1. 777 Freighter First Flight Preparation and Conduct
Flight Test Safety Workshop – Europe
Vienna, Austria
12 November, 2009
Be sure there are the proper introductions amongst the audience.
State your role at Boeing (777 S&C Engineer).
Encourage questions throughout the presentation.
Van Chaney, Boeing 777 Deputy Chief Pilot
Paul Bolds-Moorehead, Boeing 777 Stability & Control Senior Lead Engineer

2. …… following Capt. CashmanV
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”
Depending on our pace, we may take a couple of breaks throughout our discussion.
Please let me know if there are any items on the agenda that you do not wish to discuss.
12 November, 2009
777F First Flight - FTSW Europe 2009

3. 777F First Flight - FTSW Europe 2009
Agenda V
777F Airplane Description/Background
Preparation Activities
First Flight Day
First Flight Part 2
Subsequent Events
Lessons Learned
Summary
Depending on our pace, we may take a couple of breaks throughout our discussion.
Please let me know if there are any items on the agenda that you do not wish to discuss.
12 November, 2009
777F First Flight - FTSW Europe 2009

4. 777F First Flight - FTSW Europe 2009
Agenda V
777F Airplane Description/Background
Preparation Activities
First Flight Day
First Flight Part 2
Subsequent Events
Lessons Learned
Summary
Depending on our pace, we may take a couple of breaks throughout our discussion.
Please let me know if there are any items on the agenda that you do not wish to discuss.
12 November, 2009
777F First Flight - FTSW Europe 2009

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

6. 777 Introduction Family EvolutionP
1998
660,000-lb TOW
84k-98k Thrust ER
2004
775,000-lb TOW
115k Thrust
IGW
1997
632,500-lb TOW
84k-90k Thrust ER
1998
648,000-lb TOW
≤ 90k Thrust ER
2000
656,000-lb TOW
≤ 94k Thrust LR
2006
766,000-lb TOW
110k & 115k Thrust
535,000-lb TOW
74k-84k Thrust
1995
You saw this yesterday.
(A-Market)
Certified in First flight was 6/14/ MTOW 535,000 lbs. Engine thrust ratings from 74k to 84k.
ER (B-Market)
Originally certified in Same basic airframe with increased capabilities in range and performance. MTOW 632,500 lbs. Thrust up to the 84k to 90k range. LAM was added to the PFC. In 1998 and 2000, thrust and MTOW were increased further yet so as to increase capabilities in range and performance.
Certified in Longer forebody and aftbody (33 ft total). Same wing and empennage as the and ER. MTOW higher yet (660,000). Thrust offered up to 98k, (RR892, PW4090, PW4098). MMO & MD increase. Production tail skid added ER
Certified in New wing tips (constant chord tip extension + raked tip for increase performance). Empennage remains the same. MTOW up to 775,000 lbs and MTW is 777k! GE90-115BL. Flight control additions: TSP, HOSP, HSAD, new PFC hardware upgrade LR
Certified in Incorporates same wing as the ER. MTOW is 766,800 lbs. Engine options are GE90-110B1L and GE90-115BL. Performed the round the world, record flight. Incorporates same flight control additions as the ER
777-F
Freighter version of the LR passengeer airplane. From an aero standpoint, it is the same as the LR. Increased design weights (MLW, ZFW). Incorporates MLA.
777F
2009
766,000-lb TOW
110k & 115k Thrust
12 November, 2009
777F First Flight - FTSW Europe 2009

7. Summary of Changes: 777-200LR to 777FV
Summary of Changes: LR to 777F
MTOW 766,800 lb (with revised c.g. envelope)
MLW ,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
777F First Flight - FTSW Europe 2009

8. 777F Airplane Description Flight Envelope
Flight envelope is identical for all three models
VMO definition change. VMO barber pole now changes with altitude – no longer constant at 330 KCAS.
At higher altitudes, the margin between VMO and VD decreases.
Flight control system called HOSP allows this (discuss later).
12 November, 2009
777F First Flight - FTSW Europe 2009

9. 777F Airplane Description GW/CG Envelope
Most noticeable difference is at MTOW/MTW with the forward CG expansion. The LR offers a very small range between fwd and aft CG at MTOW of 766,800 lbs. On the 777F, It was desired to allow more flexible loading for the operators without a major structural redesign (weight increase) of the wing. So MLA was put on the airplane (will discuss more later) to allow for this expansion.
Note that the original had a MTOW of 535,000 lbs. And now with the 777F, the MLW is 40,000 lbs heavier than that MTOW!
12 November, 2009
777F First Flight - FTSW Europe 2009

