It's happened, regardless of the probability.

The TSA has made a stink over passengers only having some "emergency" travel docs -- or even emergency limited validity passports -- when proceeding to the screening checkpoints. CBP sometimes too makes a stink about it, but IME not as often as TSA has. More often than a problem with DHS employees is a problem with, or started by, airline reps over some such docs since the US used VWP as a carrot and stick to get other countries to increasingly centralize passport processing and whipped other countries into a frenzy to make passports "more secure".

Guess who has dealt with these problems: current and former Swedish government employees who have served in, or overseen, consular functions for Swedish citizens in the US over previous periods of time since the ID paranoia went epidemic domestically in the US after 9/11.