Manufacturing-related issues affecting Pratt & Whitney’s (P&W) PW1000G family GTF (Geared Turbofan) engines continue to cause significant capacity losses in global civil aviation. According to Cirium data, as of the end of October, 835 aircraft worldwide are grounded due to engine problems. This figure corresponds to approximately one-third of all aircraft powered by GTF engines.
The aircraft type most affected by the issue is the Airbus A320neo. As of the end of October, 720 A320neo aircraft were taken out of service due to faults in P&W GTF engines, representing 38% of the A320neo fleet equipped with these engines. In addition, 86 Airbus A220 aircraft (19% of the fleet) and 29 Embraer E-Jet E2 aircraft (16%) were also grounded for the same reason.
The source of the problem is attributed to material defects arising from the powdered metallurgy manufacturing method used in the disks of the first and second stages of the high-pressure turbine (HPT).
Although P&W management states that maintenance and recall plans are progressing according to schedule, the effects of the current engine issues for airlines may extend beyond 2026. The company acknowledges that the impacts of the GTF crisis could continue until 2030.
To address the issue, Pratt & Whitney has begun upgrading existing PW1100G engines with the “D.1 update,” which incorporates more durable components. This package increases the engine’s on-wing life by 40%. In addition, a new modernization package called “Hot Section Plus” is being developed. This package includes 35 new components and leverages technologies from the GTF Advantage version.
Planned to enter service in 2026, the GTF Advantage will offer higher thrust and up to 80% longer service life compared to early-generation engines.
