Ceramic-based thermal spray coatings have been lately introduced as abradable materials for applications in the hot section of gas turbine engines. This paper reports abradable characteristics and high-temperature oxidation resistance of plasma sprayed yttria-stabilized zirconia (YSZ) and agglomertated yttria-stabilized zirconia with Polyester (YSZP). Unlike conventional blended coatings, agglomerated YSZP plasma-sprayed coatings are more forgiving to technique and processing parameter variations during the thermal-spray operation. The abradability studies were conducted on a test rig at temperatures of 600, 900 and 980 °C using coated (hardened) and uncoated blades. The oxidation resistance of the coatings was measured as a function of the cycles to failure and was conducted at temperature ranges of 930 to 1150°C in still air. Results showed that the ceramic coating, YSZ-Pl, was capable of withstanding both mid- and high-temperature rubs with little deleterious effects to the uncoated blade-tip across the temperature range, and presented a cyclic oxidation resistance comparable to that of YSZ coating.

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