Manufacturing Ramp-Up Ensures Steady Flow For Aircraft Production

GE Aerospace announced it has ramped up production of the GE9X engines after logging 27,000 cycles and 17,000 test hours. Generating 134,000 pounds of thrust, the engines will be used to power the Boeing 777X aircraft, set to become the largest twin-jet passenger aircraft in the world.

The GE9X is the largest and most powerful commercial engine with a diameter of 3.4 meters, over 11 feet, and dwarfs other current commercial aircraft engines. It began development as early as 2012, was flight-tested in 2020 and received FAA certification the same year.

It is a high-bypass turbofan derived from the GE90, with a larger fan, higher compression ratios,  and made of advanced materials like ceramic matrix composites.

According to Cristina Seda-Hoelle, Head of the GE Aerospace GE9X program, the engines will be built in GE Aerospace’s Durham, North Carolina plant in synchrony with aircraft assembly in Boeing’s Everett, Washington facility.

She explained, “We’ve started building. And we’ll be aligning production with Boeing’s production of the 777X.”

After production, each engine goes to Peebles, Ohio, for rigorous endurance testing before being  sent to Everett. The engines have been tested for dust ingestion for up to 1,600 cycles, sufficient to withstand extreme conditions in arid regions around the world.

Tyler-Blair Sheppard, GE9X marketing lead for GE Aerospace said, “We’ve run the heck out of the engine, and customers have been really impressed by the dust test data coming back, which is the equivalent of almost three years of normal use.

“After 1,500 cycles, borescope inspections showed that the engine – especially the hot section, the high-temperature segment housing the combustion, turbine, and exhaust components – looked great and was in serviceable condition, which allowed for an extra 100 test cycles. “It will all result in a more durable engine in harsh environments,”

GE Aerospace said that in addition to raw power, emissions put out by the GE9X are 55% lower than regulatory limits. Continued testing confirms the engine’s resilience in harsh conditions and the company expects it to secure Extended Operations or ETOPS approval this year.

GE Aerospace is also putting a ton of money – over $1 billion – into an expansive MRO network for GE9X customers, ensuring their rapid access to parts and spare engines via GE’s lease pool program.

FMI:  www.geaerospace.com/