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Effect of Microstructure Refining on the Thermal Stability and Wear Resistance of Abradable AlSi-Polyester Coating

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Abstract

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.

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Acknowledgments

This work was supported by the Natural Science Basic Research Plan in Shaanxi Province of China (Grant No. 2020JQ-911, 2020JM-631, 2019JQ-910), and Natural Science Foundation of China (Grant No.51902241).

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Authors and Affiliations

  1. School of Materials Engineering, Xi’an Aeronautical University, Xi’an, 710077, People’s Republic of China

    Jian-jiang Tang, Fang-li Yu, Hai-hong Zhang & Dan Chen

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Tang, Jj., Yu, Fl., Zhang, Hh. et al. Effect of Microstructure Refining on the Thermal Stability and Wear Resistance of Abradable AlSi-Polyester Coating. J Therm Spray Tech 30, 1615–1623 (2021). https://doi.org/10.1007/s11666-021-01217-8

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