10. 777F Airplane Description Maneuver 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 unique to-date.
MLA allows for the fwd cg expansion without a major wing structurally redesign.
12 November, 2009
777F First Flight - FTSW Europe 2009

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

12. 777F First Flight - FTSW Europe 2009
Agenda P
777F Airplane Description/Background
Preparation Activities
First Flight Day
First Flight Part 2
Subsequent Events
Lessons Learned
Summary
Depending on our pace, we may take a couple of breaks throughout our discussion.
Please let me know if there are any items on the agenda that you do not wish to discuss.
12 November, 2009
777F First Flight - FTSW Europe 2009

13. 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
12 November, 2009
777F First Flight - FTSW Europe 2009

14. 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)
12 November, 2009
777F First Flight - FTSW Europe 2009

15. 777F First Flight Preparation (cont’d)V
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”
12 November, 2009
777F First Flight - FTSW Europe 2009

16. 777F First Flight - FTSW Europe 2009
Agenda V
777F Airplane Description/Background
Preparation Activities
First Flight Day
First Flight Part 2
Subsequent Events
Lessons Learned
Summary
Depending on our pace, we may take a couple of breaks throughout our discussion.
Please let me know if there are any items on the agenda that you do not wish to discuss.
12 November, 2009
777F First Flight - FTSW Europe 2009

17. 777F First Flight - FTSW Europe 2009
777F First Flight Day V
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 ( LR pax airplane)
Failures or “Opportunities”
Telemetry failure – followed “Plan B”, e.g. aborted and returned to origination field (PAE)
12 November, 2009
777F First Flight - FTSW Europe 2009

18. 777F First Flight - FTSW Europe 2009
Agenda V
777F Airplane Description/Background
Preparation Activities
First Flight Day
First Flight Part 2
Subsequent Events
Lessons Learned
Summary
Depending on our pace, we may take a couple of breaks throughout our discussion.
Please let me know if there are any items on the agenda that you do not wish to discuss.
12 November, 2009
777F First Flight - FTSW Europe 2009

19. 777F First Flight – Part TwoV
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
12 November, 2009
777F First Flight - FTSW Europe 2009

20. 777F First Flight - FTSW Europe 2009
Agenda V
777F Airplane Description/Background
Preparation Activities
First Flight Day
First Flight Part 2
Subsequent Events
Lessons Learned
Summary
Depending on our pace, we may take a couple of breaks throughout our discussion.
Please let me know if there are any items on the agenda that you do not wish to discuss.
12 November, 2009
777F First Flight - FTSW Europe 2009

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

22. 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
12 November, 2009
777F First Flight - FTSW Europe 2009

23. 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
12 November, 2009
777F First Flight - FTSW Europe 2009

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

25. Aileron Vibration DataP
12 November, 2009
777F First Flight - FTSW Europe 2009

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

27. 777 Outboard Aileron Balance TowerP
Air Flow
12 November, 2009
777F First Flight - FTSW Europe 2009

28. 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
12 November, 2009
777F First Flight - FTSW Europe 2009

29. Re-test flights : MLA Aileron “No Dwell” ZoneP
Success !
12 November, 2009
777F First Flight - FTSW Europe 2009

30. 777F First Flight - FTSW Europe 2009
Agenda V
777F Airplane Description/Background
Preparation Activities
First Flight Day
First Flight Part 2
Lessons Learned
Summary
Depending on our pace, we may take a couple of breaks throughout our discussion.
Please let me know if there are any items on the agenda that you do not wish to discuss.
12 November, 2009
777F First Flight - FTSW Europe 2009

31. 777F First Flight - FTSW Europe 2009
777F Lessons Learned V
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
12 November, 2009
777F First Flight - FTSW Europe 2009

32. 777F First Flight - FTSW Europe 2009
Agenda P
777F Airplane Description/Background
Preparation Activities
First Flight Day
First Flight Part 2
Subsequent Events
Lessons Learned
Summary
Depending on our pace, we may take a couple of breaks throughout our discussion.
Please let me know if there are any items on the agenda that you do not wish to discuss.
12 November, 2009
777F First Flight - FTSW Europe 2009

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

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