US20070003412A1 - Abradable material composition, a thermomechanical part or casing including a coating, and a method of fabricating or repairing a coating presenting said composition - Google Patents
Abradable material composition, a thermomechanical part or casing including a coating, and a method of fabricating or repairing a coating presenting said composition Download PDFInfo
- Publication number
- US20070003412A1 US20070003412A1 US11/476,845 US47684506A US2007003412A1 US 20070003412 A1 US20070003412 A1 US 20070003412A1 US 47684506 A US47684506 A US 47684506A US 2007003412 A1 US2007003412 A1 US 2007003412A1
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- United States
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- composition
- abradable
- substrate
- composition according
- primer layer
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/08—Sealings
- F04D29/16—Sealings between pressure and suction sides
- F04D29/161—Sealings between pressure and suction sides especially adapted for elastic fluid pumps
- F04D29/164—Sealings between pressure and suction sides especially adapted for elastic fluid pumps of an axial flow wheel
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
- B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
- B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
- B29C67/246—Moulding high reactive monomers or prepolymers, e.g. by reaction injection moulding [RIM], liquid injection moulding [LIM]
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K7/00—Use of ingredients characterised by shape
- C08K7/22—Expanded, porous or hollow particles
- C08K7/24—Expanded, porous or hollow particles inorganic
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D183/00—Coating compositions based on macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon, with or without sulfur, nitrogen, oxygen, or carbon only; Coating compositions based on derivatives of such polymers
- C09D183/04—Polysiloxanes
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D11/00—Preventing or minimising internal leakage of working-fluid, e.g. between stages
- F01D11/08—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator
- F01D11/12—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part
- F01D11/122—Preventing or minimising internal leakage of working-fluid, e.g. between stages for sealing space between rotor blade tips and stator using a rubstrip, e.g. erodible. deformable or resiliently-biased part with erodable or abradable material
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04D—NON-POSITIVE-DISPLACEMENT PUMPS
- F04D29/00—Details, component parts, or accessories
- F04D29/02—Selection of particular materials
- F04D29/023—Selection of particular materials especially adapted for elastic fluid pumps
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2083/00—Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/80—Repairing, retrofitting or upgrading methods
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/90—Coating; Surface treatment
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2250/00—Geometry
- F05D2250/20—Three-dimensional
- F05D2250/24—Three-dimensional ellipsoidal
- F05D2250/241—Three-dimensional ellipsoidal spherical
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/40—Organic materials
- F05D2300/43—Synthetic polymers, e.g. plastics; Rubber
- F05D2300/437—Silicon polymers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
- F05D2300/61—Syntactic materials, i.e. hollow spheres embedded in a matrix
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
- F05D2300/611—Coating
Definitions
- the invention relates to an abradable material composition (or a material that can be machined by moving parts), to a thermomechanical part (such as a casing) comprising a metal substrate covered in a wear portion comprising a covering presenting such a composition, and to a turbomachine fitted with such a thermomechanical part.
- a thermomechanical part such as a casing
- the invention also relates to a method of fabricating or repairing an abradable covering on a metal substrate and presenting such a composition.
- That type of abradable material is generally constituted by a matrix of hot-polymerizable resin, in particular a silicone resin, and a filler of hollow glass beads, for example.
- Hollow glass beads are microspheres serving firstly to reduce the density of the covering composition, and secondly to contribute to the ability of the abradable material to be abraded.
- silicone resins has replaced the earlier use of organic resins which present insufficient mechanical strength, and, on being abraded, give rise to powder that, on combustion, creates residues that deflagrate at high temperatures and under high pressures.
- new-generation turbine engines have hollow blades in their high pressure turbines that present perforations for ventilation or cooling channels connecting an internal cooling passage to the outside of the blade via ever-smaller diameters.
- An object of the present invention is to provide an abradable material composition for which the wear debris is capable of withstanding high temperatures, and a method of obtaining a part covered in said material whose wear debris can withstand temperatures that are higher than those that can be withstood by presently-proposed compositions.
