Sulzer Metco

Material Product Data Sheet Nickel Graphite Abradable Powders

Thermal Spray Powder Products: Metco 307NS, Metco 307NS-2, Metco 307NS-3, Metco 308NS, Metco 308NS-1, Metco 308NS-3, Metco 309NS-3, Durabrade 2211ZB, Durabrade 2221, Durabrade 2222, Durabrade 2223, Durabrade 2224, Durabrade 2231, Durabrade 2241 1 Introduction Sulzer Metco Nickel Graphite powders produce abradable coatings for clearance control applications where the rotating component may come into contact with the coating as a result of design intent or operational surges. The coatings are designed to minimize the wear to the rotating components while maximizing gas path efciency by providing clearance control in seal areas. An industry standard for more than 30 years, combustion powder Thermospray coatings of nickel graphite have proven reliability in gas turbine applications and are approved by all major gas turbine OEMs. The composite powders are manufactured using the hydrometallurgy autoclave process that encapsulates the graphite core inside a nickel shell to form a continuous cladding (see image at right). This provides a highquality binder-free composite powder with no tendency for segregation during transport, storage or spraying. 1.1 Typical Uses and Applications:
Photomicrograph showing a typical nickel graphite powder structure of graphite encapsulated inside a nickel shell.

In coatings, the graphite serves as a solid lubricant and, with carefully designed amounts of porosity, enhanced abradability is achieved.

Coating service temperature capability approaching 480 C (900 F) Available in a variety of chemistries and particle sizes to produce a wide array of coating properties for gas turbine compressor section applications Suitable for abradable coatings to rub against nickel alloy and steel Some grades are suitable for abradable coatings to rub against bare untipped titanium alloys Produces self-lubricating coatings that can be used for friction reducing bearing applications
Nickel Graphite Abradable Powders 1/8

Quick Facts Classication Chemistry Manufacture Morphology Apparent Density Abradable, nickel based Ni-C Chemically clad Irregular 1.2 2.0 g/cm3 Clearance control or friction reducing bearing coatings Combustion Powder Thermospray

Service Temperature 480 C (900 F) Purpose Process

DSMTS-0021.2 2012 Sulzer Metco

Sulzer Metco

2 2.1

Material Information Chemical Composition, Particle Size Distribution and Apparent Density Equivalent Durabrade Products Durabrade 2211ZB Durabrade 2222 Weight Percent Ni 60 75 75 75 75 80 85 85 85 Graphite 40 25 25 25 25 20 15 15 15 Particle Size Distribution (m) -90 +30 -90 +30 -90 +20 -90 +30 -90 +20 -106 +45 -90 +30 -90 +30 -106 +30 Apparent Density (g/cm3) 1.2 1.4 1.4 1.4 1.4 1.7 2.0 2.0 2.0

Metco Products --Metco 307NS

Metco 307NS-2 Durabrade 2223 Metco 307NS-3 Durabrade 2221 --Durabrade 2224

Metco 309NS-3 Durabrade 2231 Metco 308NS ---

Metco 308NS-1 --Metco 308NS-3 Durabrade 2241

Notes: The brand and material designations relate to OEM specications for these powders. Please refer to section 2.4. All reported values are nominal Upper particle size analysis using sieve in accordance with ASTM B214; lower size analysis using laser diffraction (Microtrac)

2.2

Key Selection Criteria Materials with 85 wt% nickel content, such as Metco 308NS, are used when higher erosion resistance is important. Higher erosion resistance is related to a decrease in abradability. Durabrade 2231, with 80 wt% nickel content, produces coatings that exhibit abradability and erosion resistance halfway between coatings made from nickel graphite powders having 85 wt% and 75 wt% nickel content. Depending on the application, spray parameters can be designed to produce coatings with varied graphite and porosity contents.

Although many of the powders are chemically identical and fall within the typical sizes shown in section 2.1, particle size distributions vary within these ranges in accordance with specic OEM requirements as indicated in section 2.4. Durabrade 2211ZB is primarily used for specialized applications (only for GE specication B50TF164, Class A and B and with GE approval) as a blend with NiCrAl (Metco 443NS or Amdry 960) typically in a proportion of 32.5% abradable to 67.5% NiCrAl by weight. Nickel graphite materials with 75 wt% nickel content produce abradable coatings that are cut by bare, untipped titanium blades and knife edges.

Nickel Graphite Abradable Powders

2/8

DSMTS-0021.2 2012 Sulzer Metco

Sulzer Metco

2.3

Related Products graphite and Metco 320NS while providing excellent abradability. All nickel graphite coatings are combustion sprayed while Sulzer Metco 2042 and Metco 320NS are plasma sprayed. When titanium compatibility is not required:

For abradable applications against bare titanium blades and blisks: Coatings produced from 75/25 nickel graphite provide better corrosion resistance than coatings produced from Metco 310NS, Metco 311NS and Metco 313NS. Metco 320NS, comprised of aluminum, silicon and hexagonal boron nitride, produces coatings that have better corrosion and erosion resistance than nickel graphite coatings. Coatings produced from Sulzer Metco 2042 have higher in-service temperature capability than nickel

When coatings having superior corrosion resistance and higher temperature capability are required, NiCrAl/Bentonite materials (Metco 312, Metco 314, Durabrade 2311 and Durabrade 2313) as well as Metco 301NS and Sulzer Metco 2043 are a better choice.

