Abstract No.:
2674

 Scheduled at:
Wednesday, September 28, 2011, Saal A 10:15 AM
Aviation Industry 2


 Title:
Robust abradable coating development for aero engine compressor applications

 Authors:
Scott Wilson* / Sulzer Metco AG, Switzerland
Daniel E. Garcia / Sulzer Metco Canada Inc., Canada
Petr Fiala/ Sulzer Metco Canada Inc., Canada
Eric Kozculab/ Sulzer Metco Canada Inc., Canada
Dieter Sporer/ Sulzer Metco Europe, Germany
Omar Sabouni/ Sulzer Metco US Inc, USA
Montia Nestler/ Sulzer Metco US Inc, USA

 Abstract:
Introducing abradable coatings into aero compressors and turbines as a means to minimise gaps between rotating and stationary components by allowing the rotating parts to cut into the stationary ones, has become the most cost effective means for improving the overall fuel efficiency and emissions control in aero engines today.

Before any abradable coating candidate is launched as a new product it needs to pass through a rigorous series of testing procedures and risk mitigation reviews to ensure product robustness. This involves testing of the coating under conditions which it is most likely to experience during service. Perhaps the most rigorous screening is required for high pressure compressor applications having titanium alloy blading. Here risk mitigation screening needs to account for titanium blade blade wear and fire risk, coating hardening effects from ageing phenomena, sufficient corrosion and oxidation resistance and sufficient thermal cycle life. In addition, the coating needs to be applied in a robust and dependable manner using thermal spray processes and parameters that can be utilised easily at any desired location.

The objective of this paper is to give an insight into the development of an abradable coating candidate for a titanium blade friendly high pressure compressor aero application. Particular emphasis on powder design principles, performance screening methods, application robustness and comparison with current products will be given


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