US-12624638-B2 - System and method for manufacture of abrasive coating

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.

Inventors

• Christopher W. Strock

Assignees

• RTX CORPORATION

Dates

Publication Date

20260512

Application Date

20230104

Claims (7)

1. 1 . A method of fabricating an abrasive coating on a component, comprising: spraying a polymer matrix which is atomized and propelled by an air jet toward the component; and communicating grit particles into the air jet such that the grit particles are entrained by the air jet and codeposited together with the polymer matrix onto the component, thereby forming an abrasive coating on the component with the grit particles bonded to the component; and further comprising curing the polymer matrix such that the polymer matrix outgases through the grit particles during curing.
2. 2 . The method as recited in claim 1 , wherein the grit particles form about 50%-75% by volume of the abrasive coating.
3. 3 . The method as recited in claim 1 , wherein the polymer matrix provides about 3%-10% by volume of the abrasive coating when cured.
4. 4 . The method as recited in claim 1 , further comprising spraying the abrasive coating onto a free end of a fan blade.
5. 5 . The method of claim 1 , wherein the grit particles have an average particle size of 220 mesh.
6. 6 . The method of claim 1 , wherein the polymer matrix includes one or more epoxies, polyimides, polyurethanes, cyanoacrylates, and acrylics.
7. 7 . The method of claim 1 , wherein the grit particles comprise hollow glass microspheres.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This is a divisional application of U.S. patent application Ser. No. 16/043,686, filed Jul. 24, 2018, which is a divisional application of U.S. patent application Ser. No. 14/687,651, filed Apr. 15, 2015, now U.S. Pat. No. 10,060,273, issued Aug. 28, 2018. BACKGROUND The present disclosure relates to an abrasive coating for gas turbine engine components. Abrasive coatings often protect rotating parts during rub interaction with associated abradeable seals to establish a mating surface with the smallest possible clearance. The abrasive coatings are often utilized to form abrasive tips of rotating blades, cantilevered vanes, and knife edge seals of gas turbine engines. Polymer composite and polymer coated aluminum fan blades may suffer from wear due to frictional heating at the interface with an abradable blade outer air seal. Both polymer bonded and thermally sprayed metal matrix abrasive coatings have been demonstrated, however, a variety of technical hurdles to cost effective implementation exist. While polymer based abrasive coatings obviate corrosion and fatigue issues, dimensional control of liquid flow polymer based abrasive coating application remain. SUMMARY A rotating component according to one disclosed non-limiting embodiment of the present disclosure can include 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. A further embodiment of the present disclosure may include, wherein the polymer matrix provides about 3%-10% volume of the abrasive coating once cured. A further embodiment of any of the foregoing embodiments of the present disclosure may include, wherein the abrasive filler is zirconia. A further embodiment of any of the foregoing embodiments of the present disclosure may include, wherein the abrasive filler has an average particle size of 220 mesh. A further embodiment of any of the foregoing embodiments of the present disclosure may include, wherein the polymer matrix outgases during elevated temperature curing. A further embodiment of any of the foregoing embodiments of the present disclosure may include, wherein the component is a fan blade. A system for spraying an abrasive coating onto a component according to another disclosed non-limiting embodiment of the present disclosure can include a spray gun from which a polymer matrix is atomized and propelled toward the component by an air jet such that grit particles are deposited onto the component. A further embodiment of any of the foregoing embodiments of the present disclosure may include, wherein the grit particles are communicated into the air jet. A further embodiment of any of the foregoing embodiments of the present disclosure may include, wherein the grit particles are sprayed separately onto the component. A further embodiment of any of the foregoing embodiments of the present disclosure may include, wherein the grit particles are coated by the polymer matrix prior to spraying by the spray gun. A further embodiment of any of the foregoing embodiments of the present disclosure may include, wherein the abrasive filler is zirconia. A further embodiment of any of the foregoing embodiments of the present disclosure may include, wherein the abrasive filler has an average particle size of 220 mesh. A further embodiment of any of the foregoing embodiments of the present disclosure may include, wherein the abrasive filler is between about 50%-75% by volume of the abrasive coating. A method of fabricating an abrasive coating according to another disclosed non-limiting embodiment of the present disclosure can include spraying a polymer matrix which is atomized and propelled by an air jet and depositing grit particles with the polymer matrix forming an abrasive coating. A further embodiment of any of the foregoing embodiments of the present disclosure may include, codepositing the grit particles with the air jet. A further embodiment of any of the foregoing embodiments of the present disclosure may include, wherein the grit particles form about 50%-75% by volume of the abrasive coating. A further embodiment of any of the foregoing embodiments of the present disclosure may include, curing the polymer matrix such that the polymer matrix outgases through the grit particles during curing. A further embodiment of any of the foregoing embodiments of the present disclosure may include, wherein the polymer matrix provides about 3%-10% a volume of the abrasive coating when cured. A further embodiment of any of the foregoing embodiments of the present disclosure may include spraying the grit particles with a second air jet. A further embodiment of any of the foregoing embodiments of the present disclosure may include spraying the abrasive coating onto a free end of a fan blade. The foregoing features and elements may be