Method for manufacturing an abradable layer

Patent metadata

Field	Value
Publication number	US-12129553-B2
Application number	US-201917255232-A
Country	US
Kind code	B2
Filing date	Jun 20, 2019
Priority date	Jun 25, 2018
Publication date	Oct 29, 2024
Grant date	Oct 29, 2024

Abstract

A process for manufacturing an abradable layer, includes compressing a powder composition including at least micrometric ceramic particles having a number-average form factor greater than or equal to 3, a mass content of said micrometric ceramic particles in the powder composition being greater than or equal to 85%, the form factor of a particle being defined as the ratio [largest dimension of the particle]/[largest cross-sectional dimension of the particle], and sintering the powder composition thus compressed to obtain the abradable layer, wherein a temperature imposed during sintering, the sintering time and the compression pressure applied are selected so as to obtain a volume porosity rate of the abradable layer greater than or equal to 20%.

First claim

The invention claimed is:

1. A process for manufacturing a substrate coated with an abradable layer, the substrate being a turbomachine part and the process comprising:
forming the abradable layer on a separate substrate comprising a powder composition comprising at least micrometric ceramic particles having a number-average form factor greater than or equal to 3, a mass content of said micrometric ceramic particles in the powder composition being greater than or equal to 85%, the form factor of a particle being defined as the ratio [largest dimension of the particle]/[largest cross-sectional dimension of the particle], by heating said micrometric ceramic particles, as well as any nanometric ceramic particles that may be present, to a first temperature T 1 greater than or equal to 600° C. and while the assembly is brought to the first temperature T 1 , increasing a compression pressure until it reaches, at a first time t 1 , a plateau at a value Pc which corresponds to the compression pressure to be applied during the sintering of the powder composition; then
increasing the temperature of the powder composition and the separate substrate to the sintering temperature T f reached at a second time t 2 ; then
maintaining the sintering temperature T f and the compression pressure P c until the third time t 3 to obtain the abradable layer; and

separating the abradable layer from the separate substrate;
depositing the abradable layer thus formed on a surface of the substrate, and
bonding the abradable layer thus deposited on the surface of the substrate wherein a temperature imposed during sintering, a sintering time and a compression pressure applied are selected so as to obtain a volume porosity rate of the abradable layer greater than or equal to 20%.

2. The process as claimed in claim 1 , wherein the powder composition further comprises nanometric ceramic particles having a number-average form factor comprised between 0.7 and 1.3, a mass content of said nanometric ceramic particles in the powder composition being less than or equal to 15%.

3. The process as claimed in claim 2 , wherein the mass content of said nanometric ceramic particles in the powder composition is comprised between 1% and 10%.

4. The process as claimed in claim 1 , wherein the powder composition consists essentially of said micrometric ceramic particles.

5. The process as claimed in claim 1 , wherein the mass content of said micrometric ceramic particles in the powder composition is greater than or equal to 90%.

6. The process as claimed in claim 1 , wherein said micrometric ceramic particles comprise at least acicular particles having a number-average form factor comprised between 3 and 5.

7. The process as claimed in claim 1 , wherein said micrometric ceramic particles comprise at least fibrous particles having a number-average form factor strictly greater than 5.

8. The process as claimed in claim 1 , wherein a compression pressure comprised between 12.5 MPa and 100 MPa is applied to the powder composition during sintering.

9. The process as claimed in claim 1 , wherein the sintering time is comprised between 1 minute and 10 minutes.

10. The process as claimed in claim 1 , wherein the temperature (T f ) imposed during sintering is comprised between 900° C. and 1150° C.

11. The process as claimed in claim 1 , wherein the powder composition is sintered by a spark plasma sintering technique.

12. The process as claimed in claim 1 , wherein one of the following two conditions is verified:
the substrate is metallic, and said micrometric ceramic particles, as well as any nanometric ceramic particles that may be present, comprise at least zirconia, or
the substrate is made of a ceramic matrix composite material, and said micrometric ceramic particles, as well as any nanometric ceramic particles that may be present, are made of rare-earth silicate.

13. The process as claimed in claim 1 , wherein the substrate is a turbine or compressor ring sector.

Assignees

• Safran Aircraft Engines
• Centre Nat Rech Scient
• Univ Paul Sabatier—Toulouse Iii

Inventors

• Selezneff Serge Georges Vladimir
• Le Biez Philippe Charles Alain
• Fregeac Arnaud Louis Gabriel
• Ansart Florence
• Estournes Claude Gilbert Jean-Pierre

Classifications

• F05D2300/2118

  Zirconium oxides · CPC title

• F05D2240/55

  Seals · CPC title

• F05D2230/90

  Coating; Surface treatment · CPC title

• F01D11/122

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

• C04B41/4545

  applied as a powdery material · CPC title