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 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 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 foldable rotor blade assembly includes a first section including a connector assembly including a plurality of through holes and a second section including a connector having a plurality of openings. The connector is receivable within a hollow interior of the first section. A plurality of fasteners insertable within the plurality of through holes and the plurality of openings. A fold assembly is operably coupled to both the first section and the second section. The fold assembly defines a blade fold axis about which the second section is rotatable to transform the rotor blade assembly between a normal configuration when the connector is received within the hollow interior of the first section, and a folded configuration when the connector has rotated outside of the hollow interior of the first section.

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 foldable rotor blade assembly includes a first section including a connector assembly including a plurality of through holes and a second section including a connector having a plurality of openings. The connector is receivable within a hollow interior of the first section. A plurality of fasteners insertable within the plurality of through holes and the plurality of openings. A fold assembly is operably coupled to both the first section and the second section. The fold assembly defines a blade fold axis about which the second section is rotatable to transform the rotor blade assembly between a normal configuration when the connector is received within the hollow interior of the first section, and a folded configuration when the connector has rotated outside of the hollow interior of the first section.

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 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 tool is provided for characterizing a blade geometry. The tool includes a first component attachable to a blade root of a blade and a second component attachable to leading and trailing edges of the blade at a blade tip and at multiple stations defined along a span-wise dimension of the blade. The second component is configured for characterization of a chord length of the blade at the blade tip and at the multiple stations. The first and second components are respectively configured for cooperative optical characterization of a sweep and a twist angle of the blade at the blade tip and at the multiple stations.

Abstract: A pitch bearing assembly includes an inboard pitch bearing including an inner race and an outer race, the outer race including a radially outwardly protruding tab, and an outboard end of the inboard pitch bearing including a plurality of rotation transmitting features. An outboard pitch bearing of the pitch bearing assembly includes an inner race and an outer race, an inboard end of the outer race of the outboard pitch bearing including a plurality of rotation transmitting features. A coupler of the pitch bearing assembly has an inboard end and an outboard end, the inboard end of the coupler having a plurality of rotation transmitting features engageable with the rotation transmitting features of the inboard pitch bearing, the outboard end of the coupler having a plurality of rotation transmitting features engageable with the rotation transmitting features of the outboard pitch bearing.

Abstract: A tool is provided for characterizing a blade geometry. The tool includes a first component attachable to a blade root of a blade and a second component attachable to leading and trailing edges of the blade at a blade tip and at multiple stations defined along a span-wise dimension of the blade. The second component is configured for characterization of a chord length of the blade at the blade tip and at the multiple stations. The first and second components are respectively configured for cooperative optical characterization of a sweep and a twist angle of the blade at the blade tip and at the multiple stations.