Some Boeing 787 turbine blades can crack within 1,000 flights: Chinese study
Some turbine blades in GE Aerospace engines on Boeing 787s can develop cracks within about 1,000 flights, leaving airlines to choose between pulling engines early and flying on under strict inspections, according to a paper published in China.
A Chinese study revealed that certain Boeing 787 turbine blades may crack after just 1,000 flights, potentially causing engine failure. The research, published in the September issue of Aviation Maintenance & Engineering, analyzed first-stage high-pressure turbine blades from GE's GEnx-1B engines in both Phase 2 and Phase 2+ configurations. The study, conducted by Xia Xiaofeng of Xiamen Airlines, examined data from global fleets and the maintenance experience of a Chinese airline.
The cracks typically form between the first and second or second and third rows of cooling holes on the blades' convex surfaces. These cracks can spread, leading to the breakage of metal fragments. The cause of the defect is attributed to thermal fatigue, a low-cycle fatigue issue linked to stress concentrations in the affected areas. Early damage to the blades does not necessarily render an engine unsafe to fly, but airlines must closely monitor the condition and replace the blades before exceeding permitted limits.
The study documented five engine removals caused by defects in Phase 2/2+ HPT blades, all involving material loss between cooling holes on the blades' convex surfaces. In one case, a Chinese airline's engine had 1,818 flight cycles before a borescope inspection revealed missing material between two sets of cooling holes. Despite the engine being deemed safe for continued operation, it was eventually removed after 12 cycles following further inspections.
As of August 2025, approximately 417 GEnx engines, or 15% of the global fleet, were still operating with Phase 2 or Phase 2+ turbine blades. GE has revised its maintenance criteria based on operational data, allowing for the monitoring of small areas of material loss through repeat inspections. The airline recommends more frequent inspections for blades past 2,000 cycles and close tracking of engine vibration, exhaust gas temperature, and other operating parameters.
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