of the agreement, Qatar will convert 20 of its 60 orders for 777X passenger aircraft to the 777-8 freighter. Qatar is also ordering two current production 777 freighters to get faster access to aircraft and meet customer demand.

Boeing said the deal is worth more than $20 billion at current list prices and represents the largest freighter commitment in Boeing history by value. First delivery of the new cargo transport is anticipated in 2027.

Qatar Airways is the largest air cargo airline in the world by throughput—not including express carriers FedEx and UPS, which get a huge boost from hauling parcels in the domestic U.S. market—and has a fleet of 26 Boeing 777, two 747-8, and two 747-400 freighters, and one Airbus A310. During the pandemic it has also operated six 777-300 passenger airplanes in dedicated cargo mode, but has returned four of them to full passenger mode. The new aircraft will be used to expand and renew the cargo fleet.

Qatar Airways urged Boeing in 2019 to offer a freighter version of the 777X, which Boeing is now calling the 777-8. The carrier had few alternatives for a large, long-haul cargo jet because of a nasty spat with Airbus and Boeing no longer offering its current lineup of freighters later this decade. Boeing is shutting down its 747-8 production line this year and must discontinue making the current 777 variant in 2027 to comply with new international emissions standards.

• READ MORE: Comparing the World’s Largest Airplanes

Boeing said it will build the 777-8 at its Everett, Washington, assembly plant. It has invested more than $1 billion to support 777X production. 

The announcement coincided with President Joe Biden’s meeting Monday at the White House with Qatar’s emir, Sheikh Tamim Bin Hamad Al-Thani.

“The economic impact of this sale will reverberate throughout the United States,” Commerce Secretary Gina Raimondo said in a statement. “It’s a win for our workers, our manufacturers and our suppliers. These new freighters will be manufactured and assembled by American workers on American soil in Everett, Washington. And the aircraft will include GE9X engines produced by GE Aviation, also built and assembled in the U.S. Both Boeing and GE Aviation rely on hundreds of suppliers located in states across the U.S., many of whom will play integral roles in the production of these freighters.”

The Middle Eastern airline’s decision is a huge validation for Boeing. Certification of Boeing’s 777X design has been delayed several years by technical snags, distractions associated with the 737 Max grounding and COVID. Boeing (NYSE: BA) lost $4.3 billion in 2021, the third consecutive year of losses but an improvement from $11.9 billion in 2020.

During a presentation of fourth-quarter earnings last week, Boeing officials said they expect to deliver the first 777X passenger airplane in late 2023. The company has completed engine and aircraft performance testing for the 777X, flown more than 1,800 flight hours, and is close to beginning certification flight testing under FAA supervision. German flag carrier Lufthansa will be the first customer for the 777X passenger platform. Boeing says it has 334 orders from eight airlines for the passenger model, with the 777-8 designed to go against the Airbus A350 and the 777-9 for a new market segment. 

The airplane should be attractive to cargo haulers because it has a payload capacity nearly identical to the 747-400 freighter while offering a 25 percent improvement in fuel efficiency, emissions, and operating costs. Technological improvements include a new carbon-fiber composite wing and fuel-efficient engines. With a range of 4,410 nm, the 777X will enable airlines to make fewer stops and reduce landing fees on long-haul routes. 

Relationship with Airbus Sours

Qatar Airways also placed a firm order for 25 737-10 aircraft and purchase rights for 25 additional airplanes, with a total value of $7 billion at list prices.  

Qatar Airways predictably spurned Airbus’ new A350 large freighter after taking Airbus to court in December over complaints that exterior paint on its A350 passenger airplanes is deteriorating and jeopardizing safety. Airbus says the paint issues are cosmetic. 

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The dispute between an airline and the major aircraft manufacturer has turned unusually nasty, with the carrier grounding 21 A350 aircraft, canceling an order for 50 Airbus A321 neo single-aisle passenger jets and releasing a video  showing the alleged damage on its A350s. 

Qatar Airways, which is seeking $600 million in damages, said the surface degradation exposes aircraft’s lightning protection system to damage and the underlying composite structure to moisture and ultraviolet light. Other defects include cracking in the composite fuselage and damage around many rivets. It is demanding Airbus investigate the root cause of the problem and determine if repairs will correct it. 

Demand for air cargo accelerated during the COVID pandemic with the drastic reduction in international passenger flights, the surge in e-commerce orders and extensive delays in ocean shipping. Boeing forecasts that the global freighter fleet will grow by 70 percent in the next 20 years as international trade and e-commerce continue to flourish.   

Boeing has dominated the factory-built freighter market for years, with Airbus completely on the sidelines after pulling the plug on the A330-200 medium-size cargo platform in the last decade following lackluster sales. Airbus has now reengaged with the introduction of a freighter version of its popular A350 twin-aisle passenger jet and since November has secured 15 orders from Singapore Airlines, CMA CG, and Air Lease Corp. (NYSE: AL). 

Boeing booked record orders for new and converted cargo platforms last year, including 84 orders for 767, 777, and 747 freighters, driven by e-commerce growth and demand for faster, more reliable transport amid widespread logjams in ocean shipping. That exceeded the previous record of 80 production cargo transports set in 2020. During the year it also opened, or made plans for, 10 new assembly lines around the world for passenger-to-freighter conversions.

The post Boeing Lands Qatar Airways as First Customer for 777X Freighter appeared first on FLYING Magazine.