Airfoil Conformable Membrane Erosion Coating

Abstract

A coating membrane for a component of a gas-turbine engine includes a solid membrane having a metallic foil or a polymeric film, and having a thickness and at least one kerf extending through the thickness to define a kerf pattern such that the solid membrane can be applied to a compound-curved surface. Also disclosed are a coated component coated with the membrane, and a method for producing a coated component with the membrane.

1 . A coating membrane for a component of a gas-turbine engine, comprising:
 a solid membrane comprising a polymeric film having a thickness and at least one kerf extending through the thickness to define a kerf pattern such that the solid membrane can be applied to a compound-curved surface.   
     
     
         2 - 4 . (canceled) 
     
     
         5 . The coating membrane of  claim 1 , wherein the polymeric film is selected from the group consisting of films of epoxy resin, polyphenylene ether, polyurethane and combinations thereof. 
     
     
         6 . The coating membrane of  claim 1 , wherein the polymeric film is an elastomeric film. 
     
     
         7 . The coating membrane of  claim 1 , wherein the polymeric film is fiber reinforced. 
     
     
         8 . The coating membrane of  claim 1 , wherein the solid membrane has a thickness of between about 0.003 and about 0.030 inches. 
     
     
         9 . The coating membrane of  claim 1 , wherein the at least one kerf has a kerf width of between 0.002 and 0.006 inches. 
     
     
         10 . The coating membrane of  claim 1 , wherein the kerf pattern defines a reticulated kerf pattern in a monolithic membrane structure. 
     
     
         11 . The coating membrane of  claim 1 , wherein the kerf pattern is a recurring pattern of intersecting kerfs. 
     
     
         12 . The coating membrane of  claim 1 , wherein the kerf pattern is defined by the at least one kerf in a spiral pattern. 
     
     
         13 . A coated gas-turbine engine component, comprising:
 a surface of a gas-turbine engine component;   a solid membrane comprising a polymeric film having a thickness and at least one kerf extending through the thickness to define a kerf pattern, wherein the solid membrane is bonded to the surface.   
     
     
         14 . The coated gas-turbine engine component of  claim 13 , wherein the surface is a compound-curved surface, and wherein the solid membrane conforms to the compound-curved surface. 
     
     
         15 . The coated gas-turbine engine component of  claim 13 , wherein the surface comprises a polymer matrix composite material. 
     
     
         16 . A method for applying an erosion resistant coating to a component of a gas-turbine engine, comprising:
 applying a solid membrane to a surface of a component of a gas-turbine engine, the solid membrane comprising a polymeric film having a thickness and at least one kerf extending through the thickness to define a kerf pattern; and   bonding the solid membrane to the surface.   
     
     
         17 . The method of  claim 16 , wherein the surface is a compound-curved surface, and wherein the applying step conforms the solid membrane to the compound-curved surface. 
     
     
         18 . The method of  claim 16 , wherein the bonding step comprises co-curing the solid membrane with the component. 
     
     
         19 . The method of  claim 16 , wherein the bonding step comprises adhesively bonding the solid membrane to the component. 
     
     
         20 . The method of  claim 16 , wherein the surface comprises a polymer matrix composite material. 
     
     
         21 . The coating membrane of  claim 1 , wherein the kerf pattern is defined by at least one elongated slit passing through the solid membrane.