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The Military

Metallurgist Admits Faking Steel-Test Results For US Navy Subs (miamiherald.com) 196

schwit1 shares a report from the Miami Herald: A metallurgist in Washington state pleaded guilty to fraud Monday after she spent decades faking the results of strength tests on steel that was being used to make U.S. Navy submarines. Elaine Marie Thomas, 67, of Auburn, Washington, was the director of metallurgy at a foundry in Tacoma that supplied steel castings used by Navy contractors Electric Boat and Newport News Shipbuilding to make submarine hulls. From 1985 through 2017, Thomas falsified the results of strength and toughness tests for at least 240 productions of steel -- about half the steel the foundry produced for the Navy, according to her plea agreement, filed Monday in U.S. District Court in Tacoma. The tests were intended to show that the steel would not fail in a collision or in certain "wartime scenarios," the Justice Department said.

There was no allegation that any submarine hulls failed, but authorities said the Navy had incurred increased costs and maintenance to ensure they remain seaworthy. The government did not disclose which subs were affected. Thomas faces up to 10 years in prison and a $1 million fine when she is sentenced in February. However, the Justice Department said it would recommend a prison term at the low end of whatever the court determines is the standard sentencing range in her case. [...] Thomas' conduct came to light in 2017, when a metallurgist being groomed to replace her noticed suspicious test results and alerted their company, Kansas City-based Bradken Inc., which acquired the foundry in 2008. Bradken fired Thomas and initially disclosed its findings to the Navy, but then wrongfully suggested that the discrepancies were not the result of fraud. That hindered the Navy's investigation into the scope of the problem as well as its efforts to remediate the risks to its sailors, prosecutors said. In June 2020, the company agreed to pay $10.9 million in a deferred-prosecution agreement.

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Metallurgist Admits Faking Steel-Test Results For US Navy Subs

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  • by RitchCraft ( 6454710 ) on Tuesday November 09, 2021 @09:18PM (#61973233)
    After all those years of putting hundreds of thousands of sailors at risk? 10 years, really? I would categorize this as treason.
    • The penalty for treason should be less than that for putting lives at risk but I get your point.
    • "she changed the tests to passing grades because she thought it was “stupid” that the Navy required the tests to be conducted at negative-100 degrees Fahrenheit (negative-73.3 degrees Celsius)."

      She doesn't understand those temperatures are important when the rift opens.

    • I'd also make sure that the fine is her entire salary for all those years with interest. She did not do the job she was paid for, so claw it back.
    • Its difficult to think what punishment makes sense. If those steels went into submarines and large ships they could be in a hundred billion dollars worth of equipment and risking thousands of lives. Tracking it all down will be difficult and it may not even be practical to retest once the steel had been incorporated into a vessel.
    • I thought the Navy concluded that this "putting hundreds of thousands of sailors at risk" didn't actually happen? Besides, what hundreds of thousands of sailors? The US has how many subs? Surely not a thousand.
  • by Joe_Dragon ( 2206452 ) on Tuesday November 09, 2021 @09:21PM (#61973239)

    Improper hazarding of vessel or aircraft.
    Espionage
    Aiding the enemy

  • by RightwingNutjob ( 1302813 ) on Tuesday November 09, 2021 @09:38PM (#61973309)

    About a precision shaft angle encoder manufacturer in the 80s or 70s. It was BEI or Itek or after they merged...anyway...

    These things measure shaft angles to an accuracy of half a second of arc and they're non-contact optical encoders. Think of the little encoder wheels in an old timey ball mouse, but about the size of a frisbee and very precisely machined.

    So anyway, back before LED light sources, these things had filament lamps to shine through the code wheel. And in order to be as accurate as advertised the illumination from the filament has to be flat and uniform so that squiggles or hot spots in the filaments don't mess up the precision and accuracy of the very accurately machined machined codewheels and photocell baffles.

    Apparently, their quality assurance for selecting these lamps was *one guy* with magic eyeballs who would put the lamp into an overhead projector and eyeball the resulting light field for uniformity and stability. No instrumentation, no backup, just one guy's say-so.

    The company, which used to charge hundreds of thousands of dollars for angle encoders delivered to telescopes on top of Mauna Kea and to NASA isn't around anymore.

    • You can find people with that kind of skill today, but I think only in Germany and Japan.

      • I remember watching something on the Discovery Channel or the History Channel, back when it aired such material, about a Japanese swordsmith who eyeballed the color of the flame in his furnace for 72 hours straight to make sure he was heating his steel to the correct temperature.

