Rub coating for gas turbine engine compressors

Abstract

Rub coatings, and methods for applying rub coatings, are provided for compressor assemblies of gas turbine engine assemblies. The coating may be applied as an initial coating to a new surface of a component, as well as a repair and replacement corrosion resistant rub coating for applying to a previously coated component of a gas turbine engine assembly such as a compressor casing. The method includes the steps of providing a component of a gas turbine engine assembly, the component having predetermined dimensions and specifications for operational use in an engine assembly. The component has a surface having a damaged rub coating thereon, the damaged rub coating not in compliance with the predetermined dimensions and specifications. The method includes removing the non-compliant damaged rub coating to expose the surface. Next, a repair corrosion resistant rub coating comprising MCrAlX is applied to the surface. Finally, the repair corrosion resistant rub coating comprising MCrAlX is machined to restore the coated component to comply with the predetermined dimensions and specifications.

1 . A coated article of a gas turbine engine assembly, the article comprising:
 a substrate having a surface; and   an abradable rub coat applied to the surface, wherein the rub coat comprises MCrAlX.   
   
   
       2 . The coated article of  claim 1 , wherein the article is a compressor casing. 
   
   
       3 . The coated article of  claim 2 , wherein the rub coat consists of MCrAlX. 
   
   
       4 . The coated article of  claim 2 , wherein the rub coat comprises NiCrAlY. 
   
   
       5 . The coated article of  claim 2 , wherein the rub coat consists of NiCrAlY. 
   
   
       6 . The coated article of  claim 3 , wherein the rub coat includes at least one groove for accepting at least one compressor blade tip. 
   
   
       7 . The coated article of  claim 4 , wherein the rub coat includes at least one groove for accepting at least one compressor blade tip. 
   
   
       8 . The coated article of  claim 5 , wherein the rub coat includes at least one groove for accepting at least one compressor blade tip. 
   
   
       9 . A repaired coated article of a gas turbine engine assembly, the article comprising:
 a substrate having a surface, the surface including a previously applied corrosion resistant rub coating that has been damaged or at least partially removed;   an abradable repair coating applied to the surface, wherein the repair coating comprises MCrAlX.   
   
   
       10 . The repaired article of  claim 9 , wherein the previously applied corrosion resistant rub coating comprises a Nickel-Aluminum (Ni—Al) alloy. 
   
   
       11 . The repaired article of  claim 9 , wherein the article is a compressor casing. 
   
   
       12 . The repaired article of  claim 11 , wherein the rub coat consists of MCrAlX. 
   
   
       13 . The repaired article of  claim 11 , wherein the rub coat comprises NiCrAlY. 
   
   
       14 . The repaired article of  claim 11 , wherein the rub coat includes at least one groove for accepting at least one compressor blade tip. 
   
   
       15 . The repaired article of  claim 12 , wherein the rub coat includes at least one groove for accepting at least one compressor blade tip. 
   
   
       16 . The repaired article of  claim 13 , wherein the rub coat includes grooves for accepting at least one compressor blade tip 
   
   
       17 . A method for providing a repair corrosion resistant rub coating on a component surface, the method comprising the steps of:
 providing a previously coated component of a gas turbine engine assembly; the component having predetermined dimensions and specifications for operational use in an engine assembly, the component having a surface having a rub coating thereon, the rub coating not in compliance with the predetermined dimensions and specifications;   removing the non-compliant rub coating to expose the surface;   providing a corrosion resistant rub coating composition comprising MCrAlX;   applying the coating composition to the surface to yield a repair corrosion resistant rub coat;   machining the repair corrosion resistant rub coat to restore the coated component to comply with the predetermined dimensions and specifications.   
   
   
       18 . The method of  claim 17 , wherein the non-compliant rub coating comprises a Ni—Al alloy. 
   
   
       19 . The method of  claim 17 , wherein the repair coating composition comprises MCrAlX. 
   
   
       20 . The method of  claim 17 , wherein the repair coating composition comprises NiCrAlY.