Self-lubricating epoxy-based composite abradable seal coating eliminating adhesive transfer via hierarchical design

doi:10.1016/j.jmst.2021.07.017

Abstract

Abstract:

Aluminum-based composite abradable seal coatings are pivotal to improving the efficiency of aero engines or gas turbines. However, the adhesive transfer frequently occurs between metallic blade tips and aluminum-based composite coatings, resulting in engine vibration and even jam. Many past studies had tried to solve this problem by reducing coating hardness, improving lubrication, or strengthening blade tips, but all had failed. In this paper, we proposed a novel epoxy-based composite abradable seal coating, eliminating adhesive transfer by changing metal-to-metal scraping pair to metal-to-polymer scraping pair. The coating was developed via a hierarchical structure design. Large spherical pores were uniformly distributed in the continuous epoxy matrix with fine graphite dispersion. By adding 20 vol.% graphite and 50 vol.% hollow microspheres, a self-lubricating epoxy-based coating of 0.26 friction coefficient with thermal conductivity of 0.28 W/(m·K), coating HR15Y hardness at 54.8, and bonding strength at 18.7 MPa can be reached. When the metallic blades scrape the epoxy-based composite coating, no adhesive transfer occurs. Besides, a smooth scraped surface is formed by pseudoplastic deformation. This epoxy-based composite abradable seal coating opens a new way to improve the efficiency and reliable operations of air engine compressors.

Key words: Epoxy-based composite coating, Hierarchical structure design, Self-lubricating, Pseudoplastic deformation

Yun-qi Tong, Wei Li, Qiu-sheng Shi, Lin Chen, Guan-jun Yang. Self-lubricating epoxy-based composite abradable seal coating eliminating adhesive transfer via hierarchical design[J]. J. Mater. Sci. Technol., 2022, 104: 145-154.

Figures/Tables 16

Fig. 1. Schematic diagram of hierarchical design model for composite coating: (a) matrix, (b) matrix + graphite, and (c) (matrix+ graphite) + HMS.

Fig. 2. Mesh and boundary conditions for element model of composite coating

Fig. 3. Abradability test: (a) schematic of scraping test rig, (b) simulated blade and (c) composite abradable seal coating.

Fig. 4. Surface morphology (a, b) of fillers and polished morphologies of cross-section(c-f) for 50 vol.% HMS coating with different graphite:(a) graphite, (b) HMS, (c) 5 vol.% graphite, (d) 10 vol.% graphite, (e) 15 vol.% graphite and (f) 20 vol.% graphite.

Fig. 5. Thermal conductivity prediction of composite systems.

Fig. 6. Laser flash test results of 50 vol.% HMS coating with different graphite: (a) thermal diffusivity, (b)thermal conductivity.

Fig. 7. Numerical analysis results: (a) epoxy temperature contour; and (epoxy + 15 vol.%G) + 50 vol.%HMS composite coating(b-d): (b) temperature contour, (c) thermal flux contour, (d) thermal flux contour vector.

Fig. 8. Scraping test results of 50 vol.% HMS coating with different graphite: (a)mass loss ratio of coating to blade, (b) wear track roughness.

Fig. 9. Scraped surface morphology of 50 vol.% HMS coating with different graphite: Macro morphology of (a)0 vol.%, (b) 10 vol.%, (c) 20 vol.%; Micro morphology of (d)0 vol.%, (e) 10 vol.%, (f) 20 vol.%; Three-dimensional morphology of (g)0 vol.%, (h) 10 vol.%, (i) 20 vol.%.

Fig. 10. Mechanical properties of coatings with different graphite: (a) Rockwell hardness (HR15Y) and (b) Bonding strength.

Fig. 11. Variation of friction coefficient (a) and the mean friction coefficient (b) of 50 vol.% HMS coating with different graphite.

Fig. 12. Performance radar map of 50 vol.% HMS coatings with different graphite.

Fig. 13. Scraped surface morphology of 50 vol.% HMS coating with different graphite: (a, d) 0 vol.% graphite, (b, e) 10 vol.% graphite, (c,f) 20 vol.% graphite.

Fig. 14. Raman patterns of pure graphite and 50 vol% HMS + 20vol% graphite coating scraped surface.

Fig. 15. Scraped cross-section morphology: (a) 50 vol.% HMS coating, (b) 50 vol.% HMS coating with 20 vol.% graphite, (c) enlarged of c area, and (d) enlarged of d area.

Fig. 16. Scraping mechanism schematic of 50 vol.% HMS coating with different graphite.

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