The ferry Chetzemoka was built by Vigor Industrial, which was formally known as Todd Pacific Shipyards.But the propellers were built by Rolls-Royce Marine.
Both businesses say they're trying to figure out what happened.
The Chetzemoka is running with patched-up propellers. Washington State Ferries says the ferry had been in dry dock in Anacortes for scheduled repairs for more than three weeks, during which time inspectors found hairline cracks on one of the 8,000-pound propellers.
Additional tests showed that each of the five blades on both propellers had cracked near the hub. The ferry system says it appears that improperly cast stainless steel is to blame for the problems. Officials believe a high-carbon content made the metal too porous and too brittle.
"These are big ships plowing the waters of Puget Sound in salt water. Stuff happens," said David Moseley of WSF. "That's why we are diligent about the maintenance of these boats, and that's why we're diligent every time we take them out of the water."
Vigor Industrial says two other new ferries of the same class - the Salish and Kennewick - have different, variable-pitch bronze propellers, and therefore should not have the same problems.
One year ago, when the $77 million Chetzemoka made its inaugural run from Whidbey Island to Port Townsend, it was heralded as a new lifeline that could handle the rough waters of Puget Sound.
Transportation officials defended the cost, and the companies that constructed it.
"We have tremendous builders in Washington state and they will help us maintain and preserve these boats for the 60-plus years they're in life," said Transportation Secretary Paula Hammond.
Replacement propellers are now being made for the Chetzemoka, but they won't be ready until April.
The state says it'll file a warranty claim against Vigor Industrial to pay for the new props, which cost $70,000 per piece.
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