Study on Structure-Matching Preparation of Spalling-Resistant Metal-Based Abradable Seal Coatings

The new generation of aero-engines has higher requirements for thrust-to-weight ratios，and the clearance between the blade-tip and the engine casing is one of the key factors affecting the efficiency of the engine.Preparing abradable seal coatings on the inner wall of the casing can effectively reduce airflow leakage and prevent the tip from rubbing against the casing，thus enable the engine to operate efficiently and safely.Abradable seal coatings usually have high porosity.However，high porosity tends to reduce the strength of the abradable layer/ceramic thermal barrier layer interface，leading to the overall spalling of the abradable coating.Therefore，the structure-matching design of abradable seal layer/ceramic thermal barrier layer interface was conducted.On the basis of ensuring the abradable seal function of the coating，while enhancing the spalling resistance at interface between the two.Firstly，numerical analysis showed that the increase in pores characteristic size and porosity at the interface of the