De Havilland Comet

The de Havilland DH.106 Comet is a four-engine narrow body aircraft developed and manufactured by de Havilland in the United Kingdom. The world's first commercial jet airliner, the Comet 1 prototype first flew in 1949. It features an aerodynamically clean design with four de Havilland Ghost turbojet engines located in the wing roots, a pressurised cabin, and large windows. For the era, it offered a relatively quiet, comfortable passenger cabin and was commercially promising at its debut in 1952.

Within a year of the airliner's entry into service, three Comets were lost in highly publicised accidents after suffering catastrophic mishaps mid-flight. Two of these were found to be caused by structural failure resulting from metal fatigue in the airframe, a phenomenon not fully understood at the time; the other was due to overstressing of the airframe during flight through severe weather. The Comet was withdrawn from service and extensively tested. Design and construction flaws, including dangerous stress concentrations around square cut-outs for the ADF (automatic direction finder) antennas were ultimately identified. As a result, the Comet was extensively redesigned, with structural reinforcements and other changes. Rival manufacturers heeded the lessons learned from the Comet when developing their own aircraft.

Although sales never fully recovered, the improved Comet 2 and the prototype Comet 3 culminated in the redesigned Comet 4 series which debuted in 1958 and remained in commercial service until 1981. The Comet was also adapted for a variety of military roles such as VIP, medical and passenger transport, as well as surveillance; the last Comet 4, used as a research platform, made its final flight in 1997. The most extensive modification resulted in a specialised maritime patrol derivative, the Hawker Siddeley Nimrod, which remained in service with the Royal Air Force until 2011, over 60 years after the Comet's first flight.

Development

Origins

thumb|upright=1.7|Design studies for the DH.106 Comet 1944–1947 (artist's impression)

On 11 March 1943, the Cabinet of the United Kingdom formed the Brabazon Committee, which was tasked with determining the UK's airliner needs after the conclusion of the Second World War. One of its recommendations was for the development and production of a pressurised, transatlantic mailplane that could carry of payload at a cruising speed of non-stop.

Aviation company de Havilland was interested in this requirement, but chose to challenge the then widely held view that jet engines were too fuel-hungry and unreliable for such a role. As a result, committee member Sir Geoffrey de Havilland, head of the de Havilland company, used his personal influence and his company's expertise to champion the development of a jet-propelled aircraft, proposing a specification for a pure turbojet-powered design.|group=N and in 1945 awarded a development and production contract to de Havilland under the designation Type 106. The type and design were to be so advanced that de Havilland had to undertake the design and development of both the airframe and the engines. This was because in 1945 no turbojet engine manufacturer in the world was drawing up a design specification for an engine with the thrust and specific fuel consumption that could power an aircraft at the proposed cruising altitude (), speed, and transatlantic range as was called for by the Type 106. First-phase development of the DH.106 focused on short- and intermediate-range mailplanes with small passenger compartments and as few as six seats, before being redefined as a long-range airliner with a capacity of 24 seats.

Revised first orders from BOAC and British South American Airways and tested to failure. The entire forward fuselage section was tested for metal fatigue by repeatedly pressurising to overpressure and depressurising through more than 16,000 cycles, equivalent to about 40,000 hours of airline service. The windows were also tested under a pressure of , above expected pressures at the normal service ceiling of . about 1,250 per cent over the maximum pressure it was expected to encounter in service. The prototype's maiden flight, out of Hatfield Aerodrome, took place on 27 July 1949 and lasted 31 minutes. At the controls was de Havilland chief test pilot John "Cats Eyes" Cunningham, a famous night-fighter pilot of the Second World War, along with co-pilot Harold "Tubby" Waters, engineers John Wilson (electrics) and Frank Reynolds (hydraulics), and flight test observer Tony Fairbrother.

The prototype was registered G-ALVG just before it was publicly displayed at the 1949 Farnborough Airshow before the start of flight trials. A year later, the second prototype G-5-2 made its maiden flight. The second prototype was registered G-ALZK in July 1950 and it was used by the BOAC Comet Unit at Hurn from April 1951 to carry out 500 flying hours of crew training and route-proving. Australian airline Qantas also sent its own technical experts to observe the performance of the prototypes, seeking to quell internal uncertainty about its prospective Comet purchase. Both prototypes could be externally distinguished from later Comets by the large single-wheeled main landing gear, which was replaced on production models starting with G-ALYP by four-wheeled bogies. Two pairs of turbojet engines (on the Comet 1s, Halford H.2 Ghosts, subsequently known as de Havilland Ghost 50 Mk1s) were buried in the wings.

