Air India flight 171 black box data found: What investigators are searching for

Dubai: Following the tragic crash of Air India Flight AI171 and the recovery of its flight data recorder (FDR), aviation experts are detailing the complex, multi-stage investigation process now underway.

Indian Civil Aviation Minister Ram Mohan Naidu Kinjarapu confirmed the black box's recovery, stating it "marks an important step forward" and will "significantly aid the inquiry." The government has formed a high-level committee to focus on preventing future occurrences.

While a complete explanation could take months, early clues and expert opinions highlight crucial focus areas.

Aviation analysts - Linus Benjamin Bauer of Bauer Aviation Advisory and Saj Ahmad, Chief Analyst at StrategicAero Research – have emphasised the critical importance of the two black boxes: the Flight Data Recorder (FDR) and the Cockpit Voice Recorder (CVR).

The FDR logs hundreds of parameters every second, from speed and altitude to engine thrust and flap positions. The CVR captures cockpit conversations for the last two hours.

"Together, these help recreate a timeline of the aircraft’s final moments—objectively and accurately," Bauer told Gulf News. Ahmad adds that the sole survivor's testimony will also be key to understanding the crash of this Boeing 787-8 Dreamliner.

Key areas of investigation

According to the experts, the investigators will pursue several lines of inquiry. “Crash investigations—especially those involving widebody aircraft like the Boeing 787—are complex, multi-jurisdictional, and highly technical. The first 48–72 hours are focused on securing evidence, stabilising the site, and initiating coordination among stakeholders,” explained Bauer.

They are:

Pilot actions and training: Experts will closely examine pilot qualifications, potential fatigue, training records, and how the crew managed resources (CRM). Ahmad said the pilots were highly experienced, making their actions under stress a key focus.

Aircraft maintenance and manufacturing: Scrutiny will fall on Air India's maintenance and upkeep records for this aircraft and its fleet. Investigators will determine if the aircraft was airworthy if any discrepancies were unresolved, and the robustness of quality control. Boeing's role in aircraft manufacturing will also be examined, as will GE Aerospace, the engine manufacturer, particularly if engine thrust issues are confirmed. “Every aspect of maintenance and operations, as well as service records, will be pored over,” said Ahmad.

“Investigators will want to know: Was the aircraft airworthy? Were any recent discrepancies unresolved? How robust was the quality control in line maintenance,” said Bauer.

System malfunctions vs. isolated events: Investigators will assess if there's a fundamental design flaw with the Boeing 787. Both experts suggest this is unlikely, given the Dreamliner's extensive service history and safety record. The focus will instead be on whether this was an isolated event, possibly escalated by other faults like engine trouble or malfunctioning flight computers. Initial questions include whether the plane’s wing flaps and slats were extended correctly and why the landing gear remained down.

External factors and environment: Air Traffic Control (ATC) communication logs and radar data will be analysed for instructions, miscommunications, or anomalies. Human factors like stress, workload, visibility, and weather conditions during takeoff or approach will be considered as well, according to Bauer.

"There were early comments about bird ingestion, but footage online doesn’t support this and there’d have to be a significant cohort of big birds to bring down a jet the size of a 787-8," said Ahmad.

“In the AI171 case, if weather was marginal, investigators will examine how well situational awareness and decision-making held up under those conditions,” said Bauer.

Investigation process, timeline

India's Aircraft Accident Investigation Bureau (AAIB) will lead the technical investigation. As per international protocols (ICAO Annex 13), Boeing and the U.S. National Transportation Safety Board (NTSB) will be invited as accredited parties, ensuring technical support and data decoding expertise, explained Bauer. Other agencies, like the FAA (USA) and potentially EASA for European components, may also observe.

The recovered black box will be shipped to a certified laboratory for decoding, which can take weeks. A preliminary report is expected within 30 days, although its scope will be limited.

The final, exhaustive report, including technical analysis, interviews, and simulations, may take 12 to 18 months to complete. This final report will be crucial for recommending changes in procedures, training, aircraft design, or regulations and for determining liability.

Dreamliner's safety record

Ahmad said that despite this tragic event, the Boeing 787 Dreamliner family remains one of the safest and most rigorously tested aircraft. With nearly 1,000 in operation globally, they have safely transported over a billion passengers. This crash marks the first "hull loss" since its entry into service in 2011, a testament to its strong safety record.

According to Bauer, “What happens in the weeks ahead is not just about understanding one aircraft’s final flight—it is about reaffirming the global system’s ability to learn, adapt, and protect passengers,” he explained. "The investigators’ job is to determine what failed and ensure it never happens again. For Air India, Boeing, and the wider industry, this is a moment to double down on transparency, rigour, and systemic safety—not just recovery,” Bauer stated.