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US 2005/0233160 A1Published application
Thermal spray compositions for abradable seals
AssigneeSulzer Metco (Canada) Inc.
InventorsPetr Fiala, Anthony Chilkowich, Karel Hajmrle
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AssigneeSulzer Metco (Canada) Inc.
InventorsPetr Fiala, Anthony Chilkowich, Karel Hajmrle
Estimating the term…
A thermal spray composition and method of deposition for abradable seals for use in gas turbine engines, turbochargers and steam turbines. The thermal spray composition includes a solid lubricant and a ceramic preferably comprising 5 to 60 wt % total of the composition in a ratio of 1:7 to 20:1 of solid lubricant to ceramic, the balance a matrix-forming metal alloy selected from Ni, Co, Cu, Fe and Al and combinations and alloys thereof. The solid lubricant is at least one of hexagonal boron nitride, graphite, calcium fluoride, lithium fluoride, magnesium fluoride, barium fluoride, tungsten disulfide and molybdenum disulfide particles. The ceramic includes at least one of albite, illite, quartz and alumina-silica.
1-5. (canceled)
A thermal spray composition as claimed in claim 74, in which the thermal spray composition is a wire, a powder or a rod.
A thermal spray composition as claimed in claim 74, additionally comprising a particulate consumable polymer comprising 1 to about 30 wt % of the composition.
26-30. (canceled)
An abradable seal as claimed in claim 75, in which the thermal spray composition is a wire, a powder or a rod.
An abradable seal as claimed in claim 75, additionally comprising a particulate consumable polymer comprising 1 to about 30 wt % of the composition.
A method of providing a three-phase abradable seal on a substrate comprising applying an adherent coating having a thickness of up to 3 mm to the substrate by thermally spraying a composition thereon comprising 5 to 60 wt % total of a solid lubricant and a ceramic in a ratio of 1:7 to 20:1 by weight of solid lubricant to ceramic, the balance a matrix-forming metal alloy, wherein the solid lubricant is hexagonal boron nitride and wherein the matrix-forming metal alloy is an alloy of Cu, Al, CuAl or AlSi.
(canceled)
A thermal spray composition for a three-phase abradable seal comprising 5 to 60 wt % total of a solid lubricant and a ceramic, the balance a matrix-forming metal alloy wherein the solid lubricant is hexagonal boron nitride, the ceramic is at least one ceramic selected from the group consisting of albite, illite and quartz mixtures and thereof and alumina-silica-based ceramics in a ratio of 1:7 to 20:1 by weight of solid lubricant to ceramic, and the matrix-forming metal alloy is an alloy of Cu, Al, CuAl or AlSi.
A three-phase abradable seal having a thickness of up to 3 mm applied as an adherent coating onto a substrate by thermally spraying a composition thereon comprising 5 to 60 wt % total of a solid lubricant and at least one ceramic selected from the group consisting of albite, illite and quartz and mixtures thereof and alumina-silica-based ceramics in a ratio of 1:7 to 20:1 by weight of solid lubricant to ceramic, the balance a matrix-forming metal alloy, wherein the solid lubricant is hexagonal boron nitride and wherein the matrix-forming metal alloy is an alloy of Cu, Al, CuAl or AlSi.
Dependencies are inferred from the claim text.