Outer airseal abradable rub strip
A blade outer airseal has a body comprising: an inner diameter (ID) surface; an outer diameter (OD) surface; a leading end; and a trailing end. The airseal body has a metallic substrate and a coating system atop the substrate along at least a portion of the inner diameter surface. At least over a first area of the inner diameter surface, the coating system comprises an abradable layer comprising a metallic matrix and a solid lubricant; and the metallic matrix comprises, by weight, 35% copper, 30.0-45.0% combined nickel, cobalt, and iron with combined iron and cobalt content at most one-third of the nickel content, 2.0-8.0% aluminum, and 5.0-15.0% chromium.
1. A blade outer airseal having:
a body comprising:
an inner diameter (ID) surface;
an outer diameter (OD) surface;
a leading end;
a trailing end;
a metallic substrate; and
a coating system atop the substrate along at least a portion of the inner diameter surface,
wherein:
at least over a first area of the inner diameter surface, the coating system comprises an abradable layer comprising a metallic matrix and a solid lubricant;
at 1200° F the metallic matrix has at least 98% by volume fee and L12 phases combined with at least 10% L12; and
the metallic matrix comprises, by weight:
≥35% copper;
30.0-45.0% combined nickel, cobalt, and iron with combined iron and cobalt content at most one-third of the nickel content;
2.0-8.0% aluminum; and
5.0-15.0% chromium.
2. The blade outer airseal of claim 1 wherein the combined cobalt and iron contents of the metallic matrix are less than 5% by weight.
3. The blade outer airseal of claim 1 wherein the metallic matrix further comprises, by weight:
no more than 5.0% combined of all other elements; and
no more than 1.5% of any individual other element.
4. The blade outer airseal of claim 1 wherein the metallic matrix further comprises, by weight:
no more than 0.5% combined of niobium, molybdenum, tantalum, tungsten, and rhenium.
5. The blade outer airseal of claim 1 wherein the metallic matrix further comprises, by weight:
≤1.0% hafnium;
≤1.0% silicon; and
≤1.0% yttrium.
6. The blade outer airseal of claim 1 wherein:
over the first area of the inner diameter surface, the coating system comprises the abradable layer and a thermal barrier layer between the abradable layer and the substrate.
7. The blade outer airseal of claim 1 wherein:
the abradable layer has a volume content of said solid lubricant of 5.0% to 80%.
8. The blade outer airseal of claim 1 wherein:
the solid lubricant comprises HBN.
9. The blade outer airseal of claim 1 wherein:
the abradable layer has a volume content of said metallic matrix of 20% to 50%.
10. The blade outer airseal of claim 1 wherein:
the abradable layer has less than 20% porosity.
11. The blade outer airseal of claim 1 wherein one or more of:
the coating system has a bondcoat between the abradable layer and the substrate; and
the substrate is a nickel-based superalloy.
12. A method for manufacturing the blade outer airseal of claim 1 , the method comprising:
thermal spray of the abradable layer.
13. A method for using the blade outer airseal of claim 1 , the method comprising:
installing the blade outer airseal on a turbine engine; and
running the turbine engine so that blade tips rub the abradable coating.
14. A blade outer airseal having:
a body comprising:
an inner diameter (ID) surface;
an outer diameter (OD) surface;
a leading end;
a trailing end;
a metallic substrate; and
a coating system atop the substrate along at least a portion of the inner diameter surface,
wherein:
at least over a first area of the inner diameter surface, the coating system comprises an abradable layer comprising a metallic matrix and a solid lubricant; and
at 1200° F the metallic matrix has by volume:
at least 88% fcc phase; and
1% to 10% bcc (A2) phase; and
the metallic matrix comprises, by weight:
≥80% copper;
≤10.0% nickel;
3.0-9.5% aluminum; and
3.0-10.0% chromium.
15. The blade outer airseal of claim 14 wherein the metallic matrix further comprises, by weight:
no more than 5.0% combined of all other elements; and
no more than 1.5% of any individual other element.
16. The blade outer airseal of claim 14 wherein the metallic matrix further comprises, by weight:
no more than 0.5% combined of niobium, molybdenum, tantalum, tungsten, and rhenium.
17. The blade outer airseal of claim 14 wherein the metallic matrix further comprises, by weight:
≤1.0% hafnium;
≤1.0% silicon; and
≤1.0% yttrium.
18. A blade outer airseal having:
a body comprising:
an inner diameter (ID) surface;
an outer diameter (OD) surface;
a leading end;
a trailing end;
a metallic substrate; and
a coating system atop the substrate along at least a portion of the inner diameter surface,
wherein:
at least over a first area of the inner diameter surface, the coating system comprises an abradable layer comprising a metallic matrix and a solid lubricant; and
at 1200° F. the metallic matrix has:
at least 40% by volume primary fcc;
at least 10% by volume gamma prime (L12), bcc (A2), and/or secondary fcc (A1) crystal structure; and
at most 10% by volume beta (B2) crystal structure.
19. the blade outer airseal of claim 18 wherein the metallic matrix comprises, by weight:
≥35% copper;
30.0-45.0% combined nickel, cobalt, and iron with combined iron and cobalt content at most one-third of the nickel content;
2.0-8.0% aluminum; and
5.0-15.0% chromium.
20. the blade outer airseal of claim 18 wherein the metallic matrix comprises, by weight:
≥80% copper;
≤10.0% nickel;
3.0-9.5% aluminum; and
3.0-10.0% chromium.
21. A gas turbine engine compressor section comprising:
a stage of blades having Ni-based substrates; and
the blade outer airseal of claim 18 wherein the inner diameter (ID) surface faces tips of the blades.