Fluoroelastomer erosion coating repair

1. A method of repairing a rear cone segment erosion coating comprising:

removing a portion of an existing fluoroelastomer erosion coating from the rear cone segment to form a repair area;

forming a cured replacement erosion coating corresponding to the repair area, wherein the cured replacement erosion coating has a layer of fluoroelastomer and a layer of fibrous reinforcement;

preparing the repair area and the cured replacement erosion coating for adhesion;

locating the prepared cured replacement erosion coating on the prepared repair area; and

adhering the prepared cured replacement erosion coating to the prepared repair area;

wherein forming the cured replacement erosion coating comprises:

providing a mold with a convex surface corresponding to the repair area;

attaching a first end of a barrier film to the convex mold surface wherein the barrier film has a first surface and a second surface and a free second end;

placing a sheet of the fibrous reinforcement on the mold surface wherein a first end of the fibrous reinforcement sheet is adjacent to the first surface of the barrier film, a second end of the fibrous reinforcement sheet is adjacent to the second surface of the barrier film, and the free second end of the barrier film extends past the first end of the sheet of fibrous reinforcement;

placing an uncured sheet of the fluoroelastomer having a first end and a second end on the sheet of fibrous reinforcement such that a joint between the first end and second end of the uncured fluoroelastomer does not align with a joint between the first and second ends of the fibrous reinforcement and the barrier film is located between the ends of the sheet of the uncured fluoroelastomer; and

curing the uncured sheet of the fluoroelastomer.

2. The method of claim 1 , wherein removing the existing fluoroelastomer coating comprises mechanically removing the existing fluoroelastomer coating by cutting, abrasive wiping, abrasive blasting, water jetting, or a combination thereof.

3. The method of claim 2 , wherein removing the existing fluoroelastomer coating further comprises chemical softening of the existing fluoroelastomer coating prior to mechanically removing the existing fluoroelastomer coating.

4. The method of claim 1 , wherein the fibrous reinforcement comprises a fiber and a polymer.

5. The method of claim 1 , wherein forming the cured replacement erosion coating comprises curing a combination of the layer of fluoroelastomer and the layer of fibrous reinforcement at a temperature of 300-400° F. and pressure greater than or equal to 20 psi.

6. The method of claim 1 , wherein forming the cured replacement erosion coating comprises curing a combination of the layer of fluoroelastomer and the layer of fibrous reinforcement at a temperature of 300-400° F. in a vacuum bag.

7. The method of claim 1 , wherein locating the prepared cured replacement erosion coating on the prepared repair area comprises wrapping the prepared cured replacement erosion coating around the rear cone segment in a direction opposite to a direction of rotation.

8. The method of claim 1 , wherein adhering the prepared cured replacement erosion coating to the prepared repair area comprises curing an adhesive at a temperature less than 300° F.

9. The method of claim 1 , wherein a gap between the adhered cured replacement erosion coating and the existing fluoroelastomer coating is filled with a second fluoroelastomer.

10. The method of claim 1 , wherein the rear cone segment includes a front attachment flange and the repair area includes the front attachment flange.

11. The method of claim 10 , wherein the cured replacement erosion coating is darted in a front attachment flange area prior to cure.