High-Speed Rubbing Behavior of Abrasive Coating Coated on Titanium Alloy Blade Tips

doi:10.1007/s40195-023-01651-3

Abstract

Abstract:

In aero-engines, abrasive coatings are typically utilized to protect the blade tip from excessive wear caused by the harder abradable sealing coating and thereby improve the sealing performance of engines. Therefore, a Ni/cBN abrasive coating was prepared on titanium alloy using electrodeposition. The high-speed rubbing tests with a linear velocity of 350 m/s and different incursion rates were performed to investigate the effect of the Ni/cBN abrasive coating on the wear behavior against NiCrAl/diatomite seal coating. Results showed that melting wear and adhesive transfer occurred on the bare blades, causing the bare blade to suffer excessive wear. While the Ni/cBN abrasive coating exhibited superior wear resistance and cutting performance. The cBN grits pullout, the abrasion of Ni matrix and transfer of seal coating to the cBN grits were the main wear mechanism of the Ni/cBN abrasive coating. Additionally, it was found that the relationship between the incursion rate and high-speed rubbing behavior is quite different for the bare blade and Ni/cBN coating. The reason for the difference in wear behavior of bare blade and Ni/cBN coating at different incursion rates was discussed in detail.

Key words: Gas turbine sealing, Abrasive coating, High-speed rubbing, Material transfer, Abradable coating

Wenshuang Gu, Shuai Yang, Shiyi Zhang, Zhiliang Pei, Weihai Xue, Deli Duan, Jun Gong, Chao Sun. High-Speed Rubbing Behavior of Abrasive Coating Coated on Titanium Alloy Blade Tips[J]. Acta Metallurgica Sinica (English Letters), 2024, 37(4): 749-762.

Figures/Tables 15

Fig. 1 Geometric dimensions of the rubbing blade samples

Fig. 2 Simplified schematic of the high-speed rubbing platform

Fig. 3 Surface a, c and cross-section b, d morphologies of Ni/cBN coating a, b and NiCrAl/diatomite coating c, d

Fig. 4 Variation of height a and weight b of the tested blades (bare blades and blades coated Ni/cBN) and the weight variation c of abradable coatings after high-speed rubbing tests

Fig. 5 Worn surface optical morphologies and three-dimensional morphologies of the bare blades a, b and NiCrAl/diatomite coatings c, d after rubbing at 0.02 μm/pass a, c, e and 0.2 μm/pass b, d, f. (e, f Three-dimensional morphologies of c, d)

Fig. 6 Surface a, b and cross-section c, d morphologies of the bare blades as well as the corresponding EDS mappings of transfer layers after rubbing at 0.02 μm/pass a, c and 0.2 μm/pass b, d

Fig. 7 Surface a, b and cross-section c, d morphologies of the NiCrAl/diatomite coatings rubbed against the bare blades as well as the corresponding EDS mappings of adhesive transfers at 0.02 μm/pass a, c and 0.2 μm/pass b, d

Fig. 8 Worn surface optical morphologies and three-dimensional morphologies of the Ni/cBN coatings a, b and NiCrAl/diatomite coatings c, d after rubbing at 0.02 μm/pass a, c, e and 0.2 μm/pass b, d, f. (e, f Three-dimensional morphologies of c, d)

Fig. 9 Surface a, c and cross-section b, d morphologies of Ni/cBN coatings after rubbing at 0.02 μm/pass a, b and 0.2 μm/pass c, d

Fig. 10 Surface a, c and cross-section b, d morphologies of adhesion of Ni/cBN coatings after rubbing at 0.02 μm/pass a, b and 0.2 μm/pass c, d

Table 1 Chemical composition of the positions marked in Figs. 10 and 11 detected by EDS (at.%)

Positions	Ni	O	Cr	Al	Si
1	87.99	8.56	2.20	0.74	0.50
2	47.74	33.01	8.73	4.07	6.44
3	64.33	17.16	12.96	1.69	3.86
4	71.24	12.03	9.71	0.52	6.51
5	46.02	36.47	9.97	2.57	4.97

Fig. 11 Surface a, b and cross-section c, d morphologies of NiCrAl/diatomite coatings rubbed against Ni/cBN coatings at 0.02 μm/pass a, c and 0.2 μm/pass b, d

Fig. 12 Hardness of the bare blade, Ni matrix in Ni/cBN coating, NiCrAl matrix in abradable coating and transfer layers formed at 0.02 μm/pass and 0.2 μm/pass

Table 2 Diffusivity of the TC17 bare blade and NiCrAl/diatomite coating at 500 °C

Sample	Thermal diffusivity (10⁶ m² s⁻¹)
TC17	4.38
NiCrAl/diatomite	0.78

Fig. 13 Schematic of wear behaviors of Ni/cBN coatings after rubbing at 0.02 μm/pass a, c, e and 0.2 μm/pass b, d, f

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