777 Freighter First Flight Preparation and Conduct

1. 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

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

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

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

5. V 777 Freighter First Flight 777F First Flight - FTSW Europe 2009

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

7. V Summary of Changes: 777-200LR to 777F MTOW766,800 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 777F First Flight - FTSW Europe 2009

8. P 777F Airplane DescriptionFlight Envelope 777F First Flight - FTSW Europe 2009

9. V 777F Airplane DescriptionGW/CG Envelope 777F First Flight - FTSW Europe 2009

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

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

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

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

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

15. V 777F First Flight Preparation (cont’d) • Developed Contingency Plans • Plan A: • Full first flight profile with a landing at Boeing Field test center • 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) • 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” 777F First Flight - FTSW Europe 2009

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

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

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

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

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

21. V 777F Aileron Vibration • Major discovery on third flight: • Significant aileron vibration present with MLA function active • Occurs at 1.8-2.0 g with a specific aileron deflection • Could have encountered on first flight without TM had the limitation not been present 777F First Flight - FTSW Europe 2009

22. V Aileron vibration discovery flights • Flutter-type testing • 2 altitudes and increasing Mach numbers • Manual controller “kicks” • Elevator frequency sweeps • Roller Coasters and “kicks” in turns (elevated g) • Aileron vibration occurred with trailing edge up deflections of ailerons. • Ailerons had never been used previously at these speeds due to aileron lock-out function. • 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 • Without MLA g bias: 60 deg bank turns and roller coaster maneuvers to higher g levels showed vibration 777F First Flight - FTSW Europe 2009

23. V Aileron Vibration Details • Pilot comments on Aileron Vibration: • “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” • Causal factor unknown. • Potential contributing factors include: • Aileron deflection angle for vibration corresponds to approximately zero hinge moment • A “scoop” is created between the mass balance tower and the lower surface of the wing when the aileron is deflected 777F First Flight - FTSW Europe 2009

24. V Aileron Vibration Video 777F First Flight - FTSW Europe 2009

25. P Aileron Vibration Data 777F First Flight - FTSW Europe 2009

26. P Aileron Vibration Mapping 777F First Flight - FTSW Europe 2009

27. P 777 Outboard Aileron Balance Tower Air Flow 777F First Flight - FTSW Europe 2009

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

29. P Re-test flights : MLA Aileron “No Dwell” Zone Success ! 777F First Flight - FTSW Europe 2009

30. V Agenda • 777F Airplane Description/Background • Preparation Activities • First Flight Day • First Flight Part 2 • Lessons Learned • Summary 777F First Flight - FTSW Europe 2009

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

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

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

34. P Questions? 777F First Flight - FTSW Europe 2009