FAA Flags Critical RAT Issue on a Few Boeing 787s
Photo Credit: Aldo Bidini (GFDL 1.2
The U.S. Federal Aviation Administration (FAA) has issued a proposed airworthiness directive that would require airlines to inspect ram air turbine (RAT) fittings on a limited number of Boeing 787 aircraft, following concerns that some components may have been manufactured with substandard titanium.
The directive, published on July 28, follows multiple supplier notices that flagged the possibility of specific RAT forward fittings being produced with a titanium alloy that falls short of the required aerospace-grade standards. According to the FAA, the issue affects just nine Boeing 787 Dreamliners, including both 787-9 and 787-10 variants.
“The titanium material that was possibly used is a Grade 1 or 2 commercially pure unalloyed titanium, which has significantly reduced strength, fatigue and damage tolerance properties” compared to the Grade 5 Ti-6Al-4V alloy that was intended, the FAA document states.
These findings raise serious safety concerns. If the fittings were to fail during flight, the RAT—a critical backup power source designed to deploy in emergencies—could malfunction or even detach from the aircraft entirely.
The Bigger Picture
The proposed action comes amid broader scrutiny over the titanium supply chain used in aircraft manufacturing. In 2023, reports emerged indicating that unapproved titanium sourced from China—and supplied by Spirit AeroSystems—had infiltrated components used by both Boeing and Airbus. The discovery highlighted the vulnerability of global supply chains following Western sanctions on Russia, a key supplier of high-grade titanium to the aerospace industry.
Although the FAA’s notice does not specify how the incorrect titanium entered the supply chain or identify the RAT supplier involved, Collins Aerospace, a major RAT producer, had taken a $175 million charge in 2024 related to transitioning to new titanium suppliers. Collins and Boeing both declined to comment on the recent FAA proposal.
Boeing’s Response
In response to the initial concerns, Boeing issued an Alert Requirements Bulletin in February 2025, instructing operators to perform non-destructive inspections on the affected RAT fittings. The bulletin recommended using high-frequency eddy current or X-ray fluorescence spectrometry to determine the alloy’s composition and ensure compliance with regulations.
What’s Next?
The FAA’s notice of proposed rulemaking (NPRM) will now undergo a public comment period before any final rule is issued. If enacted, the rule would mandate inspections on the nine affected 787 aircraft to verify the integrity of their RAT fittings and ensure they were not made with the weaker, unapproved titanium alloy.
While the scope of the issue is currently limited, it highlights the ongoing challenges aircraft manufacturers and suppliers face in ensuring material traceability and maintaining safety standards amid global supply disruptions.
