FAA memo reveals more Boeing 787 manufacturing defects, including contamination of carbon fiber composites

Los problemas del 787......... un pequeño resumen... gran artículo....... léanlo.......

https://www.arcamax.com/business/businessnews/s-2598281?fs

The FAA memo, which lists safety conditions affecting airplanes currently in service worldwide, states that these tiny gap defects are thought to be present in more than 1,000 Dreamliners. These are not considered an immediate safety concern but could cause premature aging of the airframe.

It’s unclear if coming up with fixes that will satisfy the FAA will further delay resumption of 787 deliveries into next year.

Such a delay could increase the total cost to get the 787 program back on track above Boeing’s previous $1 billion estimate and would risk an accounting write-off in the fourth quarter.

The FAA memo notes that Leonardo relies on mechanics to inspect their own work when they assemble the structures, with limited or no oversight by quality inspectors. And it states that the Italian supplier had two formal notices of missed inspections for surface waviness in 2018 and two more in 2020.

1,000+ airplanes

The FAA memo reviewed by the Seattle Times also provides updates on another 787 defect problem: the use of an incorrect alloy of titanium in certain fittings installed in fuselage sections made by Leonardo in Italy.

Parts with this incorrect metal included fuselage frame and floor beam fittings and were installed on more than 450 Dreamliners. Boeing identified the most critical installation as the floor-beam-to-fuselage-frame fittings at the side of body area where the wings attach.

The FAA said this could produce an unsafe condition if two or more adjacent fittings had used the wrong titanium alloy. Two aircraft with this immediate safety concern were identified: both All Nippon Airways jets that were parked in Victorville, California.

ANA agreed to keep the aircraft grounded while Boeing fixed them. That work was completed as of last month.

Finally, the memo notes that the FAA is still evaluating Boeing’s proposal to use statistical sampling to determine which airplanes are affected by the lack of shims and tiny gaps at the joins.

The memo states that more than 1,000 airplanes currently flying are affected and that the FAA is concerned about the lack of detailed assembly data on every airplane. Boeing submitted its proposal for inspections and indicated that the process would not require FAA approval.

“We firmly disagree,” the memo states. This standoff over what level of inspections is appropriate remains the major stumbling block to Boeing resuming 787 deliveries.

Cheeeeeeeeeeeeeeeeeeeeeeeeeers!!!