Shape Memory Alloy (SMA) Fluid Fitting System · Shape Memory Alloy (SMA) Fluid Fitting System Product Handbook & Engineering Data

Shape Memory Alloy (SMA)Fluid Fitting System

Product Handbook & Engineering Data

Aerofit, Inc.APT Laboratory1425 South Acacia AvenueFullerton, CA 92831Main: 714-521-5060Fax: 714-535-9862www.aerofit.com

Our Company:Aerofit Products was formed on September 5, 1968 and APT Laboratories was established as a hydro-mechanical testing laboratory in March 1972.

In March 2004 Aerofit Products and APT were acquired by the present owners and renamed Aerofit, Inc.

Aerofit and APT have grown into one of the largest suppliers of standard and spe-cialty fittings in the world. Our manufacturing and testing facilities now encom-pass over 67,000 square feet.

Aerofit designs, manufactures and tests thousands of parts for application in mili-tary aerospace, commercial aerospace, marine and nuclear markets. In addition to proprietary parts, we also produce parts to customer specifications, and industry standards.

Our goal is to supply our customers with economical, high quality fluid fitting sys-tems and information through a modern production facility and responsive cus-tomer support network.

Since it was founded, Aerofit has demonstrated its commitment to quality through continuous improvement in its production and product support processing.

The SMA Fitting System

www.aerofit.com4

The SMA product line is a high performance fluid fitting system using the unique characteristics of Tinel, a shape memory alloy material.

Many metals exhibit a phase change as they are heated and cooled. We can illustrate this using a crude ‘stick and ball’ model of the metallic lattice.

The phase change is an instantaneous shear transformation between a body centered cubic structure called austenite and a highly twinned martensite structure.

Shape Memory Alloys are a special class of alloys which not only change phase on cooling or heating but have the particular characteristic of a low temperature phase which gives the appearance of increased ductility.

The higher temperature austenitic structure has the characteristic stress strain curve of most metals.

The lower temperature martensitic structure has a stress strain curve more like that of an elastomer in which there is a ‘plateau’ stress.

All the deformation up to about 8% is “elastic” or in other words it can be recovered but not by simply relaxing the stress while in the marten-sitic condition.

Let’s go back to the ‘stick and ball’ model. We cool the material and it becomes martensitic. It does not change shape by being cooled, but we can now deform it mechanically. If it stays cold it will remain deformed, but if we allow it to warm up, the austenitic structure reappears and the material returns to its original shape.

This cycle from austenitic to martensitic to deformed martensitic and back to austenitic is repeatable indefinitely and is what we call ‘free re-covery‘. It is important to note that it is a one way process.

At Aerofit a Tinel coupling or separable end fitting is machined at room tempera-ture, in its high strength (austenitic) state, to an inside diameter slightly smaller than the pipes or tubes it is to join. The com-ponent is then cooled in liquid nitrogen and the metallurgical characteristics of the alloy change to a lower strength (mar-tensitic) state. With the coupling in this lower strength, cooled state, a tapered mandrel is driven through its center, expanding the inside diameter of the cou-pling.

The coupling remains in cold storage in its expanded condition until ready for use. It is then removed from this container and slipped over the tube or pipe ends to be joined. As the coupling warms to room temperature, it reverts back to its high-strength state and attempts to recover to its original shape while exerting

tremendous radial force. This permanent, live crimp action establishes a leak free, metal to metal seal between the coupling and the tube or pipe throughout the life of the joint.

This product line includes permanent couplings called CryoFit and separable end fittings called CryOlive (flare-less) and CryoFlare (flared). CryoFlare is also available in a lightweight version.

Liquid Nitrogen Bath

Austenite

2 4 6 8Strain%

Stre

ss

Martesite

Cool

WarmDeform

(max 8% strain)

The SMA Fitting System

www.aerofit.com5

The SMA Fitting System is designed for use on 2000, 3000, 4000, and 5000 psi hydraulic systems that incor-porate titanium, stainless steel, and aluminum tubing materials. The SMA Fitting System is easier and less costly to install than such traditional joining methods as welding, brazing, and swaging. It meets or exceeds the burst, impulse, and fatigue requirements of welded or brazed joints.

SMA FITTING SYSTEM BENEFITS:Aerofit, Inc.’s SMA fitting system is an excellent example of a product that helps customers dramatically reduce traditional assembly process costs and offers many advantages such as:

1. No expensive tooling 2. Limited access capability3. No leaks4. Light weight5. Visual inspection6. Quick & easy installation7. Technical support8. No hot work or flushing9. No X-ray

1. No expensive tooling - Since installation tools are not required, SMA fittings can be installed with equal ease on or off an aircraft, producing separable or permanent joints of the highest quality and reliability.

