News: 1713362415

  ARM Give a man a fire and he's warm for a day, but set fire to him and he's warm for the rest of his life (Terry Pratchett, Jingo)

Whistleblower cries foul over alleged fuselage gaps in Boeing 787 Dreamliner

(2024/04/17)


A Boeing whistleblower has called for the embattled aircraft manufacturer's fleet of 787s to be grounded for gap checks.

Engineer Sam Salehpour said the alleged flaw is "as serious as I have ever seen in my lifetime" during an [1]interview with NBC Nightly News. The issue, he claims, is gaps in the fuselage, which, even though the fuselage is fastened together, are allegedly too big and could cause structural failure.

"The plane will fall apart at the joints," Salehpour claimed, should the aircraft experience a failure. "The entire fleet, worldwide, needs attention."

[2]

Boeing was quick to deny Salehpour's claims. During an event at Boeing's South Carolina plant this week, the company's chief engineer for mechanical and structural engineering, Steve Chisholm, insisted that the aircraft was safe and that the materials from which the jet was made had passed rigorous stress testing.

[3]

[4]

The Register asked Boeing to comment on Salehpour's allegations and a spokesperson gave us the following statement:

We are fully confident in the 787 Dreamliner. These claims about the structural integrity of the 787 are inaccurate and do not represent the comprehensive work Boeing has done to ensure the quality and long term safety of the aircraft.

The issues raised have been subject to rigorous engineering examination under FAA oversight. This analysis has validated that these issues do not present any safety concerns and the aircraft will maintain its service life over several decades.

We continue to monitor these issues under established regulatory protocols and encourage all employees to speak up when issues arise. Retaliation is strictly prohibited at Boeing.

However, while the materials might be sufficient, Boeing has struggled with assembling the aircraft. Deliveries of new 787s ground to a halt in 2020 and 2021 after a [5]succession of defects were uncovered in the manufacturing process, including what appeared to be issues with gaps.

In 2023, Boeing discovered a [6]defect in a component fitted to the aircraft's horizontal stabilizer, which required some additional inspections. According to Boeing, the issue was not an immediate safety concern and did not affect manufacturing.

[7]Engine cover flies from Southwest Airlines Boeing 737 during takeoff

[8]Boeing and subsidiary file trade secrets lawsuit against Virgin Galactic

[9]Boeing top brass stand down amid safety turbulence

[10]Justice Dept reportedly starts criminal probe into Boeing door bolt incident

The 787 has suffered a number of setbacks since its introduction in 2011. There was [11]the battery problem in 2014 and the instruction in 2020 to [12]power cycle the aircraft every 51 days .

However, the demand to ground the entire fleet – currently over a thousand aircraft – for panel gap inspections is dramatic.

Away from the 787 allegations, Boeing has had a torrid time in recent months as its safety record has been repeatedly called into question. An emergency exit door plug [13]blew out during the flight of an Alaskan Airlines 737, and the company's CEO, Dave Calhoun, is due to [14]make his own exit at the end of the year.

[15]

Boeing's safety record and processes have also come under scrutiny. Last month, the chair of the US National Transportation Safety Board (NTSB) [16]told a Senate Commerce Committee that the agency was having difficulty getting records regarding maintenance on the Alaskan Airline 737's door plug.

An aviation industry insider told The Register that even the suggestion that documentation might not be available was "bizarre."

Salehpour is due to testify before US lawmakers on April 17. ®

Get our [17]Tech Resources



[1] https://www.nbcnews.com/nightly-news

[2] https://pubads.g.doubleclick.net/gampad/jump?co=1&iu=/6978/reg_offbeat/front&sz=300x50%7C300x100%7C300x250%7C300x251%7C300x252%7C300x600%7C300x601&tile=2&c=2Zh-yHvMR7sC2fuBLePEBeQAAAA8&t=ct%3Dns%26unitnum%3D2%26raptor%3Dcondor%26pos%3Dtop%26test%3D0