- a particular object of the present invention is to overcome the drawbacks of prior art abradable materials in order to avoid permanently clogging ventilation perforations or cooling channels of small size due to hollow glass beads melting.
- the hollow beads are made of refractory material, glass being excluded, so that said beads present greater resistance to high temperatures.
- This solution also presents the additional advantage of making it possible to use hollow beads that are less expensive than glass beads, particularly if the hollow beads are combustion residues from fossil fuel power stations or steelworks, in particular if they are constituted by blast furnace slag.
- the refractory material comprises alumina and/or silica and/or zirconia, and the refractory material preferably belongs to the family constituted by alumino-silicate materials.
- said refractory material presents a melting temperature greater than 700° C., preferably greater than 750° C., and more preferably greater than 900° C.
- the present invention also provides a thermomechanical part comprising a metal substrate covered in a wear portion comprising a covering presenting the above-defined composition and a bonding primer layer comprising silicone.
- the substrate is made of titanium, steel, aluminum, or an alloy of any one of said metals.
- the primer layer is colored.
- thermomechanical part is intended in particular for forming a wear portion of a sealing labyrinth, associated with wipers, in particular for a booster.
- thermomechanical part may also form part of a compressor casing, in particular for a low pressure compressor, and in particular of the booster type, or for a fan, in which the face of the wall that faces the moving blades has an abradable covering presenting the above-defined composition.
- the present invention also provides a turbomachine including such a casing or a thermomechanical part as defined above.
- the present invention also provides a method of fabricating or repairing an abradable covering on a metallic substrate, wherein the following steps are performed:
- the application step b) is performed by direct injection.
- application step b) comprises the following substeps:
- composition as defined above e.g. a strip, a ring, or a ring portion, . . . );
- the adhesive comprises hot-polymerizable silicone resin.
- a step is performed prior to step a) in which a bonding primer layer is applied to the substrate, the primer layer comprising silicone, said layer being optionally colored.
- FIG. 1 is a fragmentary half-section view of the front portion of a turbojet, with the fan and a low pressure compressor fitted with a casing.
- the present invention relates to abradable material compositions, in particular for abradable elements in a turbojet, the description below relates to one possible and non-limiting application of this composition in accordance with the present invention.
- FIG. 1 is a section view showing half of the front portion 10 of a turbojet on one side of a longitudinal axis 12 constituting the axis of circular symmetry of the various elements of the turbojet, and in particular of its various moving elements.
- FIG. 1 there can be seen more precisely, amongst the various elements disposed axially around the longitudinal axis 12 and forming the conventional structure for such a turbojet, the fan 102 and the compressor 104 that operates at low pressure.
- the fan 102 comprises a series of blades 18 projecting radially and mounted on an annular disk 20 , the assembly being mounted to rotate about the longitudinal axis 12 of the turbojet.
- the air flow direction determines an upstream portion (to the left in FIG. 1 ) and a downstream portion (to the right in FIG. 1 ).
- the compressor 104 comprises a plurality of sets of rotary moving blades 22 mounted on a disk or drum 24 that is secured to the disk 20 of the fan 102 .
- FIG. 1 there can be seen three sets of moving blades 22 mounted between five sets of stationary vanes 26 mounted on a casing 28 .
- the structure of the casing 28 is such that it includes rings 30 of abradable material on its inside face in register with the ends of the moving blades 22 .
- abradable material of the present invention mention can be made in particular of various circumstances in which the abradable elements are used in sealing labyrinths and are placed facing wipers.
- these rings of abradable material present a composition based on silicone resin having hollow beads that are made of refractory material, not of glass.
- the hollow beads can be blast furnace residues constituted by coke slag. That type of material has the particular advantage of being inexpensive and of presenting grains that are sufficiently small in size.
