Demonstration of Rotor Blades with Increased Environmental Durability

The harsh environments characteristic of current UH-60L BLACK HAWK operations have elevated the need for a durable rotor blade erosion protection system. In support of the Rotor Durability Army Technology Objective (ATO), the Aviation Applied Technology Directorate (AATD) and Sikorsky Aircraft are addressing this need. Technologies that will increase blade life to 1,000 hours of operation in harsh sand and rain environments have been identified and scaled for application onto BLACK HAWK main and tail rotor blades. The blade erosion system consists of a combination of High-Velocity-Air-Fuel (HVAF) or -Oxygen-Fuel (HVOF) spray tungsten-carbide coatings with a Cold Spray niobium metal coating on the leading edge substrate, paired with thin stainless steel and nickel foil details incorporated into the composite skins of the rotor blade and tip cap. The benefit of such a system is expected to be an order of magnitude reduction in direct operating costs related to rotor blades as well as increased aircraft availability for missions performed in severe erosive environments compared to baseline uncoated or polymer coated rotor blades. The following sections will describe in detail the design requirements, manufacturing process risk reduction, and full-scale facility setup required for demonstration of the improved system.