Abstract: A method of manufacturing a preform from uncured multiple laminates of resins impregnated fiber reinforced composite material is proposed. The preform has irregular shape such that at least one edge of any transverse cross-section of the preform varies along its length with respect to a reference co-ordinate set of axes, and further such that the cross sectional area of every cross section of the preform along the length of the preform is predetermined. A layup is formed to a length substantially equal to that of the preform from uncured multiple laminates of resin impregnated fiber reinforced composite material to have a regular shape such that no edge of any transverse cross-section varies along its length with respect to the reference co-ordinate set of axes. The cross-sectional area of every transverse cross-section of the layup along its length is substantially equal to a predetermined corresponding cross-section of the preform.

Abstract: A method of fabricating a rotor hub of a fully articulated helicoper rotor system, the rotor hub including a central portion and at least two pairs of lug arms extending therefrom, according to which composite material is dispensed onto the mandrel and wound about a pair of lug arms and an associated part of the central portion of the mandrel to form a continuous closed loop of the composite material to a desired width and thickness. The winding is repeated for each pair of lug arms and its associated part of the central portion of the mandrel so that as many loops of composite material are formed as there are lug pairs. The finally assembled loops are cured to structuralize the loops.

Abstract: What follows is a description of a composite aerodynamic rotor blade assembly which has been optimized from the standpoint of both fabrication cost and structural integrity. The rotor blade is fabricated using fewer overall assemblies to optimize cost and includes an aft fairing structure which is uniquely characterized in that it includes not only the typical elements of an aft fairing structure of the composite blade, but the spar heel as well. In assembly the skin members of the aft fairing structure are secured between the spar heel and the cap member of the assembly. This insures a fail-safe design and in this way the skin members are enabled to carry load effectively. The deicing blanket is assembled with the spar and cap member so that its supporting structural material serves as a load carrying member. Also, the spar, the inboard termination of the cap member, and the spar heel together form the root end of the rotor blade into which the torsion splices are formed.

Abstract: What follows is a description of a method of fabricating a composite assembly. In particular, the composite assembly comprises an aerodynamic rotor blade assembly which is fabricated utilizing a single matched die mold. Before utilizing the single matched die mold, the aft fairing structure of the composite blade assembly is formed. This aft fairing structure is uniquely characterized in that it includes not only the typical elements of an aft fairing structure of the composite blade, but the spar heel as well. The aft fairing structure thusly formed is then placed into the single matched die mold with the spar, nose block, cap member and deicing blanket, or with various subassemblies thereof, and the various parts brought into engagement and secured to each other in the single matched die mold through the application of heat and pressure.