Abstract: A blade has an airfoil having a tip. The blade has a metallic substrate and a coating system atop the substrate at the tip. The coating system has: a first layer of at least 99.0% weight nickel; an abrasive layer having a matrix and an abrasive at least partially embedded in the matrix; and a second layer between the first layer and the matrix. The second layer is tougher or more ductile than at least one of the first layer and the matrix.

Abstract: A blade has an airfoil having a tip. The blade has a metallic substrate and a coating system atop the substrate at the tip. The coating system has: a first layer of at least 99.0% weight nickel; an abrasive layer having a matrix and an abrasive at least partially embedded in the matrix; and a second layer between the first layer and the matrix. The second layer is tougher or more ductile than at least one of the first layer and the matrix.

Abstract: A method for forming an abrasive surface includes applying an electric current through a plating solution so as to cause an abrasive grit to be deposited onto a workpiece and varying a waveform of the electric current while building up a matrix material at least partially around the abrasive grit.

Abstract: An abrasive coating for a substrate comprises a strike layer is formed on a substrate top surface; a base layer is coupled to the strike layer; a tack layer is coupled to the base layer, wherein the tack layer is configured to adhere first grit particles to the base layer; a plurality of first grit particles are adapted to be coupled to the tack layer, a plurality of second grit particles are placed between each of the plurality of first grit particles, the second grit particles having a nominal size smaller than the first grit particles; and an overplate layer comprising a matrix material is bonded to the tack layer; the matrix material envelops the second grit particles and bonds and partially surrounds the first grit particles, wherein the first grit particles extend above the overplate layer.

Abstract: An abrasive coating for a substrate comprises a strike layer is formed on a substrate top surface; a base layer is coupled to the strike layer; a tack layer is coupled to the base layer, wherein the tack layer is configured to adhere first grit particles to the base layer; a plurality of first grit particles are adapted to be coupled to the tack layer, a plurality of second grit particles are placed between each of the plurality of first grit particles, the second grit particles having a nominal size smaller than the first grit particles; and an overplate layer comprising a matrix material is bonded to the tack layer; the matrix material envelops the second grit particles and bonds and partially surrounds the first grit particles, wherein the first grit particles extend above the overplate layer.

Abstract: An abrasive coating for a substrate comprises a strike layer is formed on a substrate top surface; a base layer is coupled to the strike layer; a tack layer is coupled to the base layer, wherein the tack layer is configured to adhere first grit particles to the base layer; a plurality of first grit particles are adapted to be coupled to the tack layer, a plurality of second grit particles are placed between each of the plurality of first grit particles, the second grit particles having a nominal size smaller than the first grit particles; and an overplate layer comprising a matrix material is bonded to the tack layer; the matrix material envelops the second grit particles and bonds and partially surrounds the first grit particles, wherein the first grit particles extend above the overplate layer.

Abstract: A method for forming an abrasive surface includes applying an electric current through a plating solution so as to cause an abrasive grit to be deposited onto a workpiece and varying a waveform of the electric current while building up a matrix material at least partially around the abrasive grit.