Nickel Graphite Abradable Powders

3/8

DSMTS-0021.2 2012 Sulzer Metco

Sulzer Metco

2.4

Customer Specications

Note: Some OEMs approve both Metco and Durabrade products. Always choose the material that meets the customer or OEM specication required for the application. Product Metco 307NS Customer Specication Honeywell EMS 57739, Cl II Honeywell FP 5045, Type XII MTU MTS 1535 Pratt & Whitney PWA 1352-1 Volvo PM 819-41 Avio 4800M/10 MTU MTS 1121 Rolls-Royce plc MSRR 9507/6 Avio 4800M/28 GE B50TF52, Cl B Snecma DMR 33.084 Volvo PM 819-81 Honeywell FP 5045, Type XI Pratt & Whitney PWA 1352-2 Rolls-Royce Corporation EMS 56755 Rolls-Royce Corporation PMI 1097 Avio 4800M/9 GE B50TF53, Cl B MTU MTS 1071 Rolls-Royce plc MSRR 9507/16 Volvo PM 819-34 GE B50TF172, Cl A Honeywell EMS 57739 Volvo PM 819-45 GE B50TF164, Cl A & B GE B50TF52, Cl B MTU MTS 1070 Snecma DMR 33.084 Pratt & Whitney PWA 1352-1 MTU MTS 1121 Rolls-Royce plc MSRR 9507/6 Pratt & Whitney PWA 1352 Rolls-Royce Corporation EMS 56754 Rolls-Royce plc MSRR 9507/12 GE B50TF172, Cl A Honeywell EMS 57739 GE B50TF53, Cl B MTU MTS 1071 Rolls-Royce plc MSRR 9507/16

Metco 307NS-2

Metco 307NS-3

Metco 308NS Metco 308NS-1 Metco 308NS-3

Metco 309NS-3

Durabrade 2211ZB Durabrade 2221

Durabrade 2222 Durabrade 2223 Durabrade 2224

Durabrade 2231 Durabrade 2241

Nickel Graphite Abradable Powders

4/8

DSMTS-0021.2 2012 Sulzer Metco

Sulzer Metco

3 3.1

Coating Information Key Thermal Spray Coating Characteristics Metco 307NS Metco 307NS-2 Metco 307NS-3 Durabrade 2221 Durabrade 2222 Durabrade 2223 Durabrade 2224 Metco 309NS-3 Durabrade 2231 Metco 308NS Metco 308NS-1 Metco 308NS-3 Durabrade 2241

Specication (1

Recommended Process Deposit Efciency Density (approx.) % (approx.) g/cm3 70 85 3.2 0.32 0.017 50 25 25

Combustion Powder Thermospray 75 85 3.5 0.35 0.018 60 20 20 27 33 1100 1300 12 15 500 600 50 None 480 900 75 85 4.9 0.49 0.025 70 15 15 25 30 1000 1200 10 12 400 500 60 None 480 900

Weight (approx.) kg/m2/0.1mm lb/ft2/0.001in Constituent vol. % Nickel Graphite Porosity Surface Roughness as-sprayed machined m Ra in Ra m Ra in Ra

25 33 1000 1300 12 15 500 600 40 None 480 900

Macrohardness (2 nominal HR15Y Thickness Limitation Service Temperature max C F

1) All reported values are nominal based on standard spray conditions and parameters. 2) See additional information in section 3.3 Measurement of Coating Hardness

Nickel Graphite Abradable Powders

5/8

DSMTS-0021.2 2012 Sulzer Metco

Sulzer Metco

3.2

Additional Processing Information Nickel graphite may be applied in ID applications using the Sulzer Metco 6PT-II-1 or the 6PT-II-2 extension module for the 6P-II combustion spray gun. The actual ID standoff distance will depend on the coating properties required and the grade of nickel graphite used. Sulzer Metco Coating Solution Centers can provide assistance in parameter development for specic applications.

Some OEMs require that nickel graphite coatings are sprayed at an angle less than 90 relative to the coated surface, depending on part geometry and application requirements. Check OEM coating specications and drawings. Coating properties such as hardness, tensile bond strength and erosion resistance are reduced when spayed at angles less than 90 relative to the coated surface. Deposit efciency will be reduced when nickel graphite is sprayed at angles less than 90 relative to the coated surface.

3.3

Measurement of Coating Hardness surface preparation, coating thickness and the number of hardness impressions used. For assistance on proper measurement of abradable coating hardness, please contact Sulzer Metco.

