Rotor System & Blade Development

COMPOSITE HELICOPTER BLADES

ATI has an extensive background in the design, analysis, fabrication, development and static and fatigue testing of advanced composite structures. We have developed software to rapidly analyze structures of hybrid composite materials in both static and rotating dynamic environments. ATI has produced tooling for autoclave, pressure bag and closed die part curing. Components ranging in size from a few square inches and weighting only 150 grams to 60 square feet weighing 1,000 pounds, have been designed, tooled, and fabricated by ATI. Computer controlled presses, ovens, ply cutting machine and large material freezer storage complement our 10,000 square foot, FAA conformed, clean room facility. We have the capability to perform endurance fatigue test on both full scale and scaled dynamic system components.

SUB SCALE WIND TUNNEL
COMPOSITE HELICOPTER BLADES

ATI produces scaled design, analysis, tooling and fabrication of blades for testing in wind tunnel facilities. These products are scaled replicas of full-scale helicopter blades and require the same demanding engineering and fabrication techniques and skills as the full scale. These blades usually incorporate internally installed instrumentation for strain gage bridges and/or dynamic pressure transducers.

FULL-SCALE COMPOSITE

ROTOR BLADES

ATI has conducted design, analysis, development, tooling, fabrication, and qualification testing towards FAA STC certification of composite main and tail rotor blades for the Sikorsky S-61 helicopter. These rotor blades incorporate advanced airfoil technology, twist and swept tips for improved performance and composites for infinite life. Flight test results show an 11% increase in hover performance with lower vibratory loading than the original rotor system with metal blades.

WIND TUNNEL COMPOSITE
COMPRESSOR FAN BLADES

ATI developed the manufacturing and quality assurance plans and processes, designed and fabricated all tooling, and produced 210 production composite compressor blades for the NASA Ames Research Center's Unitary Wind Tunnel. The all-composite blades replaced existing aluminum blades to provide infinite life and reduce operating maintenance. 18 proof test blades were also fabricated, static and endurance tested.

ATI is currently under contract to replace the existing fan blades in the NASA Ames 40 x 80 x 120 National Full-scale Aerodynamic Center (NFAC) wind tunnel. The 90 existing wooden blades will be replaced with all-composite blades offering longer life under higher operating conditions. ATI has designed and analyzed the composite/foam blade structure and is currently building the tooling and 5 test articles, which will undergo quality, structural and fatigue endurance testing prior to production manufacture. Each blade assembly will consume over 600 pounds of composite material to produce the 50 square foot surface.

MODEL HELICOPTER HUB
AND CONTROL SYSTEMS

Scaled down model helicopter hub and control systems are also produced. ATI has the technical design, analytical, fabrication and assembly skills required to produce these highly loaded dynamic products.

ATI also designs and produces transmission and gearboxes.