The U.S. Navy has discovered faulty welds on more than two dozen ships, including an aircraft carrier and two submarines, due to improper procedures at the Huntington Ingalls Industries (HII) shipyard in Newport News, Virginia. Navy Secretary Carlos Del Toro informed Congress last week that the USS George Washington, USS Hyman G. Rickover, and USS New Jersey are among the affected vessels.
The weld issues were identified on non-critical components, and the Navy has assessed that they do not compromise the safety or operational capabilities of the ships. “NAVSEA has determined the ships are safe to operate,” Del Toro wrote in a letter dated October 3, referring to the Naval Sea Systems Command.
The faulty welds stemmed from shipyard welders who failed to follow proper welding procedures, according to shipyard officials. HII acknowledged that some welders knowingly bypassed protocols but emphasized that “malicious intent” was not involved. The shipyard is working with the Navy to resolve the issue, while the Department of Justice has launched an investigation.
The weld problems were first brought to Del Toro’s attention on September 24, and the Navy is now reviewing 23 other ships under construction or maintenance to ensure there are no further defects. The vessels impacted include a mix of new constructions and ships undergoing major overhauls, like the USS George Washington, which recently completed its midlife refueling and complex overhaul (RCOH) in May 2023.
The Navy, alongside HII, is conducting a full review of the shipyard’s operations. “The safety of our sailors and ships is of paramount importance,” Del Toro stated, adding that Navy experts have been dispatched to the Newport News yard to oversee the investigation and prevent future welding errors.
Congress has urged the Navy to provide more information on how such a critical lapse occurred, stressing the importance of ensuring the U.S. fleet’s integrity and national security.
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