Microstructure and Properties of New Abradable Seal Coatings for Compressor Applications
Mr. Jochen Zwick1, Prof. Kirsten Bobzin1, Prof. Erich Lugscheider1, Dr. Dieter Sporer2, Noel Hopkins3, Dr. Manuel Hertter4, Jiri Matejicek5 and Mr. Felix Ernst1, 1Surface Engineering Institute, RWTH Aachen University, Juelicher Str. 344a, Aachen, 52070, Germany, 2Sulzer Metco Neomet Ltd., Hirnbeinstr. 2, Sonthofen, 87527, Germany, 3Abradables, Rolls-Royce PLC, PO Box 31, Derby, DE24 8BJ, United Kingdom, 4MTU Aero Engines GmbH, Dachauer Str. 665, München, 80995, Germany, 5Institute of Plasma Physics, Za Slovankou 3, Prague, 182 00, 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.

Session 24: Properties, Characterization & Testing 4

The Preliminary Program for International Thermal Spray Conference And Exposition (ITSC) (May 15-18, 2006)