Not
long after the Electra entered service, there were three crashes, two
of which involved wing separation (the other was attributed to pilot
error). As a result, performance restrictions were imposed and Lockheed
instigated a modification program which came to be known as LEAP. Several
references decode the acronym as "Lockheed Electra Achievement
Program" but Lockheed sources state that the correct title
is "Lockheed Electra Action Program".
The following account of LEAP is extracted from "Beyond the
Horizons - The Lockheed Story"
by Walter J. Boyne (St. Martin's Press, New York 1998):
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Investigation
revealed that under certain conditions of engine nacelle or power-plant
damage, a phenomenon known as 'whirl mode' could occur. 'Whirl
mode' refers to the results of the application of a force to gyroscopic
characteristics of a rotating propeller. When such a force is
applied, precession occurs; that is, like a gyroscope, the propeller
reacts ninety degrees out of phase to the applied force. This
causes the structural resistance of the engine mounting system
to apply a nose-down pitching moment. This forces the propeller
disc (as viewed from the rear) to turn to the left due to precession.
This in turn causes a nose-down propeller disc yawing to the right,
which causes a nose-up pitch, completing the cycle. This combination
of effects is termed the 'whirl mode', and its direction of rotation
is opposite to that of the propeller. In a normal aircraft, the
whirl mode could operate only within the limits of the flexibility
of the engine mounts. If, however, some structural element of
the power plant, the power-plant mounting system, or the nacelle
was in a damaged or weakened condition, the whirl mode would not
damp out, but could become more violent, increasing damage to
the structure, and could approach the natural frequency of the
wing. This would perpetuate the whirl mode in a form of induced
flutter and lead to catastrophic failure. John Margwarth, another
University of Michigan man, was director of safety for Lockheed,
and it was his insight that led to an investigation revealing
that the Electra's fatal flaw was in the three member structure
connecting the gearbox and the engine, a part supplied by the
engine manufacturers. When one member of that structure failed,
the engine mount became flexible. On an outboard engine, at the
Electra's original cruise speed, failure of the strut induced
immediate, violent flutter that tore the wing off. Technically,
Lockheed could have passed the problem off to the engine manufacturer,
disclaiming responsibility. Instead, it redesigned the wing structure
so that it would not flutter when such a failure occurred. (Allison
also redesigned the strut so that it would not fail.) Additional
mounts were added to stabilize the propeller in the event that
any mount failed, or if breakage occurred between the gearbox
and the power section. The nacelle structure was also strengthened
by the addition of reinforcements and diagonal braces. Lockheed
was rocked by the three crashes and their adverse publicity. For
weeks there was one meeting after another to handle the latest
problem. It was soon evident that engineering the wing modification
was not going to be as difficult as finding a way to pay for it.
Carl Kotchian recalled coming out of a meeting with Robert Gross,
the latter sunk deep in thought. (Gross had been under considerable
strain for some time; he would die less than two years later.)
In the garage, Gross asked, 'How much do you think the modification
is going to cost?' Kotchian hesitated and said, 'Well, I think
it's going to cost maybe $25 million.' Gross turned white, then
replied, 'Well, we've got to do it.' And Lockheed did, instituting
the Lockheed Electra Action Program (LEAP) and modifying all Electras
at its own expense, whether they were within warranty or not.
The LEAP program came in just under Kotchian's $25 million
estimate. |
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