Method of Applying Abrasion Resistant Materials to Rotors

1 . A process for applying an abrasion resistant material to a rotor of an aircraft, the rotor having a tip, a root, a leading edge, a trailing edge, a surface disposed between the tip and the root, and a chord length extending linearly from the leading edge to the trailing edge, the process comprising:

preparing the surface of the rotor for receiving the abrasion resistant material;

preparing a first coat of the abrasion resistant material, the first coat composed of a first material and a second material;

spraying the first coat onto the surface of the rotor;

preparing a second coat of the abrasion resistant material, the second coat composed of the first material and the second material; and

spraying the second coat onto the rotor such that the first coat is between at least a portion of the surface and at least a portion of the second coat;

wherein the second coat has a lesser percentage part per volume of the first material and a higher percentage part per volume of the second material than the first coat.

2 . The process according to claim 1 , wherein the first material is an elastomeric material and the second material is a metallic material.

3 . The process according to claim 2 , wherein the first coat is composed of an abrasion resistant material having a 70 percent part per volume of the elastomeric material and a 30 percent part per volume of the metallic material.

4 . The process according to claim 2 , wherein the second coat is composed of an abrasion resistant material having a 5 percent part per volume of the elastomeric material and a 95 percent part per volume of the metallic material.

5 . The process according to claim 1 , further comprising:

applying the abrasion resistant material to the rotor while the rotor remains coupled to the aircraft.

6 . The process according to claim 1 , further comprising:

removing the rotor from the aircraft; and

coupling the rotor to a support structure.

7 . The process according to claim 1 , wherein the spraying of the first coat onto the surface of the rotor is achieved by providing a coating system having a plasma spray gun.

8 . The process according to claim 7 , wherein the coating system is operably associated with an automative device for propelling abrasion resistant material onto the surface of the rotor.

9 . The process according to claim 7 , wherein the coating system is configured for manually applying abrasion resistant material onto the surface of the rotor.

10 . The process according to claim 1 , wherein the first coat is sprayed onto the surface area of the rotor to a distance up to about 30 percent of the chord length, the chord length being measured from the leading edge to the trailing edge of the rotor.

11 . The process according to claim 1 , further comprising:

preparing an intermediary coat having a plurality of abrasion resistant layers, the intermediary coat being composed of the first material and the second material; and

spraying the intermediary coat directly onto the first coat;

wherein the intermediary coat is disposed between the first coat and the second coat.

12 . The process according to claim 11 , wherein the plurality of abrasion resistant layers transitions from a smaller percentage part per volume of the second material to a larger percentage part per volume of the second material and transitions from a larger percentage part per volume of the first material to a smaller percentage part per volume of the second material as additional layers are added.

13 . A process for applying an abrasion resistant material to an abrasion strip of an aircraft, the process comprising:

preparing the abrasion strip for receiving the abrasion resistant material;

preparing a first coat of the abrasion resistant material, the first coat composed of a first material and a second material;

spraying the first coat onto the abrasion strip;

preparing a second coat of the abrasion resistant material, the second coat composed of the first material and the second material; and

spraying the second coat onto the abrasion strip such that the first coat is between at least a portion of the abrasion strip and at least a portion of the second coat;

wherein the second coat has a lesser percentage per part volume of the first material and a higher percentage per part volume of the second material than the first coat.

14 . The process according to claim 13 , wherein the first material is an elastomeric material and the second material is a metallic material.

15 . The process according to claim 13 , further comprising:

applying the abrasion resistant material to the abrasion strip while the abrasion strip remains coupled to the aircraft.

16 . The process according to claim 13 , further comprising:

removing the abrasion strip from the aircraft; and

coupling the abrasion strip to a support structure.

17 . The process according to claim 13 , further comprising:

preparing an intermediary coat having a plurality of abrasion resistant layers, the intermediary coat being composed of first material and the second material; and

spraying the intermediary coat directly onto the first coat;

wherein the intermediary coat is disposed between the first coat and the second coat.

18 . The process according to claim 17 , wherein the plurality of abrasion resistant layers transitions from a smaller percentage part per volume of the second material to a larger percentage part per volume of the second material and transitions from a larger percentage part per volume of the first material to a smaller percentage part per volume of the second material as additional layers are added.

19 . A process for applying an abrasion resistant material to a substrate, the process comprising:

preparing the substrate for receiving the abrasion resistant material;

preparing a first coat of the abrasion resistant material, the first coat being composed of a first material and a second material;

spraying the first coat onto the substrate;

preparing an intermediary coat having a plurality of abrasion resistant layers, the intermediary coat being composed of first material and the second material;

spraying the intermediary coat directly onto the first coat;

preparing a second coat of the abrasion resistant material, the second coat being composed of the first material and the second material; and

spraying the second coat on the first coat;

wherein the second coat has a lesser percentage per part volume of the first material and a higher percentage per part volume of the second material than the first coat, and

wherein the plurality of abrasion resistant layers transitions from a smaller percentage part per volume of the second material to a larger percentage part per volume of the second material and transitions from a larger percentage part per volume of the first material to a smaller percentage part per volume of the second material as additional layers are added.

20 . The process according to claim 19 , wherein the first material is an elastomeric material and the second material is a metallic material.