FAA proposes new rules for additional faulty parts in CFM Leap Engines

The May 2023 directive was initially issued after an investigation by CFM International revealed potential iron inclusion in certain engine materials. This prompted concerns about fractures leading to uncontained failures of specified components. The latest analysis suggests further deficiencies, which could lead to debris release and subsequent damage if left unaddressed.

To manage these issues, CFM International released Service Bulletin (SB) LEAP-1A-72-00-0507-01A-930A-D on January 24. This bulletin identifies affected part and serial numbers for HPT stage 1 disks, forward outer seals, and compressor rotor stages with potentially reduced material properties. Additionally, three other service bulletins published between March and November 2023 have been incorporated into this directive.

The FAA estimates that this proposal will affect around 42 LEAP-1A engines within the United States compared to the previous figure of 38 engines under the May directive. Operators are expected to replace specific components at significant costs per aircraft: $216,315 for each HPT stage disk, $48,180 for each forward outer seal, and $38,430 for each compressor rotor spool—totaling an impact on approximately 81 parts as estimated by FAA.

In terms of operational impact within the U.S., data indicates that American Airlines and Frontier Airlines may be affected due to their use of A320neo family aircraft powered by LEAP-1A engines. Other airlines such as Delta Air Lines, Hawaiian Airlines, JetBlue Airways Corp., Spirit Airlines Inc., and United Airlines Holdings Inc., operate planes equipped with alternative Pratt & Whitney PW1100G engines.

The regulatory proposal comes as both American aviation authorities like EASA also consider directives related specifically towards similar issues involving manufacturing defects reported by manufacturers including Airbus SE whose CEO acknowledged supply improvements yet cautioned about meeting delivery targets amidst these technical challenges.