Erosion Coatings for Polymer Matrix Composites in Propulsion Applications

Abstract

Polymer Matrix Composites (PMCs) offer lightweight and frequently low cost alternatives to other materials in many applications. High temperature PMCs are currently used in limited propulsion applications replacing metals. Yet in most cases, PMC propulsion applications are not in the direct engine flow path since particulate erosion degrades PMC component performance and therefore restricts their use in gas turbine engines. This paper compares two erosion resistant coatings (SANRES and SANPRES) on PMCs that are useful for both low and high temperature propulsion applications. Collaborating over a multi-year period, researchers at NASA Glenn Research Center, AADC, and Rolls-Royce Engines have optimized these coatings in terms of adhesion, surface roughness and erosion resistance. Results are described for vigorous hot gas/particulate erosion rig and engine testing of uncoated and coated PMC fan bypass vanes from the AE 3007 regional jet gas turbine engine. Moreover, the structural durability of these coatings is described in long-term high cycle fatigue tests. Overall, both coatings performed well in all tests and will be considered for applications in both commercial and defense propulsion applications.

Solid particle erosion of composite materials: A critical review

“…Sutter et al. 173 and Miyoshi et al. 174 studied solid particle erosion characteristics of coated and uncoated carbon-Kevlar fiber reinforced EP composite.…”

Solid particle erosion studies on fibre composite with egg shell as filler materials

“…During erosive wear there is a gradual loss in material is one of the major loss in erosion studies. Commonly researchers found out the erosive wear depends on air velocity, angle of impingement, size of erodent, mass flow rate of erodent and erodent material (Sutter et al, 2003;Rao, 1986;Suresh et al, 2018;Dalili et al, 2009). Some of the components are prone to erosive wear likely, water pipe, wind mill blades, helicopter rotor blades, airplane wings, pump impeller blades, etc.…”

“…Similarly, literatures are available for solid particle erosion in a controlled environment. The angle of impact, erodent velocity, erodent size, standoff distance are significant parameters influencing erosive wear of the material (Sutter et al, 2003;Rao, 1986;Suresh et al, 2018;Dalili et al, 2009;Soutis, 2005;Pool et al, 1986;Chen and Li, 2003;Chowdhury et al, 2017;Xie et al, 2016).…”

Oxidation behavior of plasma-sprayed stabilized zirconia/Al coated polymer matrix composites

“…1 However, the more comprehensive applications of PMCs in the aerospace industry are still restricted by the weak abrasion resistance, poor thermal oxidation resistance and the relatively low operating temperature. 2 Up to date, many surface technologies, such as chemical vapor deposition (CVD), 3 sol-gel process, 4,5 cold spraying 6,7 and thermal spraying, [8][9][10][11][12] were used to manufacture different protective coatings on the material surface to ameliorate the defects. As reported in the researches, 13,14 thermal barrier coating consisting of a metal bond layer and a ceramic top layer provides a temperature drop of 100-200 K and good thermal oxidation resistance for the metallic materials during thermal cycling above 1273 K. Therefore, it is considered that a protection coating deposited on the PMCs surface is helpful in enhancing the surface properties of substrate to overcome these defects, further extending the application of PMCs in aerospace industry.…”

“…Up to now, some studies are aimed to fabricate erosion resistant coatings on the PMCs substrate via plasma spraying process, 2,10,19,20 while the topic of oxidation-resistant coatings fabrication is not well studied. Consequently, the preparation of 8YSZ protecting coatings with Al interlayer on the PMCs surface via plasma spraying promises an advance in the improving thermal oxidation resistance of the substrate.…”