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Plastic airplane parts are an in-flight disaster in the making
Crosscut/The Seattle Times ^ | 7/9/08 | ByLee Gaillard

Posted on 07/09/2008 9:38:43 AM PDT by XR7

AIRLINES are desperate. With jet fuel over $4 per gallon and still climbing, American, United and other major carriers are raising fares, cutting flights, trimming fleets and laying off pilots. They're also ordering fuel-efficient Boeing 787s and Airbus A350XWBs — the new generation of plastic planes.

These new aircraft promise 20-percent-lower fuel consumption. Replacing heavier traditional aluminum alloys, 50 percent of their skins, panels and load-bearing structures are comprised of lighter, stiffer carbon-fiber-reinforced-plastic (CFRP) composites. Then add the latest, most fuel-efficient engine technology. Sounds good.

But beneath these advantages danger lurks — novel maintenance challenges for which neither airlines nor the Federal Aviation Administration (FAA) are prepared. Overall, today's jetliners have reached a plateau of such aerodynamic and propulsive efficiency that individual Boeing 737s or Airbus A300 aircraft often spend two or three decades in service, as will new 787s and A350s.

Regarding fleet recapitalization, that was good news for the airlines' bottom line — and for their stockholders — until fuse pin metal fatigue allowed engines to fall off the wings of 747s and corrosion caused the 1988 explosive decompression of an Aloha 737 at 24,000 feet, as the top of the fuselage peeled back and sucked out a flight attendant.

Now, composite aircraft components have also begun to rain from the sky.

Shortly after takeoff in November 2001, the entire composite vertical fin of American Airlines' Flight 587 was ripped from the A300's fuselage; 265 people died...

(Excerpt) Read more at crosscut.com ...


TOPICS: Extended News; News/Current Events
KEYWORDS: aerospace; aircraft; airlines; boeing; engineering; faa; flight; luddites; ludites; safety; travel
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Yikes!
1 posted on 07/09/2008 9:38:43 AM PDT by XR7
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To: XR7

Every time a new airplane, especially a revolutionary airplane is introduced into service, the doomsayers dream up scenarios where in their considered opinion, disaster will ensue. All I can say about the latest is:

If you are a retired General, no-one pays you money to write about how well a program is running. Where’s the news in that?


2 posted on 07/09/2008 9:48:10 AM PDT by Abathar (Proudly posting without reading the article carefully since 2004)
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To: XR7
After tens of thousands of flight and pressurization cycles, they can undergo hidden disbonding, delamination and ply separation from impacts or stresses from in-flight upsets.

What's 8 hours sitting on asphalt in the summer Las Vegas sun going to do to the glue that holds the plastic together? They'll have to move their long term airplane storage yards out of the dry air desert.

3 posted on 07/09/2008 9:52:02 AM PDT by Reeses (Leftism is powered by the evil force of envy.)
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To: XR7

Summary: Change is bad.


4 posted on 07/09/2008 9:55:17 AM PDT by hc87
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To: XR7

Blaming the AA587 crash on pilot error always stunk!


5 posted on 07/09/2008 9:55:26 AM PDT by True Republican Patriot
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To: Abathar; XR7

Yep. We’ve been flying plastic airplanes for quite a while now.

Nothing so gentle as commercial flight.

High load combat and training missions.

Only one loss due to mechanical failure, and that required a maintenance failure of some magnitude - not installing half the bolts needed to hold a wing on!


6 posted on 07/09/2008 9:56:00 AM PDT by null and void (every Muslim, the minute he can differentiate, carries hate of Americans, Jews & Christians - OBL)
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To: XR7
http://seattletimes.nwsource.com/html/opinion/2004104727_gaillard03.html

I knew I read this guys name before, here is his take on the 2nd amendment decision before it was made.

7 posted on 07/09/2008 9:56:08 AM PDT by Abathar (Proudly posting without reading the article carefully since 2004)
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To: Reeses
What's 8 hours sitting on asphalt in the summer Las Vegas sun going to do to the glue that holds the plastic together?

Is it making cars out there fall apart? These days cars are made of flimsier composites than aircraft. The 'glue' is epoxy and is made not to melt.
8 posted on 07/09/2008 9:58:23 AM PDT by TalonDJ
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To: null and void

I would be more concerned with a plane with parts MADE IN COMMUNIST CHINA than a plane with AMERICAN made plastic parts.

Location of the factory...not the material used...is a bigger concern


9 posted on 07/09/2008 9:59:12 AM PDT by UCFRoadWarrior (What Do You Call Someone Who Supports Free Trade With Communist China?: A Communist)
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To: XR7
Calling high-tech composites “plastic” is like calling Stainless Steel just iron.
10 posted on 07/09/2008 10:00:22 AM PDT by NavyCanDo
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To: Abathar

11 posted on 07/09/2008 10:00:37 AM PDT by Darth Hillary ("If they bring a knife to the fight, we bring a gun, Because folks in Philly like a good brawl."B.O.)
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To: XR7

What a friggin waste of bandwidth.


12 posted on 07/09/2008 10:01:41 AM PDT by scooter2 (The greatest threat to the security of the United States is the Democratic Party.)
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To: UCFRoadWarrior

Yep. QC = Quality Control, we have it, they don’t.

It’s why I would never consider flying on a Chinese or Russian made plane while I would fly on a Japanese or even a Korean plane if I had to without fear.


13 posted on 07/09/2008 10:01:51 AM PDT by Abathar (Proudly posting without reading the article carefully since 2004)
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To: UCFRoadWarrior

Made in America.

Maintained in Columbia.

Using Chinese parts...


14 posted on 07/09/2008 10:02:06 AM PDT by null and void (every Muslim, the minute he can differentiate, carries hate of Americans, Jews & Christians - OBL)
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To: Abathar
...here is his take on the 2nd amendment...

Ugh.

15 posted on 07/09/2008 10:02:07 AM PDT by XR7
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To: XR7
It all starts at the very beginning of the manufacturing process. It's much better to separate them from the rack with a hobby or utility knife. Many airplane builders are prone to twist them free, and that can ruin the structural integrity of the part...


16 posted on 07/09/2008 10:02:35 AM PDT by Joe 6-pack (Que me amat, amet et canem meum)
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To: Darth Hillary

LOL considering they made those things out of WOOD!...


17 posted on 07/09/2008 10:02:55 AM PDT by Abathar (Proudly posting without reading the article carefully since 2004)
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To: Joe 6-pack
Naw, twist them until the stress point just starts to turn white, the paint will cover it fine.
18 posted on 07/09/2008 10:05:15 AM PDT by Abathar (Proudly posting without reading the article carefully since 2004)
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To: Abathar

Wood. Just like Polaris missile nose cones...


19 posted on 07/09/2008 10:06:26 AM PDT by null and void (every Muslim, the minute he can differentiate, carries hate of Americans, Jews & Christians - OBL)
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To: XR7

Stories like this make me glad I decided some time ago to never fly again.

I feel sorry for those that have to fly every week. Putting up with all the crap must be very stressful.


20 posted on 07/09/2008 10:06:57 AM PDT by upchuck (As we doggedly march towards dystopia, my poor country is losing it's mind. God help us!)
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