Abstract: A method of fabricating a composite structure includes laying at least one composite ply about a bladder, the bladder comprising a phase change material in a first phase having a first volume, positioning an outer mold about the bladder and the at least one composite ply, and curing the at least one composite ply to form the composite structure. Curing causes the phase change material contained within the bladder to change to a second phase to expand from the first volume to a second volume and apply a pressure to an interior surface of the composite ply and press an outer surface of the composite ply against the outer mold to form an interior cavity. The bladder is not removable from the formed interior cavity.

Abstract: A method of bonding a blade cuff to a rotor blade includes installing the blade cuff to a root end of the rotor blade. The method includes mounting the rotor blade within a plurality of supports. The method includes coupling the blade cuff to a first fixture. The method includes installing a second fixture about the blade cuff. The method further includes applying localized and constant heat and pressure to the blade cuff via the second fixture.

Abstract: A method of fabricating a composite structure includes laying at least one composite ply about a bladder, the bladder comprising a phase change material in a first phase having a first volume, positioning an outer mold about the bladder and the at least one composite ply, and curing the at least one composite ply to form the composite structure. Curing causes the phase change material contained within the bladder to change to a second phase to expand from the first volume to a second volume and apply a pressure to an interior surface of the composite ply and press an outer surface of the composite ply against the outer mold to form an interior cavity. The bladder is not removable from the formed interior cavity.

Abstract: A method of forming a balanced rotor blade assembly includes measuring a weight of a plurality of sub-components of the rotor blade assembly excluding a core. A configuration of a core of the rotor blade assembly is determined. In combination, the core and the plurality of sub-components achieve a target weight distribution and moment. The core is then fabricated and assembled with the plurality of sub-components to form a rotor blade sub-assembly.

Abstract: A system for regenerating fastener holes in a replacement tip section of a rotor blade includes a first fixture, a second fixture, and a third fixture positionable adjacent a tip section of the rotor blade. The first fixture is used to verify a position of an opening formed in the spar. The second fixture includes a removable bushing having a drillable opening. The drillable opening is aligned with the at least one opening formed in the spar and defines at least one hole to be formed in the replacement tip section. The third fixture includes a countersink opening. The countersink opening is aligned with the at least one hole to be formed in the replacement tip section and the at least one opening formed in the spar to define a countersink feature to be formed in the at least one hole.

Abstract: A fastener health monitoring system includes a structure including a first component and a second component, one or more fasteners securing the first component to the second component, and an optical fiber arranged adjacent to the one or more fasteners. The fiber is configured to detect strain on the structure from the one or more fasteners. Strain patterns are derivable from sensed data from the optical fiber, and any deviation in strain value greater than a threshold value at a particular fiber position along the optical fiber is indicative of a missing, damaged, or loosened fastener amongst the one or more of fasteners corresponding to that particular fiber position.

Abstract: A flow management system for delivering air to a heat load of an aircraft includes a cover having an opening for receiving and directing an airflow, and a duct defining a non-linear fluid flow path. The fluid flow path operably couples the opening and the heat load. A configuration of the fluid flow path reduces a velocity of the airflow therein while minimizing a pressure drop of the airflow.

Abstract: A method of fabricating a composite structure includes laying at least one composite ply about a bladder, the bladder comprising a phase change material in a first phase having a first volume, positioning an outer mold about the bladder and the at least one composite ply, and curing the at least one composite ply to form the composite structure. Curing causes the phase change material contained within the bladder to change to a second phase to expand from the first volume to a second volume and apply a pressure to an interior surface of the composite ply and press an outer surface of the composite ply against the outer mold to form an interior cavity. The bladder is not removable from the formed interior cavity.

Abstract: A bond fixture includes a support structure and a first assembly coupled to the support structure. The first assembly includes a frame defining a chamber and a first pressure pad and second pressure pad coupled to the frame opposite one another and positioned within the chamber. The second pressure pad is movable to control a pressure applied by the first pressure pad and the second pressure pad.

Abstract: A method of forming a balanced rotor blade assembly includes measuring a weight of a plurality of sub-components of the rotor blade assembly excluding a core. A configuration of a core of the rotor blade assembly is determined. In combination, the core and the plurality of sub-components achieve a target weight distribution and moment. The core is then fabricated and assembled with the plurality of sub-components to form a rotor blade sub-assembly.