The original Comet was the approximate length of, but not as wide as, the later Boeing 737-100, and carried fewer people in a significantly more-spacious environment. BOAC installed 36 reclining "slumberseats" with centres on its first Comets, allowing for greater leg room in front and behind; Air France had 11 rows of seats with four seats to a row installed on its Comets. Large picture window views and table seating accommodations for a row of passengers afforded a feeling of comfort and luxury unusual for transportation of the period. Amenities included a galley that could serve hot and cold food and drinks, a bar, and separate men's and women's toilets. Provisions for emergency situations included several life rafts stored in the wings near the engines, and individual life vests were stowed under each seat. For passengers used to piston-engined propeller-driven airliners, smooth and quiet jet flight was a novel experience.

Avionics and systems

left|thumb|The flight deck of a Comet 4

For ease of training and fleet conversion, de Havilland designed the Comet's flight deck layout with a degree of similarity to the Lockheed Constellation, an aircraft that was popular at the time with key customers such as BOAC. The navigator occupied a dedicated station, with a table across from the flight engineer.

Several of the Comet's avionics systems were new to civil aviation. One such feature was irreversible, powered flight controls, which increased the pilot's ease of control and the safety of the aircraft by preventing aerodynamic forces from changing the directed positions and placement of the aircraft's control surfaces. Many of the control surfaces, such as the elevators, were equipped with a complex gearing system as a safeguard against accidentally over-stressing the surfaces or airframe at higher speed ranges.

The Comet had a total of four hydraulic systems: two primaries, one secondary, and a final emergency system for basic functions such as lowering the undercarriage. The undercarriage could also be lowered by a combination of gravity and a hand-pump. Power was syphoned from all four engines for the hydraulics, cabin air conditioning, and the de-icing system; these systems had operational redundancy in that they could keep working even if only a single engine was active. The majority of hydraulic components were centred in a single avionics bay. A pressurised refuelling system, developed by Flight Refuelling Ltd, allowed the Comet's fuel tanks to be refuelled at a far greater rate than by other methods.

thumb|The Comet 4 navigator's station

The cockpit was significantly altered for the Comet 4's introduction, on which an improved layout focusing on the onboard navigational suite was introduced. An EKCO E160 radar unit was installed in the Comet 4's nose cone, providing search functions as well as ground and cloud-mapping capabilities,|group=N the nose and cockpit layout of the Comet 1 was grafted onto the Caravelle. In 1969, when the Comet 4's design was modified by Hawker Siddeley to become the basis for the Nimrod, the cockpit layout was completely redesigned and bore little resemblance to its predecessors except for the control yoke.

Fuselage

Diverse geographic destinations and cabin pressurisation alike on the Comet demanded the use of a high proportion of alloys, plastics, and other materials new to civil aviation across the aircraft to meet certification requirements. The Comet's high cabin pressure and high operating speeds were unprecedented in commercial aviation, making its fuselage design an experimental process. The chemical bonding process was accomplished using a new adhesive, Redux, which was liberally used in the construction of the wings and the fuselage of the Comet; it also had the advantage of simplifying the manufacturing process.

When several of the fuselage alloys were discovered to be vulnerable to weakening via metal fatigue, a detailed routine inspection process was introduced. As well as thorough visual inspections of the outer skin, mandatory structural sampling was routinely conducted by both civil and military Comet operators. The need to inspect areas not easily viewable by the naked eye led to the introduction of widespread radiography examination in aviation; this also had the advantage of detecting cracks and flaws too small to be seen otherwise.

Operationally, the design of the cargo holds led to considerable difficulty for the ground crew, especially baggage handlers at the airports. The cargo hold had its doors located directly underneath the aircraft, so each item of baggage or cargo had to be loaded vertically upward from the top of the baggage truck, then slid along the hold floor to be stacked inside. The individual pieces of luggage and cargo also had to be retrieved in a similarly slow manner at the arriving airport.

Propulsion

The Comet was powered by two pairs of turbojet engines buried in the wings close to the fuselage. Chief designer Bishop chose the Comet's embedded-engine configuration because it avoided the drag of podded engines and allowed for a smaller fin and rudder since the hazards of asymmetric thrust were reduced. The engines were outfitted with baffles to reduce noise emissions, and extensive soundproofing was also implemented to improve passenger conditions.

thumb|The Comet 4's enlarged [[Rolls-Royce Avon engine intakes]]

Placing the engines within the wings had the advantage of a reduction in the risk of foreign object damage, which could seriously damage jet engines. The low-mounted engines and good placement of service panels also made aircraft maintenance easier to perform.

The Comet 1 featured de Havilland Ghost 50 Mk1 turbojet engines. Two hydrogen peroxide-powered de Havilland Sprite booster rockets were originally intended to be installed to boost takeoff under hot and high altitude conditions from airports such as Khartoum and Nairobi. These were tested on 30 flights, but the Ghosts alone were considered powerful enough and some airlines concluded that rocket motors were impractical. Comet 1s subsequently received more powerful Ghost DGT3 series engines.

