The United States Federal Aviation Administration (FAA) is set to introduce a new Airworthiness Directive (AD) for Pratt & Whitney PW2000 family engines, powering B757s and C-17s, due to issues with nickel powder metal contamination. The problems that have plagued PW1000G engines could also affect the PW2000, although aerospace company RTX Corporation confirmed to ch-aviation that operators will not need to ground their aircraft.

According to an FAA notice of proposed rulemaking (NPRM) issued on May 23, a draft for the introduction of an AD, the directive would mandate the inspection and replacement of certain high-pressure turbine (HPT) first-stage disks and turbine hubs on account of the potential presence of metal cracks. The FAA is also proposing the examination of certain HPT seal assemblies.

"This condition, if not addressed, could result in uncontained disk failure, release of high-energy debris, damage to the engine, damage to the airplane, and possible loss of the airplane," the FAA warned.

The authority revealed that the PW2000 contamination is related to the previously discovered problem with nickel powder metal found in PW1000G engines, finding that PW2000 turbine production may be affected by similar defects to PW1000G manufacturing.

The agency noted that the AD could affect 484 engines powering US-registered aircraft. However, RTX does not anticipate industry-wide problems seen with the GTF engine family.

“This AD is in line with previous service bulletins provided to operators and requires inspections of certain components originally provided as spares. The inspections will be conducted during scheduled overhauls. There are no new part life limitations and no groundings will be required,” an RTX spokesperson told ch-aviation.

Cost and time

The FAA estimates that replacing first-stage disks could cost USD730,850, while changing the turbine hub could increase the cost by USD500,850. Replacing both disks and hub would require ten working hours each.

According to the NPRM filing, the FAA will be receiving comments on the airworthiness directive proposal until July 17, 2025.

The PW2000 was introduced in the mid-1980s and powers both B757s and the C-17 military transport aircraft. According to ch-aviation Commercial Aviation Aircraft Data, 195 commercial aircraft that use the PW2000 are in active service. Delta Air Lines remains the largest operator, with 100 B757-200s and sixteen B757-300s in its fleet. Other significant operators include UPS Airlines and FedEx Express.

Meanwhile, the main operators of the C-17s are the United States Air Force, the Indian Air Force, and the Royal Air Force.