Rotor assemblies and other composite structures with aligned bearing supports and methods of manufacture

摘要

Methods of co-curing aligned annular supports in a tubular region of a composite structure, such as a rotor blade, are disclosed. Methods include assembling an uncured composite structure by positioning an inboard annular support and an outboard annular support around an arbor, forming reinforcement fiber into a tubular region in contact with the supports, and applying a matrix material to the reinforcement fiber. The inboard and outboard annular supports are substantially composed of metal. Methods also include concentrically aligning the arbor and the supports along a common axis by applying heat to cause differential expansion of the arbor with respect to the supports, wherein the differential expansion causes an interference fit of the supports against the arbor. Methods also include curing the uncured composite structure to form the composite structure.

主权项

1. A method of co-curing aligned annular supports in a tubular region of a rotor blade, the method comprising:
assembling an uncured composite structure, comprising:
positioning an inboard annular support around an arbor;positioning an outboard annular support around the arbor, spaced apart from the inboard annular support;positioning a rotational orientation support proximate to the arbor;forming reinforcement fiber into a tubular region in contact with the inboard annular support, the outboard annular support, and the rotational orientation support; andapplying a matrix material to the reinforcement fiber; concentrically aligning the arbor, the inboard annular support, and the outboard annular support along a common axis by applying heat to cause differential expansion of the arbor and the inboard annular support, and to cause differential expansion of the arbor and the outboard annular support, wherein the differential expansion causes an interference fit of the inboard annular support against the arbor and an interference fit of the outboard annular support against the arbor; curing the uncured composite structure to form the rotor blade, wherein curing includes the applying heat to cause differential expansion; and forming an aperture, at a predefined angle with respect to the orientation feature, through the rotor blade and the rotational orientation support.