Operational history

Introduction

The earliest production aircraft, registered G-ALYP ("Yoke Peter"), first flew on 9 January 1951 and was subsequently lent to BOAC for development flying by its Comet Unit. On 22 January 1952, the fifth production aircraft, registered G-ALYS, received the first Certificate of Airworthiness awarded to a Comet, six months ahead of schedule. On 2 May 1952, as part of BOAC's route-proving trials, G-ALYP took off on the world's first jetliner flight with fare-paying passengers and inaugurated scheduled service from London to Johannesburg. The final Comet from BOAC's initial order, registered G-ALYZ, began flying in September 1952 and carried cargo along South American routes while simulating passenger schedules.

thumb|left|[[British Overseas Airways Corporation|BOAC Comet 1 at Entebbe Airport, Uganda in 1952, this aircraft later crashed as BOAC Flight 115 in the same year.]]

Prince Philip returned from the Helsinki Olympic Games with G-ALYS on 4 August 1952. Queen Elizabeth, the Queen Mother, Elizabeth II and Princess Margaret were guests on a special flight of the Comet on 30 June 1953 hosted by Sir Geoffrey and Lady de Havilland. Flights on the Comet were about twice as fast as advanced piston-engined aircraft such as the Douglas DC-6 (

vs , respectively), and a faster rate of climb further cut flight times. In August 1953 BOAC scheduled the nine-stop London to Tokyo flights by Comet for 36 hours, compared to 86 hours and 35 minutes on its Argonaut (a DC-4 variant) piston airliner. (Pan Am's DC-6B was scheduled for 46 hours 45 minutes.) The five-stop flight from London to Johannesburg was scheduled for 21 hr 20 min.

In their first year, Comets carried 30,000 passengers. As the aircraft could be profitable with a load factor as low as 43 per cent, commercial success was expected. The Ghost engines allowed the Comet to fly above weather that competitors had to fly through. They ran smoothly and were less noisy than piston engines, had low maintenance costs  and were fuel-efficient above . In summer 1953, eight BOAC Comets left London each week: three to Johannesburg, two to Tokyo, two to Singapore and one to Colombo.

In 1953, the Comet appeared to have achieved success for de Havilland. Popular Mechanics wrote that Britain had a lead of three to five years on the rest of the world in jetliners. A slightly longer version of the Comet 1 with more powerful engines, the Comet 2, was being developed, and orders were placed by Air India, British Commonwealth Pacific Airlines, Qantas was interested in the Comet 1 but concluded that a version with more range and better takeoff performance was needed for the London to Canberra route.

Early hull losses

On 26 October 1952, the Comet suffered its first hull loss when BOAC Flight 115 departing Rome's Ciampino airport failed to become airborne and ran into rough ground at the end of the runway. Two passengers sustained minor injuries, but the aircraft, G-ALYZ, was a write-off. On 3 March 1953, a new Canadian Pacific Airlines Comet 1A, registered CF-CUN and named Empress of Hawaii, failed to become airborne while attempting a night takeoff from Karachi, Pakistan, on a delivery flight to Australia. The aircraft plunged into a dry drainage canal and collided with an embankment, killing all five crew and six passengers on board. The accident was the first fatal jetliner crash. and wing fences were added to control spanwise flow. A fictionalised investigation into the Comet's takeoff accidents was the subject of the novel Cone of Silence (1959) by Arthur David Beaty, a former BOAC captain. Cone of Silence was made into a film in 1960, and Beaty also recounted the story of the Comet's takeoff accidents in a chapter of his non-fiction work, Strange Encounters: Mysteries of the Air (1984).

The Comet's second fatal accident occurred on 2 May 1953, when BOAC Flight 783, a Comet 1, registered G-ALYV, crashed in a severe thundersquall six minutes after taking off from Calcutta-Dum Dum airport, India, killing all 43 on board. Witnesses observed the wingless Comet on fire plunging into the village of Jagalgori, leading investigators to suspect structural failure.|group=N Professor Natesan Srinivasan joined the inquiry as the main technical expert. A large portion of the aircraft was recovered and reassembled at Farnborough,

The inquiry's recommendations revolved around the enforcement of stricter speed limits during turbulence, and two significant design changes also resulted: all Comets were equipped with weather radar and the "Q feel" system was introduced, which ensured that control column forces (invariably called stick forces) would be proportional to control loads. This artificial feel was the first of its kind to be introduced in any aircraft. and investigators suggested that this might have contributed to the pilot's alleged over-stressing of the aircraft; Comet chief test pilot John Cunningham contended that the jetliner flew smoothly and was highly responsive in a manner consistent with other de Havilland aircraft.