For those who have a fear of flying: Pratt engine problem

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Some 3,000 engines, including PW1000Gs of all types and IAE V2500s, built from mid-2015 through mid-2021, may have parts with contaminated powder metal (PM). Cracking from PM contamination has been found in high-pressure turbine (HPT) Stage 1 and 2 disks, or hubs, installed in the motors. Pratt is also inspecting some high-pressure compressor (HPC) disks built at the same time, RTX revealed. Most of the affected engines are PW1100Gs found on A320neo-family aircraft.

Clogged engine overhaul shops and a fast-tracking of necessary inspections on higher-time PW1100G GTFs will likely drive repair turnaround times to up to as many as 300 days per engine and could ground 650 Airbus A320neos at one time early next year, RTX disclosed. According to Aviation Week Network’s Fleet Discovery database, 1,354 Pratt-powered A320neo-family aircraft are currently in service, parked, stored or in parked/reserve status.

Fleet groundings will “average” 350 at any given time through 2026, according to RTX President and Chief Operating Officer Chris Calio.
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In July, Pratt had announced that previous PW1100G parts inspection intervals, developed after the problem was first uncovered in 2020, were not aggressive enough to flag cracks that the contamination can cause. It said as many as 1,200 engines would need to be pulled in the next year, including up to 200 by Oct. 1. Some of the checks would overlap with scheduled shop visits, reducing unplanned disruptions and costs.

The revised figures now lower the number of engines that need immediate attention but narrow the removal window. The result is higher costs for Pratt and its PW1000G partners as its already full overhaul network faces a wave of engines that require extensive work scopes.