Compressor Impeller Abrasion-Resistant Coating

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Solution Overview

Problem

Existing gas compressors face durability issues when compressing gas contaminated with solid particles due to inadequate abrasion resistance and adhesiveness of existing abrasion-resistant films, which are not specifically designed for gas compressors and do not effectively withstand high-impact collisions from solid particles at various angles.

Innovation Solution

A gas-compressor impeller with abrasion-resistant films made of cermet materials, primarily containing tungsten carbide, are thermally sprayed only at the gas inlet portions of the blades, with larger coverage on ventral sides and reduced coverage towards the downstream side, using ultra high-speed flame thermal spraying to enhance adhesiveness and abrasion resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an abrasion-resistant film is applied to the entire compressor member, then abrasion resistance is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveabrasion resistanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The abrasion-resistant film is applied only to the gas inlet portions of the blades where solid particle collision is most severe, rather than the entire compressor member. This localized application reduces manufacturing complexity and cost while maintaining sufficient protection at the critical wear locations.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The blade surface is divided into different regions based on wear severity: the gas inlet portions (leading edges and hub-side regions) receive abrasion-resistant coating, while the discharge portions remain uncoated. This segmentation allows targeted protection where needed most.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If electrolytic plating is used to form abrasion-resistant film, then ease of manufacture is improved, but film thickness control and durability are insufficient

Engineering Contradiction:

Improveease of coating applicationVSAvoidfilm durability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Electrolytic plating is replaced with thermal spraying technology. Thermal spraying provides superior film durability and abrasion resistance while maintaining ease of manufacture through automated coating application. The thermal spray process allows precise control of film thickness and composition.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If abrasion-resistant film is applied to gas-compressor impeller, then abrasion resistance is improved, but adhesiveness to withstand high-impact collisions is insufficient

Engineering Contradiction:

Improveabrasion resistanceVSAvoidadhesiveness

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The abrasion-resistant film is composed of cermet material containing tungsten carbide particles bonded to a nickel-phosphorus alloy matrix. This composite structure provides both abrasion resistance from the tungsten carbide and adhesiveness from the nickel-phosphorus binder, enabling the film to withstand high-impact collisions from solid particles.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The film composition is optimized with specific ratios of tungsten carbide particles to nickel-phosphorus alloy, and the thermal spraying parameters are controlled to achieve proper film thickness, porosity, and bonding strength. These parameter optimizations ensure both abrasion resistance and adhesiveness are achieved simultaneously.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides improved durability and cost-effectiveness by targeting specific areas of damage, ensuring both abrasion resistance and adhesiveness, effectively withstanding high-speed collisions from solid particles, thus enhancing the overall performance of gas compressors.

Implementation Method 1

abrasion-resistant films made of cermet materials, primarily containing tungsten carbide, are thermally sprayed only at the gas inlet portions of the blades

Methodology Applied

Scientific EffectThermal spraying: Spray

Implementation Method 2

using ultra high-speed flame thermal spraying to enhance adhesiveness and abrasion resistance

Methodology Applied

Scientific EffectThermal spraying: Spray

Implementation Method 3

ensuring both abrasion resistance and adhesiveness, effectively withstanding high-speed collisions from solid particles

Methodology Applied

Scientific EffectAbrasion resistance: Abrasion

Data Source

PatentEP2105616B1Compressor impeller with an abrasion resistant coating

Publication Date: 2018.08.22 MITSUBISHI HEAVY INDUSTIES COMPRESSOR CORP

Figure 1
Figure 2A~2B
Figure 3A~3B

AI summary

An object is to provide a gas-compressor impeller which has excellent durability even when gas containing solid particles is compressed and which does not increase the cost. A gas-compressor impeller (3) installed in a gas compressor that compresses gas containing solid particles has a hub portion (10) and a plurality of blades (12) extending substantially radially from the outer circumferential surface of the hub portion (10). The hub portion (10) and the blades (12) are rotated about the central axial line to compress gas. The blades (12) have abrasion-resistant films (20) only at gas inlet portions.