journal article·2024-11

Protective coatings for aeroengine blade tips: a review

Shuai Yang, Bi Wu, Siyang Gao, Weihai Xue, Deli Duan

Journal of Materials Science· Volume 59· Issue 41
Publisher page

Abstract

No abstract is available for this record. The assistant can identify its topic from the title, but cannot infer the study’s results.

Source: Not provided · Quality: missing

Research context

OpenAlex topics: High-Temperature Coating Behaviors · Brake Systems and Friction Analysis · Material Properties and Applications

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (100+)

Show source-provided references
1. Padture NP, Gell M, Jordan EH (2002) Thermal barrier coatings for gas-turbine engine applications. Science 296:280–284. https://doi.org/10.1126/science.106860910.1126/science.1068609 ↗
2. Laul K, Rahemanji S (2012) Enhanced CBN blade tip systems for improving engine efficiency. AM&P Technical Articles 170 54–5610.31399/asm.amp.2012-05.p054 ↗
3. McGregor M (2020) Ni-Al-Ta alloys for high temperature abrasive coatings. University of Cambridge 1–7
4. Spittle P (2003) Gas turbine technology. Phys Educ 38:504–511. https://doi.org/10.1088/0031-9120/38/6/00210.1088/0031-9120/38/6/002 ↗
5. Reed RC (2006) The superalloys fundamental and applications. Cambridge University Press, London 1–3210.1017/CBO9780511541285 ↗
6. Huda Z (2017) Energy-efficient gas-turbine blade-material technology-a review. Mater Tehnol 51:355–36110.17222/mit.2015.196 ↗
7. Wiseman MW, Guo TH (2001) An investigation of life extending control techniques for gas turbine engines, Proceedings of the 2001 American Control Conference, (Cat. No.01CH37148) 3706–3707. https://doi.org/10.1109/ACC.2001.94621110.1109/ACC.2001.946211 ↗
8. Scott W (2012) Thermally sprayed abradable coating technology for sealing in gas turbines. In 6th international conference on the future of gas turbine technology, Brussels Belgium 1–8
9. Dorfman M, Erning U, Mallon J (2002) Gas turbines use “abradable” coatings for clearance-control seals. Seal Technol 2002:7–8. https://doi.org/10.1016/S1350-4789(02)80002-210.1016/S1350-4789(02)80002-2 ↗
10. Sporer D, Dorfman M, Xie L, Refke A, Giovannetti I, Giannozzi M (2007) Processing and properties of advanced ceramic abradable coatings, International thermal spray conference 495–500. https://doi.org/10.31399/asm.cp.itsc2007p0495.10.31399/asm.cp.itsc2007p0495 ↗
11. Metco S (2009) Improve efficiency and reduce emissions with high pressure turbine abradable coatings for industrial gas turbines. Solution flash SF 0015:1–8
12. Yang S, Gao S, Xue W, Wu B, Zhang J, Duan D (2023) High-speed rubbing behavior between nickel-based superalloy blades and ceramic-based abradable coatings. Tribol Lett 71:128. https://doi.org/10.1007/s11249-023-01798-110.1007/s11249-023-01798-1 ↗
13. Yang S, Gao S, Xue W, Wu B, Duan D (2023) Phenomenological modeling of wear mechanisms between nickel-based superalloy blades and ceramic-based abradable coatings in turbomachines. J Mater Res Technol 27:4191–4203. https://doi.org/10.1016/j.jmrt.2023.10.30610.1016/j.jmrt.2023.10.306 ↗
14. Tribomet Abrasive Coatings. http://www.praxairsurfacetechnologies.com/-/media/corporate/praxairsurface/us/documents/brochures/tribomet-abrasive-coatings.pdf (2010) (accessed December 2019).
