Abstract: A rotor blade configured to be installed on a rotary wing aircraft includes a spar including an inboard portion extending from a root of the rotor blade to a first spanwise position of the rotor blade and an outboard portion meeting the inboard portion at the first spanwise position. The rotor blade further includes an upper skin and a lower skin coupled the outboard portion of the spar. The first spanwise position is defined by a most inboard point at which the upper and lower skins are coupled to the spar. The inboard portion includes a top layer, a bottom layer, and an inner cavity. The top layer has a substantially constant first thickness and the bottom layer has a substantially constant second thickness, and the distance between an outer surface of the top layer and an outer surface of the bottom layer is substantially constant.

Abstract: A method of modifying a rotor blade is provided for a rotor blade including a spar having an inboard portion with a substantially constant overall height, the inboard portion further including a top layer having a substantially constant first thickness and a bottom layer having a substantially constant second thickness. The method includes removing a root portion of the inboard portion to thereby modify the rotor blade and installing a cuff configured to couple to the rotor blade to an aircraft.

Abstract: A rotor blade for a rotary wing aircraft includes a leading edge and a trailing edge defining a chordwise direction. The leading edge defines a forward end of the rotor blade and the trailing edge defines an aft end of the rotor blade. The rotor blade has a center of gravity and an aerodynamic center along the chordwise direction. The center of gravity is aft of the aerodynamic center.

Abstract: A method of modifying a rotor blade is provided for a rotor blade including a spar having an inboard portion with a substantially constant overall height, the inboard portion further including a top layer having a substantially constant first thickness and a bottom layer having a substantially constant second thickness. The method includes removing a root portion of the inboard portion to thereby modify the rotor blade and installing a cuff configured to couple to the rotor blade to an aircraft.

Abstract: A rotor blade assembly for a rotary wing aircraft includes a main rotor blade body comprising an upper blade skin, a lower blade skin, an inboard end, an outboard end, and a trailing edge. The rotor blade assembly further includes a trailing edge actuator assembly. The trailing edge actuator assembly includes an upper actuator skin and a lower actuator skin defining a cavity and a trailing edge flap, a control panel disposed in the cavity and coupled to one of the upper actuator skin or the lower actuator skin and one or more actuators disposed in the cavity and configured to apply force to the control panel to cause the trailing edge flap to deflect. The trailing edge actuator assembly is coupled to the trailing edge of the main rotor blade body.

Abstract: A rotor blade assembly for a rotary wing aircraft includes a main rotor blade body comprising an upper blade skin, a lower blade skin, an inboard end, an outboard end, and a trailing edge. The rotor blade assembly further includes a trailing edge actuator assembly. The trailing edge actuator assembly includes an upper actuator skin and a lower actuator skin defining a cavity and a trailing edge flap, a control panel disposed in the cavity and coupled to one of the upper actuator skin or the lower actuator skin and one or more actuators disposed in the cavity and configured to apply force to the control panel to cause the trailing edge flap to deflect. The trailing edge actuator assembly is coupled to the trailing edge of the main rotor blade body.

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: An electrical conductor assembly for a rotor blade includes a substrate and at least one electrical conductor. The substrate includes an inboard end portion and an outboard end portion. The at least one electrical conductor is attached to the substrate and extends between the inboard end portion and the outboard end portion. The at least one electrical conductor is configured to transmit electricity along a length of the rotor blade. The inboard end portion and the outboard end portion are structured such that when the electrical conductor assembly is installed within the rotor blade, the inboard end portion is securable relative to the rotor blade and the outboard end portion is movable relative to the rotor blade.

Abstract: A replacement tip section for a rotor blade, from which a legacy tip section was removed, includes a blade tip portion configured to be attached to an intermediate section of the rotor blade after removal of the legacy section. The intermediate section has a connection feature at an end of the intermediate section to which the blade tip portion is attachable. The replacement tip section includes a transition region configured to be attached to a forward end of the connection feature. The transition region is configured to form a leading edge of the rotor blade and extends from the blade tip portion to form an opening into which the intermediate section is attached. The transition region includes a first end having a first airfoil that conforms to the intermediate section airfoil at the connection feature, and a second end having a second airfoil that conforms to the blade tip portion.

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 replacement tip section for a rotor blade, from which a legacy tip section was removed, includes a blade tip portion configured to be attached to an intermediate section of the rotor blade after removal of the legacy section. The intermediate section has a connection feature at an end of the intermediate section to which the blade tip portion is attachable. The replacement tip section includes a transition region configured to be attached to a forward end of the connection feature. The transition region is configured to form a leading edge of the rotor blade and extends from the blade tip portion to form an opening into which the intermediate section is attached. The transition region includes a first end having a first airfoil that conforms to the intermediate section airfoil at the connection feature, and a second end having a second airfoil that conforms to the blade tip portion.

Abstract: A method of mounting a replacement tip section to an exposed end of a rotor blade includes removing an existing tip section from the rotor blade to create the exposed end of the rotor blade, installing the rotor blade having the exposed end onto a holding fixture, assembling the replacement tip section about the exposed end of the rotor blade, positioning a bonding fixture about the replacement tip section, and curing the replacement tip section to the exposed end of the rotor blade.

Abstract: A rotor blade of a rotary wing aircraft includes a core defining a trailing edge of the rotor blade and a skin extending from the trailing edge defining an opening including the core. The skin defines an aerodynamic surface of the rotor blade. The rotor blade additionally includes at least one trim tab assembly including a trim portion extending from the core beyond the trailing edge of the rotor blade and an actuation system including at least one actuator disposed within the core. The actuation system is operable to adjust an angle of the trim portion relative to the rotor blade.

Abstract: A method of mounting a replacement tip section to an exposed end of a rotor blade includes removing an existing tip section from the rotor blade to create the exposed end of the rotor blade, installing the rotor blade having the exposed end onto a holding fixture, assembling the replacement tip section about the exposed end of the rotor blade, positioning a bonding fixture about the replacement tip section, and curing the replacement tip section to the exposed end of the rotor blade.

Abstract: A rotor blade of a rotary wing aircraft includes a core defining a trailing edge of the rotor blade and a skin extending from the trailing edge defining an opening including the core. The skin defines an aerodynamic surface of the rotor blade. The rotor blade additionally includes at least one trim tab assembly including a trim portion extending from the core beyond the trailing edge of the rotor blade and an actuation system including at least one actuator disposed within the core. The actuation system is operable to adjust an angle of the trim portion relative to the rotor blade.

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 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 rotor blade for a rotary wing aircraft and a tip for the rotor blade. The rotor blade includes a blade root, a blade tip and a blade body that extends from the blade root to the blade tip. The blade tip includes: a continuously swept leading edge, a compound trailing edge, and a continuous anhedral.

Abstract: A replacement tip section for a rotor blade, from which a legacy tip section was removed, includes a blade tip portion configured to be attached to an intermediate section of the rotor blade after removal of the legacy section. The intermediate section has a connection feature at an end of the intermediate section to which the blade tip portion is attachable. The replacement tip section includes a transition region configured to be attached to a forward end of the connection feature. The transition region is configured to form a leading edge of the rotor blade and extends from the blade tip portion to form an opening into which the intermediate section is attached. The transition region includes a first end having a first airfoil that conforms to the intermediate section airfoil at the connection feature, and a second end having a second airfoil that conforms to the blade tip portion.

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.