Regarding 2700 vs 2850 RPM on prop performance:
We have on several occasions measured static thrust on the same plane, same day, recording values from 2850 down to 2500 with a wide array of props, 2 and 3-blade Hartzell, Mac and MT. In every single case (including the metal props), the resulting thrust was greatest at 2700 RPM and on the MT it peaked at 2650.
Then we take the same plane, same day, same weight, same pilot and do timed climb tests holding IAS the same for all props from 1000MSL up to 10,500MSL.
On the way down, cruise speed is tested at 8000 at 2700, 2600, 2500 and 2400 RPM; full power, leaned for best power.
The results are posted on this data sheet.
http://flight-resource.com/PTD/Cessna185.pdfThe 83" 2-blade MT prop is approved for all -470, -520 and -550 engines. It is clearly the fastest prop. The 83" MT 3-blade provides the best climb performance. Both MT props use exactly the same blade, so the difference is purely locked to 2 vs 3-blade operation.
On the Lycoming 4 cyl props, there is 3 different blade designs used for each of the 3 different props available for that engine application...so it is not as simple.
Leading Edges: We are now ordering all our props with the Nickel-Cobalt leading edges. It brought the price up a bit, but the resulting increase in leading edge protection is worth it. Here is a pic of a commercial steel tow bar cut clean through by a nickel edged MT prop on a SR22. The damage to the prop was so limited, the factory approved the owner to fly it back to his home field over a 100 miles away for repair.
https://www.backcountrypilot.org/images/originalphotos/1046/5369/8d4a315369105b4fec9003d5.jpg And yes, we now stock exchange blade sets for the rare event where that provides a quick solution to getting in the air fast.
Thank you all for your support and great dialog.
John