- hollow alumino-silicate beads of the type sold under the trade name Sovitec T212 that product being in the form of a very fine powder that is gray in color. 90% of the beads present a size that is less than 212 micrometers ( ⁇ m). Those beads present an apparent density at 20° C. lying in the range 0.37 kilograms per cubic decimeter (kg/dm 3 ) to 0.45 kg/dm 3 .
- That product presents the following chemical composition (in % by weight): SiO 2 55% to 70% Al 2 O 3 20% to 40% Fe 2 O 3 ⁇ 10% CaO ⁇ 4% K 2 O - NaO 2 ⁇ 8% MgO ⁇ 5%
- hollow beads e.g. silica, alumina, zirconia, . . . .
- a silicone resin or a mixture of silicone resins is used that presents viscosity making the resin suitable for being applied directly onto the substrate or for being applied thereto by injection.
- the composition is thus the result of mixing together said silicone resin (a resin that is vulcanizable at high temperature), a catalyst, and the above-described hollow beads, said beads representing a percentage by weight lying in the range 10% to 25%, and preferably in the range 13% to 20% of the composition.
- the hollow beads are preferably dried by being placed in a drying oven at 150° C. for at least one hour.
- the abradable material on the substrate which is generally made of titanium, steel, or aluminum
- the primer layer is applied with a brush, a spray gun, or a rag.
- a colored primer is used, e.g. Dows Corning 1200 primer which is red in color.
- the composition is injected under pressure directly onto those locations of the substrate in question that are covered in the primer layer.
- said composition is initially made in the form of a pre-molded element, which element may be a strip, a ring, or a ring portion, or any other element of a shape that is suitable for matching the location of the substrate that is to be covered in abradable material. Thereafter, said pre-molded element(s) is/are stuck onto the metal substrate (preferably using an adhesive made of the same type of silicone resin), and the parts are held in place for the time required for the adhesive to set, which is achieved by raising it to high temperature.
- a polymerization cycle is performed at a temperature and for a duration that are sufficient to obtain the desired degree of hardening.
- the abradable coating thus formed on the metal substrate can be machined so as to have the design dimensions.
- composition in accordance with the invention can be used for fabricating rings or elements of abradable material, and also for repairing a metal thermomechanical part forming a substrate on which said abradable element constitutes the wear portion.
- Such repair can relate to replacing an entire wear part or merely to locally retouching a damaged position, since the resin can be applied very easily to zones of small or large extent.
- composition like putty For localized repairs, it is possible to apply the composition like putty, using a tool such as a spatula.
Abstract
The invention relates to an abradable material composition comprising a resin-based matrix, in particular a silicone matrix together with filler comprising hollow beads. In characteristic manner, the hollow beads withstand high temperatures and are made of refractory material. The hollow beads are preferably made of an alumino-silicate material. The composition is applicable to making abradable coverings for compressor casings, in particular casings for compressors of the low pressure type or of the booster type, or for a fan, the covering being in register with moving blades.
Description
- The invention relates to an abradable material composition (or a material that can be machined by moving parts), to a thermomechanical part (such as a casing) comprising a metal substrate covered in a wear portion comprising a covering presenting such a composition, and to a turbomachine fitted with such a thermomechanical part.
- The invention also relates to a method of fabricating or repairing an abradable covering on a metal substrate and presenting such a composition.
- In turbine engine applications, for portions that are said to be “cold”, i.e. for which the operating temperature does not exceed 250° C., there are to be found wear portions made of an abradable material composition comprising resin.
- That type of abradable material is generally constituted by a matrix of hot-polymerizable resin, in particular a silicone resin, and a filler of hollow glass beads, for example.
- Hollow glass beads are microspheres serving firstly to reduce the density of the covering composition, and secondly to contribute to the ability of the abradable material to be abraded.
- The use of silicone resins has replaced the earlier use of organic resins which present insufficient mechanical strength, and, on being abraded, give rise to powder that, on combustion, creates residues that deflagrate at high temperatures and under high pressures.
