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Glass-to-titanium seal

Tekna Seal's glass-to-titanium hermetic seal uses the TEK-SEAL process to eliminate oxide buildup that is inherent to other glass-to-metal seals. Titanium can be used without secondary mechanical or chemical oxide removal. The seal remains dimensionally accurate and carries no residual chemicals that result from oxide removal.

Fasteners eliminate wet sealant

Developed for the Boeing C-17 Program, HI-Kote pre-coated fasteners from Aerospace Rivet Manufacturers Corp. eliminate the need for wet installations. Fasteners typically must be installed "wet," using a sealant that costs more to dispose of than to buy due to its hazardous waste properties. Thus, the coated rivets help decrease the overall cost of the aircraft and improve fatigue strength while reducing labor time.

Aluminum machining alternative

A proprietary etching process from Photofabrication Engineering, Inc. enables aluminum parts to be etched photochemically at a significantly lower cost and with faster delivery times than traditional machining methods. The process provides clean etched profiles since the aluminum does not oxidize during etching. All types of standard aluminum alloys in thicknesses up to 0.070 in can be etched.

High-definition forming of exotic alloys

High-definition stamping of super alloys such as the Inconels, Hastalloys, and exotic stainless steels can be performed by 3-Dimensional Services. High-definition forming maximizes the elongation and stretch of the super alloys, with deep draws and more complex shapes. This enables the production of parts that were not previously possible, are more intricate in design, and are more functional and efficient. In some applications, multiple part configurations can be converted to a single piece. The process requires high-tonnage pressures as well as new thinking in die design and alternative materials for tooling, metallurgy, thermal coefficients, and lubrication methods.

Connectors provide clean inputs

MIL-C-38999 EMI/RFI filter connectors from G&H Technology, Inc. are used as replacements for standard MIL-C-38999 connectors in system upgrades requiring greater processing speeds. This is because many of the new computers that are installed in the upgrades operate at significantly higher speeds than earlier versions they replace. The higher the operating speed, the cleaner the input signals must be. The firm's EMI/RFI filter connectors are available in both Series III and IV shell configurations, and in C, L, Pi, and T types of filter circuitry; in wall-mount, box-mount, or jam-nut designs, with hermetic seals and a choice of nickel or cadmium finishes; and in many styles of insert and pin arrangements.

Fire-retardant tapes

Scapa Tapes North America's Scapa P3215 is a tough, waterproof, pressure-sensitive adhesive tape for use in galley and lavatory areas on board commercial and private aircraft. The tape forms a tough, effective, waterproof barrier to contain spills and prevent corrosion in areas where both moisture protection and fire safety are a concern. This tape is conformable to accommodate angles and turns and is engineered to meet the requirements of F.A.R. 25.853(a) for fire retardancy.

Intelligent tires for JSF

Goodyear is producing "intelligent tires" for Lockheed Martin's Joint Strike Fighter (JSF) program. A transponder embedded in the rubber of the tire includes both an integrated circuit and a capacitive pressure sensor, the sensor being a microelectromechanical (MEMS) device. The device enables better prognostics and health management of key JSF systems by monitoring essential information. In the JSF, the transponder can sense and transmit inflation pressure and temperature and track a unique tire serial number that will help monitor the tire from cradle to grave.

Seals improve aerodynamics

Customer-configurable rubber seals from Rubbercraft Corp. improve the aerodynamic drag properties in many aircraft applications. The RAS series of extruded and molded seals is available in a selection of standard and custom-base rubber polymers including silicone, nitrile, fluorosilicone, and organic rubber in addition to customer-specific formulations. Various fabric reinforcements, Teflon skins, metal inserts, and foam and composite stiffeners also are offered. The rubber-to-metal and rubber-to-composite bonding designs feature seals molded directly to flight surfaces, thus reducing expensive assembly on the aircraft manufacturing floor and reducing errors on the flight line.

Abrasion-sensing wire

Tensolite Co.'s Tufflite 2000 wire comes in an abrasion-sensing version incorporating ShortWatch predictive wire-failure technology. ShortWatch senses and signals a warning of potential wire failures before they occur. Such failures may be related to abrasion or to over-temperature conditions caused by excessive current.

Nut plate system increases fatigue life

Fatigue Technology's ForceTec rivetless nut plate system offers simple installation and fatigue life benefits, which makes the system a cost-effective option that reduces labor and maintenance costs over the life of the aircraft. It eliminates the need for satellite holes and attachment rivets required for most nut plate installations, saving both manufacturing time and structural weight. The system is fastened to the structure by radially expanding the nut plate barrel into the hole. The expansion creates high interference between the barrel and the structure, creating a nut plate that is resistant to torque and pushout.

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