Fabrication of the Composite Components for the Hughes Advanced Rotor Program (HARP)

The Hughes Advanced Rotor Program (HARP) led to the design, fabrication and structural test of composite rotors in 1983 and 1984 followed by successful helicopter flight in early 1985. The fabrication process for these structures is primarily based on the use of the wet filament wound, cocured approach. The flexbeam fabrication depends on the use of Kevlar 29 unidirectional, axially oriented longos, the roving carefully placed to assure minimum slack throughout the length of the flexbeam. The blade process successfully utilizes an internally pressurized spar tube mandrel and the use of a closed cell foam as a blade afterbody. The fabrication process developed for these components is believed feasible and cost effective.