What Caused Air India Flight Crash? Black Box to Reveal Truth

Introduction

On June 12, 2025, tragedy struck Air India Flight AI171—a Boeing 787‑8 Dreamliner scheduled for London Gatwick—just 30 seconds after departing Mumbai’s Sardar Vallabhbhai Patel International Airport in Ahmedabad. What began as a routine flight turned into India’s deadliest aviation disaster in decades, leaving 241 passengers and crew dead, numerous fatalities on the ground, and one lone survivor, British national Vishwash Kumar Ramesh.

The aviation world is now closely watching the recovered Flight Data Recorder (FDR) and Cockpit Voice Recorder (CVR)—the so-called “black boxes”—considered the most vital keys to understanding the catastrophic events.

Crash Details & Human Toll

• Flight: AI171
• Aircraft: Boeing 787‑8 Dreamliner, registration VT‑ANB
• Occupants: 230 passengers, 12 crew
• Fatalities: 241 onboard, ~38 on ground; over 60 injured
• Survivor: Vishwash Kumar Ramesh (seat 11A)

Evidence suggests the aircraft climbed briefly—up to ~625 ft—before rapidly losing altitude and crashing into a hostel at BJ Medical College, Ahmedabad.

Quick Recovery of Black Boxes

Within 24 hours of the crash, authorities recovered both the FDR and CVR from the debris, located atop the hostel’s mess building. Despite the intense fire, their rugged design ensured key data remained retrievable.

Additional data sources include the aircraft’s DVR (external/cabin cameras), transponder records (ADS‑B logs), ATC transmissions, and CCTV footage.

Themes Under Investigation :

Flaps and Landing Gear Configuration

Early theories — notably by aviation analyst “Captain Steve” — suggest premature flap retraction instead of gear operation: a classic lift-loss mechanism during takeoff. Video analysis supports this: the Dreamliner showed abnormal climb mechanics and may have stalled.

Engine Performance

Investigators are examining whether there was sudden engine thrust reduction—potentially from mechanical failure or fuel issues. Boeing’s GE‑GEnx engines are generally reliable, yet speculation remains active.

Human & Pilot Factors

Pilot error or miscommunication is under scrutiny. Experts note early flap retraction and possibly incomplete runway acceleration—all critical steps that may have been missed in a high-pressure takeoff scenario.

Environmental & Technical Factors

Analysts examined heat (40 °C could reduce lift), possible bird strikes, high altitude, or heavy weight—but none appear primary. Air India’s Dreamliner fleet history, including past production concerns raised by whistleblowers, is also contributing to the investigation.

Expert Opinions

• Captain Steve (YouTube analyst): “The co‑pilot may have retracted the flaps instead of landing gear, causing sudden lift loss”.
• Keith Tonkin (Consultant): “No sign of engine failure, but a configuration error unfolding in seconds”.
• Peter Carter (Aviation Lawyer):
  Questions whether full runway acceleration was achieved .
• Chrystal Zhang (Aviation Analyst):
  Excludes bird-strike and weather—focuses on pilot ops.

Black Box: Crucial Next Steps

FDR Insights:

• Engine thrust levels
• Flap/gear positions
• Autopilot & control inputs
• Aircraft velocity/angle

CVR Analysis:

• Cockpit conversation/callouts
• Audibly recognized alerts (e.g. stall warnings)
• Pilot coordination during the 30 seconds

Integration & Timeline Reconstruction

Data synthesis will align black box inputs with video, ground tracking, and CVR, fixing precise human-system interaction at takeoff. Investigations hope to distill causal actions or technical failures.

Officials expect preliminary black box decoding within a week; full final report may take months.

Regulatory & Operator Response

• DGCA has mandated additional safety inspections on Air India’s 787‑8/9 fleets focusing on engines, flaps, hydraulics, and takeoff configurations .
• Air India grounded part of its 787 fleet for comprehensive checks; Tata Group promised expedited support and compensation.
• Boeing and GE Aerospace pledged full cooperation; Boeing shares fell ~8% on ensuing investor concern .
• International agencies (India’s AAIB, UK’s AAIB, US NTSB) have deployed investigative teams .

Historical & Technical Context

• This is the first fatal crash of a Boeing 787; other Dreamliner fleets had strong safety records .
• The incident echoes Northwest Flight 255 (1987): immediate post-takeoff stall due to missed configuration.
• Boeing’s internal turmoil, including 2024 whistleblower John Barnett’s claims of quality lapses, now aggravates scrutiny.

Broader Implications

• For Boeing: Risk of safety redesigns, delayed deliveries, deeper regulatory audits.
• For Airlines: Enhanced pilot training, stall recovery protocols, checklist reinforcement.
• For Aviation: Review of cockpit ergonomics, human factors, and automation response.
• Public Perception: Erosion of trust in modern aircraft safety—prompting swift industry reassurance.

What to Expect Moving Forward

1. Preliminary Black Box Report in next few days: Likely flare declarations, flap/gear data.
2. Interim Guidance: DGCA may issue safety suggestions based on early data.
3. Final Investigation Report: Detailed conclusions with systemic recommendations (weeks–months).
4. Industry Action: Revised Boeing 787 maintenance checklist, global audit of training and cockpit design.
5. Regulatory Impact: ICAO/IATA updates on takeoff configuration and automation reliance.

Conclusion: Awaiting Crucial Answers

Air India Flight AI171 shocked the world with a swift tragedy that claimed hundreds of lives. Amid grief, hope lies in the black box: that silent witness within steel and fire that can narrate the precise seconds leading to calamity. Whether the cause settles on configuration missteps, mechanical failure, or system deficiency, the answers gleaned will shape aviation safety strategies worldwide.