15. Watson M (2017) Modifications to blade tips in abradable contacts. University of Sheffield 1–25
16. Taylor TA, Thompson BW, Aton W (2007) High speed rub wear mechanism in in-718 versus NiCrAl-Bentonite. Surf Coat Tech 202:698–703. https://doi.org/10.1016/j.surfcoat.2007.05.05410.1016/j.surfcoat.2007.05.054 ↗
17. Rahimov E, Watson M, Hadjisoteriou A, Marshall M (2022) Investigation of wear mechanisms in AlSi-Polyester abradable-Ti(6Al4V) blade contacts using stroboscopic imaging. Wear 494–495:204207. https://doi.org/10.1016/j.wear.2021.20420710.1016/j.wear.2021.204207 ↗
18. Bounazef M, Guessasma S, Ait Saadi B (2004) The wear, deterioration and transformation phenomena of abradable coating Bn-SiAl-bounding organic element, caused by the friction between the blades and the turbine casing. Mater Lett 58:3375–338010.1016/j.matlet.2004.02.049 ↗
19. Fois N, Stringer J, Marshall MB (2013) Adhesive transfer in aero-engine abradable linings contact. Wear 304:202–210. https://doi.org/10.1016/j.wear.2013.04.03310.1016/j.wear.2013.04.033 ↗
20. Stringer J, Marshall MB (2012) High speed wear testing of an abradable coating. Wear 294–295:257–263. https://doi.org/10.1016/j.wear.2012.07.00910.1016/j.wear.2012.07.009 ↗
21. Li J, Jing J, He J, Chen H, Guo H (2020) Microstructure evolution and elemental diffusion behavior near the interface of Cr2AlC and single crystal superalloy DD5 at elevated temperatures. Mater Design 193:108776. https://doi.org/10.1016/j.matdes.2020.10877610.1016/j.matdes.2020.108776 ↗
22. Haynes JA, Pint BA, Zhang Y, Wright IG (2007) Comparison of the cyclic oxidation behavior of β-NiAl, β-NiPtAl and γ-γ′ NiPtAl coatings on various superalloys. Surf Coat Tech 202:730–734. https://doi.org/10.1016/j.surfcoat.2007.06.03910.1016/j.surfcoat.2007.06.039 ↗
23. Shi L, Xin L, Wang X, Wang X, Wei H, Zhu S (2015) Influences of MCrAlY coatings on oxidation resistance of single crystal superalloy DD98M and their inter-diffusion behaviors. J Alloy Compd 649:515–530. https://doi.org/10.1016/j.jallcom.2015.07.09510.1016/j.jallcom.2015.07.095 ↗
24. Rajendran R (2012) Gas turbine coatings-an overview. Eng Fail Anal 26:355–369. https://doi.org/10.1016/j.engfailanal.2012.07.00710.1016/j.engfailanal.2012.07.007 ↗
25. Pomeroy MJ (2005) Coatings for gas turbine materials and long term stability issues. Mater Design 26:223–231. https://doi.org/10.1016/j.matdes.2004.02.00510.1016/j.matdes.2004.02.005 ↗
26. Yang S, Gao S, Xue W, Wu B, Cheng H, Duan D (2023) Epitaxial growth and oxidation behavior of the NiCoCrAlYTa/Y2O3 coating on a nickel-based single-crystal superalloy blade tips, produced by electro spark deposition. J Alloy Compds 931:167600. https://doi.org/10.1016/j.jallcom.2022.16760010.1016/j.jallcom.2022.167600 ↗
27. Liang J, Liu Y, Li J, Zhou Y, Sun X (2019) Epitaxial growth and oxidation behavior of an overlay coating on a Ni-base single-crystal superalloy by laser cladding. J Mater Sci Technol 35:344–350. https://doi.org/10.1016/j.jmst.2018.10.01110.1016/j.jmst.2018.10.011 ↗
28. Ye X, Tan J, Song H, Zhang Q (2018) Research progress of blade tip coating for aero-engine. Mater Prot 51:87–94
29. Zhu W, Gao Y, Liu J, Meng Q, Li J, Zhang X, Wang C (2010) Preparation method of wear-resistant coating on the blade tip of a turbine first stage working blade, CN Patent No. CN101705487A 1–4.
