FAA Proposes PW2000 Engine Checks Over Metal Contamination Risk

The U.S. Federal Aviation Administration (FAA) has proposed a new Airworthiness Directive (AD) targeting Pratt & Whitney PW2000 engines due to potential nickel powder metal contamination. These engines power Boeing 757 commercial jets and C-17 military transport aircraft. The issue is similar to problems previously discovered in PW1000G engines.

In a notice of proposed rulemaking (NPRM) issued on May 23, the FAA outlined mandatory inspections and potential replacements of high-pressure turbine (HPT) first-stage disks, hubs, and seal assemblies in affected engines. The concern is that microscopic cracks caused by metal contamination could lead to uncontained disk failure and severe engine or aircraft damage.

“If not addressed, this condition could result in the release of high-energy debris and possible loss of the airplane,” the FAA stated. The proposed AD could impact 484 PW2000 engines on U.S.-registered aircraft.

RTX Corporation, parent of Pratt & Whitney, confirmed that no groundings are expected. The inspections will be carried out during scheduled overhauls, and no new part life limits are being introduced. The directive aligns with earlier service bulletins already shared with operators.

The FAA estimates that replacing a first-stage disk could cost $730,850, while turbine hub replacements may cost up to $500,850. Both tasks are expected to require 10 labor hours each.

Operators have until July 17, 2025, to submit comments on the proposal. The PW2000 engine, introduced in the 1980s, remains in use on 195 active commercial aircraft. Delta Air Lines is the largest commercial operator, with over 100 Boeing 757 aircraft in service.

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Sources: AirGuide Business airguide.info, bing.com, ch-aviation.com