Abradable coatings are used in gas-turbine engines to optimize compressor performance by maintaining tight blade tip clearances. The most common such coatings are thermally sprayed Al-Si/polyester, Al-Si/graphite, and Ni/graphite. Al-Si/graphite coatings have performed well in terms of wear but are prone to corrosion, which can lead to spalling and a reduction in engine efficiency. In this paper, we chart the development of a powder-based Al-Si/BN abradable material designed to overcome in-service corrosion and analyze laboratory and engine testing results.

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