FAA Plans 787 Inspections For Non-Compliant Titanium

The FAA has proposed mandating Boeing-recommended inspections of about 100 787-9s and -10s for fuselage fittings that may be constructed from the wrong grade of titanium.

A draft rule published May 14 would require inspections of affected aircraft within 48 months. An alert requirements bulletin issued in February lists 97 787-9s and -10s as possibly having the noncompliant parts. All affected aircraft were manufactured from early 2016 through mid-2017.

According to the draft rule, certain pressure deck area fittings may have been installed that are made from an “incorrect” grade 1 or 2 titanium. The parts should be made from Grade 5 Ti-6Al-4V, which is stronger and has higher damage tolerance.

Boeing’s proposed steps require a high frequency eddy current inspection or handheld X-ray fluorescence spectrometer inspection of the affected parts within 48 months. Any parts found that are made of the incorrect material must be replaced immediately. Certain fastener holes also must be inspected. The FAA’s draft rule is based on Boeing’s instructions.

Affected parts include pressure deck floor beam brackets and fittings at certain body stations. The pressure deck is located where the wings attach to the fuselage and separates the pressurized cabin and unpressurized wheel well.

Boeing’s bulletin and the proposed mandate stem from “reports of multiple supplier notices of escapement” reporting that the parts may have been manufactured with incorrect material, the draft rule said.

Neither the FAA draft rule nor the Boeing bulletins identify suppliers involved. Boeing declined to comment.

Boeing in 2021 reported a series of parts supplied by Leonardo, including floor beam fittings and brackets, were made out of non-conforming titanium. The FAA ordered inspections of more than 450 787-9s and -10s as a result. Leonardo said a sub-tier supplier was responsible for the affected parts.