Enhanced Blade Tipping For Improved Abradability

Abstract

An abrasive coating comprising a plurality of first grit particles placed on a top surface of a substrate and spaced to provide channels for the removal of cut chips and rub debris and heat reduction. A plurality of second grit particles are placed between each of the first grit particles, and having a nominal size smaller than the first grit particles. A mixture of the second grit particles to the first grit particles comprises from about 75-98%. The second grit particles form a single layer or multiple layers and comprise height of 10 to 60% of that of the first grit particles. A matrix material is bonded to the top surface; the matrix material envelops the second grit particles and bonds to and partially surrounds the first grit particles. The first grit particles extend above the matrix material and the second grit particles relative to the top surface.

Claims

1. An abrasive coating for a substrate, comprising: a plurality of first grit particles adapted to be placed on a top surface of said substrate, wherein said plurality of first grit particles are spaced to provide channels for at least one of the removal of cut chips and rub debris and the reduction of heat generation; a plurality of second grit particles placed between each of said plurality of first grit particles, said second grit particles having a nominal size smaller than said first grit particles, wherein a mixture of said second grit particles to said first grit particles comprises from about 75-98% of said mixture of particles wherein said plurality of second grit particles are configured in a single layer or multiple layers wherein said plurality of second grit particles comprise a total combined height of 10 to 60% of that of the first grit particles, and a matrix material bonded to said top surface; said matrix material envelops said second grit particles and said matrix material bonds to and partially surrounds said first grit particles, wherein said first grit particles extend above said matrix material and said second grit particles relative to said top surface.

2. The coating according to claim 1, wherein said first grit particles comprise a cubic boron nitride material, coated silicon carbide (SiC), or another hard ceramic phase.

3. The coating according to claim 1, wherein said matrix material comprises a matrix formed from at least one of Ni, Co and MCrAlY, wherein M is Ni or Co.

4. The coating according to claim 1, wherein said second grit particles are selected from the group consisting of alumina, silicon nitride, cubic boron nitride.

5. The coating according to claim 1, further comprising: an adhesion layer coupled to said top surface, wherein said adhesion layer is configured to adhere said first grit particles to said top surface.

6. The coating according to claim 5, wherein said adhesion layer comprises the same material as said matrix material.

7. The coating according to claim 1, wherein said second grit particles are about one tenth of the nominal size of the first grit particles.

8. A turbine engine component comprising: an airfoil having a tip; a composite abrasive coating bonded to said tip; said composite abrasive coating comprising an adhesion layer bonded to said tip; a layer of first grit particles bonded to said adhesion layer; a plurality of second grit particles dispersed around said first grit particles, said second grit particles being smaller than said first grit particles, wherein a mixture of said second grit particles to said first grit particles comprises from about 75% to about 98% of the total number of particles; and said second grit particles enveloped in a matrix material surrounding an unexposed portion of said first grit particles; said matrix material coupled to said adhesion layer.

9. The turbine engine component according to claim 8, wherein said first grit particles are sized from about 0.04 to about 1.00 millimeters.

10. The turbine engine component according to claim 8, wherein said second grit particles are sized from 0.004 to about 0.1 millimeters.

11. The turbine engine component according to claim 8, wherein a diameter of said first grit particles are 10 to 1 the size of a diameter of said second grit particles.

12. The turbine engine component according to claim 8, wherein said matrix material and said second grit particles are configured to distribute a cutting load from individual highly loaded first grit particles to adjacent first grit particles, thereby reducing stress at the matrix material.

13. The turbine engine system according to claim 8, wherein each one of said first grit particles are configured with grit spacing configured to protect said matrix material from wear by an abradable rub.

14. The turbine engine system according to claim 8, further comprising: at least one channel formed between said first grit particles, said channels having a width of 1-3 diameters of said first grit particles.

15. The turbine engine system according to claim 14, wherein said channel is located between said first grit particles that are about 40-90 percent recessed below a total height of said first grit particles.

16. The turbine engine system according to claim 14, wherein said channel comprises a composite of said matrix material and said second grit particles.

17. The turbine engine system according to claim 14, wherein said channel comprises a composite having a strength and abrasion resistance greater than a strength and abrasion of said matrix alone, said channel configured to provide support and bonding strength for said first grit particles.

18. A process for coating a turbine engine airfoil with an abrasive, said process comprising: applying an adhesion layer onto a tip of said airfoil; adhering a plurality of first grit particles to said adhesion layer, wherein spaces are formed between said first grit particles; filling said spaces between said first grit particles with a plurality of second grit particles, wherein said second grit particles are smaller than the first grit particles, wherein a mixture of said second grit particles to said first grit particles comprises from about 75% to about 98% of said mixture of particles; enveloping said second grit particles with a matrix material; and surrounding each of said first grit particles with said matrix material exposing a portion of said first grit particles above said matrix material and said second grit particles.

