Dynamic Hardness of MCrAlY Abradable Seal Coating

The purpose of this investigation is to study the dynamic hardness of MCrAlY abradable coatings under different strain rates. A dynamic indentation device based on the split Hopkinson pressure bar system (SHPB) was used. The results show that the hardness of MCrAlY coating increased with the increase of the strain rate, which has a positive strain rate effect. In addition, the difference of the static hardness of MCrAlY coating prepared by HVOF and LPPS was only 4%, while the difference in dynamic hardness was 16%.

Dynamic characteristics analysis of blade-casing rubbing faults with abradable coatings

In this paper, a dynamic model of a “0-2-1” rotor system with rubbing fault between blade and abradable coated casings is developed. The sub-model of rubbing force considers scraping work energy of coating, casing stiffness, and initial clearance between blade tip and casing. A rotor rig is established and samples of abradable coatings are introduced into the rubbing experiment. Vibration characteristics of the rotor system under blade-casing rubbing fault are analyzed. Effects of rotating speed and initial clearance on the rub force and the system vibration are studied. Results show that the vibration of rotor focuses on the fundamental and multiple fundamental frequencies due to the blade-casing rubbing with the abradable coating. The multiple fundamental frequencies, the 2 × and 3 × in particular, are greatly affected by the rotating speed. The fractional harmonic frequencies are strongly influenced by the initial clearance between the blade tip and casing. Besides, the rotating speed and the initial clearance between the blade tip and abradable coating on the casing also affect the amplitude and distribution of the rub force.

Evaluation of Microstructure, Phase Composition and Hardness of Alternative Abradable Ceramic Coating Systems Produced by Means of Atmospheric Plasma Spraying

Only a few types of commercially available high temperature ceramic abradable coatings are presented on the market and most of them consist of partially stabilized yttria zirconia with polymer porosity former agent and/or hBN solid lubricant. The basic demand placed on abradable coatings include balance between hardness and erosion resistance. The contribution focuses on the description of microstructure, phase composition and hardness of alternative atmospheric plasma sprayed ceramic abradable coatings deposited from four different experimental powder mixtures: (i) commercial yttria-zirconia + 5 wt. % of experimental BaF2/CaF2, (ii) commercial yttria stabilized zirconia + 10 wt. % of experimental BaF2/CaF2, (iii) R&D powder SrxTiOy and (iv) R&D powder SrxTiOy + 5 wt. % of polyester. The abradable coating systems were of ~ 150 μm thick CoNiCrAlY bond coat and of ~ 800-1000 μm thick ceramic top coat. The microstructure and phase composition of all atmospheric plasma sprayed coating systems were evaluated by the means of scanning electron microscopy and X-ray diffraction techniques. To estimate coatings basic parameters the Rockwell hardness HR15Y was measured.

Temperature and strain rate dependent mechanical response of METCO 601 aluminium-polyester abradable seal coating

Abradable coatings are utilised as sacrificial materials in low-pressure compressor casings, and in intermediate and high pressure compressors and seals. The adoption of abradable coatings allows for the clearance between compressor blades and casing to be minimised, increasing the overall efficiency of the engine. Quasi-static and dynamic experiments at different temperatures are conducted to characterise the mechanical response of a thermally-sprayed abradable seal coating. The material is composed of an aluminium continuum matrix and fairly well-dispersed polyester particles. Stress versus strain histories are measured in uniaxial tension and compression at strain rates ranging from 10-3 to 102 s-1, via non-standard experimental techniques. The material displays sensitivity to the strain rate and to the imposed temperature. The mechanical behaviour is brittle in tension while it exhibits higher strains to failure in compression. The material is characterised by a pronounced tension/compression asymmetry.

The Role of Different Atmospheric Plasma Spray Parameters on Microstructure of Abradable AlSi-Polyester Coatings

One of the approaches to increase the thermic efficiency of aerospace engines is the application of abradable coatings enabling minimization and control of the clearance between the stator and the rotating blades tips. The main purpose of this contribution is to define the role of different technological parameters utilized for atmospheric plasma spraying of AlSi-polyester coating on its resulting microstructure. Deposition of abradable coatings on the real engine parts is mostly dependent on spraying stand-off distance and on spraying angle. These two parameters influence not only the coating microstructure but also the deposition efficiency itself, which is directly connected with economical aspects of the coating production. The set of experimental samples with atmospheric plasma sprayed Ni-based bond coat and two in chemical composition same initial powders delivered from different powder manufacturers were used to spray thick AlSi-polymer top coats with different spraying stand-off distances and angles. Subsequently some of the samples were also heat treated to burn-out the polymer phase from the coating microstructure. The Rockwell HR15Y hardness was measured on all samples and the microstructure and coating thickness were evaluated by means of light microscopy and image analysis methods.