Boeing Defends Safety of 787 Dreamliner After Whistle-Blower’s Claims

Boeing sought on Monday to reassure the public of the safety of its 787 Dreamliner plane days before a whistle-blower is scheduled to testify before Congress about his concerns regarding the jet’s structural integrity.

In a briefing for reporters at the factory in North Charleston, S.C., where the plane is assembled, two top Boeing engineers said the company had conducted exhaustive tests, inspections and analyses of the plane, both during its development and in recent years, and found no evidence that its body would fail prematurely.

The presentation came just under a week after The New York Times reported the allegations by the whistle-blower, Sam Salehpour, who works as a quality engineer at Boeing and is set to testify before a Senate panel on Wednesday. Mr. Salehpour said that sections of the fuselage of the Dreamliner, a wide-body plane that makes extensive use of composite materials, were not properly fastened together and that the plane could suffer structural failure over time as a result. The Federal Aviation Administration is investigating his allegations.

Mr. Salehpour’s claims instantly created another public-relations problem for Boeing, which has been facing intense scrutiny over its manufacturing practices after a panel came off a 737 Max during an Alaska Airlines flight in January.

Mr. Salehpour said that the gaps where sections of the Dreamliner’s fuselage were fastened together did not always meet Boeing’s specifications, something that he said could weaken the aircraft over time. The Boeing engineers disagreed with his assessment, without naming him. They said the plane had gone through extensive testing that showed that, in a vast majority of cases, the gaps met the specifications. Even if the gaps exceeded the specifications by a reasonable amount, they would not affect the plane’s durability, the engineers added.

“Not only did we interrogate those airframes — we were taking out fasteners, we were looking for damage, we’re also doing the approval inspections to understand the build condition, and we didn’t find any fatigue issues in the composite structure,” said Steve Chisholm, a vice president and the functional chief engineer for mechanical and structural engineering at Boeing.