- Nowadays, new-generation turbine engines have hollow blades in their high pressure turbines that present perforations for ventilation or cooling channels connecting an internal cooling passage to the outside of the blade via ever-smaller diameters.
- Those small perforations or small-diameter channels thus tends to become clogged easily and to be difficult to clear with ventilation pressure differences, thereby leading to local interruption of ventilation for the moving blades of the turbine, and thus to potentially major operating problems due to high temperatures, and possibly endangering the ability of the blades to maintain mechanical strength, or indeed leading to local melting.
- At operating temperatures and in the event of a large amount of particles being given off during contact between the moving part and the abradable portion, it has been found that the use of hollow glass beads in abradable portions situated in particular upstream from the high pressure turbine, e.g. in the low pressure compressor, can lead to said material melting as it passes through the high pressure compressor, with the material then clogging the openings of the ventilation perforations in permanent manner.
- An object of the present invention is to provide an abradable material composition for which the wear debris is capable of withstanding high temperatures, and a method of obtaining a part covered in said material whose wear debris can withstand temperatures that are higher than those that can be withstood by presently-proposed compositions.
- A particular object of the present invention is to overcome the drawbacks of prior art abradable materials in order to avoid permanently clogging ventilation perforations or cooling channels of small size due to hollow glass beads melting.
- To this end, according to the present invention, the hollow beads are made of refractory material, glass being excluded, so that said beads present greater resistance to high temperatures.
- It can thus be understood that by using refractory hollow beads that present a melting temperature that is much higher than that of glass beads, the problem of the hollow beads melting is avoided and they remain solid at the temperatures to which they are subjected, even in the hottest part of the turbomachine.
- This solution also presents the additional advantage of making it possible to use hollow beads that are less expensive than glass beads, particularly if the hollow beads are combustion residues from fossil fuel power stations or steelworks, in particular if they are constituted by blast furnace slag.
- Overall, by means of the solution of the present invention, it is possible to improve the high temperature behavior of the wear debris from abradable materials, and in particular it is possible to avoid the abrasion residues formed from the hollow beads melting in the hottest portions of turbojets.
- In a preferred embodiment, the refractory material comprises alumina and/or silica and/or zirconia, and the refractory material preferably belongs to the family constituted by alumino-silicate materials.
- Advantageously, said refractory material presents a melting temperature greater than 700° C., preferably greater than 750° C., and more preferably greater than 900° C.
- The present invention also provides a thermomechanical part comprising a metal substrate covered in a wear portion comprising a covering presenting the above-defined composition and a bonding primer layer comprising silicone.
- Advantageously, the substrate is made of titanium, steel, aluminum, or an alloy of any one of said metals.
- In another advantageous disposition, the primer layer is colored.
- Such a thermomechanical part is intended in particular for forming a wear portion of a sealing labyrinth, associated with wipers, in particular for a booster.
- Such a thermomechanical part may also form part of a compressor casing, in particular for a low pressure compressor, and in particular of the booster type, or for a fan, in which the face of the wall that faces the moving blades has an abradable covering presenting the above-defined composition.
- The present invention also provides a turbomachine including such a casing or a thermomechanical part as defined above.
- Finally, the present invention also provides a method of fabricating or repairing an abradable covering on a metallic substrate, wherein the following steps are performed:
- a) preparing a composition as defined above; and
- b) applying said composition on said metal substrate to form said covering.
- In a first variant of the method, the application step b) is performed by direct injection.
- In a second variant of the method, application step b) comprises the following substeps:
- b1) providing at least one pre-molded element presenting the composition as defined above (e.g. a strip, a ring, or a ring portion, . . . );
- b2) depositing adhesive on the metal substrate and/or on said pre-molded element; and
- b3) depositing said element on the substrate and holding said element firmly against the substrate while the adhesive sets.
- Advantageously, the adhesive comprises hot-polymerizable silicone resin.
