GH3536 Honeycomb Seal Segment for Compressor Stator Application

GH3536 Honeycomb Seal Segment for Compressor Stator Application

The GH3536 Honeycomb Seal Segment is a precision-engineered gas-path sealing component specifically designed for compressor stator applications in aero-engines and gas turbines. Manufactured from GH3536 nickel-based superalloy foil — the Chinese equivalent of Hastelloy X (UNS N06002) — this honeycomb seal segment is vacuum-brazed to a support ring or backing segment, forming a complete sealing assembly that effectively reduces inter-stage leakage, improves engine efficiency, and lowers fuel consumption.

GH3536 (formerly designated GH536) is a solid-solution strengthened nickel-chromium-iron-molybdenum superalloy with excellent oxidation resistance, corrosion resistance, and good formability and weldability. It is one of the most widely used superalloys in aero-engine manufacturing and has been proven in service for over half a century.

2. Material Advantages — GH3536 Superalloy

2.1 Composition & Strengthening Mechanism

GH3536 is a Ni-Cr-Fe based solid-solution strengthened wrought superalloy, with chromium and molybdenum as the primary strengthening elements. The alloy contains a relatively high iron content (17.0–20.0%), which effectively reduces raw material costs while maintaining excellent high-temperature performance.

Element Content (wt.%) Function
Nickel (Ni) Balance (≈47.5–53%) Matrix element, provides stable austenitic structure
Chromium (Cr) 20.5–23.0% Core element for high-temperature oxidation & corrosion resistance
Molybdenum (Mo) 8.0–10.0% Key solid-solution strengthening element
Iron (Fe) 17.0–20.0% Cost reduction, process compatibility
Cobalt (Co) 0.5–2.5% Auxiliary strengthening, improves creep resistance
Tungsten (W) 0.2–1.0% Auxiliary strengthening

2.2 Key Material Properties

· Operating Temperature: Long-term service below 900°C; short-term exposure up to 1080°C
· Oxidation & Corrosion Resistance: Exceptional resistance to oxidation and corrosive media (including sulfur-containing gases and halides)
· Formability & Weldability: Excellent cold and hot working formability and welding performance
· Creep & Rupture Strength: Moderate creep and rupture strength below 900°C
· Microstructure: Austenitic matrix with fine, uniformly distributed TiN and M₆C carbides
· Density: 8.28–8.3 g/cm³
· Melting Range: 1295–1381°C

3. Product Design & Features

3.1 Honeycomb Structure

The seal segment features a regular hexagonal honeycomb cellular structure precision-formed from GH3536 superalloy foil. Typical specifications include:

Parameter Specification
Cell diameter (inscribed circle) 0.8 mm (customizable up to 3.0 mm)
Foil wall thickness 0.05 mm (or 0.1 mm)
Cell geometry Regular hexagon
Backing segment material Stainless steel or superalloy (GH4169, GH907, GH600, etc.)

3.2 Brazing Process

The honeycomb core is joined to the support ring or backing segment through precision vacuum brazing using nickel-based brazing alloys such as BNi-2.

Critical Process Achievements:

· Bonding rate: ≥ 99.5%
· Interface quality: Fine grains, uniform microstructure, no braze seam corrosion
· Mechanical strength: Plane tensile strength reaches 50 MPa; excellent strength and toughness
· Joint strength (800°C): Tensile strength ≥315 MPa, Shear strength ≥140 MPa

3.3 Sealing Principle

During compressor operation, the rotating blade tips gently cut into the honeycomb structure under centrifugal force, forming an optimal radial clearance. This "active wear" design allows the honeycomb core to function as a sacrificial abradable layer, protecting blades while minimizing gas-path leakage. Honeycomb seals can reduce leakage by 50–70% compared to traditional labyrinth seals.

4. Technical Specifications

4.1 Material System

Component Material Characteristics
Honeycomb core GH3536 (Hastelloy X) Oxidation resistance, formability, 900°C capability
Support ring / backing GH4169, GH907, GH600, or stainless steel Matched to service conditions
Brazing filler BNi-2, BNi-4, BNi-5 Nickel-based, vacuum brazing compatible

4.2 Performance Indicators

Parameter Value
Maximum service temperature 900°C (long-term); 1080°C (short-term)
Leakage reduction 50–70% vs. traditional labyrinth seals
Honeycomb bonding rate ≥ 99.5%
Plane tensile strength ≥ 50 MPa
Service life Compatible with engine overhaul intervals

5. Compressor Stator Application

5.1 Typical Installation

The GH3536 honeycomb seal segment is installed in compressor stator assemblies, where it forms a critical sealing interface between stationary vanes and rotating blade tips. It is particularly suited for:

· High-Pressure Compressor (HPC) stator vane assemblies
· Compressor discharge sealing zones
· Inter-stage sealing between compressor rotor and stator

5.2 Why GH3536 for Compressor Stators

· Thermal compatibility: The compressor section experiences significant temperature gradients — GH3536 maintains structural integrity throughout the operating range
· Oxidation resistance: Protects against oxidation from high-velocity, high-temperature airflow
· Abradability: The 0.05mm thin-wall honeycomb structure provides optimal blade tip clearance control
· Proven reliability: GH3536 is a mature alloy with extensive service history in aero-engine hot-end components

Engineered for Precision – Technical Specifications

Our honeycomb seal product line supports the following flexible specifications:

Advantages

With more than 20 years’ experience on designing and manufacturing honeycomb and metal product, Pasia Honeycomb Products Co. Ltd is versatile on supplying diversified honeycomb and sandwich products to clients of various industries including construction, transportation, marine, industrial equipment, decoration and so on. Honeycomb panels are applied and being applied in numerous fields, based on the best strength and weight ratio, extreme condition resistance such as high or low temperatures, humid or watery condition and so on, A+ fire rating, high tolerance on size, etc.

Pasia has put into significant capital on equipment investment to secure first class product fabrication. Until now, Pasia has already possessed the most advanced bending machine, panel shearing machine, digital controlled turret punch press, completely automatically controlled continuous paint coating production line and so on. It can not only mass produce flat panels, but also produce single curved, twist and all shapes of customized honeycomb panel. The production management is under ISO9001:2008 quality management system. Quality products have won good reputation in market with repeated orders from our customers. We have exported our products to Germany, Brazil, Mexico, Colombia, Korea, Singapore, Indonesia, Malaysia, Middle East, Uzbekistan, Russia, Ukraine, Australia, Algeria, etc. Large scale production, effective quality control system, complete local industry support and advanced cost control plan make Pasia capable of providing top-quality structural panels in wide variety of styles, designs and materials at competitive pricing.

The company is now performing as a fast developing manufacturer on R&D, designing, manufacturing and sales of honeycomb products including aluminum or stainless steel, paper, Aramid, PP plastic honeycomb core and their panels, stone honeycomb panels, innovation honeycomb products, customized honeycomb products including section inserted, painted, powder coated, oversized, special shape panels, parts based on CAD drawing and so on.

Please contact with us if there is any queries on product, process, property and so on. We will try our every best to deliver our quality goods and services of your expection or beyond your expectation.