With over 10,000 customer orders and commitments already secured, the Pratt & Whitney GTF engine has emerged as a game-changer in the industry.
Pratt & Whitney, a renowned aerospace manufacturer, is witnessing an unprecedented surge in demand for its Geared Turbofan (GTF) engines. With over 10,000 customer orders and commitments already secured, the GTF engine has emerged as a game-changer in the industry. Its exceptional fuel efficiency, reduced emissions, and minimized noise footprint make it an attractive choice for airlines striving for sustainable aviation solutions. The forecasted demand for 30,000 single-aisle aircraft over the next two decades further highlights the significant role that GTF-powered aircraft are set to play in shaping the future of aviation.
Pratt & Whitney’s commitment to continuous improvement is evident in the GTF engine’s superior durability compared to the V2500 engine at a similar stage in its lifecycle. The company has invested substantially in research and development to increase the time on wing for its customers, aiming to extend the operational lifespan of engines before maintenance becomes necessary. Remarkable progress has already been achieved, with dispatch reliability reaching a mature engine level of 99.96%, ensuring a high rate of on-time departures for scheduled flights.
“The GTF engine is a once-in-a-generation program that has shaped the future of sustainable aviation – delivering up to 20% less fuel and CO2 per trip and up to 25% per seat,” said Matt Teicholz, vice president of engineering for GTF engine programs, Pratt & Whitney. “Our operators know that the GTF is the most fuel-efficient and sustainable engine for single-aisle aircraft. Make no mistake – the geared fan is the architecture of today and tomorrow. The maturity progression we’ve planned for the GTF is comparable to our track record on the V2500 engine. We have more design enhancements ahead in 2024 and 2025 to further improve durability, including improved turbine and combustor hole drilling techniques and modified cooling hole patterns.” he further added.
Acknowledging the variance in time on wing based on mission and operating environments, Pratt & Whitney has introduced durability upgrades. The latest Block D hardware configuration, deployed in 60% of the fleet, incorporates longer-life parts and improved components, resulting in double the time on wing compared to the previous configuration. This significant enhancement underlines the company’s commitment to continuous improvement and customer satisfaction.
However, the industry-wide supply chain constraints have presented challenges, leading to material availability issues and increased turnaround times in maintenance, repair, and overhaul (MRO) shops. Currently, approximately 10% of the GTF-powered fleet is out of service, awaiting engines. Pratt & Whitney is fully aware of the impact on its customers and is working diligently to address these challenges. The company is diligently managing production rates, increasing material availability, and expanding its global capacity within the MRO network to mitigate the effects of these supply chain constraints.
“To meet our customers’ expectations, we need to be able produce highly efficient, reliable engines that are also highly durable, with long time on wing between shop visits,” said Rick Deurloo, president of Commercial Engines, Pratt & Whitney. “However, this metric is not yet at the level we expect, which has put stress on the operations of the fleet. Recovery will take time, but we have been increasing output throughout this year, establishing higher levels of shipments from our MRO network each month. In May we output more engines from MRO than our customers removed for servicing. We are focused on growing GTF engine aftermarket output by increasing material availability and expanding global capacity across the GTF engine MRO network,” he further added.
As a result, Pratt & Whitney sees AOG rates coming down through the end of 2023.To support the growing GTF fleet, Pratt & Whitney is actively expanding its MRO capacity worldwide. This expansion includes both internal facility expansions and collaborations with partner shops. Notably, in 2023, the company achieved significant milestones with two facility expansions and two partner shop activations. Since 2019, the GTF engine MRO network has more than doubled in size, now comprising 12 active locations globally. Furthermore, an additional seven locations are expected to be operational by 2025. This expansion demonstrates Pratt & Whitney’s commitment to providing comprehensive support for its growing customer base.
Looking towards the future, Pratt & Whitney is focused on developing the next generation of the GTF engine, known as the GTF Advantage engine. This advanced engine will offer higher thrust, improved fuel efficiency, and lower carbon emissions, aligning with the industry’s ambitious goal of achieving net-zero carbon emissions by 2050. By delivering up to 1% lower fuel consumption and CO2 emissions compared to the current GTF engine, the GTF Advantage engine sets a new benchmark for environmental performance. Additionally, it is designed to be compatible with 100% sustainable aviation fuel (SAF), further reducing its environmental impact.
The GTF Advantage engine’s certification and flight test program have already accumulated over 3,000 hours and nearly 9,000 cycles. Leveraging the knowledge gained from over 100,000 hours of engine and rig testing across all GTF programs, Pratt & Whitney has designed an engine with enhanced durability and performance. Advanced technologies are being incorporated to address hot section distress experienced in the field. This includes improved airfoil design with enhanced coatings, advanced cooling technologies, and upgraded thermal barrier coatings. Pratt & Whitney expects the certification of the GTF Advantage engine in mid-2024, enabling further hardware enhancements and ensuring mature levels of durability upon entry into service.
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Pratt & Whitney’s unwavering commitment to sustainability and innovation continues to revolutionize the aviation industry. Through its relentless pursuit of improved engine performance, increased durability, and expanded MRO capacity, the company strives to exceed customer expectations and drive the industry toward a more sustainable future. With its extensive experience and track record of success, Pratt & Whitney is at the forefront of developing advanced propulsion systems that will shape the next generation of aviation.
