Boeing has responded to whistleblower allegations by pushing back and providing insights into the meticulous process of assembling airframes.

On Monday, two Boeing engineering executives delved into detailed explanations regarding the assembly of panels, particularly focusing on the 787 Dreamliner. They emphasized that the 787's carbon-composite skin offers significant advantages, suggesting it is nearly impervious to the metal fatigue issues that commonly afflict conventional aluminum fuselages.

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Boeing is staunchly defending the structural integrity of the fuselages on two of its flagship aircraft models, amid criticism raised by a whistleblower. The whistleblower has raised concerns that panels on the exterior of one of the planes could potentially degrade and break apart during flight.

During a comprehensive media briefing on Monday, two Boeing engineering executives provided intricate details regarding the assembly process of panels, particularly focusing on the 787 Dreamliner. They highlighted the robustness of the 787's carbon-composite skin, suggesting it is highly resistant to the metal fatigue issues commonly observed in conventional aluminum fuselages.

These statements were both a response to recent news reports about the whistleblower's allegations and a preemptive measure ahead of his testimony to a congressional panel scheduled for Wednesday.

The whistleblower, Boeing engineer Sam Salehpour, had expressed concerns about excessive force being applied to fit panels together on the 787 assembly line. He warned that this practice raised the risk of fatigue, leading to microscopic cracking in the material that could potentially cause it to break apart.

The Boeing officials provided insights into the meticulous process of bringing sections of a fuselage together. They explained how shims are added to fill gaps, holes are drilled and cleaned, and fasteners are attached to apply "pull-up force." They emphasized that this process results in margins typically no greater than .005 inches (0.127 millimeters) apart — a width equivalent to that of a human hair.

Addressing a gap problem discovered in 2019 between two panels, they highlighted subsequent design and assembly changes that were implemented.

Steve Chisholm, Boeing's vice president of structural engineering, revealed that Boeing conducted rigorous testing replicating the equivalent of 165,000 flights, with no findings of fatigue in the composite structure. Chisholm noted that the average 787 aircraft completes around 600 flights annually.

Boeing assured that planes currently in operation are demonstrating safety. Steve Chisholm mentioned that 671 Dreamliners have undergone rigorous inspections for 6-year-old planes, with eight undergoing 12-year inspections, all revealing no evidence of fatigue in the composite skins.

The officials also acknowledged the discovery of cracks on metallic parts, including a component above where the wings join the fuselage. Boeing has issued inspection guidelines for these parts to ensure continued safety, they said.

The 787 Dreamliner, a twin-aisle aircraft introduced in 2011, has frequently been employed for international flights. Its composite construction renders the plane lighter, enhancing fuel efficiency.

Despite its successes, the Dreamliner faced challenges, including a series of battery fires that resulted in temporary grounding. Additionally, deliveries were halted periodically due to concerns such as wider-than-allowed gaps between fuselage panels, the utilization of unapproved titanium parts from an Italian supplier, and flaws in a pressure bulkhead.

Each 787 aircraft produced must undergo inspection and approval by the Federal Aviation Administration (FAA) before it can be delivered to an airline customer.

The whistleblower, Salehpour, alleges that after he raised safety concerns about the 787, Boeing reassigned him to work on an older widebody aircraft, the 777. Salehpour claimed to have witnessed workers jumping on fuselage panels to align them, a practice disputed by Boeing.

The New York Times reported that the FAA is conducting an investigation into Salehpour's claims. While the FAA did not comment directly on Salehpour's case, it stated that it investigates all safety reports.

Boeing has expressed full confidence in both planes mentioned in the whistleblower's claims.

Salehpour joins a series of Boeing whistleblowers who have stepped forward, frequently alleging retaliation for voicing safety concerns. Boeing maintains that it encourages employees to report issues openly.

Lisa Fahl, Boeing's vice president of engineering for airplane programs, noted that employee reports have surged, with as many reports filed in January and February as were submitted throughout the entirety of 2023. She emphasized that this increase reflects a positive trend, indicating a culture where employees are actively reporting concerns, which aligns with Boeing's goals.

Source: cnbctv18