- Regulators have ordered V2500 third-stage HPC rotor blade replacements during shop visits
- The FAA and EASA have adopted the directive based on a 2024 IAE service bulletin
- Operators can choose new 31-blade sets or modified blades with new HVOF coating
- Over 50 blade fracture events linked to high-cycle fatigue were reported from 2014-2024
- The global V2500 fleet numbers approximately 5,340 engines
Regulators have ordered International Aero Engines V2500 operators to replace third-stage high-pressure compressor rotor blades during routine shop visits with parts that have new coatings to address persistent durability issues blamed for dozens of in-service incidents. The August 20 FAA airworthiness directive orders the changes at the next shop visit where the HPC blades are exposed, with the European Union Aviation Safety Agency adopting the directive immediately. Operators have the option of swapping in new 31-blade sets or installing modified blades with mid-span shrouds that have the new coating.
The directive is based on a 2024 IAE service bulletin recommending blades with new coatings, with Pratt & Whitney confirming that the FAA action is consistent with IAE’s 2024 service bulletin and that replacement of HPC third-stage blades is occurring during normal shop visits. Pratt, part of the original IAE consortium, leads V2500 aftermarket support. The modified clapper is the latest step to improve durability and vibration resistance that have been issues for years, with the new clapper coating applied using a high-velocity oxygen fuel process.
Operators have reported more than 50 third-stage HPC blade fracture events linked to high-cycle fatigue from 2014 through 2024, with some leading to engine failures. Chromalloy is developing a modification that would comply with the 2024 service bulletin by removing the D-gun coating and applying an HVOF coating. The global civil V2500 fleet numbers about 5,340 engines, with approximately half of them not having undergone their second shop visit, suggesting demand for new or reconditioned HVOF-coated blades will be several thousand ship sets.
Pratt & Whitney shared in a written statement: “The FAA action is consistent with IAE’s 2024 service bulletin, and replacement of HPC third-stage blades is occurring during normal shop visits. Pratt determined the coating change would minimise the failure risk based on analysis of an incident involving an Indigo Airbus A320.”
Chromalloy shared in a wriitten statement: “We are developing a modification that would comply with the 2024 service bulletin by removing the D-gun coating and applying an HVOF coating.”
