Building the Boeing 777: The Journey of a Complex Jet
The story of building the Boeing 777, a complex jet created by 10,000 people over 5 years, facing technical challenges and tight deadlines.
00:00:07 The story of building the 21st century jet, the Boeing 777. A complex machine built by 10,000 people over 5 years, costing $5 billion, and facing technical challenges and tight deadlines.
đĢ The building of the Boeing 777 was a complex project that took 10,000 people nearly five years to complete, costing five billion dollars.
đ§ The plane underwent extensive testing and had to meet strict technical standards to ensure safety. Any technical issues could put lives at risk.
đ The building of the 777 happened during a recession in the airline industry. If the plane failed, Boeing's future could be in jeopardy.
00:08:11 Building the Boeing 777 engines: rigorous testing to simulate flight conditions, including ice, rain, and birdstrikes. Challenges with vibration and maintenance addressed. Debate on whether to test on a flying test bed.
đ Engine tests simulate normal and abnormal flight conditions, including birdstrikes and extreme weather.
âī¸ Regular cycles of engine activity reveal problems related to fatigue and vibration, allowing for necessary repairs.
đ ī¸ Engine design improvements aim to reduce maintenance errors and increase reliability, with the use of ground and flight tests.
00:16:18 Building the Boeing 777: The decision to use a flying testbed for engine validation leads to a dramatic surge during testing, revealing the need for design improvements.
đŠī¸ The decision to use a flying test bed for engine testing was debated, but ultimately chosen as a part of the development program for the Boeing 777.
đĨ During engine test flights, a surge occurred, causing a dramatic explosion and disrupting the airflow through the engine.
đ ī¸ The cause of the surge was identified as inadequate stiffness in the case surrounding the fan blades, leading to blade stalling.
00:24:23 The episode focuses on the testing and development of the Boeing 777, including pressure testing and cockpit simulations for handling problems.
đĄ The Boeing 777 fuselage had to withstand high-pressure conditions of 12.1 psi without leaking.
âī¸ A temporary fix was implemented to seal a defective door and the plane successfully reached 12.1 psi without leaking.
đĢ Boeing engineers built a simulator called Legos to address handling problems of a future stretched version of the plane.
00:32:28 The Boeing 777 engine undergoes tests to ensure safety, including a test to stop a flying fan blade and increase the strength of the turbine case.
đĨ During a test, an explosive bolt snapped off the fan blade, demonstrating the need to increase the wall thickness of the engine case.
đ ī¸ The Flanagan Brothers were tasked with machining a stronger turbine case for the Boeing 777 and successfully reduced the weight by 90%.
â° The engine issues caused a delay in delivering the engines on time, resulting in stress and disruptions for Pratt & Whitney and Boeing.
00:40:34 Boeing unveils the Boeing 777 in a roll out ceremony attended by thousands of employees and their relatives. The plane is larger than expected and preparations for its first flight begin.
âī¸ The first Boeing 777 was unveiled at a roll out ceremony attended by thousands of employees and their relatives.
đŦī¸ The plane had a hydraulic leak that needed to be fixed before it could taxi for the high-speed test.
đŦ The test also involved checking the plane's response to crosswinds and inducing shimmy on the nose landing gear.
00:48:42 Building the Boeing 777 - Full Episode 3: The first flight of Boeing's prototype triple 7, a milestone in a 5 billion dollar enterprise.
đĄ The Boeing 777 prototype undergoes taxi tests to check the landing gear, brakes, and stability.
đ§ A minor issue with a rubber o-ring causing a hydraulic fluid leak is discovered and fixed.
âī¸ The next day, the prototype is scheduled for its first flight, marking a significant milestone.
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