Boeing grounds 777X test fleet after failure of key engine mounting structure - The Air Current

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Boeing has sidelined its 777X test fleet after a routine post-flight inspection revealed the failure of a crucial piece of structure that mounts the engine to the aircraft. A similar finding was made on its two other active test aircraft, prompting a halt in test flying for the massive Boeing twin-engine jetliner, according to two people familiar with the issue.

Boeing confirmed the discovery and its impact on flight testing, telling The Air Current in an e-mailed statement, “During scheduled maintenance, we identified a component that did not perform as designed. Our team is replacing the part and capturing any learnings from the component and will resume flight testing when ready.”

Related: Boeing begins 777X certification flight trials with FAA

The two people familiar with the severed thrust link said the issue was discovered on Boeing’s third 777-9 test aircraft, WH003, after it completed a five-hour 31-minute flight on Aug. 16 from Kona Airport in Hawaii. Subsequent inspections on other 777-9 test aircraft back on the mainland revealed cracks in the thrust link structure.

The finding is a frustrating setback for the long-delayed 777X, which had been picking up momentum since it began Federal Aviation Administration flight testing in July, though aircraft developers and regulators overwhelmingly prefer that such issues be discovered during testing rather than in service with an airline operator.