US 5,976,695 A · Thermally sprayable powder materials having an alloyed metal phase and a solid lubricant ceramic phase and abradable seal assemblies manufactured therefrom

Abstract

Thermally sprayable powders for the formation of abradable seals and abradable seals formed by thermally spraying the powders include an alloyed metal phase material and a solid lubricant ceramic phase material. The alloyed metal phase material includes a major amount of a matrix metal which can be one or more of Ag or Cu, at least one melting point depressing metal which can be one or more of Si, B, Mn, or Al, and at least one oxidation resistant metal which can be one or more of Al, Cr, or Si. The solid lubricant ceramic phase is preferably hexagonal boron nitride, molybdenum sulphide, graphite, talc, bentonite or mica. Abradable seals formed by thermally spraying the powders are suitable for use with Ti alloy blades at temperatures up to 700.degree. C.

Claims63

Dependent claims

A powder material for the formation of an abradable seal coating, consisting essentially of:

(A) an alloyed metal phase material having a melting point in the range of about 750-1000.degree. C., the alloyed metal phase material including at least one of the metals from each of the following groups:
(i) a major amount of a matrix metal selected from the group consisting of Ag and Cu;
(ii) a melting point-depressing metal selected from the group consisting of Si, B, Mn and Al;
(iii) an oxidation-resistant metal selected from the group consisting of Al, Cr and Si;
(B) a solid lubricant ceramic phase material;
and, optionally,
(C) as much as a total of 4 weight percent, based on the alloyed metal phase material, of one or more of Y, Ce, La, or rare earth metals;
the powder material, when thermally sprayed, forming an abradable seal coating.

5 more elements

An abradable seal assembly comprising:

a substrate, and
an abradable seal coating deposited on the substrate by thermal spraying, the abradable seal coating consisting essentially of:
(A) an alloyed metal phase material having a melting point in the range of about 750-1000.degree. C., the alloyed metal phase material including at least one of the metals from each of the following groups:
(i) a major amount of a matrix metal selected from the group consisting of Ag and Cu;
(ii) a melting point-depressing metal selected from the group consisting of Si, B, Mn and Al;
(iii) an oxidation-resistant metal selected from the group consisting of Al, Cr and Si;
(B) a solid lubricant ceramic phase material;
and, optionally,
(C) as much as a total of 4 weight percent, based on the alloyed metal phase material, of one or more of Y, Ce, La, or rare earth metals.

6 more elements

A powder material for the formation of an abradable seal coating, consisting essentially of:

(A) at least 40 weight percent, based on the total weight of the powder material, of an alloyed metal phase material having a melting point in the range of about 750-1000.degree. C., the alloyed metal phase material including at least one of the metals from each of the following groups:
(i) a major amount of a matrix metal selected from the group consisting of Ag and Cu;
(ii) a melting point-depressing metal selected from the group consisting of Si, B, Mn and Al;
(iii) an oxidation-resistant metal selected from the group consisting of Al, Cr and Si;
wherein, if the matrix metal is Ag, the melting point-depressing metal is not solely Mn,
(B) at least 10 weight percent, based on the total weight of the powder material, of a solid lubricant ceramic phase material comprising hexagonal boron nitride;
and, optionally,
(C) as much as a total of 4 weight percent, based on the alloyed metal phase material, of one or more of Y, Ce, La, or rare earth metals, the powder material, when thermally sprayed, forming an abradable seal coating.

5 more elements

An abradable seal assembly comprising:

a substrate, and
an abradable seal coating deposited on the substrate by thermal spraying, the abradable seal coating consisting essentially of:
(A) at least 75 weight percent, based on the total weight of the seal coating, of an alloyed metal phase material having a melting point in the range of about 750-1000.degree. C., the alloyed metal phase material including at least one of the metals from each of the following groups:
(i) a major amount of a matrix metal selected from the group consisting of Ag and Cu;
(ii) a melting point-depressing metal selected from the group consisting of Si, B, Mn and Al;
(iii) an oxidation-resistant metal selected from the group consisting of Al, Cr and Si;
wherein, if the matrix metal is Ag, the melting point-depressing metal is not solely Mn;
(B) at least 10 weight percent, based on the total weight of the seal coating, of a solid lubricant ceramic phase material comprising hexagonal boron nitride;
and, optionally,
(C) as much as a total of 4 weight percent, based on the alloyed metal phase material, of one or more of Y, Ce, La, or rare earth metals, wherein the abradable seal coating has a theoretical density greater than about 50%.

7 more elements

Dependencies are inferred from the claim text.

Thermally sprayable powder materials having an alloyed metal phase and a solid lubricant ceramic phase and abradable seal assemblies manufactured therefrom

Life of this patent

Thermally sprayable powder materials having an alloyed metal phase and a solid lubricant ceramic phase and abradable seal assemblies manufactured therefrom

Life of this patent

Abstract

Claims63