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Thursday, May 18, 2006 - 10:20 AM
APP16.1

Microstructure and Properties of New Abradable Seal Coatings for Compressor Applications

J. Zwick, F. Ernst, Surface Engineering Institute, RWTH Aachen University, Aachen, Germany; K. Bobzin, E. Lugscheider, Surface Engineering Institute (IOT), RWTH Aachen University, Aachen, Germany; D. Sporer, Sulzer Metco Neomet Ltd., Sonthofen, Germany; N. Hopkins, Rolls-Royce PLC, Derby, United Kingdom; M. Hertter, MTU Aero Engines GmbH, München, Germany; J. Matejicek, Institute of Chemical Technology, Praha, Czech Republic

In modern jet engines, the efficiency of the compressor stages is highly dependent upon the clearance between housing and rotating compressor blades. To control the over-tip leakage, abradable coating systems are applied on the housing. In the high pressure compressor they typically consist of a thermal sprayed multiphase material, comprising a metal matrix combined with a dislocator and/or a solid lubricant as well as a defined level of porosity. In this study, novel material systems have been sprayed via different plasma and flame spray processes and compared to reference materials. Resulting microstructures have been analysed as well as important coating characteristics evaluated, including coating hardness and corrosion and erosion resistance. Furthermore rig tests were performed to analyse the coatings abradability behaviour under different operation conditions of the compressor.

Summary: In this study, novel abradable material systems have been sprayed via different plasma and flame spray processes and compared to reference materials. Resulting microstructures have been analysed as well as important coating characteristics evaluated, including coating hardness, corrosion and erosion resistance and abradability