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AGENCY:
Federal Aviation Administration (FAA), DOT.
ACTION:
Notice of proposed rulemaking (NPRM).
SUMMARY:
The FAA proposes to adopt a new airworthiness directive (AD) for certain CFM International, S.A. (CFM) Model LEAP-1A, LEAP-1B, and LEAP-1C engines. This proposed AD was prompted by a manufacturer investigation that revealed a quality escape for low-pressure turbine (LPT) disks made from forgings with nonconforming grain size. This proposed AD would require removal and replacement of the LPT stage 4 and stage 5 disks. The FAA is proposing this AD to address the unsafe condition on these products.
DATES:
The FAA must receive comments on this proposed AD by December 23, 2024.
ADDRESSES:
You may send comments, using the procedures found in 14 CFR 11.43 and 11.45, by any of the following methods:
- Federal eRulemaking Portal: Go to regulations.gov. Follow the instructions for submitting comments.
- Fax: (202) 493-2251.
- Mail: U.S. Department of Transportation, Docket Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New Jersey Avenue SE, Washington, DC 20590.
- Hand Delivery: Deliver to Mail address above between 9 a.m. and 5 p.m., Monday through Friday, except Federal holidays.
AD Docket: You may examine the AD docket at regulations.gov under Docket No. FAA-2024-2424; or in person at Docket Operations between 9 a.m. and 5 p.m., Monday through Friday, except Federal holidays. The AD docket contains this NPRM, any comments received, and other information. The street address for Docket Operations is listed above.
Material Incorporated by Reference:
- For CFM material identified in this proposed AD, contact CFM International, S.A., GE Aviation Fleet Support, 1 Neumann Way, M/D Room 285, Cincinnati, OH 45215; phone: (877) 432-3272; email:aviation.fleetsupport@ge.com.
- You may view this material at the FAA, Airworthiness Products Section, Operational Safety Branch, 1200 District Avenue, Burlington, MA 01803. For information on the availability of this material at the FAA, call (817) 222-5110.
FOR FURTHER INFORMATION CONTACT:
Mehdi Lamnyi, Aviation Safety Engineer, FAA, 2200 South 216th Street, Des Moines, WA 98198; phone: (781) 238-7743; email: mehdi.lamnyi@faa.gov.
SUPPLEMENTARY INFORMATION:
Comments Invited
The FAA invites you to send any written relevant data, views, or arguments about this proposal. Send your comments to an address listed under the ADDRESSES section. Include “Docket No. FAA-2024-2424; Project Identifier AD-2024-00416-E” at the beginning of your comments. The most helpful comments reference a specific portion of the proposal, explain the reason for any recommended change, and include supporting data. The FAA will consider all comments received by the closing date and may revise this proposal because of those comments.
Except for Confidential Business Information (CBI) as described in the following paragraph, and other information as described in 14 CFR 11.35, the FAA will post all comments received, without change, to regulations.gov, including any personal information you provide. The agency will also post a report summarizing each substantive verbal contact received about this NPRM.
Confidential Business Information
CBI is commercial or financial information that is both customarily and actually treated as private by its owner. Under the Freedom of Information Act (FOIA) (5 U.S.C. 552), CBI is exempt from public disclosure. If your comments responsive to this NPRM contain commercial or financial information that is customarily treated as private, that you actually treat as private, and that is relevant or responsive to this NPRM, it is important that you clearly designate the submitted comments as CBI. Please mark each page of your submission containing CBI as “PROPIN.” The FAA will treat such marked submissions as confidential under the FOIA, and they will not be placed in the public docket of this NPRM. Submissions containing CBI should be sent to Mehdi Lamnyi, Aviation Safety Engineer, FAA, 2200 South 216th Street, Des Moines, WA 98198. Any commentary that the FAA receives which is not specifically designated as CBI will be placed in the public docket for this rulemaking.
Background
The FAA received a report of a quality escape on LPT disks made from forgings with nonconforming material grain size on certain CFM Model LEAP-1A and LEAP-1B engines. The supplier assessed the duplex micro-structure using an arithmetic average grain size instead of considering the coarsest grain size. After a re-check of all forgings, the supplier has identified a number of parts with a coarse grain size that is below the drawing requirement.
This condition, if not addressed, could result in uncontained part release, damage to the engine, and damage to the airplane.
FAA's Determination
The FAA is issuing this NPRM after determining that the unsafe condition described previously is likely to exist or develop on other products of the same type design.
Material Incorporated by Reference Under 1 CFR Part 51
The FAA reviewed CFM Service Bulletin (SB) LEAP-1A-72-00-0519-01A-930A-D, Issue 001-00, dated September 18, 2024 (CFM SB LEAP-1A-72-00-0519-01A-930A-D); CFM SB LEAP-1B-72-00-0419-01A-930A-D, Issue 001-00, dated September 18, 2024 (CFM SB LEAP-1B-72-00-0419-01A-930A-D); and CFM SB LEAP-1C-72-00-0100-01A-930A-D, Issue 001-00, dated September 18, 2024. This material specifies the part numbers and serial numbers of affected LPT disks, and the cycles since new thresholds for the replacement of affected LPT disks. These documents are distinct because they apply to different engine models. This material is reasonably available because the interested parties have access to it through their normal course of business or by the means identified in the ADDRESSES section.
Proposed AD Requirements in This NPRM
This proposed AD would require removal and replacement of the LPT stage 4 and stage 5 disks at the next piece-part exposure, or before exceeding between 2,400 and 19,000 cycles since new, depending on the applicable threshold identified in CFM SB LEAP-1A-72-00-0519-01A-930A-D or CFM SB LEAP-1B-72-00-0419-01A-930A-D.
Costs of Compliance
The FAA estimates that this AD, if adopted as proposed, would affect 13 engines installed on airplanes of U.S. registry.
The FAA estimates the following costs to comply with this proposed AD:
Estimated Costs
| Action | Labor cost | Parts cost | Cost per product | Cost on U.S. operators |
|---|---|---|---|---|
| Remove and replace LEAP-1A LPT stage 5 disk | 150 work-hours × $85 per hour = $12,750 | $225,500 | $238,250 | $476,500 |
| Remove and replace LEAP-1B LPT stage 5 disk | 150 work-hours × $85 per hour = $12,750 | 205,100 | 217,850 | 1,742,800 |
| Remove and replace LEAP-1B LPT stage 4 disk | 150.00 work-hours × $85 per hour = $12,750 | 442,800 | 455,550 | 1,366,650 |