Modelling and performance evaluation of cermet-based erosion-resistant coatings on gas turbine blades using CFD approach

Leading edge erosion (LEE), which often begins near the blade’s tip, is one of the most important degradation processes that affect gas turbine blade. Optimizing blade maintenance and choosing the best leading edge protection (LEP) system involve a thorough understanding of the leading edge erosion (LEE) process and the effects of damaged LEs on aerodynamic performance. It is consequently crucial to provide correct modelling tools. This study, which is divided into two parts, looks into computational fluid dynamics (CFD) modelling techniques for varying degrees of erosion damage. The endurance and performance of the gas turbine blades depend heavily on the erosion-resistant turbine cermet coating system. To validate a new cermet-based coating turbine blade technology for use in rotorcraft applications, this work aimed to ascertain the erosion resistance of superior cermet coating materials under simulated gas turbine blade erosion and temperature gradient settings. New cermet coating series, including WC–Co, WC–Co–Cr, and WC–Co–Cr–Ni, were developed and processed. The erosion resistance of the low conductivity cermet coating systems was significantly improved. A thorough model based on cumulative strain damage and low cycle fatigue is developed to predict the life of blade erosion. To develop and evaluate the coating lifespan prediction models, the present effort aims to replicate engine erosion tests of modern cermet-based coated turbine blades.