# US 2009/0092842 A1 · Article and method for erosion resistant composite

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- Number: US 2009/0092842 A1
- Document ID: US20090092842A1
- Status: Published application
- Kind: A1
- Application number: 11/869,095
- Filed: 2007-10-09
- Published: 2009-04-09
- Earliest claimed: 2007-10-09
- Assignees: United Technologies Corporation
- Inventors: Kelly L. Hoover; Charles R. Watson
- Web page: https://patentgrep.com/patent/US20090092842A1

## CPC

- F01D 5/288: {Protective coatings for blades}
- B32B 3/04: characterised by {at least one} layer folded at the edge, e.g. over another layer {; characterised by at least one layer enveloping or enclosing a material}
- B32B 9/045: {of synthetic resin}
- B32B 15/08: of synthetic resin
- B32B 15/18: comprising iron or steel {(B32B15/011, B32B15/012 and B32B15/013 take precedence)}
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/28: comprising synthetic resins not wholly covered by any one of the sub-groups {B32B27/30 - B32B27/42}
- B32B 2262/101: Glass fibres
- B32B 2262/105: Ceramic fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2307/712: Weather resistant
- B32B 2605/18: Aircraft
- F05D 2300/21: Oxide ceramics
- F05D 2300/434: Polyimides, e.g. AURUM
- F05D 2300/603: Composites; e.g. fibre-reinforced
- Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft
- Y10S 428/907: Resistant against plant or animal attack
- Y10T 428/239: Complete cover or casing
- Y10T 428/24488: Differential nonuniformity at margin
- Y10T 428/24926: including ceramic, glass, porcelain or quartz layer
- Y10T 428/2495: Thickness [relative or absolute]
- Y10T 428/31504: Composite [nonstructural laminate]
- Y10T 428/31623: Next to polyamide or polyimide
- Y10T 428/31678: Of metal
- Y10T 428/31721: Of polyimide
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y10S: TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A composite layer for resisting erosion includes a sacrificial layer for exposure to an erosion environment, a body layer, and an erosion resistant layer located between the sacrificial erosion layer and the body layer for protecting the body layer upon erosion of the sacrificial layer.

## Claims

### Claim 1

A composite article for resisting erosion, comprising:
a sacrificial layer for exposure to an erosion environment;
a body layer; and
an erosion resistant layer located between the sacrificial erosion layer and the body layer for protecting the body layer upon erosion of the sacrificial layer.

### Claim 2 (depends on 1)

The composite article as recited in claim 1, wherein the sacrificial layer and the body layer comprise an organic matrix composite that includes a matrix material comprising at least one of a thermoset polymer or a thermoplastic polymer.

### Claim 3 (depends on 2)

The composite article as recited in claim 2, wherein the matrix material comprises polyimide.

### Claim 4 (depends on 3)

The composite article as recited in claim 3, wherein the organic matrix composite includes reinforcement fibers comprising at least one of carbon graphite, silicon glass, silicon carbide, or ceramic.

### Claim 5 (depends on 1)

The composite article as recited in claim 1, wherein the sacrificial layer and the body layer comprise a ceramic material.

### Claim 6 (depends on 5)

The composite article as recited in claim 5, wherein the ceramic material comprises at least one of tungsten carbide, boron nitride, titanium nitride, or silicon carbide.

### Claim 7 (depends on 1)

The composite article as recited in claim 1, wherein the erosion resistant layer comprises at least one of a metal layer or a ceramic layer.

### Claim 8 (depends on 7)

The composite article as recited in claim 7, wherein the erosion resistant layer includes the metal layer, and the metal layer comprises at least one of a nickel alloy, magnesium, lead, tin, zinc, antimony, titanium, steel, aluminum, chromium, molybdenum, tungsten, cobalt, or zinc.

### Claim 9 (depends on 7)

The composite article as recited in claim 7, wherein the erosion resistant layer includes the ceramic layer, and the ceramic layer comprises at least one of tungsten carbide, boron nitride, titanium nitride, or silicon carbide.

### Claim 10 (depends on 1)

The composite article as recited in claim 1, wherein the sacrificial layer and the body layer completely encase the erosion resistant layer.

### Claim 11 (depends on 1)

The composite article as recited in claim 1, further comprising an adhesive between the sacrificial layer and the erosion resistant layer.

### Claim 12

A method of processing a composite article for resisting erosion, comprising:
forming a body layer; and
forming a sacrificial layer with an erosion resistant layer between the sacrificial erosion layer and the body layer.

### Claim 13 (depends on 12)

The method as recited in claim 12, further comprising forming the body layer and the sacrificial layer from an organic matrix composite.

### Claim 14 (depends on 13)

The method as recited in claim 13, further comprising selecting the organic matrix composite to include at least one of a thermoplastic polymer or a thermoset polymer.

### Claim 15 (depends on 14)

The method as recited in claim 14, further including selecting the organic matrix composite to include polyimide.

### Claim 16 (depends on 14)

The method as recited in claim 14, further comprising selecting the organic matrix composite to include reinforcement fibers comprising at least one of carbon graphite, silicon glass, silicon carbide, or ceramic.

### Claim 17 (depends on 12)

The method as recited in claim 12, further comprising forming the erosion resistant layer from a metal layer comprising at least one of a nickel alloy, magnesium, lead, tin, zinc, antimony, titanium, steel, aluminum, chromium, molybdenum, tungsten, cobalt, or zinc.

### Claim 18 (depends on 12)

The method as recited in claim 12, further comprising forming the erosion resistant layer from a ceramic material comprising at least one of tungsten carbide, boron nitride, titanium nitride, or silicon carbide.

### Claim 19 (depends on 12)

The method as recited in claim 12, further comprising forming the sacrificial layer and the body layer from a ceramic material comprising at least one of tungsten carbide, boron nitride, titanium nitride, or silicon carbide.

### Claim 20 (depends on 19)

The method as recited in claim 19, further comprising forming the ceramic material from a preceramic polymer.

### Claim 21 (depends on 19)

The method as recited in claim 19, further comprising slip casting the ceramic material.

### Claim 22 (depends on 12)

The method as recited in claim 12, further comprising depositing an adhesive between the sacrificial layer and the erosion resistant layer to bond the sacrificial layer and the erosion resistant layer together.

### Claim 23 (depends on 12)

The method as recited in claim 12, further comprising partially curing the body layer prior to forming the sacrificial layer.

### Claim 24

A method of processing a composite article for resisting erosion, comprising:
laying-up at least one pre-impregnated molding layer for forming a body layer;
laying-up a pre-fabricated erosion resistant layer adjacent to the pre-impregnated molding layer;
laying-up a pre-impregnated molding layer for forming a sacrificial layer on the erosion resistant layer such that the erosion resistant layer is between the pre-impregnated molding layer for forming the body layer and the pre-impregnated molding layer for forming the sacrificial layer; and
curing the pre-impregnated molding layers to form the composite article.

### Claim 25 (depends on 24)

The method as recited in claim 24, further comprising partially curing the at least one pre-impregnated molding layer for forming the body layer prior to laying-up and curing the pre-impregnated molding layer for forming the sacrificial layer.