[3] https://pubads.g.doubleclick.net/gampad/jump?co=1&iu=/6978/reg_offbeat/front&sz=300x50%7C300x100%7C300x250%7C300x251%7C300x252%7C300x600%7C300x601&tile=4&c=44Zh-yHvMR7sC2fuBLePEBeQAAAA8&t=ct%3Dns%26unitnum%3D4%26raptor%3Dfalcon%26pos%3Dmid%26test%3D0

[4] https://pubads.g.doubleclick.net/gampad/jump?co=1&iu=/6978/reg_offbeat/front&sz=300x50%7C300x100%7C300x250%7C300x251%7C300x252%7C300x600%7C300x601&tile=3&c=33Zh-yHvMR7sC2fuBLePEBeQAAAA8&t=ct%3Dns%26unitnum%3D3%26raptor%3Deagle%26pos%3Dmid%26test%3D0

[5] https://aviationweek.com/air-transport/new-boeing-787-fix-details-reveal-extent-gap-check-challenge

[6] https://www.theregister.com/2023/06/07/boeing_787_production_defect/

[7] https://www.theregister.com/2024/04/08/engine_cowling_boeing/

[8] https://www.theregister.com/2024/03/27/boeing_aurora_virgin_galactic/

[9] https://www.theregister.com/2024/03/25/boeing_leadership_exits/

[10] https://www.theregister.com/2024/03/11/us_department_of_justice_boeing/

[11] https://www.theregister.com/2014/01/16/us_safety_authorities_on_boeings_case_787_batteries_fail/

[12] https://www.theregister.com/2020/04/02/boeing_787_power_cycle_51_days_stale_data/

[13] https://www.theregister.com/2024/01/08/boeing_737_max_9_airplanes/

[14] https://www.theregister.com/2024/03/25/boeing_leadership_exits/

[15] https://pubads.g.doubleclick.net/gampad/jump?co=1&iu=/6978/reg_offbeat/front&sz=300x50%7C300x100%7C300x250%7C300x251%7C300x252%7C300x600%7C300x601&tile=4&c=44Zh-yHvMR7sC2fuBLePEBeQAAAA8&t=ct%3Dns%26unitnum%3D4%26raptor%3Dfalcon%26pos%3Dmid%26test%3D0

[16] https://www.theregister.com/2024/03/07/ntsb_boeing_door_plug/

[17] https://whitepapers.theregister.com/



Glad I'm retired

STOP_FORTH

This is not a good story for Boeing or the poor people obliged to spend lots of time in flying metal tubes.

I only make about four shortish flights a year now.

Usually on Airbus 'planes.

Re: Glad I'm retired

Androgynous Cupboard

Composite tubes in this case, which I think is the problem. Gaps in the layup - maybe they used regular plywood not marine plywood?

Re: Glad I'm retired

b0llchit

and they used quite expensive paint (*) to cover the gap properly. You can't see it, therefore it isn't there.

(*) water soluble, of course, to protect the environment

Re: Glad I'm retired

Steve Button

*only* four flights a year!? Guess you are from North America.

I only make about ONE flight every four years, and will probably take the train from now on wherever possible. It takes a bit longer, but so much more fun.

I really fucking hate flying because :-

o It hurts my ears.

o You have to queue for hours to get through security theatre / baggage, etc.

o It's just stressful.

o I hate being squashed into a tiny seat.

o The noise.

o The food.

So, basically this is just one more reason to add to my list of avoiding flying. If I could afford business class then it would remove many of these things from my list, but I can't.

If I'm going from England to Scotland I'll just drive or take the train. To Europe I'll take the train.

Probably by the time I reach retirement, It'll be like the Cote D'azure in Scunthorpe, so not much reason to fly for warm weather.

(For the benefit of some Americans - I'm joking - Scunthorpe has an interesting middle bit in the word which used to flummox profanity filters, but that's about all)

Re: Glad I'm retired

spacecadet66

Why would anybody want to filter out the name of the Norse god of weather?

Easy solution

Anonymous Coward

Fly the Boeing board to a meeting on a 787

Que sera sera.

