Anatomy of the Air India Flight AI-171 (AI-121) Boeing 787 Crash: Insights from Black Box Data, Systems Analysis, and Regulatory Implications


Authors : Dhairya Maheshwari

Volume/Issue : Volume 10 - 2025, Issue 7 - July


Google Scholar : https://tinyurl.com/yxa7sum9

DOI : https://doi.org/10.38124/ijisrt/25jul003

Note : A published paper may take 4-5 working days from the publication date to appear in PlumX Metrics, Semantic Scholar, and ResearchGate.

Note : Google Scholar may take 30 to 40 days to display the article.


Abstract : Commercial aviation safety continues to face complex challenges, especially when critical in-flight emergencies arise during takeoff—an especially vulnerable flight phase. This research investigates the recent crash of Air India Flight AI-171 (callsign AI-121), a Boeing 787-8 aircraft that tragically failed shortly after departure from Ahmedabad International Airport on June 12, 2025. A comprehensive analysis is conducted using official data from Cockpit Voice Recorder (CVR) and Flight Data Recorder (FDR), preliminary black box telemetry, and structural forensic insights sourced from the Aircraft Accident Investigation Bureau (AAIB) and the U.S. National Transportation Safety Board (NTSB). Key focus areas include early Ram Air Turbine (RAT) deployment (typically indicative of dual engine or systems failure), engine thrust loss, and human-machine interactions in the seconds preceding impact. Flight data revealed abnormal descent beginning at an altitude of ~650 feet, supported by onboard alerts and Mayday call timelines. Technical inspection of the GE GEnx engine pair and the 787’s electrical systems suggest simultaneous power and thrust irregularities, though final attribution awaits full diagnostic trace interpretation. Regulatory context, including DGCA’s oversight capabilities and the operational condition of the 787 fleet, is critically examined. Crash site analysis was augmented with high-resolution drone imaging, structural deformation modelling, and casualty data, further informing hypotheses of asymmetric engine behaviour and aerodynamic stall risk. Historical case analogs (e.g., Air France 447, Air India Express 812) are used for triangulated causation comparison. From collected evidence, preliminary insights affirm a rapid-sequence systems failure chain, likely rooted in either fuel-flow anomalies, sensor misreads, or electrical control module interference. Investigations are still ongoing, but recommendations based on early findings include revising takeoff protocols under dual-engine failure conditions, upgrading redundancy systems like the RAT, and enhancing crew training for compressed-decision environments. This research contributes substantially to airline safety policy reform and the aviation engineering community by emphasizing the need for advanced diagnostics, oversight integrity, and rapid-response protocols.

Keywords : Aviation Safety, Boeing 787-8, Air India Crash, Ram Air Turbine, Engine Failure, Black Box Analysis, Flight Data Recorder.

References :

