As it reaches its 10-year revenue service anniversary, the GEnx engine recently achieved outstanding endurance test results, completing over 3,000 cycles of dust ingestion testing in a simulated severe environment using a specialized dust ingestion rig.
The dust endurance testing is part of GE Aviation’s continued investment in the next generation of technology for the engine line, ensuring that the fastest-selling, high-thrust engine in GE Aviation history continues to deliver for customers into its next decade.
Ten years ago today, the GEnx engine entered into service powering a Cargolux 747-8. Developed for the Boeing 787 Dreamliner and 747-8 aircraft, the GEnx has the advantage of lower fuel consumption and reduced CO2 emissions up to 15% compared to GE’s CF6 engine.
The endurance tests validated several hardware improvements, including an improved combustor deflector and redesigned high pressure turbine stage 1 blade.
“We are taking GEnx durability to the next level,” said GEnx General Manager David Kircher. “I’m confident, and the endurance testing proves, that these design improvements will meet our time-on-wing and durability goals, even in the harshest environments. It’s exciting to celebrate the 10-year service anniversary while investing in the future of product.”
The endurance testing mimicked the dust GEnx engines encounter flying in some of the most severe operating environments in the world. In partnership with GE Research, dust was reversed engineered to replicate specific field conditions.
The dust, which can lead to hardware distress, is so fine that it cannot be seen with the naked eye. Test engineers used sophisticated equipment, including sensors sensitive enough to detect to the dust, and lean principles to improve the findings during the test campaign.
Representing a giant leap forward in propulsion technology, GEnx uses lightweight durable materials and advanced design processes to reduce weight, improve performance, and lower maintenance, making it the best engine choice for many long-haul flights, including several recording-breaking longest flights.
- Customers have ordered more than 2,700 GEnx engines, making it the fastest-selling high-thrust engine in GE’s history.
- The GEnx’s innovative lean burning twin-annular pre-swirl (TAPS) combustor dramatically reduces NOx and other regulated gases below today’s regulatory limits and enhances durability.
- The GEnx has delivered over 46 million metric tons of cargo in its 10-year history, in addition to moving over 370 million passengers, all while providing up to 15% improved fuel efficiency.
- GEnx has enabled several record-breaking longest flights, including:
- The Qantas QF14 record-breaking 787-9 repatriation flight on October 7, 2021, covering 9,332 miles from Buenos Aires to Darwin, touching down after 17 hours and 25 minutes in the air
- The Comlux 20 hour and 19 minute flight on March 29, 2021, from Seoul Incheon to Buenos Aires
- The Qantas 787-9 flight from New York to Sydney as part of Qantas’ Project Sunrise research flight, covering 10,200 miles in 19 hours and 16 minutes
- The first additively manufactured part installed on a GEnx was approved by the FAA in November 2018 for the power door opening system (PDOS) bracket.