The Influence of Composition and Microstructure on the Abradability of Aluminum-Based Abradable Coatings

Liu, Jianming; Yu, Yueguang; Liu, Tong; Cheng, Xiaoying; Shen, Jie; Li, Changhai

doi:10.1007/s11666-017-0526-9

Cited by 27 publications

(5 citation statements)

References 16 publications

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“…Coatings with porosity around 20% and pore diameters approaching 1 µm were prepared in the laboratory and then utilized to test the abradability and tensile bonding strength. The abradability tests were carried out on a high-speed scraping test rig (BKV-HVT300/800; BGRIMM, Beijing, China) [25,26]. A 3-axis force sensor is mounted to the specimen stage to record the scraping contact force on the coating.…”

Section: Simulation Model Validationmentioning

confidence: 99%

Mesoscale Simulation and Evaluation of the Mechanical Properties of Ceramic Seal Coatings

Cheng

Liu

et al. 2022

Coatings

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Microstructure feature extraction and performance simulations of a Yttria-Stabilized Zirconia (YSZ) abradable coating applied in the high-pressure turbines of aero-engines, with a service temperature over 1000 °C were conducted. The finite element method (FEM) numerical models of the abradability, bonding strength, and thermal shock resistance of the YSZ coating were established. The effects of porosity and pore diameter on the properties of the coating were obtained through simulations and calculations. The results indicated that the abradability, bonding strength, and thermal shock resistance of the coating were jointly determined by porosity and pore diameter. With the porosity increasing from 5% to 50%, the bonding strength of the coating decreased gradually, but the abradability and thermal shock resistance of the coating were significantly improved, especially when the porosity was above 20%. With the pore diameter increased from 0.5 μm to 1.5 μm, the abradability, bonding strength, and thermal shock resistance of the coating increased initially, and then decreased. An evaluation function using the normalized weighting strategy was proposed to characterize the comprehensive properties of the coating. The results of the evaluation showed the optimal abradability, bonding strength, and thermal shock resistance of the coating were obtained under a combination of 25% porosity and 1 μm pore diameter. This study may provide guidance for design optimization, and an improvement in the microstructure and properties of coatings in future research.

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Section: Simulation Model Validationmentioning

confidence: 99%

Mesoscale Simulation and Evaluation of the Mechanical Properties of Ceramic Seal Coatings

Cheng

Liu

et al. 2022

Coatings

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“…Abradable coatings would also experience hot gases and thereby the coatings shall be resistant against oxidation, corrosion, and thermal shock. Abradable coatings are usually the composite mixtures of three phases viz., metal matrix, second phase a solid lubricant also called dislocator phase and porosity to meet the requirements of better abradability, and the resistance against corrosion and erosion [12][13][14][15][16]. These abradable coatings are carried out through the thermal spray coating processes viz., Atmospheric Plasma Spray (APS) and Powder Flame Spray.…”

Section: Introductionmentioning

confidence: 99%

The Effect of Fuel Gas Pressure on The Properties of Nickel-Chromium-Iron-Aluminum-Boron Nitride Abradable Coating

Venkataraman,

Bagade

2024

JTSE

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Abradable coating of Nickel Chromium Iron Aluminium Boron Nitride Cermet Powder sprayed by flame spray process is used as clearance control coating on the aero engine components. Nimonic alloy Su-263 is used as substrate material for this coating. Ni5%Al composite powder sprayed through atmospheric plasma spray is used as bond coat. Different trials on test samples were carried out with varying pressures of fuel gas acetylene in the flame spray process. Coated samples from all the trials were analysed for hardness measurement and microstructure evaluation. It was observed that pressure of fuel gas acetylene in the flame spray process has direct influence on the hardness as well as microstructure of the coating. Appreciable change in rate of deposition of coating was also noticed due to variation in fuel gas pressure.

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“…acceptable abradability only at moderate incursion rates and temperature, coatings with secondary fillers like Al-hBN and Al-AlSi-hBN performed significantly better, with filler diameter and spacing playing crucial roles in enhancing abradability. [11] Developing new and more effective abradable materials has been challenging due to the complex "rubbing" interactions between the blade and the coating, resulting in extreme strain rates (up to 10 6 s À1 ) in a high-temperature environment, making direct measurements difficult. Operational conditions make it challenging to discern the effects of thermal and mechanical contributions on this material during severe contact.…”

Section: Introductionmentioning

confidence: 99%

Microstructural Modifications and Failure Mechanisms of an Aluminum‐Based Abradable Coating System during Isothermal and Cyclic Aging

Prillieux,

Thouron,

Josse

et al. 2024

Adv Eng Mater

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Abradable systems are used in the aeronautical industry to improve the efficiency of gas turbine. Those materials are exposed in service to temperature up to 450 °C. The increase in gas turbine efficiency requires to increase the operating temperature and therefore the service temperature of abradable coating. The present study focuses on the isothermal and cyclic thermal aging of the Al–Si abradable coating system in a laboratory air at high temperature up to 500 °C. The investigation encompasses the microstructural evolution, phase transformation, and the formation of cracks, along with their interrelated effects. During aging, silicon particles precipitate in the abradable top coat. In addition, coarsening of those particles is observed and the coarsening kinetics appears to be faster in cyclic thermal aging conditions compared to isothermal aging. During cyclic and isothermal aging, brittle aluminides develope at the abradable top–coat/bond–coat interface, due to the interdiffusion of Al and Ni species. During cyclic aging, thermal cycles create thermomechanical stress at the top‐coat/bont‐coat interface due to coefficient of thermal expansion mismatch between the Al‐Si deposit and intermetallic phases. The stress generated results in the formation of cracks and porosities at the top–coat/bond–coat interface resulting in a dramatic failure of the system.This article is protected by copyright. All rights reserved.

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The Influence of Composition and Microstructure on the Abradability of Aluminum-Based Abradable Coatings

Cited by 27 publications

References 16 publications

Mesoscale Simulation and Evaluation of the Mechanical Properties of Ceramic Seal Coatings

Mesoscale Simulation and Evaluation of the Mechanical Properties of Ceramic Seal Coatings

The Effect of Fuel Gas Pressure on The Properties of Nickel-Chromium-Iron-Aluminum-Boron Nitride Abradable Coating

Microstructural Modifications and Failure Mechanisms of an Aluminum‐Based Abradable Coating System during Isothermal and Cyclic Aging

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