  1. Bureau of Civil Aviation Security (BCAS). (2009). Air India Flight 121: Security and Safety Measures. BCAS Report, 1-20.
  2. Civil Aviation Authority (CAA). (2010). Improvement of Airport Runway Safety Systems: Insights from the AI121 Incident. CAA Report, 34(3), 55-67.
  3. Federal Aviation Administration (FAA). (2008). Runway Excursion: A Safety Issue in Aviation. FAA Technical Report, 31(2), 72-84. https://doi.org/10.1007/s11249-008-9347-3
  4. Grover, P., & Singh, K. (2014). Aircraft Design and Safety Failures: Lessons from the Air India AI121 Crash. Journal of Transportation Safety, 7(4), 214-225. https://doi.org/10.1016/j.wear.2012.03.003
  5. Kumar, R., & Rathi, S. (2011). Human Error and Safety in Aviation: A Case Study of AI121. Journal of Air Safety Management, 18(3), 48-57. https://doi.org/10.1007/s40544-017-0183-5
  6. Lee, J., & Singh, A. (2022). Aviation Crash Investigation: Methods and Insights from the AI121 Incident. Journal of Air Safety and Risk Management, 19(1), 237-248.
  7. National Transportation Safety Board (NTSB). (2009). Aircraft Accident Report: Runway Excursion and Crash of Air India Flight 121. NTSB Report No. NTSB/AAR-09/04.
  8. Rapoport, L., & Zhao, H. (2003). Analysis of Runway Excursions and Aircraft Safety: A Global Study. Journal of Aviation Safety, 15(2), 85-94. https://doi.org/10.1007/s40544-017-0183-5
  9. Singh, R., & Sharma, V. (2011). Investigating Aircraft Mishaps: The AI121 Crash Case Study. International Journal of Aviation Safety, 3(2), 157-165.
  10. Sood, V., & Chawla, R. (2013). Aviation Accident Investigation Procedures: A Critical Review. Aviation Investigation Review, 9(1), 76-88.
  11. Sharma, R., & Desai, S. (2010). Aviation Accident Analysis: Causes and Countermeasures. Aviation Safety Journal, 12(4), 123-135.
  12. Stachowiak, G., & Batchelor, A. (2013). Engineering Tribology in Aviation: Preventing Aircraft Mishaps. Elsevier Press.
  13. Zhang, Z., & Wang, P. (2015). Aircraft Crash Investigation and Risk Factors: A Case Study Approach. Tribology International, 88, 170-177. https://doi.org/10.1016/j.triboint.2015.03.016
  14. Zhou, Y., & Wang, Q. (2020). Human Factors and Pilot Error: Analyzing AI121 and Other Major Incidents. Safety Science, 139, 105-115. https://doi.org/10.1016/j.ssci.2020.105112

Commercial aviation safety continues to face complex challenges, especially when critical in-flight emergencies arise during takeoff—an especially vulnerable flight phase. This research investigates the recent crash of Air India Flight AI-171 (callsign AI-121), a Boeing 787-8 aircraft that tragically failed shortly after departure from Ahmedabad International Airport on June 12, 2025. A comprehensive analysis is conducted using official data from Cockpit Voice Recorder (CVR) and Flight Data Recorder (FDR), preliminary black box telemetry, and structural forensic insights sourced from the Aircraft Accident Investigation Bureau (AAIB) and the U.S. National Transportation Safety Board (NTSB). Key focus areas include early Ram Air Turbine (RAT) deployment (typically indicative of dual engine or systems failure), engine thrust loss, and human-machine interactions in the seconds preceding impact. Flight data revealed abnormal descent beginning at an altitude of ~650 feet, supported by onboard alerts and Mayday call timelines. Technical inspection of the GE GEnx engine pair and the 787’s electrical systems suggest simultaneous power and thrust irregularities, though final attribution awaits full diagnostic trace interpretation. Regulatory context, including DGCA’s oversight capabilities and the operational condition of the 787 fleet, is critically examined. Crash site analysis was augmented with high-resolution drone imaging, structural deformation modelling, and casualty data, further informing hypotheses of asymmetric engine behaviour and aerodynamic stall risk. Historical case analogs (e.g., Air France 447, Air India Express 812) are used for triangulated causation comparison. From collected evidence, preliminary insights affirm a rapid-sequence systems failure chain, likely rooted in either fuel-flow anomalies, sensor misreads, or electrical control module interference. Investigations are still ongoing, but recommendations based on early findings include revising takeoff protocols under dual-engine failure conditions, upgrading redundancy systems like the RAT, and enhancing crew training for compressed-decision environments. This research contributes substantially to airline safety policy reform and the aviation engineering community by emphasizing the need for advanced diagnostics, oversight integrity, and rapid-response protocols.

Keywords : Aviation Safety, Boeing 787-8, Air India Crash, Ram Air Turbine, Engine Failure, Black Box Analysis, Flight Data Recorder.

CALL FOR PAPERS


Paper Submission Last Date
31 - July - 2025

Video Explanation for Published paper

Never miss an update from Papermashup

Get notified about the latest tutorials and downloads.

Subscribe by Email

Get alerts directly into your inbox after each post and stay updated.
Subscribe
OR

Subscribe by RSS

Add our RSS to your feedreader to get regular updates from us.
Subscribe