Erosion/Corrosion Resistant Coatings for Gas Turbine Engine Compressor Systems Operating in both Sand and Maritime Environments

NCMS Project #: 140428/140440/140459/140476

Problem: Several U.S. Military aircraft operate in both sand and salt environments resulting in both erosion and corrosion of gas turbine engine compressor airfoils.

Shipboard gas turbine engines can experience both erosion and corrosion due to water wash maintenance procedures used to remove salt deposits with the engine.

Benefits:

  • Increase flight-readiness of such aircraft as the C-130, P-3, E-2 and V-22.
  • Estimated cost savings of $100M annually in increasing mean-time-between-overhaul (MTBO) by 1.5X.
  • Increase system reliability, maintain engine shaft horsepower, decrease fuel consumption and enhance safety-of-flight.
  • Increase MTBO of compressor system by 1.5 to 2X in desert and maritime operations.

Implementation: The application of MDS-PRAD’s ER-7 erosion resistant coating has resulted in an average Time-On-Wing (TOW) of coated T64 engines of 1,000+ hours. The result was a significant TOW that equated to a savings of $8M per H-53 aircraft. Through a collaborative partnership with NCMS and the CTMA program, MDS-PRAD will continue the research and development of erosion corrosion coatings and applying erosion/corrosion coatings on compressor airfoils representing the T56/501K engines. In addition, MDS-PRAD would apply erosion resistance coatings both ER-7 and NGCV4 (next generation coating) and conduct erosion/corrosion tests as a basis of comparison.

Impact on Warfighter: Additional TOW for the T56 engine equates to additional C-130 aircraft being available and ready to complete another mission. A reduction in spare engines and a decrease in maintenance support crew would be required. Additionally, an engine operating with a healthy compressor will consume less fuel that will decrease the amount of logistical fuel support required.

DoD Participation:

  • S. Navy (Patuxent River)
  • U.S. Navy (FRC East)
  • U.S. Marine Corps (ALS)
  • U.S. Air Force (Oklahoma City ALC)
  • U.S. Army (TARDEC)
  • U.S. Army (Anniston)

Industry Participation:

  • MDS Coating Technologies
  • Rolls-Royce
  • StandardAero
  • Honeywell
  • NCMS

Benefit Area(s):

  • Cost savings
  • Maintenance avoidance & reliability
  • Maintenance management improvement
  • Environmental
  • Safety
  • Improved readiness