        It's both awe-inspiring and absolutely appalling. Yeah the dude has balls to stay up staring into a fire that long for the sake of quality. But he ain't beating no thermostat that's been around since the thermometer was invented. An

        • But he ain't beating no thermostat that's been around since the thermometer was invented.
          That is not the only point. It is oxygen level / carbon monoxide that influences the colour of the flame.

          And it's a damned lie to say he could.
          And why would anyone say that?

          He makes traditional sword. You can not use a thermometer for that, or it is no longer a traditional sword

          The concept of tradition is something you grasp right?

          Or do you grasp the difference between:
          a) fraud, selling a non traditional sword as a traditional
          b) money, a traditional forged sword costs $40,000 upward. A fake one, and fake starts with using a thermostat, or hammering it with pneumatic hammers: start at $500 - depending how much fake you put into it. A somewhat traditional one, goes from $2,500 - $3,000 upward, but usually is far below $10,000

          He probably would lose even his license if he switched to a thermostat. So no idea where you got this meme from, when it is not about claiming he is better than a thermostat. On the other hand: an oven is huge. Perhaps at the spot where it is important for him: he is indeed better.

          P.S.
          I practice martial arts where such swords are involved, and I'm a fan of Japanese Art, swords crafting is one of those arts.

        • In the case of traditional Japanese swords "nihonto" it has to be that way for a few reasons, none of them practical or engineering. The first is because of the way weapons are regulated in Japan its difficult to own really anything. They don't have a 2nd amendment. But katana have a special exemption in the law because they are considered significant to the Japanese cultural identity. But to prevent the market from being flooded by swords manufactured by modern processes which have no "cultural" or "artist

  • Dry Labbing (Score:5, Informative)

    by Retired Chemist ( 5039029 ) on Tuesday November 09, 2021 @09:41PM (#61973319)
    Its called Dry Labbing. Instead of testing the sample an analyst makes up the data. It often happens in understaffed labs or when there is management pressure to get results more rapidly than is possible. If the product is being made properly, you can get away with it, so most of the steel in question was probably fine, but there is no easy way to know, since it wasn't tested. It can be difficult to catch this especially in labs with only one or two analysts, although statistical analysis of the data can often detect it. It is really hard to simulate random error. Sooner or later a bad sample gets caught or another analyst notices the irregularities and the analyst gets caught. This problem is more common than most people want to admit.
    • Re:Dry Labbing (Score:5, Informative)

      by F.Ultra ( 1673484 ) on Tuesday November 09, 2021 @10:30PM (#61973439)
      Doesn't sound like Dry Labbing, sounds more that she performed the tests but changed the results of some of them when she thought that the requirements where "stupid"

      When confronted with the doctored results, Thomas told investigators, “Yeah, that looks bad,” the Justice Department said. She suggested that in some cases she changed the tests to passing grades because she thought it was “stupid” that the Navy required the tests to be conducted at negative-100 degrees Fahrenheit (negative-73.3 degrees Celsius).

      • by evanh ( 627108 )

        Lol, that's one cold ocean! One now wonders if that spec might get raised up somewhat in the not too distant future.

      • Re:Dry Labbing (Score:5, Interesting)

        by OneSmartFellow ( 716217 ) on Wednesday November 10, 2021 @04:56AM (#61974119)

        While it is true that many of the so-called requirements for MilSpec are indeed idiotic, it doesn't change the fact that they are requirements, so falsifying them is a HUGE error of judgement. It's just safer to assume they exist for a reason, even if the reason is beyond your comprehension.

        Part of the problem is that not knowing all the background decisions that went into making the spec., it is simply dangerous to assume they are nonsense. Even very smart people get caught up in this fallacy, much to their demise.

      • Doesn't sound like Dry Labbing, sounds more that she performed the tests but changed the results of some of them when she thought that the requirements where "stupid"

        When confronted with the doctored results, Thomas told investigators, “Yeah, that looks bad,” the Justice Department said. She suggested that in some cases she changed the tests to passing grades because she thought it was “stupid” that the Navy required the tests to be conducted at negative-100 degrees Fahrenheit (negative-73.3 degrees Celsius).

        Regardless of her intent, we will see just how critical this is, if and when they recall and rebuild, submarines.

        • Regardless of her intent, we will see just how critical this is, if and when they recall and rebuild, submarines.

          Is that a standard practice? I would have imagined that they would build new ones because the tech would have advanced since the last time, and retrofits are nearly always suboptimal in at least one way.

