Key facts
- Pratt & Whitney reports a 40% reduction in grounded aircraft due to engine issues.
- Disruptions are nearly eliminated for Airbus A220 and Embraer E2 models.
- The issue stems from contaminated powdered metal used in manufacturing between late 2015 and mid-2021.
- The problem affects high-pressure turbine and compressor components, requiring extensive inspections and repairs.
- An estimated 600-700 engines require removal for inspection and repair between 2023 and 2026.
- Shop visit turnaround times average 300-360 days, contributing to prolonged aircraft downtime.
Jet engine manufacturer Pratt & Whitney announced on Tuesday that the number of aircraft grounded due to engine-related issues has decreased by 40% from an unspecified peak. The company stated that groundings for smaller aircraft models like the Airbus A220 and Embraer E2 have virtually disappeared and are expected to reach zero in the coming months.
These issues stem from a manufacturing defect involving contaminated powdered metal used in the production of high-pressure turbine and compressor components between the fourth quarter of 2015 and the third quarter of 2021. This contamination can lead to cracking, necessitating inspections and repairs. The problem has contributed to a broader industry crisis of engine shortages, leaving hundreds of aircraft idle.
Pratt & Whitney has disclosed that an estimated 600 to 700 engines require removal for inspection and repair between 2023 and 2026. The company announced a pre-tax charge of approximately $3 billion in the third quarter of 2023, with total projected gross costs ranging from $6 billion to $7 billion over several years. The Federal Aviation Administration has issued a series of Airworthiness Directives to mandate these inspections and replacements.
A significant factor contributing to the prolonged grounding of aircraft is the extended shop visit turnaround time, which averages between 300 and 360 days per engine, far exceeding initial projections. This has led to an average of approximately 350 jets being grounded annually through 2026, with as many as 650 jets idle globally in the first half of 2024. Despite these challenges, Pratt & Whitney reported a 21% increase in its Maintenance, Repair & Overhaul (MRO) output year-to-date through the third quarter of 2025, and anticipates more than 150 GTF-powered aircraft returning to service in 2026.