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 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 water separator (108) includes a tube (112) defining a longitudinal axis, wherein the tube (112) includes a tube wall separating an interior (114) of the tube from an exterior (116) thereof. A tube insert (118) is mounted within the tube (112). The tube insert (118) includes a sheet (119) that is helically twisted about the longitudinal axis. An environmental control system (100) includes an air conditioner (102) with a discharge duct (104) for providing cooled air to an air conditioned space. A water separator (108) as described above is connected in line with the discharge duct (104) for passage of cooled air therethrough.

Abstract: A holding fixture includes a first blade support assembly and a second blade support assembly. The second blade support assembly is spaced at a distance from the first blade support assembly and includes a base plate removably mounted to a milling machine, an adjustable conic support connectable to the base plate via a spacer block, and a blade adjustment assembly movable to control a pressure applied by the blade adjustment assembly.

Abstract: A method of manufacturing a part is provided. The method includes heating a gear in the presence of carbon to carburize a material of the gear to create a carburized gear, the gear having a plurality of gear teeth and which comprises a selected material. Next, the carburized gear is high pressure gas quenched to drive the carbon into the material of the gear to create a quenched gear. Next, the quenched gear is at least one of cavitation peened and laser peened to create a peened gear. Finally, superfinishing is performed on surfaces of the peened gear.

Abstract: An aircraft is provided 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. A cockpit in the airframe, the cockpit including two seats and a single collective control input positioned between the two seats.

Abstract: A method of constructing a mandrel generally complementary to a spar cavity of a spar includes connecting a first component and a second component to form a central space there between and inserting a center component within the central space such that the center component retains the first component and second component in a desired position forming an outer surface of the mandrel which corresponds to an inner surface of the spar cavity.

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: An aircraft is provided and includes an airframe, an extending tail, 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 sensor and at least one inertial measurement unit (IMU) to sense current flight conditions of the aircraft, an interface to execute controls of a main rotor assembly in accordance with control commands and at least one flight control computer (FCC) to issue the control commands. The at least one FCC includes a central processing unit (CPU) and a memory having logic and executable instructions stored thereon, which, when executed, cause the CPU to issue the control commands based on the current flight conditions and a result of an execution of the logic for the current flight conditions.

Abstract: A rotor blade for a rotary aircraft is disclosed. The rotor blade includes a body and an airflow duct extending within the body of the rotor blade. An airflow outlet of the airflow duct is located at a tip of the blade. The airflow outlet has a cross-sectional area that is equal to or greater than a cross-sectional area of the airflow duct. The rotor blade is used to mitigate brownout during flight. Air exits the rotor blade at the airflow outlet in order to disrupt a blade vortex created by rotation of the rotor blade.

Abstract: A fuel supply system for an aircraft includes a fuel tank configured to supply fuel to an engine of an aircraft, a boost pump in operational communication with the fuel tank, wherein the boost pump is configured to control at least one of a fuel level and a fuel pressure in the fuel tank, and an electronic controller in communication with the boost pump and configured to control the boost pump. The electronic controller is configured to receive received information including (i) fuel information, (ii) flight information, and (iii) aircraft information, and configured to control the boost pump based on the received information.

Abstract: An aircraft is provided including at least one pilot input and a flight control system n communication with the at least one pilot input. The flight control system is operable in a manual mode and a pointing mode. In the manual mode, a velocity, position, and attitude of the aircraft are controlled manually, and in the pointing mode, at least one of the velocity and position of the aircraft is controlled by the flight control system and at least one of the attitude and heading of the aircraft is controlled manually.

Abstract: An active vibration control system for an aircraft includes a gearbox operably coupling a power source and a component rotatable about an axis. The gearbox includes a flexible region which allows flexure between a first stage and a second stage. At least one active vibration control actuator is arranged in vibrational communication with the flexible region to counteract vibrations transmitted between the power source and the rotatable component.

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: An electric propulsion system includes a static mast defining an axis of rotation and a stationary rotor hub assembly coupled to the static mast. A rotating system is rotatably mounted to the stationary rotor hub assembly. The electric propulsion system additionally includes an electric motor including a stator assembly associated with the rotor hub assembly and a rotor assembly associated with the rotating system.

Abstract: A bond fixture includes a first frame defining a chamber configured to receive a leading edge of a rotor blade and a second frame pivotally coupled to the first frame. The second frame is movable between a first position and a second position. In the second position, the second frame restricts movement of the bond fixture relative to the rotor blade. At least one supporting assembly extends from the first frame towards the chamber. The at least one supporting assembly is adjustable to apply a pressure to an adjacent surface of the rotor blade.

Abstract: A system for starting a gas turbine engine includes a rotor drive system and a hydraulic motor system operatively connected to the rotor drive system. A gas turbine engine is operatively connected to the hydraulic motor system for starting the gas turbine engine. A method for starting an engine includes initiating single-engine-operation on a multi-engine aircraft. Single-engine operation includes operating a first engine and powering down a second engine. The method includes running a hydraulic motor system. The hydraulic motor system is driven by the rotor drive system and is operatively connected to the second engine. The method includes identifying a need to start the second engine and starting the second engine using the hydraulic motor system.

Abstract: A rotorcraft is provided and includes a fuselage. The fuselage includes drag generating portions, a main rotor assembly and an auxiliary propulsor having an expected propulsion efficiency. The auxiliary propulsor is disposed to ingest boundary layer flows and in wake regions associated with the drag generating portions and is provided with a corresponding increase in the expected propulsion efficiency thereof.

Abstract: A transfer member includes a body including a first end having a first diameter and a second end having a second diameter. The second diameter is greater than the first diameter. A plurality of engagement features are positioned coaxially about the body and are separated by an axial gap. Each of the plurality of engagement features includes a beveled surface engageable to transfer rotation to or from the transfer member.

Abstract: A rotor system of a tail-sitter aerial vehicle configured to rotate about an axis of rotation is provided including a rotor hub which rotates about the axis of rotation and at least one rotor blade operably coupled to the rotor hub. The at least one rotor blade is configured to rotate about a folding axis between an extended position where the at least one rotor blade is substantially within a plane perpendicular to the axis of rotation and a stowed position where the rotor blade is arranged out of the plane of at an angle less than ninety degrees to the axis of rotation.