Development of Multifunctional Erosion-Resistant Damping Coating Systems and Application Methods for IBRs and Blisks

The objective of the proposed work is to further develop the erosion-resistant damping coating technology to Technology Readiness Level (TRL) 5 & 6 and to demonstrate TRL 5 & 6 by testing a coated IBR via a bench test and by testing in a relevant environment engine test, respectively. The efforts will be carried out by a team of investigators at Herman Advanced Engineering and several other institutions. The successful completion of the effort will advance this erosion-resistant damping coating and coating process technologies to a position of readiness in entering the service with an effective solution, providing not only significant damping but also significant improvement in resistance to erosion, fatigue, and corrosion for large size blisks/IBRs. The primary goal of the proposed project is to develop new advanced multifunctional thin-layered erosion-resistant damping (ERD) coating systems and process technologies for large size blisks/IBRs. For this, in this project, we are proposing innovative and advanced multifunctional damping coating systems (ERDs) in thin layer configurations (0.001-0.005 in) that include erosion-resistant damping coating to significantly suppress blade vibration and improve interface adhesion as well as to resist surface related degradations of fan and compressor components in harsh sand ingestion and/or combustion gas environments. Emphasis is placed on the development of affordable industrial scale thermal spray and physical vapor deposition methods for IBRs/Blisks.