FAA Proposes Crack Checks for Pratt and Whitney Engine Parts
Published Date: 6/6/2025
Proposed Rule
Summary
The FAA wants to keep certain Pratt & Whitney engines safe by checking for cracks in key parts like turbine hubs and disks. If cracks show up, those parts must be fixed or replaced to avoid engine trouble during flights. Engine owners need to act fast and comment by July 21, 2025, or risk costly repairs later.
Analyzed Economic Effects
3 provisions identified: 0 benefits, 3 costs, 0 mixed.
Immediate replacement for listed HPT air-seal serials
For HPT 1st-stage air seals with the serial numbers listed in table 1 to paragraph (g)(1) of the AD (serial numbers shown as 50L663 and 50L959 in the table), the AD requires removal from service and replacement at the next piece part opportunity after the AD becomes effective. The FAA estimates 6 engines will need replacement of the HPT 1st-stage air seals, with an estimated cost per replacement of $763,085 and a total estimated cost to U.S. operators of $4,578,510.
Estimated U.S. operator compliance costs
The FAA estimates this proposed AD would affect 124 engines on U.S.-registered airplanes. Estimated inspection cost totals for U.S. operators are $42,160 for AUSI of the HPC 15th-stage disk (124 engines × $340) and $52,700 each for AUSIs of the front turbine hub, HPT 2nd-stage hub, and HPT 1st-stage air seal (124 engines × $425 each). The FAA also provided on-condition replacement cost estimates per product: replace HPC 15th-stage disk = $312,850; replace front turbine hub = $910,850; replace HPT 2nd-stage hub = $816,850; replace HPT 1st-stage air seals = $763,850.
Mandatory repetitive ultrasonic inspections
If you operate Pratt & Whitney PW4074, PW4074D, PW4077, PW4077D, PW4084D, PW4090, or PW4090-3 engines, you must perform angle ultrasonic scan inspections (AUSIs) of the HPC 15th-stage disks, front turbine hubs, HPT 1st-stage air seals, and HPT 2nd-stage hubs at the next "piece part opportunity" after the AD becomes effective and at every subsequent piece part opportunity. The AD requires removal from service and replacement before further flight if any crack indication is found. The FAA estimates each AUSI costs $340 for the HPC 15th-stage disk (4 work-hours at $85/hr) and $425 for each of the other parts (5 work-hours at $85/hr).
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