- In addition, and preferably, a step is performed prior to step a) in which a bonding primer layer is applied to the substrate, the primer layer comprising silicone, said layer being optionally colored.
- Other advantages and characteristics of the invention appear on reading the following description made by way of example and with reference to the accompanying drawing, in which:
-
FIG. 1 is a fragmentary half-section view of the front portion of a turbojet, with the fan and a low pressure compressor fitted with a casing. - Given that the present invention relates to abradable material compositions, in particular for abradable elements in a turbojet, the description below relates to one possible and non-limiting application of this composition in accordance with the present invention.
-
FIG. 1 is a section view showing half of the front portion 10 of a turbojet on one side of a longitudinal axis 12 constituting the axis of circular symmetry of the various elements of the turbojet, and in particular of its various moving elements. - In
FIG. 1 , there can be seen more precisely, amongst the various elements disposed axially around the longitudinal axis 12 and forming the conventional structure for such a turbojet, the fan 102 and the compressor 104 that operates at low pressure. - The fan 102 comprises a series of blades 18 projecting radially and mounted on an annular disk 20, the assembly being mounted to rotate about the longitudinal axis 12 of the turbojet.
- In
FIG. 1 , the air flow direction determines an upstream portion (to the left inFIG. 1 ) and a downstream portion (to the right inFIG. 1 ). - The compressor 104 comprises a plurality of sets of rotary moving blades 22 mounted on a disk or drum 24 that is secured to the disk 20 of the fan 102.
- In
FIG. 1 , there can be seen three sets of moving blades 22 mounted between five sets of stationary vanes 26 mounted on a casing 28. - The structure of the casing 28 is such that it includes rings 30 of abradable material on its inside face in register with the ends of the moving blades 22.
- Amongst other applications of the abradable material of the present invention, mention can be made in particular of various circumstances in which the abradable elements are used in sealing labyrinths and are placed facing wipers.
- According to the invention, these rings of abradable material present a composition based on silicone resin having hollow beads that are made of refractory material, not of glass.
- By way of example, the hollow beads can be blast furnace residues constituted by coke slag. That type of material has the particular advantage of being inexpensive and of presenting grains that are sufficiently small in size.
- Thus, it is advantageous to use hollow alumino-silicate beads of the type sold under the trade name Sovitec T212, that product being in the form of a very fine powder that is gray in color. 90% of the beads present a size that is less than 212 micrometers (μm). Those beads present an apparent density at 20° C. lying in the range 0.37 kilograms per cubic decimeter (kg/dm3) to 0.45 kg/dm3.
- That product presents the following chemical composition (in % by weight):
SiO2 55% to 70% Al2O3 20% to 40% Fe2O3 ≦10% CaO ≦4% K2O - NaO2 ≦8% MgO ≦5% - It is also possible to use other refractory materials for the hollow beads, e.g. silica, alumina, zirconia, . . . .
- A silicone resin or a mixture of silicone resins is used that presents viscosity making the resin suitable for being applied directly onto the substrate or for being applied thereto by injection.
- The composition is thus the result of mixing together said silicone resin (a resin that is vulcanizable at high temperature), a catalyst, and the above-described hollow beads, said beads representing a percentage by weight lying in the range 10% to 25%, and preferably in the range 13% to 20% of the composition.
- Before making the mixture, it should be observed that the hollow beads are preferably dried by being placed in a drying oven at 150° C. for at least one hour.
- In order to facilitate bonding the abradable material on the substrate, which is generally made of titanium, steel, or aluminum, it is preferable to begin by applying a bonding primer layer on the substrate, the primer layer comprising silicone in a solvent.
- The primer layer is applied with a brush, a spray gun, or a rag.
- Advantageously, a colored primer is used, e.g. Dows Corning 1200 primer which is red in color.
- In this way, it can be seen where the primer layer has already been deposited, so as to ensure that certain portions of the surface are not forgotten and also to avoid applying too much primer in other locations.