19. The process of claim 18, further comprising: spacing said first grit particles apart, wherein said spacing is configured to protect said matrix material from wear by an abradable rub.

20. The process of claim 19, further comprising: distributing a cutting load from individual highly loaded first grit particles to adjacent first grit particles, thereby reducing stress at the matrix composite material.

21. The process of claim 19, wherein said matrix material and said second grit particles combined comprise a strength and abrasion resistance greater than said matrix material alone.

22. The process of claim 19, further comprising applying a base layer to said blade tip prior to applying said adhesion layer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is a schematic representation of abrasive composite coating applied to a tip of a turbine engine component; and

[0026] FIG. 2 is a schematic cross-sectional view of the exemplary abrasive blade tip coating.

DETAILED DESCRIPTION

[0027] Referring now to FIG. 1 there is illustrated a turbine engine component 10, such as a compressor blade or vane. The blade 10 has an airfoil portion 12 with a tip 14. The tip 14 has an abrasive coating 16 applied to it. The abrasive coating 16 comprises a composite material that includes an abrasive particulate/grit or simply first grit 18, such as cubic boron nitride (CBN), coated silicon carbide (SiC), or another hard ceramic phase. The grit 18 can be sized as a coarse grit. In an exemplary embodiment the grit 18 can be sized from about 40 to about 1000 microns. The first grit 18 is embedded in a plating, vapor deposited or other type layer matrix composite 20. The matrix 20 comprises a suitable oxidation-resistant alloy matrix. In an exemplary embedment the layer comprises a matrix formed from Ni, Co, or MCrAlY, the M standing for either Ni or Co or both. In an exemplary embodiment, the matrix 20 can comprise pure nickel, nickel alloy, copper, copper alloy, cobalt, cobalt alloy, chrome or other alloys. A second grit 22 is interspersed between the first grit 18. The second grit 22 is a smaller sized particle than the larger first grit material 18. In an exemplary embodiment, the second grit 22 is sized to about 1/10 the size of the first grit 18. The second grit 22 can be from about 5% to about 20% of the diameter of the first grit 18. The second grit 22 may be Al.sub.2O.sub.3 (alumina), Si.sub.3N.sub.4 (silicon nitride), CBN (cubic boron nitride), or other similar abrasive particles. The percentage of particles within the mixture should range from 2% to 25% of first grit 18 to second grit 22 particles. Second grit particles range from about 75% to about 98% of the total number of particles.

[0028] Second grit 22 are placed within the plating layer 20 in one or more layer, to produce a total height from the base tip material that is 10-60% of the height of the first grit 18. First grit particles 18 are 40%-90% recessed below the height of the first grit particle total height. The resulting blade tip 14 with abrasive coating 16 is particularly well suited for rubbing metal as well as ceramic abradable seals (not shown).

[0029] The turbine engine component/blade 10 may be formed from a titanium-based, nickel-based, iron-base, or other alloy. In an exemplary embodiment, the blade 10 includes a (Ti) titanium-based alloy.

[0030] Referring to FIG. 2 an exemplary abrasive coating 16 is shown. The abrasive coating 16 includes the large first grit particles 18 and relatively smaller second grit particles 22 interspersed throughout the matrix 20, but typically in the range of 10 to 1 diameter ratio.

[0031] In an exemplary embodiment, the first grit particles 18 range in size from about 0.04 to about 1.00 millimeters (mm) nominally. First grit 18 particle sizes can range up to about 1.00 mm nominally.

[0032] This abrasion protection thus, enables greater first grit 18 retention by maintaining support from the matrix composite material 20.

[0033] In alternative embodiments, the large grit particles 18 can comprise hard materials. In an exemplary embodiment, the grit 18 can comprise: zirconia, aluminum di-boride, aluminum nitride, aluminum nitride-carbon, diamond or other engineered grit particles. In an exemplary embodiment, the second grit 22 can range in size from about 0.004 to about 0.10 mm nominally. The second grit particles 22 can comprise the same material as the larger grit particles 18. Other materials can be employed for the small grit 22. In an exemplary embodiment, the second grit particles 22 can comprise a smaller, high modulus, higher strength, and/or higher abrasion resistant material that is less costly than the first grit particle 18. Thus, the larger first grit particle 18 can be a more expensive material such as, diamond and the second grit 22 can be less expensive since, it does not perform the bulk of the cutting and instead performs the function of improving the strength of the matrix composite material and the function of spacing the first grits and also providing conduits for the chips and debris removal 20.

[0034] The smaller second grit particles 22 function to increase the strength and abrasion resistance of the matrix material 20 and support and hold the first grit particles 18 increasing the load resistance and adherence of the first grit 18.

[0035] The abrasive coating 16 can include a base layer 24 bonded to the blade tip 14. The base layer 24 can be the same material as the matrix 20. The base layer 24 can be from about 1 to about 100 microns in thickness. In an exemplary embodiment, the base layer 24 can be from about 25 to about 50 microns in thickness. The base layer 24 can be optionally applied.

[0036] An adhesion layer 26 comprising the plating, vapor deposited, brazed or other application process material utilized in the matrix 20 can be applied to the base layer 24 or can be coated directly to the blade tip 14. The adhesion layer 26 prepares the surface of the tip 14 for the first grit 18 to adhere to during application of the first grit 18. The adhesion layer 26 can comprise the same basic material as the matrix 20 or other beneficial materials that bind the first grit 18 to the blade tip 14 or alternatively the base layer 24. In an exemplary embodiment the adhesion layer 24 comprises a Ni alloy matrix material.

[0037] The exemplary abrasive coating 16 includes a portion of each first grit particle 18 projecting outward above the surface of the matrix material 20, thereby enabling favorable sliding contact (rubbing) interaction with metal or ceramic seals during engine operation. The unexposed portion of the first grit particles 18 are surrounded by matrix material 20 and second grit 22. The first grit particles 18 can be spaced apart from each other with an optimal distance of separation and arranged uniformly spaced apart. The optimal distance of separation of large grit particles can be defined by the competition between the average heat generation at the abradable surface that reduces with the distance between the grits and the force acting on the individual grit that is increasing with the distance between the grits. The optimal point depends on the material properties of the rub couple and on the incursion rate. However, for typical incursion rates (lower than 80 mils/s) and for metallic porous abradable material the optimal distance would be close to half of the blade thickness. The matrix material 20 and smaller second grit 22, as well as first grit particles 18 can be securely bonded to the blade tip 14.

[0038] The spaces between the first grit 18 should be such that the first particles are spaced at a linear length of 1 to 3 first grit diameters to produce sufficient spacing to produce channels 30 for cut chips and debris to pass during the cutting process. The first grit particles 18 are specifically spaced apart. The spacing can provide channels 30 between each first grit particle 18. Engineered abrasive resistance of the composite of second particles 22 and matrix composite material 20, which provides abrasion resistance of the recessed channels 30 between the first particles 18. The channel 30 comprises a composite having a strength and abrasion resistance greater than a strength and abrasion of the matrix 20 alone. The channel 30 can be configured to provide superior support and bonding strength for the first grit particle 18.

[0039] The combination of the smaller grit 22 blended with the matrix material 20 securely bonded and surrounding the grit particles 18 achieve a higher strength and abrasion resistance than merely having only the matrix 20 surrounding the first grit 18. The combination of smaller grit 22 and matrix 20 also provides superior support to the first grit 18.

[0040] The abrasive blade tip coating takes advantage of the characteristics of a composite structure within the channels by distributing cutting load from individual highly loaded grit particles to adjacent grit particles, thus reducing stress within the composite matrix, which holds individual grit particles. The exemplary abrasive blade tip coating demonstrates superior durability that is associated with the ability of individual grits to withstand higher loads. The principle is to create sufficient spacing between the coarse particles to increase the loading on them during the rub and therefore increase the cut-per-blade pass, which is beneficial for small incursion rates due to observed, as well as predicted by modeling, decrease of heat generation. It is also beneficial at both high and low incursion rates through providing optimal abrasion resistant channels for chips and debris to be removed, which in turn reduce the overall pressure within the rub system.

[0041] Better transfer of loads between first abrasive particles and optimal abrasion resistant channels between first particles allows individual first grits to support higher cutting loads and higher cutting time before being pulled out of the abrasive composite blade tip. Another benefit of the exemplary abrasive tip coating is that the optimum first grit spacing and application of second grit particles within the composite matrix provides better protection of the Ni matrix from wear by abraded rub debris. The exemplary abrasive composite blade tip coating enables for retention of the matrix that also relates to better first grit retention.

[0042] There has been provided an abrasive blade tip coating. While the abrasive blade tip coating has been described in the context of specific embodiments thereof, other unforeseen alternatives, modifications, and variations may become apparent to those skilled in the art having read the foregoing description. Accordingly, it is intended to embrace those alternatives, modifications, and variations that fall within the broad scope of the appended claims.