Re: Easy solution

STOP_FORTH

Put the boardroom in a 787.

Re: Easy solution

MJI

No 737 Max 8

So No Change

Will Godfrey

I seem to remember Boeing claiming something else was perfectly safe, yet two planes full of people died.

Re: So No Change

STOP_FORTH

Maybe they were talking about the safety of their bottom line and bonuses.

Did you think they meant the passengers/victims of corporate irresponsibility?

wolfetone

" The issues raised have been subject to rigorous engineering examination under FAA oversight. "

The thing is, most of Boeing's problems have stemmed from the FAA looking over their work.

All the best words have at least two meanings

STOP_FORTH

Oversight is a useful word.

aerogems

The problem is conservatives have allowed Boeing employees to be the FAA inspectors.

spacecadet66

Greetings, visitor from a different timeline.

Anything to see here...?

Little Mouse

Boeing has been at the pointy end of a lot of criticism recently, and deservedly so. But that's usually a result of their poor working practices, cutting corners, shaving costs, etc. i.e. Just plain doing their job wrong .

In this case though, all the whistleblower is saying is that, in his opinion, the actual design of the aircraft is wrong. The same design that actually does go through a LOT of rigorous testing and sign-off. (regardless of how shoddily it's all assembled at the end). If there really were fundamental flaws in the blueprints, someone else absolutely would have noticed.

This smells more of someone wanting their 15 minutes of fame.

Re: Anything to see here...?

Spazturtle

Deficiencies in the construction of early 787s (specifically in how the sections are attached) has been raised multiple times over the years by different people. The different sections would end up with quite different diameters making joining them together difficult, they managed to get the variation down on the later made ones.

All of the early Dreamliner's will be going through a D check soon as they get to 12 years of age, so hopefully if there are any issues they will be caught at that stage.

Re: Anything to see here...?

JoeCool

No, Actually.

The Allegations are that the manufactured items are not close enough to the spec designs, reuslting in larger gaps than the design allows.

The solution would be to manufacture to better tolerances, but Boeing, to use your phrasing, is cutting corners and instigating poor working practices in order to shave costs.

So yeah, they are still doing the "thing" that has caused them so much recent trouble : profits over sound products.

And it's not opinion. It is a standard assembly practice to MEASURE the gaps, and if within tolerances, apply *designed* corrections.

But for that you need to keep records, right ?

I find it totally bizarre that you reach for the "15 minutes of fame" cover excuse. If you are going to mindlessly defend Boing, then I'd appreciate a little more effort.

This smells of pointlessly argumentative.

rlightbody

I recently changed my plans, at my own cost, to avoid flying on a Ryanair Max 8. I was concerned that when confronted by the plane at the airport gate, I wouldn't be able to make myself get on board.

However, if you look at the statistics, even the "crashy" Max 8 is far, far, far safer than your drive to the airport in your car/taxi/bus.

Homo Sapien Floridanus

Yes, especially if you let my father in law drive you to the airport.

Zibob

You know at this point in history, I will gladly side with the person who thinks its unsafe.

It strikes me as very suspicious and handwaving to say there is no issue on the basis of "trust me bro"

Even if it is a worry on that one plane, you bring it in, assess, then tell them yes or no if it was a good idea a founded in reality.

If issues as described arrived on the one plane you immediately ground all others and remediate the problem followed by extensive testing and recertification of those craft before returning it to service.

Then you can confidently say yes we looked, here are the results, there indeed was or wasn't a problem and you can rest assured.

The fobbing off of potential lives at risk is hard to take from the company that deliberately crash 2 planes killing 346 people, after ignoring the same warnings before.

"We are fully confident in the 787 Dreamliner"

Pascal Monett

Well duh. It's not like you're going to actually say anything like : "well we are considering grounding our entire fleet for an extensive security review".

That would basically shut down the company. Permanently.

So no, head chief engineer and all spokesdrones are going to be "confident" in their planes - even though they avoid flying on them.

Standards are crucial. And the best thing about standards is: there are
so ____many to choose from!