The present invention provides a turbofan engine including leading edge
erosion protection for composite stator vanes contained therein. The
composite stator vanes are defined by a leading edge, a trailing edge, a
concave surface and a convex surface. The vanes are generally formed of a
graphite fiber and an aramid fiber braided preform that is laminated with
an epoxy matrix resin or other high temperature matrix resin. A wire mesh
screen is embedded during a molding process into an outermost surface of
the leading edge of the epoxy matrix resin. A tapering erosion protection
layer comprised of an erosion protective material is applied to the wire
mesh screen at the leading edge of the composite stator vane an aids in
protecting the leading edge of the stator vane from debris and
contaminants, including operational fluids, dust, and sand that may be
carried in an air stream passing therethrough the turbofan engine, as
well as an erosive operational environment.