P 777 Freighter First Flight Preparation and Conduct

P 777 Freighter First Flight Preparation and Conduct Flight Test Safety Workshop – Europe Vienna, Austria 12 November, 2009 Van Chaney, Boeing 777 Deputy Chief Pilot Paul Bolds-Moorehead, Boeing 777 Stability & Control Senior Lead Engineer 12 November, 2009 777 F First Flight - FTSW Europe 2009

V …… following Capt. Cashman n 14 years later, much is the same n 6 th generation of 777 n Confidence built on past success n Not a new airplane n Pressure to do less (time, conditions, money) n “Keep it simple” 12 November, 2009 777 F First Flight - FTSW Europe 2009 2

V Agenda n n n n 12 November, 2009 777 F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Subsequent Events Lessons Learned Summary 777 F First Flight - FTSW Europe 2009 3

V Agenda n n n n 12 November, 2009 777 F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Subsequent Events Lessons Learned Summary 777 F First Flight - FTSW Europe 2009 4

V 777 Freighter First Flight 12 November, 2009 777 F First Flight - FTSW Europe 2009 5

P 777 Introduction Family Evolution 777 -200 1995 535, 000 -lb TOW 74 k-84 k Thrust 777 -200 IGW 1997 632, 500 -lb TOW 84 k-90 k Thrust 777 -300 1998 777 -300 ER 2004 660, 000 -lb TOW 84 k-98 k Thrust 775, 000 -lb TOW 115 k Thrust 777 -200 ER 2000 777 -200 ER 1998 648, 000 -lb TOW ≤ 90 k Thrust 656, 000 -lb TOW ≤ 94 k Thrust 777 -200 LR 2006 766, 000 -lb TOW 110 k & 115 k Thrust 777 F 2009 766, 000 -lb TOW 110 k & 115 k Thrust 12 November, 2009 777 F First Flight - FTSW Europe 2009 6

V Summary of Changes: 777 -200 LR to 777 F MTOW 766, 800 lb (with revised c. g. envelope) MLW 575, 000 lb (a 17% increase) No aerodynamic changes -Same wing -Same fuselage -Same empennage Addition of Maneuver Load Alleviation (MLA) function in Primary Flight Computers 12 November, 2009 777 F First Flight - FTSW Europe 2009 7

777 F Airplane Description Flight Envelope 12 November, 2009 777 F First Flight - FTSW Europe 2009 P 8

777 F Airplane Description GW/CG Envelope 12 November, 2009 777 F First Flight - FTSW Europe 2009 V 9

777 F Airplane Description Maneuver Load Alleviation P Maneuver Load Alleviation (MLA) n Purpose: Reduce wing bending loads due to positive maneuver conditions n Function: Symmetrically deflects some lateral control surfaces as a function of normal load factor n Benefit: Forward CG expansion without additional structure n Application: 777 F unique to-date. 12 November, 2009 777 F First Flight - FTSW Europe 2009 10

777 F Airplane Description MLA Details P Design Intent: a) Handling Qualities unchanged during normal maneuvers b) Handling Quality changes during elevated “g” maneuvers to be imperceptible 12 November, 2009 777 F First Flight - FTSW Europe 2009 11

P Agenda n n n n 12 November, 2009 777 F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Subsequent Events Lessons Learned Summary 777 F First Flight - FTSW Europe 2009 12

P 777 F First Flight Preparation n Predicted Flight Characteristics document n Very thorough, rigorous evaluation of many different maneuvers and characteristics n Mapped across entire flight envelope n Less breadth than for a new airplane n Pilot training in engineering simulator n Procedure review/modification n Flight condition reasonableness/attainability n Familiarization with handling n Crew Resource Management development n Establish or refine abort/safety criteria 12 November, 2009 777 F First Flight - FTSW Europe 2009 13

777 F First Flight Preparation (cont’d) P n Control law issues n MLA/HOSP interaction (HOSP = Hardened Overspeed Protection) n First flight dry run n Simulator used with most test participants n Treated as actual flight n Ground testing n System specific component tests n “Gauntlet” n Flight test tools in use at BCA n Engineering CAB / Fixed Based Simulator n Flight Emulation Test System (FETS) n Lab. VIEW Airplane Display System (LADS) n Airborne Data Acquisition & Monitoring System (ADAMS) 12 November, 2009 777 F First Flight - FTSW Europe 2009 14

777 F First Flight Preparation (cont’d) V n Developed Contingency Plans n Plan A: - Full first flight profile with a landing at Boeing Field test center n Plan B: - In case of telemetry failure or other mechanical problems - only do low and med risk test conditions (no high risk) - return landing at origination base (Paine Field manufacturing center) n Added a temporary limitation to prevent activation of MLA function - turned out to be very wise as we essentially chose the time and place to do battle with any “discoveries” 12 November, 2009 777 F First Flight - FTSW Europe 2009 15

