Thermal spray compositions for abradable seals
AssigneeSulzer Metco (Canada) Inc.
InventorsPetr Fiala, Anthony Peter Chilkowich, Karel Hajmrle
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Abstract
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.
Claims39
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 and mixtures 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 CuAl, AlSi or an alloy of Cu or Al.
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 CuAl, AlSi or an alloy of Cu or Al.
Dependencies are inferred from the claim text.