Controlling YSZ Abradable Erosion Performance by Optimizing Spray Parameters

This study investigates the effect of plasma spray parameters on the erosion rate of abradable seals used for clearance control in gas turbine engines. Coating samples were sprayed using YSZ powder containing polyester that was entrapped in the deposit then subsequently removed by heating. Test results show that erosion behavior is influenced by gun voltage and spray distance. A higher voltage results in a denser coating with a lower erosion rate. Increasing spray distance, on the other hand, increases porosity, which results in a higher erosion rate. Further analysis shows that the erosion rate is proportional to the inverse square of the spray distance and the square of the gun voltage.