Development and Certification of Composite Rotor Blades and Certification of...Development and...
Transcript of Development and Certification of Composite Rotor Blades and Certification of...Development and...
![Page 1: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/1.jpg)
Development and Certification of Composite
Rotor Blades
Presentation for FAA Composite Modifications Workshop
July 19-20, 2016
James R. Van Horn, CEO Van Horn Aviation, LLC
Tempe, Arizona
![Page 2: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/2.jpg)
Company Description • Located in Tempe, Arizona • Founded in 2001, now more
than 25 employees • Business Model
• Design, test, certificate, and manufacture composite main and tail rotor blades
• Focus on legacy helicopters (developed 1960s-1970s) that still use metal rotor blades
• VHA composite blades offer improved performance and increased service life versus metal OEM blades
![Page 3: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/3.jpg)
Bell UH-1 Bell 206B/L
Models Supported (Current/Future)
MD 500 Series Bell 412/212
Bell 505
![Page 4: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/4.jpg)
• Use 2X Estimated Ultimate Load • Avoid secondary bonds
• Root end metallic components are fastened • Exception: bushings are pressed
• Co-cure Composite Assembly • Uses structural foam as layup mandrel (Fly away tooling) • Upper surface layup mold • Shell concept with no internal structure (NDI not required!) • Tolerate lower surface imperfections
Rotor Blade Design Approach
![Page 5: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/5.jpg)
• Root Doublers Stacked Internally • Avoids any highly loaded ply drop-offs
• Sacrifice Design Elegance for Manufacturability • Simple airfoil/twist contours • Surface preparations to reduce sanding/paint prep
• Not Focused on Weight Savings • Direct replacement blades need to be approximately
same weight as OEM • More plies of carbon than needed for minimum strength
Rotor Blade Design Approach
![Page 6: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/6.jpg)
Legend Dark Blue = Carbon/Epoxy Prepreg Light Blue = Structural Foam Core Green = Fiberglass/Epoxy Machined From Pre-cured Sheet Other = Metallic
UH-1 Tail Rotor Blade
![Page 7: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/7.jpg)
Bell 206B/L/OH-58 Tail Rotor Blade
Legend Dark Blue = Carbon/Epoxy Prepreg Light Blue = Structural Foam Core Green = Fiberglass/Epoxy Machined From Pre-cured Sheet Other = Metallic
![Page 8: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/8.jpg)
206 Tail Rotor Blade Manufacturing
![Page 9: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/9.jpg)
Bell 412/212 Tail Rotor Blade
Legend Dark Blue = Carbon/Epoxy Prepreg Light Blue = Structural Foam Core Green = Fiberglass/Epoxy Machined From Pre-cured Sheet Other = Metallic
![Page 10: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/10.jpg)
Bell 206B Main Rotor Blade
Legend Dark Blue = Carbon/Epoxy Prepreg Light Blue = Structural Foam Core Green = Fiberglass/Epoxy Machined From Pre-cured Sheet Other = Metallic
![Page 11: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/11.jpg)
206B Main Rotor Blade Tooling
![Page 12: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/12.jpg)
206B Main Blade Sub-Assembly
![Page 13: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/13.jpg)
206B Main Blade Root Bonding
![Page 14: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/14.jpg)
Test Methodologies • DOT/FAA/AR-10/6 Report Used as Basis for
Structuring Lab Test Program • Coupon Testing
• Actual layups used • Establish Weibull shape factors
• Flight Testing • Flight strain survey to measure flight loads to be used in
structural tests and analyses
![Page 15: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/15.jpg)
206B Main Blade Flight Strain Survey
![Page 16: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/16.jpg)
Test Methodologies • Service Life/Fatigue Testing
• Spectrum loading used • Analyses used to determine failure modes for three
environmental factors: • RTD – Room Temperature Dry (ambient) • CTD – Cold Temperature Dry • ETW – Elevated Temperature Wet
• Loads obtained from flight strain survey • Maintain fidelity between flight test loads and fatigue
test loads • Include affected components
![Page 17: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/17.jpg)
206B/L Tail Rotor Blade Fatigue Test
![Page 18: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/18.jpg)
206B Main Rotor Blade Fatigue Test
![Page 19: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/19.jpg)
Main Rotor Grip Main Rotor Yoke
206B Affected Component Fatigue Tests
![Page 20: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/20.jpg)
Main Rotor Pitch Horn Main Rotor Control System
206B Affected Component Fatigue Tests
![Page 21: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/21.jpg)
Future Development Work • What is the actual rate and level of long term
moisture absorption for composite rotor blades utilizing several layers of protection (primers and topcoats)?
• What is the rate of cooling through the cross section of main and tail rotor blades from stopped to operating rpm?
• Fretting protection for composite and metallic mechanically fastened components
![Page 22: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/22.jpg)
Future Development Work • Embedded real time rotor blade load
measurements • Thermoplastic vs thermoset rotor blade
construction
![Page 23: Development and Certification of Composite Rotor Blades and Certification of...Development and Certification of Composite Rotor Blades . Presentation for FAA . Composite Modifications](https://reader030.fdocuments.in/reader030/viewer/2022040604/5ea53a7bbf4ab7307a453ec6/html5/thumbnails/23.jpg)
Thank you for your attention!
Contact Information: James R. Van Horn, CEO Van Horn Aviation, LLC
[email protected] (480) 483-4202