Each plane, like any other piece of technology, has a life expectancy. However, treating anything with care extends its lifespan. How long can today’s aircraft stay airworthy?
Classic planes still take to the skies.
Airshows worldwide showcase classic antique aircraft. Many aviation enthusiasts dedicate hours to fiddling with their cherished aircraft in order to keep them flying. While many antique aircraft are still operational, why are jetliners being retired and scrapped?
An aircraft’s lifespan is determined by pressurization cycles, which stress the fuselage and wings, rather than in years. Given that an airplane is held together by numerous fasteners and rivets, they might become stressed over time, resulting in metal fatigue.
Airlines make significant investments when purchasing new aircraft, and guaranteeing their longevity is crucial to the airline’s bank sheet. Understanding how long one of their aircraft can remain in service helps the world’s biggest airlines plan for the future and run their operations more effectively.
Ensuring that commercial aircraft have durability and longevity, and can manage their maintenance properly, will provide the airline a clear perspective of what affects their lifespan.
Frequent maintenance and repairs occur.
An aircraft’s lifespan is mainly dependent on the airline’s investment in maintenance and repair. Aircraft inspections are scheduled on a regular basis to ensure normal servicing and compliance with manufacturer specifications.
Airlines have strict maintenance programs in place, resulting in aircraft that regularly outlast their expected lives.
However, if the airline does not pay enough care to the airplane and neglects it, their investment may retire prematurely, costing the airline more money in the long term.
Aircraft manufacturers have a set of regular maintenance recommendations that airlines should adhere to, and if they do, their aircraft will be operational for many years.
If these rules are followed, the average Boeing 747 should be able to fly up to 25 years, while the smaller Boeing 737 is expected to last roughly 20 years in the air. Differences in airline longevity are determined by design, materials used, intended use, and climate conditions.
Usage patterns influence the overall lifespan of an aircraft.
The operational use of an aircraft can affect its overall durability and longevity. One example is when airplanes are used for multiple short-haul flights every day.
This will result in more takeoffs and landings, increasing strain on the aircraft and causing greater wear and tear. These have fewer takeoffs and landings than long-haul flights. However, the stress of flying at greater altitudes can take its toll.
The environment in which airplanes operate can also influence their performance. Extreme weather conditions, such as flights to the Arctic or Australia’s outback, can have an impact on an aircraft’s longevity.
High humidity levels will pump moisture into the aircraft’s nooks and crannies, causing erosion, and harsh weather will also have an impact on surface damage. If airlines operate in these tough settings, maintenance safeguards are required to alleviate the aircraft’s stresses.
Technology also has a significant role in increasing aircraft lifespans. Today, we observe ongoing breakthroughs in technology, materials, and engineering that have helped to extend aircraft lifespans.
Today’s aircraft have advancements like as corrosion-resistant materials, which assist lessen the likelihood of wear and tear.
Up to 90,000 flying cycles for the Boeing 737.
Commercial aircraft are projected to remain between 20 and 30 years in operation, with some lasting longer with increased expenditure in maintenance and repairs. As previously stated, flight cycles and flight hours are used to determine the longevity of commercial aircraft.
The Boeing 747 has a flight time of around 90,000 hours, with a potential lifespan of up to 25 years. The Boeing 737 has a lifespan of approximately 90,000 flight cycles (55,000 hours).
Emirates’ most popular Airbus aircraft, the A380, has an anticipated lifespan of 25 years or 60,000 flying hours. The Airbus A320 has a lifespan of approximately 60,000 hours (24,000 flight cycles).
Commercial aircraft lifespans have evolved over the decades, as opposed to the early days of flying, when aircraft were made with cheap materials and operated for only a decade or so.
Developments in aviation history
Aircraft lifespans began to increase in the late 1950s and 1960s as a result of improved maintenance and new engine technologies.
The Boeing 707 and Douglas DC-8 defied expectations and remained operational for a long time. In the 1980s, the development of composite materials and improved aerodynamics enhanced aircraft functionality and longevity, resulting in the Boeing 757 and Airbus A320 flying for several decades.
Today’s new aircraft benefit from cutting-edge technology and superior avionics, extending the average lifespan of commercial jet aircraft to 25 to 30 years. Some airlines continue to operate airplanes that are more than 30 years old.
The progression represents the industry’s continual commitment to improve reliability, efficiency, and safety so that airplanes can operate for extended periods of time.
What will happen next?
While you can spend hundreds of thousands of dollars to keep an airplane in the air, its operational life will eventually come to an end. When this happens, airplanes undergo a multi-step procedure.
During the COVID-19 Pandemic, airlines aimed to enhance liquidity by offloading older aircraft from their fleets, leading to increased aircraft retirement.
Retired airplanes are frequently transported to dry regions, such as the Mojave Desert or Alice Springs, where they can be maintained and collected for parts.
When an airline sends an aircraft for long-term storage, it could be for two reasons: preservation to be brought back to life later, or dismantling and salvaging of parts. When it is the latter, engines and avionics can be removed and reconditioned for use in another aircraft.
Metals and composites can be recycled to lessen their environmental impact. Hazardous chemicals, such as lubricants, are safely disposed of, and the fuselages are commonly reused in new applications, such as hotels or even a McDonald’s in New Zealand (see link below)!
While it is usually assumed that commercial aircraft will live between 20 and 30 years, these figures will ultimately rely on how the aircraft is maintained.
While many people consider chronically aging airplanes to be dangerous, they can operate much longer than predicted if they are subjected to a comprehensive maintenance program.
The oldest aircraft flying for the ‘Big Three’ US carriers
The three major airlines in the United States, American, Delta, and United, are known as the ‘Big Three’. While these airlines have begun fleet renewal efforts, they still have numerous retiring aircraft. With this in mind, what are the oldest aircraft still in service with these carriers?
American Airlines’
- N649AW aircraft is an Airbus A320-200.
Fort Worth-based American Airlines’ fleet still includes a 26-year-old Airbus A320. The aircraft, which was inherited from US Airways in October 2015, was originally delivered to America West Airways in April 1998 before joining US Airways in November 2006.
According to Flightradar24, the aircraft will be based in Phoenix and fly domestically to St. Louis, Sacramento, and Fresno.
Delta Air Lines’
- N649DL – Boeing 757-200.
This 35-year-old aircraft entered service for Delta in May 1989 and is outfitted as a VIP with 72 first-class seats.
The airline plans to remove the aged aircraft during the next few years as a large number of Airbus A321neos and Boeing 737 MAX 10s are delivered, providing as appropriate replacements for the 757.
According to Flightradar24, the aircraft was still active at the time of writing, flying between Pittsburgh and Toronto, Milwaukee and Minneapolis, and Denver and Bedford.
United Airlines’
- Boeing 767-300ER (N641UA)
This 33-year-old aircraft, which was delivered to United in April 1991, is still in service with the Star Alliance member.
At the time of writing, the aircraft was planned to fly between Houston and Amsterdam, San Juan, and Geneva. United’s sub-fleet of 767s has an average age of nearly 29 years and is anticipated to be decommissioned by 2030, to be replaced by the 150 787s on order.