Navy ramps up large-scale investigation into welding work at Newport News Shipbuilding

Peter Dujardin, Daily Press on Oct 9, 2024

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NEWPORT NEWS, Va. — The Navy is embarking on a large-scale investigation to determine the scope of the problems with welding performed at Newport News Shipbuilding, according to a letter to federal lawmakers last week.

Navy Secretary Carlos Del Toro told the House and Senate Armed Services Committees that after welding deficiencies were discovered at the Newport News shipyard, “we have given top priority to the task of defining and examining the scope of improper welds conducted on operational in-service ships.”

“While I am deeply disappointed about this failure to uphold quality on the part of the shipyard as required by contract, my top priority is ensuring the safety of our Sailors … and communicating transparently with the Congress and the American people,” said Del Toro’s letter, sent Thursday.

He said three operating warships have so far been identified as having faulty welding.

Those are the USS George Washington aircraft carrier, which completed its midlife overhaul at the Newport News shipyard in 2023 and is en route to its new homeport of Japan. Two recently commissioned Virginia-class submarines — the USS Hyman G. Rickover and the USS New Jersey — also were found to have substandard welds.

But Del Toro said the Navy’s division overseeing ship construction has determined the three vessels are still safe to operate.

“The Naval Sea Systems Command … has assessed that the welds were not on components or systems that affect ship safety or operations,” he wrote.

It wasn’t immediately clear whether the Navy is looking at the welding on any other warships in service. But the letter said the Navy and shipyard are investigating the welding work on 23 other vessels in various stages of construction or maintenance at the Newport News yard.

Those ships — to include another aircraft carrier undergoing its midlife overhaul and various submarines under construction — are undergoing a “joint-by-joint analysis” to determine “the degree of deficiency” of their welds, Del Toro’s letter said.

Meanwhile, Del Toro said the Navy has asked the U.S. Department of Justice “to investigate any potential claims for breach of contract or submission of false claims” on the part of Newport News Shipbuilding. “Rest assured, the Navy is evaluating all legal options and reserving our rights accordingly,” he wrote.

As the problems with the welding work began to come to light in late September, Newport News Shipbuilding President Jennifer Boykin posted on LinkedIn that she has “very serious and disappointing news to share.”

“We recently discovered that the quality of certain welds on submarines and aircraft carriers under construction here at NNS do not meet our high-quality standards,” she wrote in the post. “Most concerning is that some of the welds in question were made by welders who knowingly violated weld procedures.”

The problem was reported by shipyard workers “who did the right thing and came forward,” Boykin added. “I thank them for their honesty and bravery.”

She said the shipyard notified the Navy, the Justice Department and regulators.

“We do not tolerate any conduct that compromises our company’s values and our mission of delivering ships that safeguard our nation and its sailors,” Boykin wrote.

Newport News Shipbuilding spokesman Todd Corillo previously told the Daily Press that while some welders “knowingly circumvented” certain welding procedures, the company’s initial investigation indicates that they did not act with “malicious intent.”

Welding is used widely in ship construction. It was not immediately clear what specific steps the yard workers violated in that process.

After the problems came to light in late September, the House Armed Services Committee said it would launch an investigation.

“We need to immediately understand any risks associated with the faulty work,” the committee said. “Absolute transparency with Congress is essential.”

On Friday, Del Toro sent 23 identical letters to the House and Senate Armed Services Committees, including lawmakers with leadership roles on those panels.

Del Toro said in the letter that he learned Sept. 24 that Newport News Shipbuilding found issues with welding work on both submarines and aircraft carriers. He added that he discussed “the seriousness of the matter” with Kirkland Donald, the chairman of Huntington Ingalls Industries, the shipyard’s parent company.

“I have directed more detailed inspections, and I have asked to see the results by mid-October,” Del Toro wrote in the letter, saying he would notify lawmakers of “any required rework and any projected delays to delivery timelines” and other “updates on this matter as they develop.”

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