Substrates coated with wear resistant layers and methods of applying wear resistant layers to same

Abstract

Components with improved erosion resistance are disclosed. A surface of the component or a substrate of the component is modified by coating the substrate with an elastomer layer. The elastomer layer is then modified by embedding hard particles onto an outer side of the elastomer layer. The hard particles exhibit higher fractured toughness providing enhanced erosion protection. The elastic properties of the elastomer experience little reduction because the surface embedded particles are located only at the outer side or outer surface of the elastomer layer. Therefore, the bond between the inner side of the elastomer layer and the substrate or component surface is not interfered with and the potential for electro-chemical corrosion and poor adhesion are not increased by the presence of the hard particles as the hard particles are located away from the inner face between the elastomer layer and the substrate.

1 - 5 . (canceled) 
     
     
         6 . A method of repairing a damaged leading edge of an airfoil, comprising:
 coating the damaged leading edge of the airfoil with a first uncured elastomeric material;   partially curing the first uncured elastomeric material to form a partially cured elastomeric layer, the partially cured elastomeric layer having an inner surface coupled to the damaged leading edge of the airfoil and an outer surface disposed opposite the inner surface;   embedding hard particles having a diameter greater than or equal to five microns into the outer surface;   further curing the partially cured elastomeric layer to form a matrix, and   coating the matrix with a second uncured elastomeric material and curing the second uncured elastomeric material.   
     
     
         7 . (canceled) 
     
     
         8 . The method of repairing a damaged leading edge according to  claim 6  wherein the second uncured elastomeric material is the same as the first uncured elastomeric material. 
     
     
         9 . The method of repairing a damaged leading edge according to  claim 6  wherein the second uncured elastomeric material is different than the first uncured elastomeric material. 
     
     
         10 . The method of repairing a damaged leading edge according to  claim 6 , wherein the first uncured elastomeric material is selected from the group consisting of polyurethanes, polyureas, silicones, silicone rubbers, fluoropolymers, natural rubber, chlorosulfonated polyethylene, chlorinated polyethylene, ethylene octene copolymers and combinations thereof. 
     
     
         11 . The method of repairing a damaged leading edge according to  claim 6 , wherein the second uncured elastomeric material is selected from the group consisting of polyurethanes, polyureas, silicones, silicone rubbers, fluoropolymers, natural rubber, chlorosulfonated polyethylene, chlorinated polyethylene, ethylene octene copolymers and combinations thereof. 
     
     
         12 . The method of repairing damaged leading edge according to  claim 6 , wherein the partially curing is initiated by mechanism selected from the group consisting of an additional reaction, nucleophilic substitution reaction, nucleophilic aromatic substitution reaction and free radical. 
     
     
         13 . The method of repairing a damaged leading edge according to  claim 6 , wherein the hard particles are selected from the group consisting of alumina, silicon carbide, silicon nitride, boron carbide, tungsten carbide, steel alloys, nickel alloys, diamond, chromium carbide, mullite, zirconia, yttria-stabilized zirconia, magnesium-stabilized zirconia and combinations thereof. 
     
     
         14 . The method of repairing a damaged leading edge according to  claim 6 , wherein the hard particles have a diameter greater than or equal to 100 microns. 
     
     
         15 . The method of repairing a damaged leading edge according to  claim 6 , wherein the hard particles have a diameter greater than or equal to 500 microns. 
     
     
         16 . A method of coating an airfoil, comprising:
 applying a partially crosslinked elastomer to a surface of the airfoil to form an elastomeric layer, the elastomeric layer including an inner surface attached to the surface of the airfoil and an outer surface disposed opposite the inner surface;   entrenching hard particles having a diameter greater than or equal to five microns into the outer surface; and   crosslinking the elastomeric layer to form a matrix, and   coating the matrix with an elastomeric material and crosslinking the elastomeric material.   
     
     
         17 . (canceled) 
     
     
         18 . The method of coating an airfoil according to  claim 16 , wherein the hard particles are selected from the group consisting of alumina, silicon carbide, silicon nitride, boron carbide, tungsten carbide, steel alloys, nickel alloys, diamond, chromium carbide, mullite, zirconia, yttria-stabilized zirconia, magnesium-stabilized zirconia and combinations thereof. 
     
     
         19 . The method of coating an airfoil according to  claim 16 , wherein the hard particles have an aspect ratio less than or equal to twenty. 
     
     
         20 . The method of coating an airfoil according to  claim 16 , wherein the hard particles have an aspect ratio less than or equal to 5.