Multi-Zone Abradable Runner for Gas Turbine Wear Management

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Solution Overview

Problem

Existing abradable coatings in gas turbine engines fail to effectively manage wear and erosion between rotating and static components while maintaining close tolerances, leading to reduced engine efficiency and lifespan.

Innovation Solution

A multi-zone abradable runner coating system with varying microstructures and porosities, comprising sintered and unsintered zones with different grain sizes and phases, applied using a thermal spray process, is developed to reduce wear and enhance erosion resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a uniform abradable coating is applied to protect rotating components, then wear resistance is improved, but the coating cannot adapt to different operational conditions and maintain close tolerances effectively

Engineering Contradiction:

Improvewear resistanceVSAvoidadaptability to operational conditions

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent applies local quality by creating zones with different microstructures and properties within the abradable coating. The coating includes a first zone with a first microstructure and a second zone with a second microstructure different from the first, allowing different regions to serve different functional purposes - some areas provide wear resistance while others maintain close tolerances and adapt to operational conditions

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If thermal spray process is used to apply abradable coating, then coating application is simplified, but control over microstructure and porosity patterns is limited

Engineering Contradiction:

Improvecoating applicationVSAvoidmicrostructure control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies parameter changes by varying microstructural parameters (grain size, porosity, phase composition) within different zones of the coating while maintaining thermal spray application. The coating includes zones with different porosity levels and microstructural characteristics, achieving precise microstructure control through parameter variation during the thermal spray process

Inventive Principle:

Principle #35Parameter changes

3Productivity

If close tolerance is maintained between rotating and static components, then engine efficiency is improved, but wear and erosion between components increases

Engineering Contradiction:

Improveengine efficiencyVSAvoidwear and erosion

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies blessing in disguise by designing the abradable coating to undergo controlled erosion and wear. The coating is formulated with specific microstructures that erode in a controlled manner to maintain close tolerances and engine efficiency, converting the harmful wear and erosion into a beneficial self-adjusting mechanism that preserves component clearance and performance

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 coating system effectively reduces wear and erosion, maintains close tolerances, and provides improved durability and efficiency in gas turbine engines by adapting to different operational conditions through controlled microstructure and porosity patterns.

Implementation Method 1

The abradable runner may be formed from an abradable material using a thermal spray process

Methodology Applied

Scientific EffectThermal spray: Plasma Spray

Implementation Method 2

The first microstructure may comprise substantially solid particles within a matrix, and the second microstructure may comprise hollow particles within a matrix. The first microstructure may be substantially sintered

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentEP3018296B1Gas turbine engine assembly with an abradable blade track and corresponding formation method

Publication Date: 2019.12.04 ROLLS ROYCE CORP

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AI summary

A gas turbine engine assembly comprising a rotor (24), a gas path component, and a carrier (36). The rotor (24) includes a shaft (34) adapted to rotate about an axis (11) and a gas-path component that extends from the shaft (34) for rotation therewith about the axis (11). The carrier (36) extends around the gas-path component to block gases from passing over the gas-path component during rotation of the rotor (24), and an abradable runner (38) that extends from the carrier (36) toward the gas-path component to reduce a gap between the carrier (36) and the gas-path component, wherein the abradable runner (38) includes a first zone (41) having a first microstructure and a second zone (42) having a second microstructure different from the first microstructure with the first zone (41) arranged in a predetermined location relative to the second zone (42) such that the first zone (41) is positioned circumferentially adjacent to the second zone (42). A corresponding method for forming an abradable runner is also provided.