System and method for manufacture of abrasive coating

Patent metadata

Field	Value
Publication number	US-10060273-B2
Application number	US-201514687651-A
Country	US
Kind code	B2
Filing date	Apr 15, 2015
Priority date	Apr 15, 2015
Publication date	Aug 28, 2018
Grant date	Aug 28, 2018

Abstract

A component for a gas turbine engine includes an airfoil section including a free end and an abrasive coating sprayed onto the free end, the abrasive coating including a polymer matrix and an abrasive filler, the abrasive filler between about 50%-75% by volume of the abrasive coating.

First claim

What is claimed:

1. A fan blade, comprising:
an airfoil section of a fan blade for a gas turbine engine, the fan blade including a free end; and
a sprayed on abrasive coating bonded to the free end, the abrasive coating comprising a polymer matrix and an abrasive filler, the abrasive filler between about 50%-75% by volume of the abrasive coating wherein the filler comprises hollow glass microspheres.

2. The component as recited in claim 1 , wherein the polymer matrix provides about 3%-10% volume of the abrasive coating once cured.

3. The fan blade as recited in claim 1 , wherein the abrasive filler is zirconia.

4. The fan blade as recited in claim 1 , wherein the abrasive filler has an average particle size of 220 mesh.

5. The fan blade as recited in claim 1 , wherein the polymer matrix outgases during elevated temperature curing.

6. The fan blade as recited in claim 1 , wherein the polymer matrix maintains porosity between grit particles of the abrasive filler.

7. The fan blade as recited in claim 1 , wherein the polymer matrix includes at least one of an epoxy, polyimide, polyurethane, cyanoacrylate, acrylic, and combinations thereof.

8. The fan blade as recited in claim 7 , wherein the abrasive filler includes at least one of zirconia, alumina, silica, cubic boron nitride (CBN), and combinations thereof.

9. The fan blade as recited in claim 1 , wherein the abrasive filler is of a volume of the abrasive coating such that capillary action facilitates retention of the polymer matrix between particles of the abrasive filler.

10. The fan blade as recited in claim 9 , wherein the free end comprises a distal end and an extension around a sides of said airfoil section.

11. The fan blade as recited in claim 1 , wherein capillary action facilitates retention of the polymer matrix between particles of the abrasive filler.

12. The fan blade as recited in claim 1 , wherein the fan blade is a polymer composite upon which the abrasive coating is sprayed.

13. The fan blade as recited in claim 1 , wherein the fan blade is a polymer coated aluminum upon which the abrasive coating is sprayed.

14. The fan blade as recited in claim 1 , wherein the free end comprises a distal end.

15. The fan blade as recited in claim 1 , wherein the polymer matrix is not utilized to carry the abrasive filler during spraying.

16. A fan blade, comprising:
an airfoil section of a fan blade for a gas turbine engine, the fan blade including a free end; and
a sprayed on abrasive coating bonded to the free end, the abrasive coating comprising a polymer matrix and an abrasive filler, the abrasive filler between about 50%-75% by volume of the abrasive coating, the polymer matrix comprises about 3%-10% of the volume of the abrasive coating when cured wherein the filler comprises hollow glass microspheres.

17. The fan blade as recited in claim 16 , wherein the abrasive filler is zirconia.

18. The fan blade as recited in claim 17 , wherein the abrasive filler has an average particle size of 220 mesh.

19. The fan blade as recited in claim 16 , wherein the polymer matrix includes at least one of an epoxy, polyimide, polyurethane, cyanoacrylate, acrylic, and combinations thereof.

20. The fan blade as recited in claim 19 , wherein the abrasive filler includes at least one of zirconia, alumina, silica, cubic boron nitride (CBN), and combinations thereof.

Assignees

• United Technologies Corp

Inventors

• Strock Christopher W

Classifications

• B05D1/34

  Applying different liquids or other fluent materials simultaneously · CPC title

• B05D1/12

  Applying particulate materials (B05D1/06, B05D1/10 take precedence) · CPC title

• F05D2300/43

  Synthetic polymers, e.g. plastics; Rubber · CPC title

• F05D2300/134

  Zirconium · CPC title

• F01D5/288 Primary

  Protective coatings for blades · CPC title