- In a first variant technique for applying the composition, the composition is injected under pressure directly onto those locations of the substrate in question that are covered in the primer layer.
- In a second variant technique for applying the composition, said composition is initially made in the form of a pre-molded element, which element may be a strip, a ring, or a ring portion, or any other element of a shape that is suitable for matching the location of the substrate that is to be covered in abradable material. Thereafter, said pre-molded element(s) is/are stuck onto the metal substrate (preferably using an adhesive made of the same type of silicone resin), and the parts are held in place for the time required for the adhesive to set, which is achieved by raising it to high temperature.
- With both application techniques, once the composition has been applied by injection (first technique) or after molding one or more pre-molded elements (second technique), a polymerization cycle is performed at a temperature and for a duration that are sufficient to obtain the desired degree of hardening.
- Thereafter, if necessary, the abradable coating thus formed on the metal substrate can be machined so as to have the design dimensions.
- This composition in accordance with the invention can be used for fabricating rings or elements of abradable material, and also for repairing a metal thermomechanical part forming a substrate on which said abradable element constitutes the wear portion.
- Such repair can relate to replacing an entire wear part or merely to locally retouching a damaged position, since the resin can be applied very easily to zones of small or large extent.
- For localized repairs, it is possible to apply the composition like putty, using a tool such as a spatula.
Claims (15)
1. A composition of abradable material comprising a matrix based on resin, in particular silicone resin, and filler comprising hollow beads, wherein the hollow beads are made of refractory material, glass being excluded.
2. A composition according to claim 1 , wherein the refractory material comprises alumina and/or silica and/or zirconia.
3. A composition according to claim 1 , wherein the refractory material belongs to the family constituted by alumino-silicate materials.
4. A composition according to claim 1 , wherein said refractory material presents a melting temperature greater than 700° C., preferably greater than 750° C.
5. A thermomechanical part comprising a metal substrate covered in a wear portion comprising a covering presenting the composition according to claim 1 and a bonding primer layer comprising silicone.
6. A thermomechanical part according to claim 5 , wherein the substrate is made to titanium, steel, aluminum, or an alloy of any one of said metals.
7. A thermomechanical part according to claim 5 , wherein the primer layer is colored.
8. A thermomechanical part according to claim 5 , the part serving to form a wear portion of a sealing labyrinth, associated with wipers, in particular for a booster.
9. A casing for a compressor or a fan, in which the face of the wall that is to be in register with the moving blades includes an abradable covering presenting the composition according to claim 1 .
10. A turbomachine including a casing according to claim 9 or a thermomechanical part according to claim 5 .
11. A method of fabricating or repairing an abradable covering on a metal substrate, wherein the following steps are performed:
a) preparing a composition according to claim 1; and
b) applying said composition on said metal substrate in order to form said covering.
12. A method according to claim 11 , wherein application step b) is performed by direct injection.
13. A method according to claim 11 , wherein application step b) comprises the following substeps:
b1) providing at least one pre-molded element presenting the composition according to claim 1;
b2) depositing adhesive on the metal substrate and/or on said pre-molded element; and
b3) depositing said element on the substrate and holding said element firmly against the substrate while the adhesive sets.