30. Strock CW, Guo C (2016) Hard phaseless metallic coating for compressor blade tip, U.S. Patent No. 14/630958 1–4
31. Seth BB, Gregg PW (2004) Mixed powder deposition of components for wear, erosion and abrasion resistant applications, U.S. Patent No. 6706319 1–5
32. Wang D, Xie Y, Wang W, Wang M, Chen X, Chi C, Lu D (2018) Preparation of a nanoparticle-enhanced wear-resistant coating on the blade tip of a single-crystal turbine blade, CN Patent No. CN108486567A 1–3
33. Yang S, Gao S, Xue W, Wu B, Duan D (2023) Investigations on microstructure, oxidation, and tribological behavior of NiCoCrAlYTa/Y2O3 blade tip protective coating produced by electro spark deposition over a wide temperature range. Tribol Int 180:108274. https://doi.org/10.1016/j.triboint.2023.10827410.1016/j.triboint.2023.108274 ↗
34. Manier KH (2010) Solder coating, method for coating a component, component, and adhesive tape having a solder coating, U.S. Patent No. 12811314 1–3
35. Perkins RJ, Hillery RV, Farr HJ (1992) Long life abrasive turbine blade tips, CA Patent No. CA2048804A1 1–21
36. Eichmann W et al (2011) Turbomachine blade with a blade tip armor cladding, U.S. Patent No. 7942638 1–3
37. Meier R (2004) Turbo machine blade and method for producing armour plating on the tips of turbo machine blades, WO Patent No. WO2005068784A1 1–11
38. Freling M et al (2001) Columnar zirconium oxide abrasive coating for a gas turbine engine seal system, U.S. Patent No. 6190124 1–5
39. Sun C, Liu Y, Liu J, Pei Z, Gong J (2019) A gas turbine blade tip protective coating and its preparation method and application, CN Patent No. CN109338288A 1–5
40. Schell JD, Howard JF (1999) Abrasive ceramic matrix turbine blade tip and method for forming, U.S. Patent No. 5952110 1–4
41. Everett MA, Alan RB (1995) Method for laser cladding thermally insulated abrasive particles to a substrate, and clad substrate formed thereby, U.S. Patent No. 5453329 1–6
42. Eaton HE, Richard CN, Alfred PM (1986) Abrasive surface coating process for superalloys, U.S. Patent No. 4610698 1–5
43. Stalker KM, John WZ, Norman PF (1979) Method for making an improved gas seal, U.S. Patent No. 4169020 1–3
44. Malak MF, Derek R, Thomas ES (2009) Turbine blade tip and shroud clearance control coating system, U.S. Patent No. 7473072 1–4
45. Wang M, Wang Y, Zhao Y et al (2004) The categories methods and application of surface coating/deposition of super-hard abrasives (I). Diam Abras Eng 143:68–72
46. Guo J, Yang Y, Ji X et al (2016) The research progress of wear resistant seal coating material on the tip of gas turbine blade. J Therm Spray Technol 3:5–8. https://doi.org/10.3969/j.jssn.1674-7127.2016.03.00210.3969/j.jssn.1674-7127.2016.03.002 ↗
47. Johnson GF, Peter WS (1981) Alumina coated silicon carbide abrasive, U.S. Patent No. 4249913 1–3
48. Scott W (2011) Process for treating the tip of a turbine blade and turbine blade treated by such a process, EP Patent No. EP1743957A1 1–4
49. Condit DA, Harry EE (1988) Silicon carbide abrasive particles having multilayered coating, U.S. Patent No. 4741973 1–5
50. Wiltshire AD, Terry ER (1994) Abrasive medium, U.S. Patent No. 5355637 1–3
51. Schmid RK (1997) New high temperature abradables for gas turbines, Phd Diss, ETH Zurich 1–4