Abstract: An assembly for removing a bushing is provided including a mandrel having a size and shape similar to the bushing and a receiver having a hollow interior cavity. A fastener extends through an opening formed in both the mandrel and the receiver. A socket attachment has a first opening configured to removably couple to a first end of the fastener and a second opening configured to removably couple to a torque delivery tool. A biasing mechanism arranged adjacent a second end of the fastener is configured to generate a biasing force to drive the mandrel against a bushing in response to a coupling of the socket attachment and the fastener.

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 gearbox includes a housing including a lubricant reservoir, at least one gear system arranged in the housing, at least one lubricant delivery passage operable to direct a flow of lubricant from a lubricant reservoir onto the at least one gear system, at least one lubricant return passage operable to guide the flow of lubricant to the lubricant reservoir, and a lubricant-out sensor fluidically connected to the at least one lubricant return passage. The lubricant-out sensor is operable to detect a non-pressure based parameter of the lubricant.

Abstract: A bond assembly includes a fixture having a first section movably coupled to a second section. The first section and the second section are disposed opposite one another. A bladder assembly is mounted to at least one of the first section and the second section. The bladder assembly is configured to apply controlled, localized pressure and heat to a component receivable between the first section and the second section.

Abstract: A portable computerized device for an aircraft control system includes an input system for inputting commands, a device display for displaying information on the computerized device, a processor, a wireless communication module, and a non-transitory computer readable medium comprising computer executable instructions, the computer executable instructions configured to cause the processor to perform a method. The method can include detecting whether the portable computerized device is in a cockpit state such that the portable computerized device is in and/or docked to an aircraft cockpit or if the portable computerized device is in a remote state such that the portable computerized device is not in an aircraft cockpit or is not docked to an aircraft cockpit. If the portable computerized device is determined to be in a remote state, the method includes operating the remote device in a remote mode.

Abstract: A gearbox system includes a first drive gear rotatable about an axis of rotation and a second drive gear disposed coaxial with the first drive gear and rotatable about the axis of rotation. An input shaft provides a first torque and includes an input gear. Driving pinions are operably connected to the input gear and positioned between the first drive gear and the second drive gear compliantly along a direction parallel to the axis of rotation. Each driving pinion drives the first drive gear in a first direction about the axis of rotation and drives the second drive gear in a second direction opposite the first direction about the axis of rotation. Each driving pinion transfers an equal second torque to the first drive gear and the second drive gear.

Abstract: A gear box includes a casing having an interior. A rotating component is arranged in the interior of the casing. A bearing including a rotating element, and a fixed element is connected with the casing in the interior. A submersible pump is arranged in the interior of the casing. The submersible pump includes a first housing portion extending about the rotating component fixedly mounted to the casing at the interior. A second housing portion is fixedly mounted to the casing at the interior and is aligned with the first housing portion. The first and second housing portions form a lubricant reservoir which holds lubricant. An impeller is mounted to the rotating component and arranged in the lubricant reservoir. One of the first and second housing portions includes an outlet through which the pumped lubricant is directed toward the rotating element.

Abstract: An aircraft rotor system includes a rotating pitch change shaft which rotates about an axis, a translating element disposed within the rotating pitch change shaft and movable along the axis and a pitch change bearing assembly which transfers movement of the translating element to the pitch change shaft. The pitch change bearing assembly includes a primary bearing and a secondary bearing coupled to the rotating pitch change shaft via the translating element when the primary bearing is in a first mode. A thrust shoulder is coupled to the translating element. The thrust shoulder is movable into engagement with the secondary bearing in response to failure of the primary bearing such that in a second mode, movement of the translating element is primarily transferred to the pitch change shaft via the secondary bearing.

Abstract: An aircraft is provide including an airframe, an extending tail, and a counter rotating, coaxial main rotor assembly including an upper rotor assembly and a lower rotor assembly. A translational thrust system positioned at the extending tail, the translational thrust system providing translational thrust to the airframe. At least one flight control computer configured to independently control the upper rotor assembly and the lower rotor assembly through a fly-by-wire control system. A plurality of sensors to detect sensor data of at least one environmental condition and at least one aircraft state data, wherein the sensors provide the sensor data to the flight control computer.

Abstract: A rotary-wing aircraft and system for flying a rotary-wing aircraft. The aircraft includes a servo system for actuating a rotor of the aircraft. A hydraulic system provides hydraulic power to the servo system, and a sensor measures a parameter of the hydraulic system. A processor determines a condition of the hydraulic system from the parameter and enforces an effective flight envelop based on the condition of the hydraulic system in order to fly the aircraft within the effective flight envelope.