Max phase reinforced polymer matrix composite abradables with enhanced thermal conductivity

Patent metadata

Field	Value
Publication number	US-10036402-B2
Application number	US-201514709721-A
Country	US
Kind code	B2
Filing date	May 12, 2015
Priority date	May 14, 2014
Publication date	Jul 31, 2018
Grant date	Jul 31, 2018

Abstract

A turbine engine system comprising a turbine engine component, such as a fan includes a fan casing and a fan blade rotatable within the fan casing. An abradable seal coupled to the fan casing proximate the fan blade. The abradable seal comprising an abradable composite layer including a MAX phase solid and a polymer based abradable composition.

First claim

What is claimed is:

1. A turbine engine system comprising:
a turbine engine fan section; said fan section including a fan casing and a fan blade rotatable within said fan casing;
an abradable seal coupled to said fan casing between said fan casing and said fan blade, said abradable seal comprising an abradable composite layer formed by a MAX based solids reinforcement and a polymer based composition, wherein said abradable composite layer includes said MAX phase solids from 1% to 66% by volume and said polymer based abradable composition being the remainder.

2. The turbine engine system according to claim 1 , wherein said MAX phase solids is a composite having MAX phases and a metal matrix.

3. The turbine engine system according to claim 2 , wherein said MAX phase solids are defined by the formula M n+1 AX n where M is an early transition metal element, A is an A-group element, X is C or N, and n=1 to 3.

4. The turbine engine system according to claim 1 , further comprising a coating layer deposited between said fan casing and said abradable seal.

5. The turbine engine system according to claim 1 , wherein said abradable composite layer includes said MAX phase solids and a polymer based abradable material and a hollow micro sphere material.

6. A turbine engine abradable outer air seal comprising:
a casing substrate;
an abradable composite layer coupled to said substrate; and
said abradable composite layer formed by a MAX based solids reinforcement and a polymer based composition, wherein said abradable composite layer includes said MAX phase solids of between 1 wt. % and 10 wt. % and said polymer based abradable composition being from 90 wt. % to 99 wt. %.

7. The turbine engine abradable outer air seal according to claim 6 wherein said turbine engine abradable outer air seal comprises a fan abradable outer air seal.

8. The turbine engine abradable outer air seal according to claim 6 , wherein said MAX phase solids include a composite having MAX phases and a metal matrix.

9. The turbine engine abradable outer air seal according to claim 8 , wherein said MAX phase solids are defined by the formula M n+1 AX n where M is an early transition metal element, A is an A group element, X is carbon or nitrogen, and n=1 to 3.

10. The turbine engine abradable outer air seal according to claim 6 , further comprising a bond coat coupled between said substrate and said abradable composite layer.

11. A process for manufacturing a turbine engine abradable outer air seal component, said process comprising the steps of:
forming an abradable composition formed of a MAX phase solids reinforcement and a polymer based composition;
mixing said MAX phase solids of between 1 wt. % and 10 wt. % and said polymer based abradable material from 90 wt. % to 99 wt. % into the abradable composition;
applying said abradable composition to a fan casing substrate in the form of an outer air seal.

12. The process of claim 11 , further comprising:
coupling a bond coating to said substrate between said substrate and said abradable composition.

13. The process of claim 11 , wherein said MAX phase solids comprise MAX phases and a metal matrix.

14. The process of claim 13 , wherein said metal matrix is metal or metal alloy and said MAX phase solids are defined by the formula M n+1 AX n where M is an early transition metal element, A is an A group element, X is carbon or nitrogen, and n=1 to 3.

15. The process of claim 11 further comprising:
combining a filler with said MAX phase solids and said polymer based abradable material into said abradable composition.

Assignees

• United Technologies Corp

Inventors

• Amini Shahram
• Strock Christopher W
• Guo Changsheng

Classifications

• F01D21/045

  special arrangements in stators or in rotors dealing with breaking-off of part of rotor · CPC title

• F01D11/122

  with erodable or abradable material (blades having cutting or grinding tips F01D5/20) · CPC title

• F01D11/12

  using a rubstrip, e.g. erodible. deformable or resiliently-biased part · CPC title

• F01D5/28 Primary

  Selecting particular materials; {Particular measures relating thereto;} Measures against erosion or corrosion · CPC title

• F05B2280/5011

  Surface roughness · CPC title