52. Alpert CP, Chan HM, Bennison SJ, Lawn B (1988) Temperature dependence of hardness of alumina-based ceramics. J Am Ceram Soc 71:371–373. https://doi.org/10.1111/j.1151-2916.1988.tb06394.x10.1111/j.1151-2916.1988.tb06394.x ↗
53. Morscher GN, Pirouz P, Heuer AH (1991) Temperature dependence of hardness in yttria-stabilized zirconia single crystals. J Am Ceram Soc 74:491–500. https://doi.org/10.1111/j.1151-2916.1991.tb04049.x10.1111/j.1151-2916.1991.tb04049.x ↗
54. Mehan RL (1989) Method of forming turbine blades with abradable tips, U.S. Patent No. 4854196 1–3
55. Brown LE et al (1993) Abrasive blade tips for cast single crystal gas turbine blades, U.S. Patent No. 5264011 1–7
56. Davenport JR, Mendez-Garcia L, Purkayastha S, Hancock ME, Stearn RJ, Clegg WJ (2014) Material needs for turbine sealing at high temperature. Mater Sci Tech 30:1877–1883. https://doi.org/10.1179/1743284714Y.000000052710.1179/1743284714Y.0000000527 ↗
57. Pike RA (1987) Method for adhesion of grit to blade tips, U.S. Patent No. 4689242 1–5
58. Kushner BA et al (1991) Turbine rotor blade tip coated with alumina-zirconia ceramic, U.S. Patent No. 5059095 1–4
59. Schaefer RP et al (1989) Method for making a turbine blade having a wear resistant layer sintered to the blade tip surface, U.S. Patent No. 4851188 1–5
60. Manier KH, Ilya C, Robert S (2016) Method for manufacturing an abrasive coating on a gas turbine component, U.S. Patent No. 9322100 1–3
61. Das S, Fuesting TP, Danyo G, Brown LE, Beaman JJ, Bourell DL (2000) Direct laser fabrication of superalloy cermet abrasive turbine blade tips. Mater Design 21:63–73. https://doi.org/10.1016/S0261-3069(99)00057-610.1016/S0261-3069(99)00057-6 ↗
62. Strock CW, Guo C (2017) Method for coating compressor blade tips, U.S. Patent No. 14/630965 1–4
63. Allen D (2005) Turbine blade tip with optimized abrasive, U.S. Patent No. 10/733738 1–3
64. Hewitt A, Matthew H (2013) Wear-resistant coating and use thereof, U.S. Patent No. 13/625478 1–5
65. Nenov KP, Richard F, Joseph AF, Peter H (1999) Method for producing abrasive tips for gas turbine blades, U.S. Patent No. 5935407 1–3
66. Wheat GE, Terri KB, Roger DW (2002) Method of applying a particle-embedded coating to a substrate, U.S. Patent No. 6434876 1–4
67. Manier KH, Josef L, Andre W (2009) Component with a reinforcing plating, U.S. Patent No. 12/296985 1–2
68. Mittendorf D, Jason S, Brent L (2020) Method of producing an abrasive tip for a turbine blade, U.S. Patent No. 10857596 1–5
69. Bintz ME, Strock CW (2016) Turbine compressor blade tip resistant to metal transfer, U.S. Patent No. 9341066 1–3
70. Stoyanov P, Strock CW, Agnieszka MW (2020) Air seal abrasive coating and method, U.S. Patent No. 10544698 1–9
71. Wu B, Gao S, Xue W, Li S, Duan D (2023) Anti-adhesion mechanism of TiB2-deposited Ti6Al4V blade tip against Al-hBN seal coating during high-speed rubbing. Tribol Lett 71:51. https://doi.org/10.1007/s11249-023-01717-410.1007/s11249-023-01717-4 ↗
72. Yang S, Gao S, Xue W, Wu B, Duan D (2023) Structural design and high temperature tribological behavior of a new turbine blade tip protective coating. Surf Coat Tech 457:129316. https://doi.org/10.1016/j.surfcoat.2023.12931610.1016/j.surfcoat.2023.129316 ↗
73. Gao S, Yang S, Duan D, Chi C, Xue W, Wu B, Zhao Z, Lin L, Li S (2022) A high-temperature turbine blade tip wear-resistant cutting coating and its preparation method and application, CN Patent No. 115595486 B 1–6
