Static testing for the 787 Dreamliner is set to begin early next week, a key milestone on the road to first flight, Boeing has confirmed.
ZY997, Boeing’s static 787 test airframe, will be put through a series of grueling structural tests to validate the strength of the composite structure.
The tests are expected to continue through the fourth quarter of 2008.
The static test will begin with the “high-blow” test to validate the pressure seals inside the aircraft cabin. During the test, Boeing will raise the internal pressure of the cabin to 14.9 PSI, or about 1.5 times normal pressurization.
Because of the 787’s composite one-piece barrel design, there are significantly fewer points along the fuselage where pressure seals could fail.
During the test, the aircraft will be draped in plastic wrap in the event the cabin breaks a pressure seal. If this occurs, the plastic will billow out easily identifying the source of the leak.
In a health and safety advisory sent to staff ahead of the test, “creaking and popping noises are normally noted” due to the “expansion and flexing” of the structure during static testing.
The aircraft, which will never fly, was rolled on April 25 to the static test rig inside Building 40-23 where the testing will take place.
Boeing has not yet determined if it will bring the wings to ultimate load, or the point at which they break. The FAA requires all aircraft structure to withstand 150% of the maximum loads that will ever be encountered in flight.
In January 1995, wings of Boeing’s 777 were brought to 154% of maximum design load in before they snapped with an explosive bang. The wings were deflected 24-feet before they succumbed to the punishing loads.
Even with the commencement of static testing next week, all 787 assembly is still frozen as the IAM strike begins its third week, though a certain portion of static testing must be completed before Dreamliner One can take to the sky.
Image credit: FlightBlogger
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This post originally appeared at Flightglobal.com from 2007 to 2012.