Thermally sprayed coating for high temperature static seals in aeroengines

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Reliability, safety and sustainability are all significant driving forces in the aerospace industry. Developments of new materials, processes and manufacturing steps, must meet these needs and also be economically viable. This proposal is focused on addressing these driving forces for a particular component that is found throughout a gas turbine engine, called a 'static seal'. This seal brings the surfaces of two components together to create a barrier between two sections of the engines at differing temperatures. The challenge is that the seal experiences vibration and exposure to high temperatures that leads to damage and eventual failure of the seal. Current technology for static seals is only capable of meeting the needs of the current generation of engines and do so with the caveat that seals will need to be inspected, repaired and replaced quite regularly. Using thermal spray, a technology that applies a protective coating, we will develop four new coatings based on materials that have shown promise for their high temperature capabilities. Development of innovative coatings that resist damage at high temperatures better than current technology will make static seals in gas turbine engines more reliable, safer and sustainable.