Modeling Deformation and Failure in Alsi-Polyester Abradable Sealcoating Material Using Microstructure-Based Finite Element Simulation

42 Pages Posted: 1 Mar 2022

See all articles by Jiahao Cheng

Jiahao Cheng

Oak Ridge National Laboratory - Manufacturing Science Division

Xiaohua Hu

Government of the United States of America - Oak Ridge National Laboratory

Drew Lancaster

affiliation not provided to SSRN

Xin Sun

Government of the United States of America - Oak Ridge National Laboratory

William Joost

affiliation not provided to SSRN

Abstract

A plasma-sprayed aluminum-silicon (AlSi)/polyester coating is applied in gas turbine engines as an abradable sealcoating to maintain tight clearances between rotating blades and static casing. While running the engine, the rotating blades “rub” with the abradable coating, resulting in extreme strain rate (up to 106) dynamics and a high-temperature environment. Due to the difficulty of direct-collecting measurements, predictive computational models are important for analyzing deformation and failure of abradable material, to help meet the design target of avoiding damage to the blade tip and maintaining high-fuel-efficiency. In this research, a microstructure-based finite element  computational model was developed to capture the complex mechanical behavior of the abradable material. The model is based on a virtual representative-volume-element (RVE) of a metal-polymer microstructure, reconstructed from x-ray computed tomography. It models the plastic deformation and damage in each AlSi and  polyester constituents, and failure at their interface. The model was calibrated and validated with uniaxial tension and compression experiments, with further study on  influence of varying microstructure. The material exhibited strongly tension-compression asymmetry and  sensitivity to temperature, which was well-captured by model.  The model is expected to facilitate the development of improved abradable materials by bypassing the conventional trial-and-error approach and extensive testing requirements.

Keywords: abradable material, AlSi/polyester microstructure, finite element modeling, Failure mechanism

Suggested Citation

Cheng, Jiahao and Hu, Xiaohua and Lancaster, Drew and Sun, Xin and Joost, William, Modeling Deformation and Failure in Alsi-Polyester Abradable Sealcoating Material Using Microstructure-Based Finite Element Simulation. Available at SSRN: https://ssrn.com/abstract=4046348 or http://dx.doi.org/10.2139/ssrn.4046348

Jiahao Cheng (Contact Author)

Oak Ridge National Laboratory - Manufacturing Science Division ( email )

Xiaohua Hu

Government of the United States of America - Oak Ridge National Laboratory ( email )

1 Bethel Valley Road, P.O. Box 2008, Mail Stop 608
Room B-106, Building 5700
Oak Ridge, TN 37831
United States

Drew Lancaster

affiliation not provided to SSRN ( email )

No Address Available

Xin Sun

Government of the United States of America - Oak Ridge National Laboratory ( email )

1 Bethel Valley Road, P.O. Box 2008, Mail Stop 608
Room B-106, Building 5700
Oak Ridge, TN 37831
United States

William Joost

affiliation not provided to SSRN ( email )

No Address Available

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