Rolls-Royce’s Trent XWB-97 durability upgrades are outperforming expectations in ongoing dust-ingestion testing, the engine maker says, a development that could ease long-standing operator concerns about A350-1000 operations in sandy, hot environments. FlightGlobal reported the test results on 14 November 2025, quoting Phil Curnock, Trent XWB chief engineer, and Rolls-Royce media material.
What happened and why it matters
Rolls-Royce has been running an intensive test programme at its Derby Testbed 80 facility since late 2024 to simulate the abrasive conditions seen in the Middle East. The company says the third phase of durability upgrades, which includes redesigned high-pressure turbine blades, ceramic-matrix composite (CMC) seals and combustor modifications, is showing results that “meet or exceed” expectations, with more than 1,000 dust-ingestion cycles completed to date. The goal: double time-on-wing for the XWB-97 in harsh conditions and cut removals and maintenance for operators.
Technical upgrades and test program
- Phase work: The upgrades are being introduced across three phases. Earlier phases focused on thermal margins and coatings; the third phase adds internal HPT cooling passage changes, CMC seal use and combustor tweaks to reduce hotspots.
- Testing: Rolls-Royce ran over 1,000 cycles of dust-ingestion testing on a production XWB-97, and will run further multi-month sand-ingestion tests and flight/certification tests aboard an A350-1000 in 2027, with full in-service introduction targeted for 2028.
Why that matters: engine core damage from CMAS (molten deposits from dust/sand) shortens component life; the upgrades aim to reduce CMAS attack and extend on-wing intervals, vital for carriers operating long daily cycles in the Gulf.
Operator context and past concerns
Gulf carriers, especially Emirates, initially withheld orders for the A350-1000 pending demonstrable engine durability improvements. Emirates’ president Sir Tim Clark publicly set expectations for multi-thousand cycle on-wing targets. Rolls-Royce’s programme is a direct response to those operational requirements.
Timeline & quick facts
- Late 2024: Dust-ingestion testing campaign began on a production XWB-97 at Derby.
- 2025 (Nov): FlightGlobal reports >1,000 cycles achieved; Phase 3 nearing completion.
- 2027: Planned flight and certification tests aboard A350-1000.
- 2028: Targeted entry into service for full Phase 3 upgrades and in-service retrofit plan.
Implications for airlines and MROs (A350-1000 engine)
- Airline operations: Longer time-on-wing reduces unscheduled removals and maintenance costs, especially important for high-utilisation carriers in dusty regions.
- Fleet decisions: Satisfactory durability could shift purchasing calculus for carriers still on the fence about the A350-1000.
- MRO planning: Extended on-wing intervals change overhaul schedules and spare-parts provisioning, affecting MRO throughput and aftermarket revenue patterns.
Expert caveats & what remains to prove
Rolls-Royce’s testing is rigorous, but real-world confirmation requires multi-year fleet data. FlightGlobal and the OEM both stress that while rig testing has “met or exceeded” expectations, the firm still plans thorough flight verification and more long-duration tests in 2027 before declaring full success. Operators and lessors will look for fleet leader reports before fully adjusting maintenance plans.
What’s Next? Industry outlook
- Watch for Rolls-Royce flight test announcements in 2027 and subsequent regulatory or service-bulletin publications.
- Airlines (notably in the Middle East) will monitor in-service reports before revising procurement or fleet plans.
- MROs and lessors will update maintenance programmes and residual-value assessments as empirical durability data becomes available.
Sources
- Dominic Perry, FlightGlobal, “Rolls-Royce trusts in dust as Trent XWB-97 durability upgrades ‘exceed expectations’ in testing”, 14 Nov 2025.
- Rolls-Royce media pages detailing Trent XWB-97 durability upgrade programme and timelines.
- Supporting trade coverage: Aviation Week reporting and other industry outlets.
