# US 10,309,233 B2 · Abrasive tip blade manufacture methods > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,309,233 B2 - Document ID: US10309233B2 - Status: Granted - Kind: B2 - Application number: 15/943,991 - Filed: 2018-04-03 - Published: 2018-08-09 - Granted: 2019-06-04 - Earliest claimed: 2014-03-28 - Assignees: United Technologies Corporation - Applicants: United Technologies Corporation - Inventors: Christopher W. Strock - Web page: https://patentgrep.com/patent/US10309233B2 ## CPC - F01D 5/288: {Protective coatings for blades} - B05D 1/02: performed by spraying - B05D 3/007: {After-treatment} - C23C 4/06: Metallic material - C23C 4/08: containing only metal elements (C23C4/073 takes precedence) - C23C 24/06: Compressing powdered coating material, e.g. by milling - C23C 28/044: {coatings specially adapted for cutting tools or wear applications} - F01D 11/122: {with erodable or abradable material (blades having cutting or grinding tips F01D5/20)} - F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D) - B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02) - C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04) ## Abstract A method is disclosed for manufacturing a blade tip coating. The blade tip coating (152) comprising an abrasive (156) and a matrix (154). The method comprises forming a mixture comprising the abrasive, a precursor of the matrix, and an additional particulate (158). The mixture is pressed, the additional particulate acting as a stop to limit thickness reduction of the mixture. ## Claims ### Claim 1 A method for manufacturing an airfoil tip coating, the airfoil tip coating comprising an abrasive and a matrix, the method comprising: forming a mixture comprising the abrasive, a precursor of the matrix, and an additional particulate; and pressing the mixture, the additional particulate having a larger characteristic size than the abrasive and acting as a stop to limit thickness reduction of the mixture. ### Claim 2 (depends on 1) The method of claim 1 further comprising: curing the precursor of the matrix. ### Claim 3 (depends on 1) The method of claim 1 further comprising: releasing a release member from the mixture. ### Claim 4 (depends on 1) The method of claim 1 wherein the airfoil comprises: a root end and a tip; and a substrate along at least a portion of the airfoil, and the method comprises: applying the mixture to the tip. ### Claim 5 (depends on 4) The method of claim 4 wherein: the pressing comprises pressing a member against the applied mixture, the additional particulate acting as a stop to limit proximity of the member to the substrate. ### Claim 6 (depends on 5) The method of claim 5 further comprising: curing the precursor of the matrix; and releasing the tip coating from the member. ### Claim 7 (depends on 1) The method of claim 1 wherein: the tip coating is a first layer; and the method further comprises forming a second layer having a lower abrasive content than the first layer. ### Claim 8 (depends on 7) The method of claim 7 wherein: the second layer is formed atop the first layer by: forming a second mixture comprising a second abrasive, a second matrix precursor, and a second additional particulate; and pressing the second mixture, the second additional particulate acting as a stop to limit thickness reduction of the second mixture. ### Claim 9 (depends on 1) The method of claim 1 wherein: the tip coating has a content of the abrasive of at least twenty volume percent; and the tip coating has a content of the additional particulate of three volume percent to ten volume percent. ### Claim 10 (depends on 1) The method of claim 1 wherein: the additional particulate has characteristic diameter of 0.20 mm to 0.80 mm; and the abrasive has a characteristic size of ten micrometers to 150 micrometers. ### Claim 11 (depends on 1) The method of claim 1 wherein: the additional particulate is glass bead. ### Claim 12 (depends on 1) The method of claim 1 wherein: the abrasive is at least 50 percent by weight oxide of one or more of aluminum, titanium, and zirconium. ### Claim 13 (depends on 1) The method of claim 1 wherein: the tip coating has a characteristic thickness of 0.1 mm to 0.3 mm. ### Claim 14 (depends on 4) The method of claim 4 wherein: prior to the applying, a release agent is between the first release member and the mixture and the second release member and the mixture; and the release agent comprises polydimethylsiloxane polymer. ### Claim 15 (depends on 1) The method of claim 1 further comprising: after applying the tip coating, applying a polymeric coating to a pressure side and a suction side of the airfoil. ### Claim 16 (depends on 15) The method of claim 15 wherein: the polymeric coating is also applied atop the tip coating. ### Claim 17 A method for manufacturing a coating, the coating comprising an abrasive and a matrix, the method comprising: forming a mixture comprising the abrasive, a precursor of the matrix, and an additional particulate; and pressing the mixture, the additional particulate being beads and acting as a stop to limit thickness reduction of the mixture. ### Claim 18 (depends on 17) The method of claim 17 wherein: the beads are glass beads. ### Claim 19 (depends on 17) The method of claim 17 wherein: the matrix comprises an epoxy; and the abrasive is at least 50 percent by weight oxide of one or more of aluminum, titanium, and zirconium.