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Micro–macro finite element modeling method for rub response in abradable coating materials

  • The Physics of Metal Plasticity: in honor of Professor Hussein Zbib
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Abstract

Gas turbine engines experience “rub” when the rotating blades come in contact with a static abradable coating. This results in extreme strain rates and dynamics inside a high-temperature/high-pressure environment. Current rub models are phenomenological and do not reflect the underlying microstructures, thus limiting their prediction accuracy. In this work, a microstructure-informed, reduced order modeling framework is introduced for simulating abradable coating “rub" behavior. This framework comprises a microscale model constructed based on digitized abradable microstructure and explicitly simulates the mechanical behavior of each constituent phases and their interactions. After calibration and validation with experiment data, the calibrated microscale model is used to generate data across a vast range of applied strain rates and temperature with various load paths. Then, the virtually generated data are used to fit the macroscopic-reduced order model, which enables fast component scale rub simulation without compromising the integrity of the complex material behavior. The proposed effort will address the technical challenge of predicting abradable material behavior during rub through the application of multiscale modeling from microstructure to engines behavior, effectively reducing the development costs and time of new abradable material for better “rub” properties.

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Acknowledgements

This research was sponsored by the Oak Ridge National Laboratory (ORNL). ORNL is managed by UT-Battelle, LLC for the U.S. Department of Energy under Contract DE-AC05 00OR22725. This work was funded by the HPC4materials program supported by U.S. Department of Energy Office of Fossil Energy in collaboration with Raytheon Technologies Corporation—Pratt & Whitney Division. Computing support by the Compute and Data Environment for Science (CADES) at Oak Ridge National Laboratory is gratefully acknowledged.

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Authors and Affiliations

  1. Oak Ridge National Laboratory, Oak Ridge, TN, 37831, USA

    Jiahao Cheng, Xiaohua Hu & Xin Sun

  2. Formerly Materials and Processes Engineering, Pratt and Whitney, East Hartford, CT, 06118, USA

    William Joost

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  1. Jiahao Cheng
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  2. Xiaohua Hu
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  4. Xin Sun
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Contributions

JC was contributed by writing—original draft, investigation, and formal analysis; XH was respnsible for writing—review and editing, investigation, supervision, funding acquisition, and project administration; WJ was performed by writing—review and editing, investigation, supervision, funding acquisition, project administration, and validation; and XS was involved in writing—review and editing, conceptualization, supervision, and funding acquisition.

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Correspondence to Xiaohua Hu.

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Handling Editor: M. Grant Norton.

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Cheng, J., Hu, X., Joost, W. et al. Micro–macro finite element modeling method for rub response in abradable coating materials. J Mater Sci 59, 4934–4947 (2024). https://doi.org/10.1007/s10853-023-09327-0

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  • DOI: https://doi.org/10.1007/s10853-023-09327-0

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