14. A method according to claim 13 , wherein the adhesive comprises hot-polymerizable silicone resin.
15. A method according to claim 11 , wherein an additional step is performed prior to step a) in which a bonding primer layer is applied to the substrate, the primer layer comprising silicone.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/464,678 US20090223632A1 (en) | 2005-06-30 | 2009-05-12 | Abradable material composition, a thermomechanical part or casing including a coating, and a method of fabricating or repairing a coating presenting said composition |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FR0506736A FR2887890B1 (en) | 2005-06-30 | 2005-06-30 | ABRADABLE MATERIAL COMPOSITION, THERMOMECHANICAL PART OR CASING COMPRISING A COATING AND PROCESS FOR MAKING OR REPAIRING A COATING HAVING THE SAME |
FR0506736 | 2005-06-30 |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/464,678 Division US20090223632A1 (en) | 2005-06-30 | 2009-05-12 | Abradable material composition, a thermomechanical part or casing including a coating, and a method of fabricating or repairing a coating presenting said composition |
Publications (1)
Publication Number | Publication Date |
---|---|
US20070003412A1 true US20070003412A1 (en) | 2007-01-04 |
Family
ID=35809787
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/476,845 Abandoned US20070003412A1 (en) | 2005-06-30 | 2006-06-29 | Abradable material composition, a thermomechanical part or casing including a coating, and a method of fabricating or repairing a coating presenting said composition |
US12/464,678 Abandoned US20090223632A1 (en) | 2005-06-30 | 2009-05-12 | Abradable material composition, a thermomechanical part or casing including a coating, and a method of fabricating or repairing a coating presenting said composition |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/464,678 Abandoned US20090223632A1 (en) | 2005-06-30 | 2009-05-12 | Abradable material composition, a thermomechanical part or casing including a coating, and a method of fabricating or repairing a coating presenting said composition |
Country Status (5)
Country | Link |
---|---|
US (2) | US20070003412A1 (en) |
EP (1) | EP1739145B1 (en) |
CA (1) | CA2551337A1 (en) |
DE (1) | DE602006009187D1 (en) |
FR (1) | FR2887890B1 (en) |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20110002779A1 (en) * | 2008-12-24 | 2011-01-06 | Laurent Schuster | Method for Manufacturing by Molding a Machine Structural Element Having an Abradable Surface, and Structural Element |
US20150209915A1 (en) * | 2011-12-28 | 2015-07-30 | Rolls-Royce Deutschland Ltd & Co Kg | Method for repairing an abradable coating of a compressor of a gas turbine |
US10107111B2 (en) | 2012-07-20 | 2018-10-23 | Safran Aéro Boosters | Corrosion-resistant abradable covering |
EP3419821A4 (en) * | 2016-02-26 | 2019-09-25 | Standard Aero Limited | Coating for lining a compressor case |
US10480330B2 (en) * | 2013-01-29 | 2019-11-19 | United Technologies Corporation | Blade rub material |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB0705696D0 (en) * | 2007-03-24 | 2007-05-02 | Rolls Royce Plc | A method of repairing a damaged abradable coating |
FR3040446B1 (en) * | 2015-08-25 | 2020-02-28 | Safran Aircraft Engines | ANNULAR THERMOMECHANICAL PART FOR TURBOMACHINE |
US20220281134A1 (en) * | 2019-07-11 | 2022-09-08 | Safran Aircraft Engines | Method for producing a part from composite material by injecting a filled slip into a fibrous texture |
FR3113474B1 (en) * | 2020-08-18 | 2022-10-07 | Safran Helicopter Engines | PART COMPRISING AN ABRADABLE COATING AND ASSOCIATED MANUFACTURING METHOD |
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US4112179A (en) * | 1975-12-10 | 1978-09-05 | Maccalous Joseph W | Method of coating with ablative heat shield materials |
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US6287372B1 (en) * | 2000-03-31 | 2001-09-11 | Themec Company Incorporated | Anti-corrosive coating |
