Nickel Aluminide Abrasive Matrix for High-Temperature Turbine Sealing
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Solution Overview
Problem
Existing abrasive materials for aircraft engine turbine sealing systems smear across abradable materials at higher operating temperatures, failing to effectively cut into them, which is critical for maintaining blade tip clearance and efficiency.
Innovation Solution
A nickel aluminide intermetallic phase with a Laves phase, specifically β-NiAl with Ta additions, forms a matrix for abrasive particles like cubic boron nitride, silicon nitride, and zirconia, ensuring strong anchorage and vertical distribution to maintain cutting performance at elevated temperatures, combined with a directed laser deposition process for uniform coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional abrasive materials (CoNiCrAlY metal matrix or superalloy matrix) are used, then they can cut into abradable material at lower temperatures, but they smear across the abradable material instead of cutting at higher operating temperatures
Solution Approach 1:
The patent changes the material parameters by developing a nickel aluminide intermetallic phase matrix with specific compositional ranges (Ni: 60-80 at.%, Al: 15-30 at.%, Cr: 3-10 at.%, Co: 3-10 at.%, Ti: 1-5 at.%, B: 0.1-1 at.%) to achieve high-temperature stability. This compositional parameter change enables the abrasive material to maintain cutting performance at temperatures above 1000°C where conventional materials fail and smear.
Solution Approach 2:
The patent creates a composite abrasive material by embedding abrasive particles (cubic boron nitride, silicon carbide, boron) within a nickel aluminide intermetallic phase matrix. This composite structure combines the high-temperature stability of the intermetallic phase with the cutting ability of the abrasive particles, resolving the contradiction between temperature resistance and cutting performance.
2Strength
If the abrasive material uses a metal matrix to hold abrasive particles, then it provides strong anchorage, but the material loses strength and becomes soft at high temperatures
Solution Approach 1:
The patent transforms the matrix material from conventional metals (CoNiCrAlY, superalloys) to a nickel aluminide intermetallic phase with specific compositional parameters. This parameter change fundamentally alters the thermal-strength characteristics, enabling the matrix to maintain yield strength above 250 MPa at 1200°C, thus resolving the softening issue at high temperatures while retaining anchorage capability.
3Manufacturing precision
If directed laser deposition process is used to apply abrasive material, then uniform coverage can be achieved, but the process complexity increases
Solution Approach 1:
The patent modifies the deposition process parameters by optimizing powder feed rate, laser power, scanning speed, and substrate preheat temperature to achieve uniform abrasive material coverage. These parameter changes enable controlled deposition of the nickel aluminide matrix with embedded abrasive particles, achieving uniform coverage while managing process complexity through systematic parameter optimization.
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 new abrasive material retains strength and cutting ability at temperatures above 1100°C, anchoring abrasive particles effectively and maintaining yield strength above 250 MPa at 1200°C, significantly outperforming prior art materials in high-temperature applications.
Implementation Method 1
an abrasive material comprising a nickel aluminide intermetallic phase, in particular a beta nickel aluminide (β-NiAl) intermetallic phase with a Laves phase
Implementation Method 2
the Laves phase comprises Ta, in particular in the form of τ1NiAlTa
Implementation Method 3
a directed laser deposition process for uniform coverage
Implementation Method 4
the substrate is heated or pre-heated for the deposition of the matrix and/or the abrasive particles. This prevents cracks in the materials. The heating can e.g. be effected by induction or high temperature lamps
Implementation Method 5
The heating can e.g. be effected by induction or high temperature lamps
Implementation Method 6
The abrasive material cuts into the abradable material in a defined way and is used e.g. for turbine blade tip clearance control
Data Source
AI summary
The invention relates to an abrasive material including a nickel aluminide intermetallic phase, in particular a beta nickel aluminide (β-NiAl) intermetallic phase with a Laves phase, as a matrix for abrasive particles. It also relates to a method manufacturing an abrasive material and a blade in a turbomachinery with an abrasive material.