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A321 NEO PW1100 case crack on DEP from Brussels.

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A321 NEO PW1100 case crack on DEP from Brussels.

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Old 28th Nov 2018, 16:35
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A321 NEO PW1100 case crack on DEP from Brussels.

Turkish Airlines A321 NEO PW1100 gearbox case crack and oil leakage on DEP from Brussels. Ac returned to Brussels for engine change.

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Old 28th Nov 2018, 18:01
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Was an accessory gearbox according to this:

https://aviation-safety.net/wikibase/wiki.php?id=218702
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Old 28th Nov 2018, 18:27
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Originally Posted by RufusXS
Was an accessory gearbox according to this:

https://aviation-safety.net/wikibase/wiki.php?id=218702
Gearbox/Accessory Gearbox is the same thing. The engine gearbox is there to provide drive for the accessories - oil pump, fuel systems, electrical systems etc.

Another PW1100 problem. In my experience cracked gearboxes like this are very rare especially so early on.
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Old 28th Nov 2018, 18:53
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Gearbox case is the operative term here. jeez

All the same, a very unusual looking crack in a new engine accessory gearbox case.

Doesnt look like a crack, but more like tear failure?

Last edited by underfire; 28th Nov 2018 at 19:11.
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Old 28th Nov 2018, 18:54
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Great! Another round of inspections.
That's a hell of a failure. Wonder how long it takes to produce a full suite of new gearbox casings for all the PW1000s out there?
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Old 28th Nov 2018, 19:11
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What did John Glenn say about "sitting on top of 2 million parts all bought from the low bidder" ?
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Old 28th Nov 2018, 19:13
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Originally Posted by FE Hoppy
Great! Another round of inspections.
That's a hell of a failure. Wonder how long it takes to produce a full suite of new gearbox casings for all the PW1000s out there?
Very good point...
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Old 28th Nov 2018, 19:24
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The casting in that region looks very strange - the surface faceted as though the metal was applied with a trowel.
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Old 28th Nov 2018, 19:27
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Closeup of break...(and limits of break)



Avio Aero gearbox:

Last edited by underfire; 28th Nov 2018 at 19:42.
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Old 28th Nov 2018, 20:02
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Originally Posted by Loose rivets
The casting in that region looks very strange - the surface faceted as though the metal was applied with a trowel.
I was thinking the same myself, maybe the lighting but it doesn't give the impression of a beautifully finished component.

Casting or forging ?
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Old 28th Nov 2018, 20:21
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Aluminum casting.

One part shows a manufactured date of 10.05.2017
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Old 28th Nov 2018, 20:56
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Gearbox/Accessory Gearbox is the same thing. The engine gearbox is there to provide drive for the accessories - oil pump, fuel systems, electrical systems etc.
I don't disagree that it appears to be the Accessory Gearbox, but on the PW1100 don't they have a separate 'gearbox' for the geared fan?
I'm not very familiar with the PW1100 architecture but I'd assumed they they had two gearboxes - the accessory gearbox, driven off the high spool, and a fan gearbox driven from the low spool?
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Old 28th Nov 2018, 21:05
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Originally Posted by tdracer
I don't disagree that it appears to be the Accessory Gearbox, but on the PW1100 don't they have a separate 'gearbox' for the geared fan?
I'm not very familiar with the PW1100 architecture but I'd assumed they they had two gearboxes - the accessory gearbox, driven off the high spool, and a fan gearbox driven from the low spool?
PW1100G fan gearbox (3:1 gearing):
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Old 29th Nov 2018, 00:56
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Originally Posted by WHBM
I was thinking the same myself, maybe the lighting but it doesn't give the impression of a beautifully finished component.

Casting or forging ?
It looks like the lighting and a degree of tonal separation (posterization) in the heavily compressed image are exaggerating the appearance of surface unevenness.
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Old 29th Nov 2018, 13:58
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The gearbox is an aluminum sand casting, not an investment casting where surfaces as cast are much smoother. Almost all accessory gear boxes are sand cast either made out of aluminum or magnesium and are not polished to make them look good. Nothing new about the way the surface looks except for the crack.

Last edited by Turbine D; 29th Nov 2018 at 14:01. Reason: added a word
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Old 29th Nov 2018, 14:31
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Originally Posted by DaveReidUK
PW1100G fan gearbox (3:1 gearing):
Shiver me timbers. With such a simple mechanical part, what could go wrong? Looks like a Rube Goldberg device.
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Old 29th Nov 2018, 14:37
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As Dave noted, the planetary gear assembly is directly on the shaft...the fan is connected to the outer ring, and the shaft through the center...I believe the planetary gear assembly is made by Kawasaki...


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Old 29th Nov 2018, 16:29
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Originally Posted by Sqwak7700
Shiver me timbers. With such a simple mechanical part, what could go wrong? Looks like a Rube Goldberg device.
C'mon guys, it's a straightforward Epicyclic sun & planet gear train, been used for all sorts of uses for about 100 years or more. For Pratt & Whitney, the good old PT6 turboprop, like most turboprops, had its reduction gearing using the same concept, though that had three intermediate carrier gears instead of five.
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Old 29th Nov 2018, 16:45
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Also, where is the subject gearbox in this thread title?

Can someone tell me which way the Fan turns, the LPC turns, the HPC turns, the HPT turns and the LPT turns ? I'm getting mixed up with two rotor system and a fan as a separate rotor?
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Old 29th Nov 2018, 17:04
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Would there normally be sufficient stress on the casing to cause such a fracture, unless it had a manufacturing fault?

Surely the casing is a container, rather than a load-bearing component.
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