Advanced Design Concepts for High Performance Helicopter Masts

Piasecki Aircraft Corporation (PiAC) proposes to develop an innovative approach to substantially upgrade helicopter main rotor shaft designs, materials, and manufacturing processes. A number of design concepts will be addressed and a matrix of coating materials and application methods selected for further examination. A systems engineering analysis on plating material and the application process will be conducted addressing field problems, maintenance requirements, and the dynamic characteristics of the entire drive system, with a design criteria document resulting. With the design criteria established, PiAC will examine the candidate material systems and coating processes in conjunction with an appropriate morphology matrix, leading to the selection of a plating process that will provide at least equivalent performance with today’s cadmium-based coatings, along with durability and reliability improvements. Static and dynamic analysis of the shaft with the selected experimental coating will be conducted and a qualification test plan for Phase II developed. During the Option Phase, PiAC will update and release the design package, develop the statement of work (SOW) and identify the raw material/specimen and coating/application tools to support the Phase II fabrication and test program.