The COMPOCOAT project developed a new surface protection system for the development of composite aero-engine aerofoil structures with metallic leading edge. The surface protection system was based on TWI’s CompoSurfTM family of coating technologies and provide erosion protection for the metallic leading edge and thermal protection for the composite body. In addition to the surface protection system, the Comeld® joining process was utilised for achieving high strength bonding in the metal-composite interface. The leading edge itself comprised of two fishbone shaped parts that facilitated further strength to the bond. The two parts were welded together by laser, ensuring aerodynamic surface at the edge tip.

The operating temperature for the new aerofoil structure was in excess of 360°C. Out-of-Autoclave (OoA) processing enabled the rate manufacture of the demonstration parts, thus improving the cost effectiveness of the production.