Boeing retracts whistleblower's allegations

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Boeing is defending the integrity of the fuselages on its two biggest planes, which have come under fire from a whistleblower who warned that panels on the outside of one of the planes could tear off in flight.

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On Monday, two Boeing engineers went into great detail to describe how the panels are put together, specifically on the 787 Dreamliner. They said the 787's carbon composite skin is nearly impervious to the metal fatigue that weakens conventional aluminum fuselages.

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Their comments at a lengthy media briefing were both a response to news of the whistleblower's allegations last week and a preemptive strike before they testify before a congressional panel on Wednesday.

The whistleblower, Boeing engineer Sam Salehpour, said excessive force was used to join the panels on the 787 assembly line, increasing the risk of fatigue or microscopic fractures in the material that could cause it to come apart.

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The Boeing staff described how they put the fuselage pieces together, how the shims are added to fill the holes, how the holes are drilled and cleaned, and how the fasteners are attached to apply “pulling force,” which results in no more than 99% of the time edges. 005 inches (0.127 millimeters) apart is the width of a human hair, they say. In 2019, a gap problem was discovered between the two panels, which led to design and assembly changes, they said.

Boeing has conducted 165,000 repeated flights on the composite structure with no signs of fatigue, said Steve Chisholm, Boeing's vice president of structural engineering. On average, the 787 makes 600 flights a year, he said.

The company said the planes already in service were safe. Chisholm said the 671 Dreamliners underwent intensive testing for 6-year-old aircraft, and eight were tested for 12 years with no signs of fatigue in the composite skins.

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Cracks were found in metal parts, including the top where the wings join the fuselage, and Boeing has issued instructions to inspect those parts, officials said.

The 787 Dreamliner is a two-aisle airliner that has been used on international flights since its debut in 2011. The composite material makes the aircraft lighter, which contributes to increased fuel efficiency.

Several battery fires stopped the planes for a short time. The plane's deliveries have been halted at times due to questions about wider gaps between fuselage panels than Boeing standards allow, the use of unauthorized titanium parts from a supplier in Italy, and flaws in the pressure bulkhead.

The Federal Aviation Administration must inspect and approve every 787 that rolls off the assembly line before it is shipped to an airline customer.

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According to the whistleblower, Salehpour, after he raised safety concerns about the 787, Boeing moved him to work on the older wide-body 777. He told the Seattle Times that he saw workers jumping on the fuselage panels to align them. .

The New York Times reported that the FAA is investigating Salehpour's claims. The FAA said it would investigate all safety reports, though it would not comment specifically on Salehpur.

Boeing says it is “absolutely confident” in both planes.

Salehpour is the latest in a string of Boeing whistleblowers who have often claimed retaliation for raising safety concerns. The company said it encourages employees to speak up about problems.

Lisa Fahl, vice president of engineering for Boeing's aircraft programs, said the staff reports were “exploding” — the number of reports filed in January and February for all of 2023 _ “we want.”

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