PW1100G Geared Turbo Fan

Pratt and Whitney have found themselves in a strange situation. Their order book is brimming with orders for the PW1100G ( Geared Turbo Fan) but the engine used in the Airbus 320/321 Neo is being removed in record numbers for repair. In total 1200 engines will need repairs. The problem is a number of small cracks appearing in the powdered metal used in the engines High Pressure Turbine disks that were manufactured between 2015 and 2021.

At the moment Pratt and Whitney are producing more engines than are being removed to bring AOG (Aircraft On Ground) rates down. The defect is having an effect on multiple airlines in the busy summer season. Pratt and Whitney have increased engine production to minimize the downtime of existing customers by having engines available. Despite this, approximately 10% of the GTF fleet is parked awaiting engines. Indian airline Go First recently cited the engine as the primary reason they filed for bankruptcy.

There are also problems with the PW1500G series engine installed in the Airbus 220. The reliability of the engine is well below the target that Pratt and Whitney expect. Some PW1524G engines in the A220-300 are being removed at less than a thousand landings instead of the forecast 5260 landings. There is an Engine Airworthiness Directive for inspection of the engine fan due to inflight shutdowns and the failure of fan blades.

Now, in my experience there are always teething troubles with new designed engines that only appear after operational real world experience. The manufacturers do their best to cover all the bases to achieve certification from the regulator but, they can’t anticipate all the environmental affects that the engines will experience.