General Electric starts series production of GE9X

Public debut of 777X at Dubai Air Show featuring GE9X engines (Photo: GE Reports)

Turning to look at something a little different, General Electric has started series production of its new GE9X high-bypass turbofan engine at its plant in Durham, North Carolina.

The engine, which was designed specifically for the new Boeing 777X aircraft family, is said to be the largest and most powerful commercial aircraft engine produced to date. There are some impressive stats to back that up.

Weighing in at about 18 tons, each engine has a fan made up of 16 composite blades - six less than the preceding engine to help maximise airflow and minimise drag. The fan measures 3.4 metres (134 inches) in diameter. Certified to 105,000 pounds of thrust, the engine can actually produce up to 134,000 pounds, the most of any aircraft engine.

Inside the engine, the use of ceramic matrix composites in components such as the third-gen TAPS III combustor has doubled the unit strength over like-for-like predecessors, permitting the use of higher temperatures that drive increased efficiency. Additionally, the material choice requires 59% less cooling.

A high-pressure compressor delivers the highest overall pressure ratio (27:1) used in commercial aviation (Fan/Booster/Compressor stages: 1/3/11). The overall pressure ratio at maximum power is greater than 60:1.

Just in case you were wondering, there are a total 35,370 parts in each engine.

The GE9X has undergone 27,000 cycles and 17,000 hours of testing at the site in Peebles, Ohio. This includes 1,600 cycles of dust ingestion to ensure high levels will not impact performance. This involves a dedicated particle separator to remove dust from the flow path that cools the turbine. It is blockages in these cooling passages which can cause heating issues in the turbine blades.

According to reports, the engine has undergone more testing hours than any GE Aerospace commercial aircraft engine prior to entering service.

While producing more power, the new engine still offers reduced emissions. Engineers state that NOx emissions are 55% lower than regulatory limits require and almost half those of any other engine in the class.

Further, the engine supports a 5% improvement in fuel consumption compared to any other twin-aisle aircraft engine available and a 10% improvement over the preceding GE90-115B model.

The reduced number of fan blades (see note above) also helps to cut overall noise output to where the GE9X is the quietest engine ever produced by GE Aerospace.

While a series of airlines have placed orders for the new 777X, it is reported that Lufthansa will be the first company to take delivery of the aircraft in 2026.