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

A method of applying an elastomer to a leading edge of an airfoil, consisting of:

• coating the leading edge of the airfoil with a first uncured elastomeric material;
• curing the first uncured elastomeric material to form a cured elastomeric layer, the cured elastomeric layer having an inner surface coupled to the leading edge of the airfoil;
• coating the cured elastomeric layer with a second elastomeric material, the second elastomeric material having an outer surface disposed opposite the inner surface;
• and
• embedding hard particles 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 and having a diameter of 5 to 3000 microns into the outer surface.

A method of coating an airfoil, consisting of:

• applying an 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 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 and having a diameter of 5 to 3000 microns into the outer surface;
• and
• curing the elastomeric layer to form a matrix.