Abstract: A rotor blade disassembly method includes applying spanwise support to a rotor blade body and heating a bond disposed on an end of the rotor blade body. The method also includes removing the spanwise support from the rotor blade body and exerting shear stress on the bond using weight of the rotor blade body. A blade disassembly system is also described.

Abstract: A cuff-blade attachment bushing removal tool system includes an alignment plate comprising alignment holes defined through the alignment plate in a pattern of a plurality of bushing holes of a blade root, a bladder plate connected to the alignment plate, and a bladder positioned on the bladder plate such that a gap is formed between the bladder and the alignment plate to receive a blade root to align the alignment holes and the bushing holes of the blade root, wherein the bladder is transitionable between an uninflated position where the blade root can be inserted into the gap and an inflated position where the blade root is clamped between the bladder and the alignment plate.

Abstract: A method and apparatus for securing a rotor blade is disclosed. The apparatus includes a base and an offset member configured to maintain the base at a selected distance from a set point. A clamping member is supported by the base and is receptive of the rotor blade at a selected location of the rotor blade, wherein the rotor blade is positioned against the set point. A slidable component supports the clamping member and slides the clamping member within the base to the selected location of the rotor blade. The free end of the clam shell assembly can be secured to a support beam that raises the clam shell assembly and rotor blade from the base for immersion testing.

Abstract: A tool for machining chamfers includes a tool body defining a first reference and a second reference configured for proper positioning of the tool body on a workpiece. A router port is defined through the tool body to provide access to the workpiece for a router. A router attachment proximate the router port is configured to position a router mounted to the router attachment for machining a chamfer in the workpiece with reference to the first and second references.

Abstract: A cuff-blade attachment bushing removal tool system includes an alignment plate comprising alignment holes defined through the alignment plate in a pattern of a plurality of bushing holes of a blade root, a bladder plate connected to the alignment plate, and a bladder positioned on the bladder plate such that a gap is formed between the bladder and the alignment plate to receive a blade root to align the alignment holes and the bushing holes of the blade root, wherein the bladder is transitionable between an uninflated position where the blade root can be inserted into the gap and an inflated position where the blade root is clamped between the bladder and the alignment plate.

Abstract: A pressure tool for rotor blade repair including a mobile support system including a support surface, a first bladder support assembly including a first inflatable bladder fixedly mounted to the support surface, a second bladder support assembly including a second inflatable bladder pivotally mounted relative to the support surface, and an activation mechanism operatively coupled to the second bladder support assembly. The activation mechanism is operable to selectively shift the second bladder support assembly relative to the first bladder support assembly. A fluid delivery system is operable to direct a fluid into each of the first inflatable bladder and the second inflatable bladder.

Abstract: A rotor blade disassembly method includes applying spanwise support to a rotor blade body and heating a bond disposed on an end of the rotor blade body. The method also includes removing the spanwise support from the rotor blade body and exerting shear stress on the bond using weight of the rotor blade body. A blade disassembly system is also described.

Abstract: A method is disclosed for repairing a worn helicopter rotor blade made of composite materials by adhesively securing a supplemental leading edge abrasion wear strip made of nickel to the leading edge of the rotor blade. The periphery of the bonding surface of the leading edge of the rotor blade is masked. The bonding surfaces of the supplemental leading edge strip and the rotor blade are cleaned with a medium-grit scrubbing pad, grit-blasted with aluminum oxide and then rinsed with DI water. A strip of a structural adhesive film is hot bonded to the bonding surface of the supplemental leading edge strip using vacuum and a high temperature oven cure. The side of the structural adhesive film bonding surface which will be secured directly to the rotor blade bonding surface is first abraded and then wiped with a solvent. An epoxy adhesive mix is applied to the bonding surfaces of the rotor blade and the structural adhesive film of the supplemental leading edge strip.