I previously posted that my i7 8GB 512GB custom-build shipped from China would hang within a few seconds to a few minutes after connecting to any kind of wifi network. By hang, I mean screen frozen and no response from mouse or keyboard or anything else. Only recourse was to power down and cold boot (an old expression, for you youngsters.) All the configuration tricks mentioned here were tried, to no avail. This was tested with a Time Machine (802.11n version), iPhone tether, a Comtrend wireless router/modem (802.11n), a Cisco router (802.11g) and a rather old Linksys router (802.11g). Connecting to any of them caused the MBA to hang in short order. The MBA worked flawlessly in all other respects -- even with a USB wifi dongle.
I also posted that Apple Customer Service was outstanding, escalating the problem quickly to an expert in the Network group who had me run tests that proved the problem was bad hardware (I booted from the Recovery partition with the same result.) Apple deemed the machine DOA and replaced it.
When the replacement MBA arrived (again from China), I backed up the fist MBA to Time Machine. Rather than migrate immdiately, I booted the new MBA with the stock install and tested wifi. It worked perfectly. I then reloaded the new MBA from the Time Machine backup and tested it extensively with all the wifi devices listed above. Operation was flawless without changing any configuration parameters. Also went to Starbucks and tested three local wifi networks (two 802.11n and one 802.11g.) Again, flawless operation. No hangs, no disconnects.
I haven't been able to test 802.11ac yet because I don't have (or yet need) ultra high-speed wireless at home (got gigabit Ethernet for that), and no one has it running loacally either (I live in a small town with only an Authorized Apple Reseller, no Apple-owned store.) I'll be traveling this weekend and will stop into a Apple-owned store to test 802.11ac.
My fingers are crossed, but I believe I have a good machine now.
Once I had the new MBA working, I erased the Macintosh HD partition on the bad MBA and attempted to reinstall OS X. This part of recovery needs some work -- it wants to download the latest version of the OS, and it comes up assuming you have wifi and tries to connect. Of course, the bad MBA would quickly hang after connecting. I managed to figure out that I could click on X to disconnect from my wifi network, plug in the Thunderbolt Ethernet cable, reboot, and download OS X that way, but it took several tries. The download estimate was 6-7 hours, so I went to bed. When I awoke, the install was in progress, with 23 minutes to go. But the MBA was hung. I think it might have reconnected to wifi after the download, but there's no way to tell. I tried running the install again and again, probably half a dozen times, and it always hung immediatley or after a few minutes.
Then, having read the thread that speculated about a power problem that disables the mouse pad, I tried continuously "swirling" the mouse while the installation proceeded. I had to do that for something like 25 minutes, but by golly it worked! Got OS X installed. Amazing. Could have been a coincidence, but I don't think so.
I booted into the vanilla install and deliberately turned on wifi to make the MBA hang. It did, and then I tried plugging in a USB memory stick and an SD card. I figured if it was just the mouse pad being torched, maybe the CPU would show some life when I plugged in another device. The MBA did not respond. Obviously the memory stick is USB, which might be part of the same bus as the mouse pad. Not sure about the SD card. My sense is that the CPU was either stopped or in an infinitel loop, but there's no way of knowing.
Unfortunately, I was in a hurry to pack up the bad MBA and initiate shipping, so I didn't test "swirling" the mouse while connected to wifi to see if that would prevent the hang. I didn't have 20 minutes or so to do that, and it's hard to prove a negative.
So, it's clear that my MBA had a hardware problem related to the wifi components. I'm sure that the small number of wifi-hung (dead) MBAs that have been reported here suffer from the same problem.
As for the much more commonly reported problem in this thread, wifi disconnect shortly after connect, my guess is that the root cause is also defective or marginal wifi hardware, but that the severity of the problem varies from one MBA to another. I believe that's why certain "fixes" (WPA2, changing order of network devices, etc.) work in some cases, but they don't work in other cases.
I'm very doubtful that the disconnect problem is due to bugs in OS X or the firmware because there are likely lots of new MBAs that work perfectly (like the one I just got), and most of the machines in question are running the same software and firmware. It's possible the migration process has bugs that allow bad configuration information to get migrated from another Mac, but I'm sort of doubtful about that, too. It's possible that the new wifi chipset doesn't work with certain routers, or only works with them if you change configuration parameters, but I suspect there are a very small number of such cases and Apple can probably address those in software or firmware.
If I'm right that most of the problems reported here are caused by defective or marginal hardware, I wouldn't panic yet. It may be possible for Apple to fix the disconnect problems in firmware or hardware. It could be as simple as dealing with bogus loss of signal statuses or revising the power-saving algorithms to compensate for variations in chip tolerances (the latter is my leading theory on the hardware problem -- unexpected variations in voltage or current tolerances in the new wifi chips Apple is using.)
One way or the other, I believe Apple will solve this problem.