Boeing Dreamliner 787 could break apart mid-flight, says whistleblower

Boeing Dreamliner 787 could break apart mid-flight, says whistleblower

A whistleblower has revealed that there are structural flaws in Boeing’s 787 Dreamliner, which could eventually cause it to break apart mid-flight. The whistleblower spoke out after the Federal Aviation Administration, the air safety body of the US, announced a probe into his claims about the Dreamliners. Â

Boeing strongly refuted the claims, stating it was “fully confident” in the 787’s safety, citing comprehensive testing.

The US Federal Aviation Administration (FAA) is investigating the whistleblower’s claims. According to The New York Times, FAA is investigating claims by a Boeing engineer that “sections of the fuselage of the 787 Dreamliner are improperly fastened together and could break apart mid-flight after thousands of trips”.

Boeing, a Virginia-based aircraft industry company, is under renewed scrutiny after the whistleblower, Sam Salehpour, raised concerns about the structural integrity of the company’s 787 Dreamliner aircraft.

Engineer Sam Salehpour has worked at Boeing for more than 10 years.

He told The New York Times that changes to the manufacturing process introduced shortcuts that could lead to parts of the fuselage (the main part of the plane) failing after thousands of flights.Â

Salehpour said the plane’s fuselage comes in several large pieces from different manufacturers that are fastened together on an assembly line.

Before this, in 2019, other Boeing workers in the Charleston, South Carolina, factory (where the 787 is built) said they were rushing to finish planes and their safety worries were ignored.

One of the whistleblowers, a quality checker named John Barnett, was found dead in March while suing Boeing over safety concerns he raised at the 787 factory. Even though he’s dead, a legal expert says his case can still continue, reported the New York Times.Â

Salehpour, an engineer, has sent his concerns to both the Federal Aviation Administration (FAA) and the Senate Homeland Security and Governmental Affairs Committee.

Boeing, however, emphasised the benefits of the composite materials used in the 787’s construction, including reduced fatigue and corrosion compared to traditional metals.

“Another benefit of the 787’s composite structure is the material does not fatigue or corrode like traditional metals, which reduces maintenance over many decades in service,” the Boeing company was quoted as saying by the New York Times.

A single plane could be in service for 40 to 50 years, the company said.

Salehpour’s allegations come at a difficult time for the Virginia-based company, following a series of damaging stories about the safety of its jets, and the recent announcement of CEO Dave Calhoun’s departure.

Calhoun said that a door plug blowout on a Boeing 737 Max plane flown by Alaska Airlines in January was a “watershed moment for Boeing” — and now the company he leads until the end of the year is again forced to defend its safety record and protocols.

COMMITTEE INVESTIGATING BOEING SAFETY

Senator Richard Blumenthal of Connecticut chairs the Senate committee investigating Boeing’s safety culture and has invited Salehpour to testify next week. Blumenthal, along with committee ranking member Ron Johnson of Wisconsin, previously received whistleblower claims about “potentially catastrophic safety risks” with the 787.

Salehpour’s lawyers alleged that Boeing ignored his concerns and even sidelined him after raising them. They claimed a culture at Boeing that prioritises production over safety.

“Rather than heeding his warnings, Boeing prioritised getting the planes to market as quickly as possible, despite the known, well-substantiated issues he raised,” said attorneys Debra Katz and Lisa Banks.Â

Boeing denied any retaliation against whistleblowers and said it encouraged employees to report safety concerns.

The FAA echoes this sentiment, emphasising the importance of voluntary reporting in aviation safety.

“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,” Boeing said in a statement.

The investigation into Salehpour’s claims is ongoing.

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