An abradable
coating composition for use on shrouds in gas
turbine engines or other hot gas path
metal components exposed to high temperatures containing an initial
porous coating phase created by adding an amount of inorganic microspheres, preferably
alumina-
ceramic microballoons, to a
base metal alloy containing high Al, Cr or Ti such as β-
NiAl or, alternatively, MCrAlY that serves to increase the brittle nature of the
metal matrix, thereby increasing the abradability and
oxidation resistance of the
coating at elevated temperatures. Coatings having a total open and closed
porosity of between 20% and 55% by volume due to the presence of
ceramic microballoons
ranging in size from about 10 microns to about 200 microns have been found to exhibit excellent abradability for applications involving
turbine shroud coatings. An abradable
coating thickness in the range of between 40 and 60 ml provides
improved performance for
turbine shrouds exposed to gas temperatures between 1380° F. and 1800° F. Abradable coatings in accordance with the invention can be used for new
metal components or to repair existing equipment. The coatings can be applied to the metal shroud using thermal spray, processes that integrate
sintering and
brazing, or direct write techniques.