V Agenda n n n n 12 November, 2009 777 F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Subsequent Events Lessons Learned Summary 777 F First Flight - FTSW Europe 2009 16

V 777 F First Flight Day n 14 July, 2008 n At the airplane n Final prep activities n Taxi testing n Telemetry (control) room activities n Anticipating reception of telemetry data n Successes n Airplane flew exactly as predicted (simulator) and the same as the parent model (777 -200 LR pax airplane) n Failures or “Opportunities” n Telemetry failure – followed “Plan B”, e. g. aborted and returned to origination field (PAE) 12 November, 2009 777 F First Flight - FTSW Europe 2009 17

V Agenda n n n n 12 November, 2009 777 F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Subsequent Events Lessons Learned Summary 777 F First Flight - FTSW Europe 2009 18

V 777 F First Flight – Part Two n 16 July, 2008 n Completed what had been planned for first flight profile n Telemetry repeater van local for this test attempt n Arrived at primary Boeing test facility (Boeing Field, Seattle) (originally planned for completion of first flight) n Planned layup and inspections followed 12 November, 2009 777 F First Flight - FTSW Europe 2009 19

V Agenda n n n n 12 November, 2009 777 F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Subsequent Events Lessons Learned Summary 777 F First Flight - FTSW Europe 2009 20

V 777 F Aileron Vibration n Major discovery on third flight: n Significant aileron vibration present with MLA function active n Occurs at 1. 8 -2. 0 g with a specific aileron deflection n Could have encountered on first flight without TM had the limitation not been present 12 November, 2009 777 F First Flight - FTSW Europe 2009 21

Aileron vibration discovery flights V n Flutter-type testing n 2 altitudes and increasing Mach numbers - Manual controller “kicks” - Elevator frequency sweeps - Roller Coasters and “kicks” in turns (elevated g) n Aileron vibration occurred with trailing edge up deflections of ailerons. n Ailerons had never been used previously at these speeds due to aileron lock-out function. n With additional MLA g bias applied (e. g. - PFC thinks it’s under a 1. 8 G load): column kicks, shallow bank turns exhibited vibration n Without MLA g bias: 60 deg bank turns and roller coaster maneuvers to higher g levels showed vibration 12 November, 2009 777 F First Flight - FTSW Europe 2009 22

V Aileron Vibration Details n Pilot comments on Aileron Vibration: n n “Alarming. ” “Feels like driving over a washboard road. ” “Feels like something is going to come off. ” “Distracting and you naturally want to unload and slow down” n Causal factor unknown. n Potential contributing factors include: 1. Aileron deflection angle for vibration corresponds to approximately zero hinge moment 2. A “scoop” is created between the mass balance tower and the lower surface of the wing when the aileron is deflected 12 November, 2009 777 F First Flight - FTSW Europe 2009 23

V Aileron Vibration Video 12 November, 2009 777 F First Flight - FTSW Europe 2009 24

P Aileron Vibration Data 12 November, 2009 777 F First Flight - FTSW Europe 2009 25

P Aileron Vibration Mapping 12 November, 2009 777 F First Flight - FTSW Europe 2009 26

777 Outboard Aileron Balance Tower 12 November, 2009 777 F First Flight - FTSW Europe 2009 P 27

Aileron Vibe - Potential remedies P n Aerodynamic modifications n External wing treatments n Aerodynamic sealing n Internal flow diversion n Flight control software modifications n Change to basic MLA aileron travel schedule n Addition of aileron “No-Dwell zone” function 12 November, 2009 777 F First Flight - FTSW Europe 2009 28

Re-test flights : MLA Aileron “No Dwell” Zone 12 November, 2009 777 F First Flight - FTSW Europe 2009 P 29

V Agenda n n n 12 November, 2009 777 F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Lessons Learned Summary 777 F First Flight - FTSW Europe 2009 30

V 777 F Lessons Learned n Thorough checkout of ALL systems for the test program is crucial n Although telemetry is not a flight critical system, it is necessary for test success n Past success doesn’t guarantee future success n Fly-By-Wire airplane control laws present opportunities to remedy issues such as this n Team approach to problem solving is required n Especially when pilot opinion and engineering data differ n The “right thing” will still prevail once thorough communication occurs n Important to capture lessons learned on specific technical “discoveries” to share between programs n Pilot distraction needs to be considered as certification issue n Contingency planning (“Plan B”) is a necessary step n Envelope expansion for new functionality (MLA limitation) is required 12 November, 2009 777 F First Flight - FTSW Europe 2009 31

P Agenda n n n n 12 November, 2009 777 F Airplane Description/Background Preparation Activities First Flight Day First Flight Part 2 Subsequent Events Lessons Learned Summary 777 F First Flight - FTSW Europe 2009 32

P Summary Never assume that a test program will escape problems, no matter how seemingly “minor” the effort is ! 12 November, 2009 777 F First Flight - FTSW Europe 2009 33

P Questions? 12 November, 2009 777 F First Flight - FTSW Europe 2009 34