For abradable coatings such as those in this publication using the HR15Y scale is a good indicator of proper spraying technique. To achieve consistent and more accurate results, special consideration must be given to

3.4

Recommended Coating Finishing Setting Sharp point tungsten carbide machining tool Slow / Slow Light Dry
Coatings should not be ground. Pressure and heat generated by grinding will compress the coating and alter its properties.

Specication Tool Work Speed / Traverse Rate Feed Rate Condition

Important note:

3.5

Available Coating Parameter Sheets: Process Combustion Powder Thermospray Spray Guns 6P-II 6P-II-1* 6P-II-2*

Coating parameters for the combustion powder Thermospray process are available to Sulzer Metco customers for all materials listed in this publication with the exception of Durabrade 2211ZB. Please contact your local Sulzer Metco Account Representative. Support for specic application requirements are available through Sulzer Metco Coating Solutions Centers.
Nickel Graphite Abradable Powders 6/8

* Extension modules for which a 6P-II spray gun is required

DSMTS-0021.2 2012 Sulzer Metco

Sulzer Metco

4 4.1

Commercial Information Ordering Information and Availability Order No. Package Size 5 lb (approx. 2.25 kg) 5 lb (approx. 2.25 kg) 5 lb (approx. 2.25 kg) 25 lb (approx. 11.3 kg) 5 lb (approx. 2.25 kg) 5 lb (approx. 2.25 kg) 5 lb (approx. 2.25 kg) 10 lb (approx. 4.5 kg) 5 kg (approx. 11 lb) 2.5 kg (approx. 5.5 lb) 10 lb (approx. 4.5 kg) 10 lb (approx. 4.5 kb) 75 kg (approx. 165 lb) 2.5 kg (approx. 5.5 lb) 10 lb (approx 4.5 kg) 2.5 kg (approx. 5.5 lb) 10 lb (approx. 4.5 kg) 100 kg (approx. 220 lb) 10 lb (approx. 4.5 kg) Availability Stock Stock Stock Stock Stock Stock Stock Stock Special Order Stock Stock Special Order Special Order Stock Special Order Special Order Special Order Stock Stock Distribution Global Global Global Global Global Global Global Global Global Global Global Global Global Global Global Global Global Global Global

Metco 307NS Metco 307NS-2 Metco 307NS-3 Metco 308NS Metco 308NS-1 Metco 308NS-3 Metco 309NS-3 Durabrade 2211ZB Durabrade 2221 Durabrade 2222 Durabrade 2223 Durabrade 2224 Durabrade 2231 Durabrade 2241

1000299 1000370 1000356 1000302 1000448 1000357 1000444 1043518 1043517 1043522 1043525 1043529 1043531 1043533 1043536 1043539 1043541 1043543 1043546

4.2

Handling Recommendations Open containers should be stored in a drying oven at temperatures to prevent moisture pickup. Avoid prolonged storage at elevated temperatures.

Store in the original container in a dry location. Carefully tumble contents prior to use to prevent segregation, but avoid breakdown of friable components.

Nickel Graphite Abradable Powders

7/8

DSMTS-0021.2 2012 Sulzer Metco

Sulzer Metco

4.3

Safety Recommendations

See the correct MSDS (Materials Safety Data Sheet) for the product of interest localized for the country where the material will be used. MSDS are available from the Sulzer web site at www.sulzer.com (Resources Online Tools). Product Metco 307NS Metco 307NS-2 Metco 307NS-3 Metco 308NS Metco 308NS-1 Metco 308NS-3 Metco 309NS-3 Durabrade 2211ZB Durabrade 2221 Durabrade 2222 Durabrade 2223 Durabrade 2224 Durabrade 2231 Durabrade 2241 MSDS No. 50-156 50-156 50-156 50-429 50-429 50-429 50-430 50-1055 50-1054 50-1054 50-1054 50-1054 50-1056 50-1056

www.sulzer.com [email protected]
Sulzer Metco (US) Inc. 1101 Prospect Avenue Westbury NY 11590 USA Tel. +1 516 334 1300 Fax +1 516 338 2414 Sulzer Metco (Japan) Ltd. 4-2 Hikawadai 3-Chome, Nerima-ku, Tokyo 179-0084 Japan Tel. +81 359 203 302 Fax +81 359 203 512 Sulzer Metco Europe GmbH Spreestrasse 2 65451 Kelsterbach Germany Tel. +49 6142 6033 0 Fax +49 6142 6033 400 Sulzer Metco AG (Switzerland) Rigackerstrasse 16 5610 Wohlen Switzerland Tel. +41 56 618 81 81 Fax +41 56 618 81 01 Sulzer Metco (Singapore) Pte. Ltd. 2 Loyang Lane # 06-02 Singapore 508913 Tel. +65 6545 0870 Fax +65 6545 0816

Information is subject to change without prior notice

Nickel Graphite Abradable Powders

8/8

DSMTS-0021.2 2012 Sulzer Metco