Newport News Shipbuilding contractor welds a bolting ring on the rim of a catapult cover on the flight deck of the aircraft carrier USS John C. Stennis in Newport News, Va., in 2022. (Jong S. Park/U.S. Navy)

WASHINGTON — The Navy is investigating how 26 warships, including three that are operational, received faulty welds while undergoing construction or maintenance at Newport News Shipbuilding, according to a letter from the service secretary to senators and House lawmakers.

“We have given top priority to the task of defining and examining the scope of improper welds conducted on operational in-service ships and I have directed my Navy technical experts co-locate with the shipyard immediately to support a thorough review,” Navy Secretary Carlos Del Toro wrote in a letter dated Oct. 3 to nearly two dozen lawmakers associated with four Senate and House defense committees.

Del Toro said he learned Sept. 24 of the substandard welds that did not follow proper procedure. The welds were done at Newport News Shipbuilding, a division of Huntington Ingalls Industries, which is the sole maker of carriers for the Navy and one of only two firms that make submarines.

The welding deficiencies were made on noncritical components of three in-service ships: aircraft carrier USS George Washington, and submarines USS Hyman G. Rickover and USS New Jersey. The Washington completed its midlife overhaul at the Newport News shipyard in 2023 and is en route to its new homeport of Japan. The two submarines were recently commissioned and delivered to the Navy.

All three ships have been certified as safe to operate by Naval Sea Systems Command, Del Toro’s letter reads.

The technical experts from the Navy and the shipbuilder are working to evaluate and identify solutions to bad welds on 23 other warships, including ones being constructed now and those undergoing maintenance. Results from the inspections are expected by mid-October.

As an additional measure, the shipbuilder is conducting training across the entire welding community and related non-welding trades.

It is unknown whether the faulty welds will delay the delivery of any of the 23 warships. Del Toro said the Navy will update Congress and stakeholders of any necessary rework.

“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 platforms and communicating transparently with the Congress and the American people. The safety of our sailors and ships is of paramount importance,” Del Toro wrote in the letter.

Navy Secretary Carlos Del Toro gives remarks during the commissioning ceremony of USS New Jersey on Sept. 14, 2024, at Naval Weapons Station Earle, N.J. The New Jersey is one of the ships that received faulty welds at Newport News Shipbuilding in Virginia. (William Bennett/U.S. Navy)

On Sept. 27, Newport News Shipbuilding President Jennifer Boykin announced the faulty welds on social media — a discovery that was made by other shipbuilders. The company subsequently launched an investigation, made up of internal and independent experts, to validate the reports.

“Most concerning is that some of the welds in question were made by welders who knowingly violated weld procedures,” Boykin said.

The shipbuilder notified the Navy, as well as the Department of Justice.

“I cannot over stress that individual actions and behaviors either strengthen — or weaken — our ethical culture in an instant. Every choice you make as a shipbuilder has long lasting impact. Ask for help when you are unsure. And speak up if you see questionable behavior or actions by others,” Boykin said.

According to Del Toro, the Justice Department is investigating any potential breaches of contract or submission of false claims.

“Rest assured, the Navy is evaluating all legal options and reserving our rights accordingly,” the letter reads.