787 woes continue as new quality issues with structural composite parts
have been found earlier this year. As the Wall Street Journal and
The Seattle Times revealed on November 19,
the FAA is requesting more evidence that the problems have been solved
The agency will grant permission to restart the production and deliveries.
Boeing found that the composite wings produced by
Mitsubishi Heavy Industries (MHI) Aero Structures business had been
contaminated with PTFE or polytetrafluorethylene.
This could affect the bonding process in an autoclave of composite
sub-assemblies and parts inside the wing and bonded to the surface.
The memo reportedly explains that while The Bonding Quality
Was Affected By The Contamination,
Boeing said it was still within design limits. (that's the Kool-Aid talking)
But further investigation by the airframer has learned in October that
not only MHI has suffered from PTFE contamination, but also the suppliers
of fuselage sections (which are Leonardo, Kawasaki Heavy Industries,
and Spirit AeroSystems), and those of the tail section
(which includes parts from Leonardo, Boeing).
The Bonding Has Been Found To Be Below The Design Limits.
The FAA memo also identifies the problem of gaps around the doors in the
Leonardo-produced aft fuselage sections that are too big.
Again, The FAA Is Not Convinced Of The Boeing Standards Of Execution
Of The Work and wants Boeing to come up with a solution that guarantees
that the structure around the doors meets the design requirements.