Sat, Oct 22, 2011
Examined How FAA And EASA Assess Composite Materials In
Dreamliner Fuselage And Wings
In a report released Thursday, the Government Accountability
Office said that it had identified safety concerns related to the
repair and maintenance of the composite materials used in the
Dreamliner's wings and fuselage, but also reported that the FAA had
properly followed its internal procedures in certifying the
airplane.
GAO Graphic
GAO was asked to review FAA’s and EASA's certification
processes and FAA's oversight of the composite airplanes once they
enter service. GAO examined how FAA and EASA assessed the use of
composite materials in the Boeing 787 fuselage and wings, and the
extent to which FAA has addressed safety-related concerns
associated with the repair and maintenance of composite airplanes.
GAO reviewed certification documentation, conducted a literature
search, discussed repair and maintenance issues with experts, and
interviewed FAA and EASA officials and Boeing representatives. GAO
is not making recommendations in this report. FAA, EASA, Boeing,
and others provided technical comments, which were incorporated as
appropriate.
GAO found that the FAA followed its certification process in
assessing the Boeing 787 airplane's composite fuselage and wings
against its own airworthiness standards. The agency applied five
special conditions when it found that its airworthiness standards
were not adequate to ensure that the composite structures would
comply with existing safety levels. These special conditions
require Boeing to take additional steps to demonstrate the 787's
structures meet current performance standards. The FAA also granted
Boeing an equivalent level of safety finding when the manufacturer
determined it could meet the standard but prove it differently from
the method specified in that standard. On the basis of a review of
the FAA’s special condition requirements, Boeing submissions,
and discussions with FAA and Boeing officials, GAO found that the
FAA followed its process by documenting the technical issues
related to the design of the composite fuselage and wings,
determining the special conditions and equivalent level of safety
finding, obtaining public comments on draft special conditions, and
monitoring Boeing’s compliance with those conditions.
Based on expert interviews and a review of Boeing and other
documents, GAO identified four key safety-related concerns with the
repair and maintenance of composites in commercial airplanes:
- Limited information on the behavior of airplane composite
structures.
- Technical issues related to the unique properties of composite
materials.
- Standardization of repair materials and techniques.
- Training and awareness.
None of the experts believed these concerns posed extraordinary
safety risks or were insurmountable. GAO says that the FAA is
taking action to help address these concerns it identified related
to the repair and maintenance of composite airplane structures.
However, the report says, until these composite airplanes enter
service, it is unclear if these actions will be sufficient.
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