Abrasive tip treatment for use on compressor blades

A co-spray process was used which simultaneously but separately introduces abrasive grits and metal matrix powder into the plasma stream and entraps the abrasive grits within a molten matrix to form an abrasive coating as the matrix material solidifies on test specimen surfaces. Spray trials were conducted to optimize spray parameter settings for the various matrix/grit combinations before actual spraying of the test specimens. Rub, erosion, and bond adhesion tests were conducted on the coated specimens in the as-sprayed condition as well as on coated specimens that were aged for 100 hours at a temperature of 866K (1100 F). Microscopic examinations were performed to determine the coating abrasive-particle content, the size and shape of the adhesive particles in the coating, and the extent of compositional or morphological changes resulting from the aging process. A nickel chromium/aluminum composite with No. 150 size (0.002 to 0.005 inch) silicon carbide grits was selected as the best matrix/abrasive combination of the candidates surveyed for coating compressor blade tips.