NORTH CAROLINA- The GE Aerospace GE90 program has achieved yet another significant milestone, marking the delivery of its 3,000th production engine.
The GE90 engine program is a special and iconic one in the realm of engine production. It has garnered widespread recognition in the aviation industry and holds a unique place in the hearts of those who have been involved in its development at GE Aerospace.
GE Delivers 3000th GE90
Among commercial engines, the GE90 has achieved numerous groundbreaking achievements over the years, making it a trailblazer in the field:
- It was the first engine to enter service with carbon-fiber composite fan blades.
- It became the first engine to be certified at over 100,000 pounds of thrust.
- It was the first engine certified for ETOPS (Extended-range Twin-engine Operational Performance Standards).
- It was the first engine certified with an additive part.
- It pioneered the use of analytics-based maintenance.
- It was the first to utilize GE 360 Foam Wash technology.
These achievements underscore the remarkable legacy of the GE90 program in the world of aviation.
However, the road to success for the GE90 engine was far from certain when it made its debut in 1990.
According to Nate Hoening, the GE90 program manager, its journey is nothing short of epic. In the early 1990s, leaders like Brian Rowe, who was then the president of GE Aviation, took significant risks to launch the original version of the GE90.
This venture represented a bold bet on the future of air travel, envisioning a shift from four-engine wide-body aircraft to two-engine wide-body aircraft.
Boeing Support
Rowe shared Boeing’s belief that large jetliners flying long-distance international routes could be efficiently powered by two engines, offering advantages in terms of fuel and maintenance costs.
However, achieving this vision required the development of significantly larger engines and the use of materials that had never been applied in civilian aviation before.
Rowe famously stated,
“The GE90 will be the engine that will lead the way to the 21st century.”
The GE90 engine received certification from the Federal Aviation Administration on February 2, 1995, and was officially put into service with British Airways in November 1995.
Nevertheless, by 1998, GE faced stiff competition from Rolls-Royce and Pratt & Whitney for the opportunity to power the Boeing 777.
Some major airlines expressed concerns about the GE90’s cost and the perceived risks associated with its technology for powering long-haul passenger jets with only two engines.
This limited market demand led to delays in the certification of the next variant of the engine. At one point, then-CEO Jack Welch was even rumored to have said, “The GE90 is dead, put a stake in its heart.”
The Successful GE90 Program
To put it simply, the outlook for the GE90 program was far from promising. Nate Hoening remarks, “Many thought that it wouldn’t even fly again.” However, in 1999, Jim McNerney, who served as the president at the time, decided to take a bold approach.
First and foremost, the engineering team developed a more advanced compressor for the GE90.
Building on favorable feedback regarding improved fuel efficiency from operators in the field, McNerney and his team launched an assertive marketing campaign, actively engaging with potential airline customers to generate excitement for a new variant capable of delivering 115,000 pounds of thrust.
The additional thrust this new variant offers would enable the engines to carry larger payloads over longer distances.
Following extensive negotiations, Boeing eventually agreed to designate the GE90-115B turbofan engine as the exclusive powerplant for its extended-range 777-300ER and 777-200LR aircraft.
Pioneering Next-Gen Tech
“The engine’s performance has been nothing short of phenomenal since it entered service,” states Hoening. “It has set the standard for all wide-body engines. Considering its challenging beginnings, remarkable progression, and role as the prototype for numerous subsequent GE engines designed based on its principles, it’s truly remarkable.”
In fact, the GE90’s engineering and mechanical concepts, from its carbon-fiber composite fan blades to its incorporation of 3D-printed additive components, have left an indelible mark on every GE and CFM turbofan produced over the last two decades.
This influence extends to engines like the GEnx, CFM LEAP, Passport, and the next-generation GE9X engine designed for the Boeing 777X.
Hoening emphasizes the pivotal role played by analytics-based maintenance, describing it as a “game changer” that has significantly enhanced customers’ ability to maximize the “time on wing” of their GE90 engines.
Unlike typical aircraft maintenance schedules that allow for overnight maintenance windows, GE90-powered 777s are almost always in operation, flying from one location to another with only brief layovers. This underscores the critical importance of reliability and durability for these engines.
Collaborating closely with airlines to continually monitor engine performance on a 24/7 basis has enabled proactive maintenance planning.
By leveraging data-driven insights, airlines can effectively time repairs and engine overhauls, contributing to the prolonged operational life of the majority of GE90 engines.
FedEx Takes 3000th GE90
As FedEx celebrates the reception of the 3,000th GE90 engine this month, Hoening deeply admires the program’s extensive and occasionally challenging history.
He shares this sentiment with others who have been part of the GE90 journey. “One of the things that amazes me is the legacy of leaders that were involved in the GE90,” he remarks.
He then proceeds to list names, including Rowe, McNerney, former GE90 program managers Russ Sparks, Chaker Chahrour, Bill Millhaem, and former GE Aviation CEO David Joyce. “Talk to anybody who’s been involved in the GE90, and it’s almost like their eyes light up.”
For Hoening, this sentiment remains unchanged. “I definitely have a soft spot in my heart for both the people who have contributed to the program and the engine itself,” he says. “I still love sitting on a 777-300ER and hearing it start up. It’s an amazing sound.”
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