Abradable coatings have been used in the gas-turbine engine to optimise performance in compressors by maintaining blade tip clearances since the early 70's [1], Abradable coatings are generally applied by thermal spraying and have included Al-Si/Polyestcr, Al-Si/Graphite Ni/Graphite and porous Ni-alloy material structures [2,3,4]. Those based on Al- Si/graphite have performed well in terms of there wear characteristics, but can be prone to corrosion in service which can lead to sections of the liner material spalling, reducing the performance of the engine and increasing the cost of operation of the engines to airlines. This paper charts the development of an Aluminium-Silicon/hBN abradable material designed specifically to overcome the service corrosion through powder design, the initial laboratory and engine testing.

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