FAA Orders Inspections of Boeing 787 Dreamliners Over Wing Fatigue Risks
The US Federal Aviation Administration (FAA) has issued an airworthiness directive requiring inspections of dozens of Boeing 787 Dreamliners due to concerns over wing structure fatigue risks.
The issue stems from a manufacturing problem discovered in 2019, where an outdated method was used to measure shims during production. This resulted in excessive gaps between aircraft components, which could lead to fatigue cracks and weaken the primary wing structure.
According to the FAA, improper shim gaps could allow fatigue cracks to develop and grow, potentially leading to a loss of continued safe flight and landing. The directive applies to 17 US-registered aircraft and 77 worldwide, covering certain 787-8, 787-9, and 787-10 models.
The inspections will involve ultrasonic testing to detect any cracking inside or beneath the structure, which may not be visible on its surface. The FAA estimates the inspections could take up to 286 work hours and cost as much as $24,310 per aircraft for each inspection cycle.