  • Sounds fishy (Score:5, Interesting)

    by John Cavendish ( 6659408 ) on Tuesday November 09, 2021 @11:03PM (#61973531)

    So according to the story a single employee is solely responsible for testing and certifying steel, which is going to be used for the US nuclear submarines' hulls and nobody checks it, no random additional tests, no supervision, nobody noticed for 10 years, was there any other human being involved in such important tests - really?

    • ... sorry, not 10, but for more then 40 years not other human being was ever involved in doing these important tests to notice anything wrong?

      • by kmoser ( 1469707 )
        Yeah, you would figure that they would *occasionally* send out samples to another lab, just for giggles. Trust but verify, right?
      • They might have checked and steel came with ok result, although likely different in detail then faked data - but who would normally compare specific result between different passing tests? The problem here is not a production method and crappy output, but nonexistent QA - unless something went wrong any random sample should easily pass the requirements. Finding this random bad batch with random additional tests is pretty unlikely.

      • ... sorry, not 10, but for more then 40 years not other human being was ever involved in doing these important tests to notice anything wrong?

        Uh, HOW many submarines were built and deployed under her "specs"?

        HOW many are still in use, like right now?

        I wouldn't exactly say "not other human being was ever involved" here...sounds like we've literally been doing live field validation, for near four decades. So here's a question after 40 years; Is there anything wrong? One would think everything from minor design annoyances to massive disasters would have surfaced by now.

    • Re:Sounds fishy (Score:5, Interesting)

      by thegarbz ( 1787294 ) on Wednesday November 10, 2021 @03:41AM (#61974009)

      No no no no. It was a single ISO9001 certified employee. The paperwork is what makes all the difference. /s

      3 weeks ago I received a 304 SS valve body. We PMI'd it on site and it was 304 SS. We compared it to the order and it was 304 SS. All good right? Well the vendor material traceability certificate said 316L SS but otherwise had all correct details of the valve. We literally paid for something which according to the process should have failed and never been delivered to the customer, except the process was so wrong that we actually got the right part with the wrong documentation. There were 3 signatures on the certificate.

      That's the kind of shit you deal with. And I'm happy to name and shame Emerson here, a large American mega provider to industry, not some fly by night workshop.

      • Re:Sounds fishy (Score:4, Insightful)

        by WierdUncle ( 6807634 ) on Wednesday November 10, 2021 @10:31AM (#61975101)

        The point about ISO9001 is not to improve quality. It is to have a paperwork trail to make sure the right person gets fired when there is a cock-up. Welcome to the modern world, where we spend more money blaming people for problems than we do actually solving problems.

    • by RobinH ( 124750 )
      Well, someone else checked, didn't they? Eventually...
  • I mean, we just went through that whole thing where Facebook and other sites were trying to ban people from screaming, "Stop the steel!" (Oh, wait....)

  • Thomas faces up to 10 years in prison and a $1 million fine ...

    that's all?

    considering how many Navy service personnel are being put at risk and the very real possibility that some of those subs using lower grade steel may be nuclear powered and a hull failure could be a minor environmental disaster, plus the factor that the affected subs will need to be replaced sooner than expected at a huge expense to the taxpayers I would have hoped her sentence would be a lot heavier.

  • Swell, so they paid for the paperwork man-hours necessary to straighten it all out.

  • by The Evil Atheist ( 2484676 ) on Wednesday November 10, 2021 @02:09AM (#61973837)
    Great, so now Australia's going to be saddled with the quality of Made in USA subs.
  • I mean, a 10M for fine for the company? That is ridiculous.

    Now, I wonder. Did these people also make steel for nuclear reactors?

  • by KILNA ( 536949 ) * on Wednesday November 10, 2021 @02:23PM (#61976007) Journal

    ...a problem with a system.

    Any rule set for which there is critical life-ending consequences if not followed, must be redundant in its application in some way (multiple tests or multiple eyes on a single test).

    Why was this test not redundant? It would have cost more money or time.

    Why did cost win out over safety? Profit and speed was valued more than human life as codified into the rule-set, by the foundry and the Navy.

    Why the company would behave this way is clear; profit motive.

    Why would the Navy failed to have implemented rule for redundancy? I do not see them as naive. To me the answer is almost certainly some form of capitalist influence on the process.

    Wars are capitalist in nature. So long as much of the production of war machines is ultimately geared toward the end goal of giving capitalists more money and power, we will always have more wars and war-footing, with war machines made with maximum grift by the wealthy.

    This woman's career was allowed to exist, and it benefitted the bottom line of the owners of the foundry for decades, for a dollar value far more than the cost of the fine.

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