One year after the announcement that a significant portion of the PW1100G-JM engines in the global A320neo fleet would have to be taken to the workshop due to defective components, the picture is mixed. Pratt & Whitney, a leading manufacturer of aircraft engines, has made progress in resolving the problems, but the situation remains tense. The necessary inspection and repair of the engines remains a major logistical and financial challenge for the aviation industry.

The problems with the PW1100G-JM engines first came to light over a year ago when it was revealed that these engines were suffering from defects due to contaminated metal powder used in their manufacture. The contaminated parts, including the blisks (integrally bladed rotors) of the high-pressure turbine and the disks of the high-pressure compressors, were prone to cracking, affecting the safety and efficiency of the engines.

By the end of 2023, these faulty parts were still being installed in engines, leading to a massive recall and inspection program. The impact on air traffic was significant: In April 2024, the number of Airbus A320neo aircraft grounded due to engine problems peaked at around 625 aircraft. Currently, 480 to 500 aircraft are still affected, as Lars Wagner, CEO of MTU Aero Engines, reported on August 1, 2024.

Progress in the inspection programme

Pratt & Whitney, part of parent company RTX, has committed to improving the situation. Chris Calio, president of RTX, expressed optimism on July 24 about the progress of the inspection program. The company has significantly expanded its capacity to handle the affected engines. In September 2023, Pratt & Whitney predicted that the "wing-to-wing" time - the time it takes an engine to be inspected - would be between 250 and 300 days, of which the engines spend up to 150 days in the workshop.

Currently, workshop stays are even longer because spare parts are not always immediately available. MTU Aero Engines reports that when spare parts are available, inspections can be completed much faster, in less than 100 days. Production of new parts made from improved metal powder has increased by 100 percent compared to last year, which should contribute to a gradual improvement in the situation.

To minimize the impact on aircraft fleets, Pratt & Whitney has also expanded its maintenance network. Since the beginning of the year, the number of maintenance workshops worldwide has been increased from 12 to 18. In addition, three existing workshops have increased their capacity to cope with the increased demand. This expansion should help to shorten turnaround times and get the affected engines back into service more quickly.

Industry-wide impact

The problems with the PW1100G-JM engines have not only affected Pratt & Whitney and MTU Aero Engines, but also numerous airlines around the world that operate Airbus A320neo aircraft. The delays and additional costs caused by the engine inspections and repairs have a significant impact on airlines' operating costs and the availability of their aircraft.

The aviation industry is now faced with the challenge of managing these problems while facing new challenges such as rising operating costs and stricter environmental regulations. The inspection and repair measures are an essential step in ensuring the safety and reliability of aircraft fleets, but they also represent a significant burden for the companies concerned.

Despite the progress made by Pratt & Whitney and its partners in resolving the engine issues, the situation remains tense. Challenges in spare parts availability and ongoing operational stresses continue to require patience and efficient solutions. The ongoing expansion of the maintenance network and improvement of production capacities are critical to speeding up the return to normality and minimizing the impact on air traffic.