74. Sato A, Chiu Y-L, Reed RC (2011) Oxidation of nickel-based single-crystal superalloys for industrial gas turbine applications. Acta Mater 59:225–240. https://doi.org/10.1016/j.actamat.2010.09.02710.1016/j.actamat.2010.09.027 ↗
75. Birks N, Meier GH, Pettit FS (2009) Introduction to the high-temperature oxidation of metals. Cambridge University Press, Cambridge
76. Xiao Q, Huang Q, Yang L, Ren P, Yang Y, Wang Q (2022) The cyclic oxidation behavior of a Pt modified γ’ nanocrystalline coating at 1150 °C. Corros Sci 208:110638. https://doi.org/10.1016/j.corsci.2022.11063810.1016/j.corsci.2022.110638 ↗
77. Hu Y, Cao T, Cheng C, Zhang L, Zhao J (2019) Oxidation behavior of a single-crystal Ni-based superalloy over the temperature range of 850 °C-950 °C in air. Appl Surf Sci 484:209–218. https://doi.org/10.1016/j.apsusc.2019.04.08910.1016/j.apsusc.2019.04.089 ↗
78. Saber D, Emam IS, Abdel-Karim R (2017) High temperature cyclic oxidation of Ni based superalloys at different temperatures in air. J Alloy Compd 719:133–141. https://doi.org/10.1016/j.jallcom.2017.05.13010.1016/j.jallcom.2017.05.130 ↗
79. Subanovic M, Sebold D, Vassen R, Wessel E, Naumenko D, Singheiser L (2008) Effect of manufacturing related parameters on oxidation properties of MCrAlY-bond coats. Mater Corros 59:463–470. https://doi.org/10.1201/978100342149810.1201/9781003421498 ↗
80. Guo C, Duan X, Fang Z, Zhao Y, Yang T, Wang E (2022) A new strategy for long-term complex oxidation of Max phases: database generation and oxidation kinetic model establishment with aid of machine learning. Acta Mater 241:118378. https://doi.org/10.1016/j.actamat.2022.11837810.1016/j.actamat.2022.118378 ↗
81. Yang YF, Jiang CY, Zhang ZY, Bao ZB, Chen MH, Zhu SL (2017) Hot corrosion behaviour of single-phase platinum-modified aluminide coatings: effect of Pt content and pre-oxidation. Corros Sci 127:82–90. https://doi.org/10.1016/j.corsci.2017.08.01510.1016/j.corsci.2017.08.015 ↗
82. Yang YF, Liu ZL, Ren P, Wang QW, Bao ZB, Zhu SL (2020) Hot corrosion behavior of Pt+Hf co-modified NiAl coating in the mixed salt of Na2SO4-NaCl at 900 °C. Corros Sci 167:108527. https://doi.org/10.1016/j.corsci.2020.10852710.1016/j.corsci.2020.108527 ↗
83. Rapp RA (2002) Hot corrosion of materials: a fluxing mechanism? Corros Sci 44:209–221. https://doi.org/10.1016/S0010-938X(01)00057-910.1016/S0010-938X(01)00057-9 ↗
84. Vasudev H, Thakur L, Singh H, Bansal A (2020) A study on processing and hot corrosion behaviour of HVOF sprayed inconel718-nano Al2O3 coatings. Mater Today Commun 25:101626. https://doi.org/10.1016/j.mtcomm.2020.10162610.1016/j.mtcomm.2020.101626 ↗
85. Eliaz N, Shemesh G, Latanision RM (2002) Hot corrosion in gas turbine components. Eng Fail Anal 9:31–43. https://doi.org/10.1016/S1350-6307(00)00035-210.1016/S1350-6307(00)00035-2 ↗
86. Jiang SM, Li HQ, Ma J, Xu CZ, Gong J, Sun C (2010) High temperature corrosion behaviour of a gradient NiCoCrAlYSi coating II: Oxidation and hot corrosion. Corros Sci 52:2316–2322. https://doi.org/10.1016/j.corsci.2010.03.03210.1016/j.corsci.2010.03.032 ↗
