The Economist's Gulliver blog sums up the unfortunate problems with Boeing's biggest project:
The latest delay looks like the most serious yet. In May, routine bending tests in the workshop showed the wing structure to have separated from its skin ("delaminated") at 120%-130% of the load limit. To pass muster with the Federal Aviation Administration and other certification bodies, wings have to sustain at least 150% of the load limit without rupturing. The problem...has been identified in the past and recognised as a problem. The issue has arisen on other composite airplanes. Indeed, the stress point at the end of the 787 stringers showed up as a 'hot spot' in Boeing’s computer models before the delamination in the wing bend test—but for some reason was never addressed.
The latest delay looks like the most serious yet. In May, routine bending tests in the workshop showed the wing structure to have separated from its skin ("delaminated") at 120%-130% of the load limit. To pass muster with the Federal Aviation Administration and other certification bodies, wings have to sustain at least 150% of the load limit without rupturing.
The problem...has been identified in the past and recognised as a problem. The issue has arisen on other composite airplanes. Indeed, the stress point at the end of the 787 stringers showed up as a 'hot spot' in Boeing’s computer models before the delamination in the wing bend test—but for some reason was never addressed.
It's worth a read, as are the articles Gulliver linked to.
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