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<p>Abradable coatings play a critical role in improving aerospace engine efficiency and supporting sustainable operation by reducing fuel consumption and protecting blade integrity during blade-casing interactions. This study aims to address gaps in the literature on the erosion behavior of different aluminum–silicon-based (AlSi) thermal spray abradable coatings through comprehensive characterization of their features and properties. Three abradable formulations were investigated: AlSi-40&#xa0;wt.% polyester, AlSi-40&#xa0;wt.% polyester with minor additions of Mo and Cr, and AlSi-20&#xa0;wt.% polyester-6&#xa0;wt.% hBN. The behavior of each abradable was evaluated considering: dry air jet erosion test on 30°, 60° and 90° impingement angles with alumina as erodent, density measurements and porosity characterization through mercury intrusion porosity. All coatings exhibited generally ductile erosion behavior, with wear rates slightly decreasing at higher impingement angles. Statistically, no significant differences in erosion rate were observed among the tested abradables. The abradables have up to 17% of porosity and pore size within the range of 1–4&#xa0;µm. The study concludes that erosion behavior in AlSi-polyester abradable coatings is governed by the complex interplay of hardness, density, porosity, filler content and microstructure, resulting in similar erosion rates across all tested coatings.</p>

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Erosion performance of thermally sprayed AlSi-polyester based abradable coatings: the effects of microstructure and hBN/Mo-Cr additives

  • 期刊论文

  • 发表日期：

    2026年6月24日

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  • Natália de Oliveira Sousa,
  • Bruno E. Arendarchuck,
  • Francisco Rivadeneira,
  • Barry Barnett,
  • Kaue Bertuol,
  • Pantcho Stoyanov

摘要

Abradable coatings play a critical role in improving aerospace engine efficiency and supporting sustainable operation by reducing fuel consumption and protecting blade integrity during blade-casing interactions. This study aims to address gaps in the literature on the erosion behavior of different aluminum–silicon-based (AlSi) thermal spray abradable coatings through comprehensive characterization of their features and properties. Three abradable formulations were investigated: AlSi-40 wt.% polyester, AlSi-40 wt.% polyester with minor additions of Mo and Cr, and AlSi-20 wt.% polyester-6 wt.% hBN. The behavior of each abradable was evaluated considering: dry air jet erosion test on 30°, 60° and 90° impingement angles with alumina as erodent, density measurements and porosity characterization through mercury intrusion porosity. All coatings exhibited generally ductile erosion behavior, with wear rates slightly decreasing at higher impingement angles. Statistically, no significant differences in erosion rate were observed among the tested abradables. The abradables have up to 17% of porosity and pore size within the range of 1–4 µm. The study concludes that erosion behavior in AlSi-polyester abradable coatings is governed by the complex interplay of hardness, density, porosity, filler content and microstructure, resulting in similar erosion rates across all tested coatings.