Aerospace Industry

Aircraft Engine


Problem :

The Aerospace industry is one of the first industries that have completely accepted Thermal spray coatings. An aircraft engine is a component of the propulsion system for an aircraft that generates mechanical power. Aircraft engines are almost always either lightweight piston engines or gas turbines. A variety of degradation problems exist in aircraft engines as a result of metal to metal wear, fretting, hot corrosion, particle erosion etc. This degradation is accelerated due to the high temperature conditions involved. Thermal sprayed coatings impart the required surface condition to increase the life of certain engine components. There are more than hundred critical components inside an aircraft engine which are coated. Without the use of these thermal sprayed coatings a turbine will not operate at optimum levels. Performance guarantee of coatings in the Aviation industry is at most important. Any failure in coating may lead to major mishap.

Solution :
High Temperature Wear, Corrosion and Oxidation Resistant Coatings

We can provide a range of ceramic, carbide and cermet based coatings for various parts operating at different sections in an aircraft engine. The coating material and grade selection is primarily done by the OEM. However the control of coating process and the implementation of Quality Management System is what matters in execution of coatings for Aerospace parts. We have successfully adopted and implemented AS 9100 Rev D. Quality Management System and continuously undergoing process qualifications from different OEM’s. The principles of PDCA and Risk Management are imbibed deep in our day to day functioning. Our HVOF and Plasma control systems are completely automated and programmed with necessary safety interlocks to ensure that neither the process nor the customer component shall be hampered. We also have an in-house sophisticated machine shop to cater to all manufacturing requirements of Aero engine parts.

Coating applications in Aircraft engine parts have been standard for a long while. The Aircraft engine can primarily divided into three section based on their operation :

  • Combustion section
  • Turbine section
  • Compressor section



Below is a list of parts that are coated to sustain varying operating conditions :

Combustion Section
Part Name Coating Type Coating Objective
Combustion Chamber Liners and Domes Thermal Barrier Thermal Barrier
Combustion Chamber Cases Al-Ceramic Corrosion Resistance
Combustion Chamber Clamp and Liner Chrome Carbide Fretting Wear Resistance
Combustion Chamber Positioning Pin Tungsten Carbide and Chrome Carbide Fretting Wear Resistance
Combustion Chamber Support Assembly Chrome Carbide Fretting Wear Resistance
Fuel Nozzle Nut and Swirler Chrome Carbide Fretting Wear Resistance
Turbine Section
Part Name Coating Type Coating Objective
Air Sealing Rings Chrome Carbide Fretting Wear Resistance
Exhaust Pins and Bushings Tungsten Carbide Fretting Wear Resistance
Outer Air seals and Turbine Shrouds Thermal Barrier Thermal Barrier with Erosion Resistance
Turbine Blades LCO-17, Tungsten Carbide Rubbing and Fretting Wear Resistance
Turbine Blade Tips Abradables Sealing at tip of turbine blade
Turbine Blades and Vanes Thermal Barrier Thermal Barrier
Turbine brush Seals Chrome Carbide Sliding Wear Resistance
Turbine Stator Shrouds Chrome Carbide Fretting Wear Resistance
Compressor Section
Part Name Coating Type Coating Objective
Bevel Gear and Gearbox Drive Tungsten Carbide Fretting Wear Resistance
Bleed Manifold Expansion Joint Liners and Sleeves Tungsten Carbide Fretting Wear Resistance
Compressor Blades Alumina Titania, Tungsten Carbide and Chrome Carbide Wear Resistance, Solid particle Erosion Resistance
Compressor Vanes and Stators Al-Ceramic Corrosion Resistance
Compressor Case AL-Ceramic, Tungsten Carbide Corrosion and Oxidation Resistance, Fretting Wear Resistance
Compressor Hubs and Disks Tungsten Carbide Fretting Wear Resistance
Turbine brush Seals Chrome Carbide Sliding Wear Resistance
Compressor Rotor Tubes and Sleeves Tungsten Carbide Fretting Wear Resistance
Diffusers, Impellers and Vane Sectors Tungsten Carbide Erosion Resistance
Bearing & Other Accessories
Part Name Coating Type Coating Objective
Bearing Housings and Seal Assemblies Tungsten Carbide and Chrome Carbide Sliding Wear Resistance
Bearing Seal Housings Tungsten Carbide Fretting Wear Resistance
Bearing Seal Seats and Spacers Tungsten Carbide and Chrome Carbide Sliding Wear Resistance
Labyrinth Seal Fins Tungsten Carbide and Chrome Carbide Sliding Wear Resistance
Oil Pump Gears and Breather Tubes Tungsten Carbide Fretting Wear Resistance


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