Abradable coatings are used in gas turbines to minimize the clearance distance between the stationary components and rotating blade tips. In this study, the effect of microstructure refining on the properties of abradable AlSi-polyester coatings was investigated. The coatings were deposited by conventional atmospheric plasma spraying system (APS) and high efficiency supersonic atmospheric plasma spraying system (SAPS). The results showed that the average area of single polyester phase was 351 ± 27 µm² in SAPS coating, about 25.2% lower than that of APS coating (469 ± 22 µm²). The hardness and bonding strength of as-sprayed SAPS coating were 79 HR15Y and 15.2 MPa, respectively, about 16.2 and 28.8% higher than the hardness and bonding strength of as-sprayed APS coating (68 HR15Y and 11.8 MPa). The track depth and friction coefficient of SAPS coating were about 51.1 and 16.9% lower than those of APS coating. When the coatings were subjected to hot-corrosion and thermal shock tests, the hardness and bonding strength of SAPS coating (47 HR15Y and 6.3 MPa) were about 67.9 and 200% higher than those of APS coating (28 HR15Y and 2.1 MPa). Additionally, the track depth and friction coefficient of SAPS coating were about 61.3 and 12.1% lower than those of APS coating. This work shows that the refinement of polyester phase, low porosity and less amount of Si phase precipitation were beneficial to improve the thermal stability and in-service performance of the abradable AlSi-polyester coatings.

可磨损涂层用于燃气轮机，以最大限度地减少固定部件和旋转叶片尖端之间的间隙距离。在这项研究中，研究了微观结构细化对耐磨铝硅聚酯涂层性能的影响。涂层采用常规大气等离子喷涂系统（APS）和高效超音速大气等离子喷涂系统（SAPS）进行沉积。结果表明，SAPS涂层中聚酯单相的平均面积为351±27μm ²，比APS涂层（469±22μm ²）。喷涂态 SAPS 涂层的硬度和结合强度分别为 79 HR15Y 和 15.2 MPa，比喷涂态 APS 涂层的硬度和结合强度（68 HR15Y 和 11.8 MPa）高约 16.2% 和 28.8%。SAPS涂层的轨道深度和摩擦系数比APS涂层低约51.1%和16.9%。涂层进行热腐蚀和热冲击试验时，SAPS涂层（47 HR15Y和6.3 MPa）的硬度和结合强度比APS涂层（28 HR15Y和2.1 MPa）高约67.9和200%。此外，SAPS涂层的轨道深度和摩擦系数比APS涂层低约61.3%和12.1%。这项工作表明，聚酯相的细化，