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Optimization of HVOF-Applied Erosion-Resistant Coatings for Large Compressor and Fan Airfoils in STOVL Aircrafts

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Abstract

Short Take-off and Vertical Landing (STOVL) aircrafts operate in dust or desert environments and suffer from impact and erosion damages caused by particles ingested into the engines and lift fans. The effects of such ingestion and damage to the engine compressor and fan airfoils can result in loss of aircraft system performance and flight safety. Erosion-resistant coatings used currently in the compressor sections of helicopter engines are proven effectively in increasing time-on-wing and engine performance retention of the engines. However, the same coating systems may not be applied directly to the large-sized airfoils in STOVL aircrafts. The authors proposed to apply HVOF nano-carbide coatings for better erosion resistance of the STOVL components such as airfoils. The advantage of the HVOF technology is that it enables the application of various coatings on those large components with good erosion-resistant properties. Unique powder morphology and optimal nanostructures of the HVOF-sprayed nano-WC coatings were proven to provide superior erosion-resistant properties. The optimal coatings were developed by design of experiments (DOE) statistical technique, and the resultant coatings were characterized qualitatively and quantitatively for their erosion behavior, physical and mechanical properties. Solid particle erosion resistance of the optimized coating was improved at 3-10 times relative to the titanium alloy counterpart depending on impingement angles.

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Acknowledgment

The authors gratefully acknowledge technical assistance and experimental support from Mr. D. Reynolds and Ms. T. Frost, Curtiss-Wright Surface Technologies; Mr. J. Clark and Ms. R. Reed for SEM work, UES Inc.; Financial support from SBIR DoD contract #F864920P0327 managed by Dr. R. Sikorski.

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Authors and Affiliations

  1. Curtiss-Wright Corporation, East Windsor, CT, USA

    X. Ma & P. Ruggiero

  2. UES Inc., Dayton, OH, USA

    R. Bhattacharya & A. K. Rai

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  1. X. Ma
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  2. P. Ruggiero
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  3. R. Bhattacharya
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  4. A. K. Rai
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Correspondence to X. Ma.

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Ma, X., Ruggiero, P., Bhattacharya, R. et al. Optimization of HVOF-Applied Erosion-Resistant Coatings for Large Compressor and Fan Airfoils in STOVL Aircrafts. J Therm Spray Tech 33, 367–380 (2024). https://doi.org/10.1007/s11666-023-01681-4

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  • DOI: https://doi.org/10.1007/s11666-023-01681-4

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