Takata Airbag Recall Testing Reveals Hundreds of Ruptures
Newly released NHTSA documents show 660 Takata airbags ruptured during post-recall testing, highlighting ongoing safety risks linked to ageing ammonium nitrate inflators.
Documents from the US National Highway Traffic Safety Administration (NHTSA) show that 660 Takata airbags ruptured during testing after being removed from vehicles under recall, underlining the persistent risk posed by the defective inflators. The findings, reported in late 2016, come from a sample of 245,000 airbags tested as part of Takata’s consent order obligations.
The rupture rate equates to roughly one in every 370 airbags tested. Takata is required to submit ongoing test results as part of regulatory oversight following the largest automotive recall in history. The defective airbags, which use ammonium nitrate as a propellant, have been linked to at least 15 deaths and more than 100 serious injuries in the United States, with metal and plastic fragments entering the cabin when inflators fail.
Why ammonium nitrate inflators fail
While the precise failure mechanism is still under investigation, evidence points to the instability of ammonium nitrate propellant as it ages, especially in hot and humid climates. Moisture and temperature fluctuations accelerate the chemical’s degradation, increasing the risk of rupture over time. A study funded by affected manufacturers found that older inflators are more likely to malfunction, pushing regulators to prioritise recall campaigns for vehicles in regions with high humidity and for the oldest vehicles nationwide.
Recall implications and ongoing risks
The scale of ruptures in post-recall testing highlights the urgency of replacing affected airbags, particularly in older vehicles and those operating in humid environments. With the recall still underway in 2016, US regulators and manufacturers are focusing on the most at-risk vehicles first. Owners of affected models are advised to respond promptly to recall notices. For details on specific models and recall rounds, see BMW recalls 1.6 million E46 3 Series cars for Takata airbag risk.
