Dense, Hard Tough Coatings for Corrosion and Erosion Resistance Applications

"Engine corrosion and erosion of compressor blades and vanes has been a critical degrader of gas turbine engine fleet for naval applications. Corrosion of compressor airfoils has also been found to be a major problem causing high compressor airfoil scraprate, more frequent engine overhauls and an appreciable engine performance reduction with operational time. Protection of these systems involves coating the gas turbine compression system parts with an erosion/corrosion resistant coating. Surmet proposesan innovative coating structure that will combat the naval environment involving corrosion and erosion (salt, air steam sand and dust ingestion). The structure provides high toughness, high strength and very low coefficient of friction. Preliminary erosiontests indicate high potential of these coatings for providing erosion resistance. In Phase I, Surmet will demonstrate feasibility of achieving high erosion resistance via fabrication of coated coupons and extensive microstructural, mechanical and erosioncharacterization. Surmet has teamed up with a major aircraft manufacturer to demonstrate applicability of the coating to a prototype component in Phase I Option. In Phase II, the coating technology will be optimized through coating and system levelcharacterization of a large number of components. A Phase III commercialization plan will be developed for rapid insertion of the technology in operating aircraft. Gas turbine engines (SDCs)