87. Chen L, Lan H, Huang C, Yang B, Du L, Zhang W (2017) Hot corrosion behavior of porous nickel-based alloys containing molybdenum in the presence of NaCl at 750 °C. Eng Fail Anal 79:245–252. https://doi.org/10.1016/j.engfailanal.2017.05.00910.1016/j.engfailanal.2017.05.009 ↗
88. Mahobia GS, Paulose N, Singh V (2013) Hot corrosion behavior of superalloy IN718 at 550 and 650 °C. J Mater Eng Perform 22:2418–2435. https://doi.org/10.1007/s11665-013-0532-010.1007/s11665-013-0532-0 ↗
89. Liu YD, Sun J, Pei ZL, Li W, Liu JH, Gong J (2020) Oxidation and hot corrosion behavior of NiCrAlYSi+NiAl/cBN abrasive coating. Corros Sci 167:108486. https://doi.org/10.1016/j.corsci.2020.10848610.1016/j.corsci.2020.108486 ↗
90. Yang S, Gao S, Xue W, Wu B, Duan D (2024) Oxidation and hot corrosion behaviors of NiAlTa protective material for turbine single crystal blade tips. Corros Sci 230:111899. https://doi.org/10.1016/j.corsci.2024.11189910.1016/j.corsci.2024.111899 ↗
91. Hou G, An Y, Zhao X, Zhou H, Chen J (2015) Effect of alumina dispersion on oxidation behavior as well as friction and wear behavior of HVOF-sprayed CoCrAlYTaCSi coating at elevated temperature up to 1000 °C. Acta Mater 95:164–175. https://doi.org/10.1016/j.actamat.2015.05.02510.1016/j.actamat.2015.05.025 ↗
92. Rynio C, Hattendorf H, Klöwer J, Eggeler G (2014) The evolution of tribolayers during high temperature sliding wear. Wear 315:1–10. https://doi.org/10.1016/j.wear.2014.03.00710.1016/j.wear.2014.03.007 ↗
93. Yin C, Liang Y, Liang Y, Li W, Yang M (2019) Formation of a self-lubricating layer by oxidation and solid-state amorphization of nano-lamellar microstructures during dry sliding wear tests. Acta Mater 166:208–220. https://doi.org/10.1016/j.actamat.2018.12.04910.1016/j.actamat.2018.12.049 ↗
94. Österle W, Dmitriev AI (2011) Functionality of conventional brake friction materials-perceptions from findings observed at different length scales. Wear 271:2198–2207. https://doi.org/10.1016/j.wear.2010.11.03510.1016/j.wear.2010.11.035 ↗
95. Stott FH (2002) High-temperature sliding wear of metals. Tribol Int 35:489–495. https://doi.org/10.1016/S0301-679X(02)00041-510.1016/S0301-679X(02)00041-5 ↗
96. Lou M, Chen X, Xu K, Deng Z, Chen L, Lv J (2021) Temperature-induced wear transition in ceramic-metal composites. Acta Mater 205:116545. https://doi.org/10.1016/j.actamat.2020.11654510.1016/j.actamat.2020.116545 ↗
97. Feng K, Shao T (2021) The evolution mechanism of tribo-oxide layer during high temperature dry sliding wear for nickel-based superalloy. Wear 476:203747. https://doi.org/10.1016/j.wear.2021.20374710.1016/j.wear.2021.203747 ↗
98. Gao S, Xue W, Duan D, Li S (2016) Tribological behaviors of turbofan seal couples from friction heat perspective under high-speed rubbing condition. Friction 4:176–190. https://doi.org/10.1007/s40544-016-0114-x10.1007/s40544-016-0114-x ↗
99. Wu B, Gao S, Zhang R, Xue W, Li S, Duan D (2022) Investigation of the Al-adhesive transfer mechanism on Ti6Al4V blade tips under high-speed rubbing in an aero-turbine engine. Eng Fail Anal 142:106692. https://doi.org/10.1016/j.engfailanal.2022.10669210.1016/j.engfailanal.2022.106692 ↗
100. Xue WH, Gao SY, Duan DL, Liu Y, Li S (2015) Material transfer behaviour between a Ti6Al4V blade and an aluminium hexagonal boron nitride abradable coating during high-speed rubbing. Wear 322–323:76–90. https://doi.org/10.1016/j.wear.2014.10.00110.1016/j.wear.2014.10.001 ↗