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US20050058541A1 (en) * | 2002-10-22 | 2005-03-17 | Snecma Moteurs | Casing, a compressor, a turbine, and a combustion turbine engine including such a casing |
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US6133340A (en) * | 1996-03-25 | 2000-10-17 | Ashland Inc. | Sleeves, their preparation, and use |
ES2134729B1 (en) * | 1996-07-18 | 2000-05-16 | Kemen Recupac Sa | IMPROVEMENTS INTRODUCED IN OBJECT APPLICATION FOR A SPANISH INVENTION PATENT N. 9601607 FOR "PROCEDURE FOR THE MANUFACTURE OF EXACT SLEEVES AND OTHER ELEMENTS OF MAZAROTAJE AND FEEDING FOR CAST MOLDS. |
JP2000303022A (en) * | 1999-04-21 | 2000-10-31 | Dow Corning Toray Silicone Co Ltd | Silicone rubber coating composition for air bag |
FR2834751B1 (en) * | 2002-01-17 | 2004-09-10 | Snecma Moteurs | ROTOR ARRANGEMENT OF A TURBOMACHINE |
JP2005515932A (en) * | 2002-01-29 | 2005-06-02 | コラス ユーケイ リミテッド | Laminated body and method for producing the same |
DE60231219D1 (en) * | 2002-12-03 | 2009-04-02 | Techspace Aero Sa | Inner shroud of an axial compressor and its use |
-
2005
- 2005-06-30 FR FR0506736A patent/FR2887890B1/en not_active Expired - Fee Related
-
2006
- 2006-06-28 CA CA002551337A patent/CA2551337A1/en not_active Abandoned
- 2006-06-28 DE DE602006009187T patent/DE602006009187D1/en active Active
- 2006-06-28 EP EP06116197A patent/EP1739145B1/en active Active
- 2006-06-29 US US11/476,845 patent/US20070003412A1/en not_active Abandoned
-
2009
- 2009-05-12 US US12/464,678 patent/US20090223632A1/en not_active Abandoned
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US4112179A (en) * | 1975-12-10 | 1978-09-05 | Maccalous Joseph W | Method of coating with ablative heat shield materials |
US4580794A (en) * | 1984-11-16 | 1986-04-08 | Jamak, Inc. | Silicon rubber gasket and material |
US20020017361A1 (en) * | 1998-05-15 | 2002-02-14 | Walker Michael S. | Method for forming a fluid seal between rotating and stationary members |
US6287372B1 (en) * | 2000-03-31 | 2001-09-11 | Themec Company Incorporated | Anti-corrosive coating |
US20050058541A1 (en) * | 2002-10-22 | 2005-03-17 | Snecma Moteurs | Casing, a compressor, a turbine, and a combustion turbine engine including such a casing |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20110002779A1 (en) * | 2008-12-24 | 2011-01-06 | Laurent Schuster | Method for Manufacturing by Molding a Machine Structural Element Having an Abradable Surface, and Structural Element |
US8491258B2 (en) * | 2008-12-24 | 2013-07-23 | Techspace Aero S.A. | Method for manufacturing by molding a machine structural element having an abradable surface, and structural element |
US20150209915A1 (en) * | 2011-12-28 | 2015-07-30 | Rolls-Royce Deutschland Ltd & Co Kg | Method for repairing an abradable coating of a compressor of a gas turbine |
US9403244B2 (en) * | 2011-12-28 | 2016-08-02 | Rolls-Royce Deutschland Ltd & Co Kg | Method for repairing an abradable coating of a compressor of a gas turbine |
US10107111B2 (en) | 2012-07-20 | 2018-10-23 | Safran Aéro Boosters | Corrosion-resistant abradable covering |
US10480330B2 (en) * | 2013-01-29 | 2019-11-19 | United Technologies Corporation | Blade rub material |
EP3419821A4 (en) * | 2016-02-26 | 2019-09-25 | Standard Aero Limited | Coating for lining a compressor case |
Also Published As
Publication number | Publication date |
---|---|
CA2551337A1 (en) | 2006-12-30 |
EP1739145B1 (en) | 2009-09-16 |
EP1739145A1 (en) | 2007-01-03 |
US20090223632A1 (en) | 2009-09-10 |
FR2887890B1 (en) | 2007-10-12 |
DE602006009187D1 (en) | 2009-10-29 |
FR2887890A1 (en) | 2007-01-05 |
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Legal Events
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AS | Assignment |
Owner name: SNECMA, FRANCE Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:LE BIEZ, PHILIPPE, CHARLES, ALAIN;MONS, CLAUDE MARCEL;REEL/FRAME:018057/0613 Effective date: 20060619 |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |