Wear analysis of microstructure image-based 3D models to help design the best abradable coating composition.
Topic(s) : Material and Structural Behavior - Simulation & Testing
Co-authors :
Jadhav PRAKASH (INDIA), Anitha ANITHA AZMEERAAbstract :
Innovative abradable or wearable coating is proposed in gas turbine engines for military or commercial fixed-wing and rotary-wing aircraft in the hot section of the engine for improved efficiency and high-density power. Coated materials are generally used to make improvements in gas turbine engine efficiency. The high-power density is the main driver with the goal of improving wear resistance, erosion resistance and to reduce the variety of failures in blade. To accomplish this, use of abradable coatings/ seals are proposed. With an abradable seal/coatings, blade tip digs into the shroud, thereby minimizing the gap between rotor and the shroud to a minimum. Abradable coatings are commonly multiphase materials applied using thermal spray techniques. The most common three phases are metal matrix, oxide particles, and porosity. Effectiveness of seal is determined by right combination of properties like erosion resistance and hardness; and this is accomplished by maintaining proper combination of the ingredients while manufacturing. The current study intends to develop abradable coating with the abradability ratio of approximately twenty using a theoretical/modeling approach.
This work's primary goal was to study abrasion-resistant coatings, which are mostly multiphase materials made by the thermal spraying technique. Using ink scab software, a 3D model in DFX format is created in this study using high-resolution SEM pictures of abrasive coatings at varying porosity and hardness levels. The microstructure images of the actual coating in DFX format are used to construct the coating 3D FEA models using a particular tool or method (Fusion 360). To build mesh for various coating compositions (metal matrix, oxide, and porosity) according to their form and size, the finite element analysis (FEA-HYPER MESH) methodology was also developed. By employing a FEA modelling technique (LS-DYNA), the rub rig test, which measures the coating's abrasion resistance from five to twenty, is recreated. The stress vs. strain curve for the blade as well as the metal matrix, oxide, and porosity input parameters (density, Young's modulus, tangent modulus, and failure criterion) are all used as input in the study. In microstructure image-based FEA models, for coating compositions, abradability is computed after sixty passes of the blade over an abradable seal. Abrasion resistance rises with porosity and falls with hardness, according to this research for the microstructure-based FEA simulation. High-resolution SEM images will be used in future research to develop the ability to predict abrasion, and any FEM method will be used to determine the characteristics and performance of any unknown coating composition merely by looking at the coating's microstructure image.
This work's primary goal was to study abrasion-resistant coatings, which are mostly multiphase materials made by the thermal spraying technique. Using ink scab software, a 3D model in DFX format is created in this study using high-resolution SEM pictures of abrasive coatings at varying porosity and hardness levels. The microstructure images of the actual coating in DFX format are used to construct the coating 3D FEA models using a particular tool or method (Fusion 360). To build mesh for various coating compositions (metal matrix, oxide, and porosity) according to their form and size, the finite element analysis (FEA-HYPER MESH) methodology was also developed. By employing a FEA modelling technique (LS-DYNA), the rub rig test, which measures the coating's abrasion resistance from five to twenty, is recreated. The stress vs. strain curve for the blade as well as the metal matrix, oxide, and porosity input parameters (density, Young's modulus, tangent modulus, and failure criterion) are all used as input in the study. In microstructure image-based FEA models, for coating compositions, abradability is computed after sixty passes of the blade over an abradable seal. Abrasion resistance rises with porosity and falls with hardness, according to this research for the microstructure-based FEA simulation. High-resolution SEM images will be used in future research to develop the ability to predict abrasion, and any FEM method will be used to determine the characteristics and performance of any unknown coating composition merely by looking at the coating's microstructure image.