GE90 turbofan engine marks over three decades powering Boeing's commercial fleet

The unique sound of the GE90 is attributed to its high-efficiency fan blades made from advanced composite materials. These materials contribute to a lightweight yet strong design that allows fan blades to operate at supersonic speeds during high-thrust settings. According to GE Aerospace, “Commercial engine with composite fan blades for double the strength at one-third the weight of traditional titanium fan blades – now a hallmark on GE Aerospace’s widebody engines.”

Additive Manufacturing (AM) techniques have been integrated into various components of the GE90 engine. These techniques include methods such as Material Jetting and Powder Bed Fusion. A notable component made using AM is the high-pressure compressor sensor which enhances accuracy and reliability while reducing noise through efficient material use.

Continuous improvements have led to nearly a four percent reduction in fuel burn compared to initial specifications. Nate Hoening from GE Aerospace acknowledges this achievement: “Not many would have believed that we’d come close to this 3,000-engine milestone during the early years of the GE90 program.”

High-temperature-resistant materials are employed in critical areas of the engine where temperatures can exceed 3,000 degrees Fahrenheit. The cooling techniques used ensure that these components maintain optimal performance levels while extending their lifespan.

Mike Kauffman from GE Aerospace remarked on reaching another milestone: “We are excited to celebrate another GE90 milestone and would like to congratulate everyone involved in the engine’s success.” The company remains committed to maintaining these reliable engines throughout their lifecycle.

The GE90's high bypass ratio has contributed significantly towards achieving more than 100 million flight hours by providing an overall pressure ratio of up to forty-to-one (40:1).