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 heater mat assembly for a rotor blade spar is provided including a plurality of electrically conductive heater wires extending in a spaced parallel configuration along a path of the rotor blade spar. An electrical current is flowed through the plurality of heater wires to inhibit ice accumulation on a portion of the rotor blade spar. At least one layer of a first insulating material is arranged adjacent a first side of each of the plurality of heater wires such that the at least one layer of the first insulating material is disposed between the plurality of heater wires and an adjacent surface of the rotor blade spar. The first insulating material comprises a thermally and electrically insulating material.

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 main rotor trim tab retention system includes, a blade housing having flanges separated by a cavity defined between the flanges, and a trim tab assembly. The trim tab assembly includes, a trim tab having an aerodynamic surface, at least one arm extending from the trim tab positionable within the cavity while the trim tab extends outward from the cavity, and a spherical bearing connecting the trim tab and the at least one arm, the spherical bearing having a first axis which is substantially perpendicular to the aerodynamic surface of the trim tab. The at least one arm is pivotable about the spherical bearing about a second axis substantially perpendicular to the first axis to rotate the trim tab relative to the blade housing.

Abstract: A main rotor trim tab retention system includes, a blade housing having flanges separated by a cavity defined between the flanges, and a trim tab assembly. The trim tab assembly includes, a trim tab having an aerodynamic surface, at least one arm extending from the trim tab positionable within the cavity while the trim tab extends outward from the cavity, and a spherical bearing connecting the trim tab and the at least one arm, the spherical bearing having a first axis which is substantially perpendicular to the aerodynamic surface of the trim tab. The at least one arm is pivotable about the spherical bearing about a second axis substantially perpendicular to the first axis to rotate the trim tab relative to the blade housing.

Abstract: A heater mat assembly for a rotor blade spar is provided including a plurality of electrically conductive heater wires extending in a spaced parallel configuration along a path of the rotor blade spar. An electrical current is flowed through the plurality of heater wires to inhibit ice accumulation on a portion of the rotor blade spar. At least one layer of a first insulating material is arranged adjacent a first side of each of the plurality of heater wires such that the at least one layer of the first insulating material is disposed between the plurality of heater wires and an adjacent surface of the rotor blade spar. The first insulating material comprises a thermally and electrically insulating material.

Abstract: A method of assembling a rotor blade assembly includes determining a first spanwise moment of a first component of the rotor blade assembly and comparing the first spanwise moment to a target first spanwise moment. The first spanwise moment of the first component is adjusted based on a result of the comparison. A second spanwise moment of a second component of the rotor blade assembly is determined and compared to a target second spanwise moment. The second spanwise moment of the second component is adjusted based on a result of the comparison. The first component is assembled to the second component, resulting in a rotor blade assembly meeting a target spanwise moment of the rotor blade assembly.

Abstract: A mandrel for use in manufacturing a spar having a spar cavity is provided including a first component, a second component, and a center component. The first component is configured to define at least an interior first surface of the spar cavity. The second component is configured to define at least an interior second surface of the spar cavity and form a space between the first and second components. The second component has a second side arranged in contact with a first side of the first component. The center component is arranged within the space to separate the first and second components and to engage at least a portion of each of the first and second components to retain the first and second components in a desired position.

Abstract: A method of assembling a rotor blade assembly includes determining a first spanwise moment of a first component of the rotor blade assembly and comparing the first spanwise moment to a target first spanwise moment. The first spanwise moment of the first component is adjusted based on a result of the comparison. A second spanwise moment of a second component of the rotor blade assembly is determined and compared to a target second spanwise moment. The second spanwise moment of the second component is adjusted based on a result of the comparison. The first component is assembled to the second component, resulting in a rotor blade assembly meeting a target spanwise moment of the rotor blade assembly.

Abstract: A rotor blade for a rotary-wing aircraft includes a core member having a first end that extends to a second end, and a spar member positioned about the core member. The spar member includes a first end section that extends to a second end section. A tip core assembly is mounted at the second end section of the spar member. The tip core assembly is formed from a honeycombed material. The rotor blade also includes a rotor blade skin mounted about the spar member and the tip core assembly.

Abstract: A rotor blade for a rotary-wing aircraft includes a core member having a first end that extends to a second end, and a spar member positioned about the core member. The spar member includes a first end section that extends to a second end section. A tip core assembly is mounted at the second end section of the spar member. The tip core assembly is formed from a honeycombed material. The rotor blade also includes a rotor blade skin mounted about the spar member and the tip core assembly.