# US 11,111,808 B2 · Coating with property gradient for inner wall of turbomachine

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- Number: US 11,111,808 B2
- Document ID: US11111808B2
- Status: Granted
- Kind: B2
- Application number: 16/770,416
- Filed: 2018-12-06
- Published: 2020-12-10
- Granted: 2021-09-07
- Earliest claimed: 2017-12-06
- Assignees: Safran Aircraft Engines
- Applicants: Safran Aircraft Engines
- Inventors: Jacky Novi Mardjono; Arnaud Dubourg; Edith-Roland Fotsing; Annie Ross
- Web page: https://patentgrep.com/patent/US11111808B2

## CPC

- B32B 5/028: {Net structure, e.g. spaced apart filaments bonded at the crossing points}
- F01D 11/122: {with erodable or abradable material (blades having cutting or grinding tips F01D5/20)}
- B32B 5/12: characterised by the relative arrangement of fibres or filaments of {different layers, e.g. the fibres or filaments being parallel or perpendicular to each other}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/02: Physical, chemical or physicochemical properties
- F01D 25/24: Casings (modified for heating or cooling F01D25/14); Casing parts, e.g. diaphragms, casing fastenings (casings for rotary machines or engines in general F16M {; special arrangements in stators dealing with breaking-off of part of rotor F01D21/045})
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2262/02: Synthetic macromolecular fibres
- B32B 2307/102: Insulating
- B32B 2307/554: Wear resistance
- B32B 2307/56: Damping, energy absorption
- B32B 2307/726: Permeability to liquids, absorption
- B32B 2603/00: Vanes, blades, propellers, rotors with blades
- B32B 2605/18: Aircraft
- B33Y 80/00: Products made by additive manufacturing
- F05D 2230/90: Coating; Surface treatment
- F05D 2300/6031: Functionally graded composites
- F05D 2300/611: Coating
- F05D 2300/6111: functionally graded coating
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS

## Abstract

A property gradient coating to be applied by additive manufacture to an inner wall of a casing mounted on the periphery of moving blades of a turbomachine rotor, the coating including in superimposed layers from an outer surface of the coating to this inner wall of the casing, on the one hand, a first layer consisting of a three-dimensional scaffolding of filaments of an abradable material forming an ordered network of channels or microchannels whose pore sizes are between 50 and 250 microns and whose porosity is greater than 85%, and, on the other hand, a second layer having a function of dissipating energy from acoustic waves striking the outer surface of the coating and consisting of a three-dimensional scaffolding of filaments of a first thermosetting material forming an ordered network of channels or microchannels whose pore sizes are between 50 and 400 microns and whose porosity is greater than 60%.

## Claims

### Claim 1

A property gradient coating intended to be applied by additive manufacture to an inner wall of a casing mounted on the periphery of moving blades of a turbomachine rotor, comprising superimposed layers of an outer surface of said coating on said casing inner wall:
a first layer consisting of a three-dimensional scaffolding of filaments of an abradable material forming an ordered network of channels or microchannels with pore sizes between 50 and 250 microns and a porosity greater than 85%, and
a second layer having a function of dissipating energy from acoustic waves striking said outer surface of said coating and consisting of a three-dimensional scaffolding of filaments of a first thermosetting material forming an ordered network of channels or microchannels with pore sizes between 50 and 400 microns and porosity greater than 60%.

### Claim 2 (depends on 1)

The property gradient coating as claimed in claim 1, wherein the filaments of said first layer are alternately oriented at 0° or 90° without any offset in the superposition of filaments having the same direction of orientation.

### Claim 3 (depends on 1)

The property gradient coating as claimed in claim 1, wherein the filaments of said second layer are alternately oriented with a direction of orientation of the filaments offset or not by the same angular deviation, between 20° and 40°.

### Claim 4 (depends on 1)

The property gradient coating as claimed in claim 1, wherein the coating further comprises a layer of a clearance compensating material deposited directly on said inner casing wall to obtain a deposition surface of known geometry.

### Claim 5 (depends on 1)

The property gradient coating as claimed in claim 1, wherein the coating further comprises a third layer having a function of draining fluids passing through said coating and consisting of a three-dimensional scaffolding of filaments of a second thermosetting material forming an ordered network of channels or microchannels whose pore sizes are greater than 250 microns and whose porosity is greater than 70%.

### Claim 6 (depends on 5)

The property gradient coating as claimed in claim 5, wherein said third layer has specific patterns with channels directing the evacuation of fluids passing through said coating to determined areas and having a channel size greater than 500 microns.

### Claim 7 (depends on 6)

The property gradient coating as claimed in claim 6, wherein the filaments of said third layer are alternately oriented at 0° or 90° without any offset in the superposition of filaments having the same direction of orientation.

### Claim 8 (depends on 1)

The property gradient coating as claimed in claim 1, wherein the coating further comprises a fourth layer having a function of absorbing ballistic energy resulting from a volatile impact, hail ingestion, or even blade loss and consisting of a three-dimensional scaffolding of filaments of a third thermosetting material forming an ordered network of channels or microchannels whose pore sizes are less than 400 microns and whose porosity is less than 60%.

### Claim 9 (depends on 8)

The property gradient coating as claimed in claim 8, wherein the filaments of said fourth layer are alternately oriented at 0° or 90° and have an offset in the superposition of filaments having the same direction of orientation.

### Claim 10 (depends on 1)

The property gradient coating as claimed in claim 1, wherein the coating further comprises at least one additional layer of an abradable material added locally on said first layer to take into account a non-axisymmetric geometry of said casing.

### Claim 11 (depends on 1)

The property gradient coating as claimed in claim 1, wherein said abradable material is a solvent-free thixotropic mixture consisting of a polymer base and a cross-linking agent in a weight ratio of polymer base to cross-linking agent of between 1:1 and 2:1, and a flow facilitating component present between 5 and 15% by weight of the total weight of said thixotropic mixture.

### Claim 12 (depends on 11)

The property gradient coating as claimed in claim 11, wherein said first, second and third thermosetting materials consist of said abradable material.

### Claim 13 (depends on 1)

The property gradient coating as claimed in claim 1, wherein said casing is a turbomachine fan casing of woven composite material.