FAA Orders Boeing 787 Titanium Alloy Safety Inspections Now
Published Date: 12/9/2025
Rule
Summary
If you own or operate Boeing 787-9 or 787-10 airplanes, listen up! The FAA found some parts made with the wrong titanium alloy, which could be unsafe. Starting January 13, 2026, these planes need special inspections and fixes to keep flying safely—so plan ahead, as this might cost some time and money.
Analyzed Economic Effects
3 provisions identified: 1 benefits, 2 costs, 0 mixed.
Mandatory inspections and fixes for 787-9/787-10
If you own or operate Boeing 787-9 or 787-10 airplanes identified in Boeing Alert Requirements Bulletin B787-81205-SB530091-00 RB (Issue 001, Feb 7, 2025), you must inspect the stub beam horizontal pressure deck (HPD) attach fittings and upper splice fitting to determine the titanium alloy and do required on-condition actions. This AD is effective January 13, 2026, and on-condition actions include crack inspections, repairs, and replacing affected fittings with Ti-6Al-4V fittings.
FAA cost estimates and possible warranty coverage
The FAA estimates this AD affects 13 U.S.-registered airplanes. The inspection is estimated at up to 12 work-hours (12 x $85/hr = $1,020) per airplane (total up to $13,260 for U.S. operators); on-condition open-hole HFEC inspection is up to 3 work-hours ($255), and replacement cost is estimated up to $21,990 per airplane (labor 52 hours = $4,420 plus parts up to $17,570). The manufacturer stated some or all costs may be covered under warranty, which could reduce the operator cost impact.
Two accepted inspection methods (HFEC or XRF)
The FAA allows either a High Frequency Eddy-Current (HFEC) inspection or a handheld X-Ray Fluorescence (XRF) spectrometer inspection to determine the titanium alloy material for the affected stub beam HPD attach fittings. Operators may use HFEC as an alternative to XRF per the Boeing requirements bulletin and FAA response in the AD.
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