Boeing 787 GE engines develop early turbine blade cracks, Chinese study claims

A newly published study by a China-based researcher has claimed that certain General Electric (GE Aerospace) engines on Boeing 787 Dreamliners are developing premature cracks in their high-pressure turbine blades. According to the South China Morning Post, high-pressure turbine blades in certain GE engines have been reported to develop cracks after as few as 1,000 flight cycles. These engine cracks do not make the planes immediately unsafe, but increase repair costs and strain airline operations — all while U.S. aerospace companies face heavy global criticism over manufacturing quality. As of August 2025, about 417 GEnx engines (15% of the global fleet) were operating with Phase 2 or Phase 2+ blades. The airline experienced five engine removals tied specifically to these HPT blade defects. Early blade damage Writing in the September issue of the Chinese aviation journal Aviation Maintenance & Engineering, Xia Xiaofeng, an engineer with Xiamen Airlines, detailed how first-stage HPT blades in GE’s Phase 2 and Phase 2+ engine configurations are developing premature thermal fatigue. Operating under extreme thermal and mechanical stress, these blades often develop radial cracks between cooling holes within 1,000 flight cycles. Over time, these cracks can expand and connect, eventually causing metal fragments to break away inside the engine. Cracks can surface within about 1,000 flight cycles, creating missing metal between cooling holes and forcing five recorded engine removals in one fleet. While the early wear doesn’t make engines immediately unsafe, airlines face rising maintenance costs and operational strain from frequent inspections and part swaps before safety limits are breached. This discovery further heightens concerns regarding the manufacturing quality and overall reliability of American aerospace products. Scrutiny on US manufacturing Reportedly, the study also described additional engine issues. For instance, thermal barrier coating decay that exposes metal to oxidation and blade-root platform cracks that forced three global engine removals. In one detailed case, a Chinese airline discovered missing blade material in an engine during a routine borescope inspection after 1,818 flight cycles. Standard guidelines called for engine removal within 10 flights. The airline safely operated the engine for 12 additional cycles before securing a replacement. GE updated its maintenance guidelines to allow regular inspections every 100 to 250 cycles instead of requiring immediate engine removal for minor material loss. About 417 GEnx engines are still operated with Phase 2 or Phase 2+ turbine blades as of August 2025. Data reveals wide performance variations, with maximum on-wing times reaching up to 4,729 flight cycles American aviation manufacturers face ongoing scrutiny over quality control and safety following a series of high-profile incidents. Fatal 737 Max crashes in 2018 and 2019 linked to MCAS software, a 2024 door plug blowout caused by missing factory bolts, and a fatal 2025 Air India 787 crash have intensified global regulatory focus. Amid these safety concerns, GE analyzed recent engine defects on the Boeing 787 and determined that thermal fatigue, driven by stress concentrations near cooling holes, is causing low-cycle blade deterioration.To mitigate risks, the study recommends shorter inspection intervals for blades exceeding 2,000 flight cycles, along with real-time monitoring of engine vibration and exhaust gas temperatures. For now, maintenance crews need to keep their borescopes ready and maintain tight inspection schedules.Get the latest in engineering, tech, space & science - delivered daily to your inbox.Mrigakshi is a science journalist who enjoys writing about space exploration, biology, and technological innovations. Her work has been featured in well-known publications including Nature India, Supercluster, The Weather Channel and Astronomy magazine. If you have pitches in mind, please do not hesitate to email her.