Abradable Coatings for Small Turboprop Engines: A Case Study of Nickel-Graphite Coating

Ziegelheim, J.; Lombardi, Lucia; Česánek, Zdeněk; Houdková, Šárka; Schubert, Jan; Jech, David; Čelko, Ladislav; Pala, Zdeněk

doi:10.1007/s11666-019-00838-4

Cited by 23 publications

(5 citation statements)

References 9 publications

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“…Although predominantly plasma spray is used to melt ceramic powders, HVOF could be used for some fine ceramic particle sizes, ranging from 10-20 microns [23]. Plasma-sprayed coatings [37] generally achieve a higher tensile strength compared to flame sprayed [11]. The selection of the nozzle bore size in the plasma gun is dependent on the amount of powder which needs to be deposited through the gun.…”

Section: Process Parameter Developmentmentioning

confidence: 99%

A Guiding Framework for Process Parameter Optimisation of Thermal Spraying

et al. 2023

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Currently, most thermal spray coating service providers expect original equipment manufacturers (OEMs) to suggest the coating recipe, comprising of the right coating equipment, starting process parameters, type of inert gases, and robot program. The microstructure and mechanical properties may not comply in the first few runs. Feedback from a competent material testing service provider forms the initial step to adjust the parameters in the development journey, toward identifying the processing parameters required to obtain an acceptable coating. With the surge of interest in sustainable manufacturing, the time spent on trials in the future will shrink, and a more rigorous process needs to be applied to achieve the “right-first-time manufacturing” approach in thermal spraying. However, a framework for the systematic development of thermal spray parameter optimisation is lacking. This article provides a framework, based on a logical acumen, in selecting the right process parameters, using available data and prior knowledge about the thermal spraying process. To that end, the article summarises the extant developmental journey of thermal spray process parameters, by covering the aspects of equipment choice, robot and spray parameters, and how to minimise iterations, using diagnostic tools to get to the end solution most efficiently. This article, in its current form, will serve as a good guide for early career engineers and scientists or workers, to minimise the time processing window, by avoiding endless iterations to deposit a certain type of coating using thermal spraying. Besides, this work is also aimed at transforming academic research innovations to a robust and repeatable industrial manufacturing process.

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Section: Process Parameter Developmentmentioning

confidence: 99%

A Guiding Framework for Process Parameter Optimisation of Thermal Spraying

et al. 2023

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“…The solution crystallization-high-temperature reduction process can be controlled, and the coating thickness can easily be adjusted. [24][25][26] In this study, a new process route of fluidized crystallization granulation-hydrogen reduction was proposed for the preparation of Ni/Al 2 O 3 composite powder using 100-125 µm alumina as the substrate, and the effects of process feasibility and nickel concentration on the Ni/Al 2 O 3 -coated powder were investigated. The reaction path of the preparation of Al 2 O 3 (core)/Ni (coating) composite powder was studied and controlled from a macroscopic point of view, which can provide a useful reference for the industrial production of composite powders prepared by the new process route of fluidized crystallization granulation-hydrogen reduction.…”

Section: Introductionmentioning

confidence: 99%

“…Finally, the composite powder is reduced at high temperatures in H 2 atmosphere. The solution crystallization–high‐temperature reduction process can be controlled, and the coating thickness can easily be adjusted 24–26 …”

Section: Introductionmentioning

confidence: 99%

Research on the preparation of Ni/Al₂O₃ powder by fluidized crystallization granulation–hydrogen reduction

Wang

Gui

Yang

et al. 2023

Int J Applied Ceramic Tech

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This paper proposes a new process route for the preparation of Ni/Al2O3 composite powder through fluidized crystallization granulation–hydrogen reduction and investigates the effects of process feasibility, nickel concentration, nucleation method, and hydrogen reduction on Ni/Al2O3‐coated powder. The decrease in nickel concentration, heterogeneous nucleation, and natural air‐drying properties of precursor particles was beneficial to the formation of a complete and uniform cladding layer, and the increase in hydraulic retention time could improve the thickness of the cladding layer. The optimum process involves a nickel concentration of 50 mg/L; hydraulic residence time of 75 h to ensure heterogeneous nucleation; two‐step hydrogen reduction of precursor particles to obtain a complete and uniform Ni/Al2O3 cladding layer; and a powder surface nickel content of 59.5%.

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“…10 Ziegelheim et al. 11 studied the impact of spraying parameters on the physical and functional properties of the abradable coating which is used in turboprop engines. Xiao et al.…”

Section: Introductionmentioning

confidence: 99%

Minimum clearance technology to improve performance of twin-screw refrigeration compressors by spraying coating on rotors

Sun

Chen

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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During the operating of twin-screw refrigeration compressors, the leakage has a significant influence on the performance of compressors. In this paper, a novel minimum clearance technology that applies the abradable coating to the rotor surface is proposed to lessen the leakage. In order to adapt to the application of the abradable coating, the deformation of rotors during operation is analyzed and a suitable clearance is designed based on the fluid-solid coupling analysis. Then, a suitable coating pre-treated by sandblasting is obtained according to the results of friction coefficient and abradability test. Finally, a prototype is tested and the total efficiency, volumetric efficiency, refrigerating capacity, and COP of the prototype are compared before and after spraying the coating. Test results show that the volumetric efficiency and refrigerating capacity increase significantly after spraying the abradable coating, and the input power decreases slightly. As a result, the COP increases by 6.71% and 7.89% at two nominal operating conditions.

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Abradable Coatings for Small Turboprop Engines: A Case Study of Nickel-Graphite Coating

Cited by 23 publications

References 9 publications

A Guiding Framework for Process Parameter Optimisation of Thermal Spraying

A Guiding Framework for Process Parameter Optimisation of Thermal Spraying

Research on the preparation of Ni/Al₂O₃ powder by fluidized crystallization granulation–hydrogen reduction

Minimum clearance technology to improve performance of twin-screw refrigeration compressors by spraying coating on rotors

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Abradable Coatings for Small Turboprop Engines: A Case Study of Nickel-Graphite Coating

Cited by 23 publications

References 9 publications

A Guiding Framework for Process Parameter Optimisation of Thermal Spraying

A Guiding Framework for Process Parameter Optimisation of Thermal Spraying

Research on the preparation of Ni/Al2O3 powder by fluidized crystallization granulation–hydrogen reduction

Minimum clearance technology to improve performance of twin-screw refrigeration compressors by spraying coating on rotors

Contact Info

Product

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Research on the preparation of Ni/Al₂O₃ powder by fluidized crystallization granulation–hydrogen reduction