In comparison with alternative methods, process throughput increases have been demonstrated without any additional investment in manpower or capital. Dramatic reductions in production flow time, manufacturing labor and required skill level are achievable.

2. Limited access capability - Installation of a the SMA Fitting System can be easily achieved in densely packed, tight access areas due to the unique toolless package. The installer needs only his/her hand, which allows for simple installation in any area accessible by the installer’s fingers.

3. No leaks – The SMA Fitting System’s product lines are tailored to the demanding performance requirements of the aerospace industry. It has been thoroughly tested and approved and meets or exceeds high-performance aircraft fitting requirements, including AS18280, AS85421, AS85720, and major OEM specifications. The CryoFit coupling is rated up to 5000 PSI working pressure, and provides a highly reliable metal to metal con-nection that is both leak proof and permanent.

4. Light weight – Since no bulky tooling is required designers can eliminate the need for “tool access” bends.

Tool envelope - must bedesigned in for external swage

CryoFit’s tool-less installationallows simplest, lightest design

www.aerofit.com6

The SMA system can be installed adjacent to bends because no tool en-velope spacing is required allowing the designer to reduce tube length and system weight.

As a reference the CryoFlare and CryOlive end fittings are about 10% lighter than a comparable welded on fitting.

5. Visual Inspection – Preparation, installation, and inspection of a SMA joint takes only seconds, reducing overall installation costs and produc-ing a superior joint. Dissimilar pipe and tube materials may be con-nected to each other, since Tinel does not support galvanic corrosion. Additionally, tubes with different wall thicknesses can be connected.

6. Quick & easy installation – The installation of an SMA fitting takes about 5 seconds. Operators with minimal training easily install SMA fittings, producing consistent results. No bulky swaging tools or welding equip-ment are required. The entire pipe or tube preparation, installation and inspection of a joint takes only minutes and is a fraction of the time required for welding or brazing

7. Technical Support – Requests for quotes or general pricing information are handled quickly. Aerofit, Inc. encourages customers to call for answers to technical questions on applications, installation and product design. Prompt response to these inquiries is aimed at the most proficient and cost effective use of Aerofit, Inc.’s products

All of Aerofit, Inc.’s products are evaluated and qualified in the company’s own testing facilities and indepen-dent laboratories. Validation of product performance is proven through extensive testing of sealing integrity, flexure fatigue, impulse and burst strength. Product quality, reliability and consistency are ensured by careful control of raw materials and the use of statistical process control during machining. Aerofit, Inc. also main-tains complete documentation and traceability at each step of the manufacturing process. The company is both NADCAP and AS9100 certified.

8. No hot work or flushing – Unlike welding and brazing, SMA Fitting installation presents no danger of damage to neighboring components from flame or splatter. It produces no contaminants, so does not require fume extraction. Since it is installed directly on clean pipe or tube without contamination of the system by flux, slag or oxides, there is no need to flush the system.

9. No X-ray - Inspecting the SMA installation simply requires verifying that the fitting lines up with the prein-stallation position marks. It does not require x-ray certified inspectors or expensive equipment.

Reduced Tube Length

Axially Swaged

SMA

Couplings & Compatibles

www.aerofit.com8

Introduction CryoFit couplings and CryoyFit Compatible fitting shapes are complete systems used in joining aerospace tubing. The CryoFit fitting system combines superior performance and high reli-ability with easy installation and inspection. The CryoFit sys-tem consists of SMA couplings and a wide array of non SMA shape fittings (tees, elbows, crosses, etc.).

The compact, one piece CryoFit coupling is manufactured from Tinel, a nickel-titanium alloy with shape memory char-acteristics.

CryoFit Compatible fittings are manufactured from titanium, and in conjunction with the CryoFit coupling, they produce a

complete system. An extensive selection of fittings is available for both separable and permanent connections.

CryoFit Couplings are installed by simply positioning the coupling at a tube joint or tube and CryoFit Compat-ible fitting leg, and allowing the coupling to warm from its cryogenic storage temperature. As it warms, the coupling shrinks and crimps down on the tube or compatible fitting with tremendous radial force, forming a permanent, metal to metal seal by coining the surface of the tube.

CryoFit couplings are easier and less costly to install than traditional joining methods such as welding, brazing and swaging. Installation of a CryoFit coupling can be easily achieved in densely packed, tight access areas due to the unique tool less package. The package allows for simple installation in any area accessible by the installer’s fingers. Preparation, installation, and inspection of a CryoFit joint takes only seconds, reducing overall installa-tion costs.

The shape memory capability of Tinel ensures that the couplings always shrink with the same force, making consistent, repeatable connections. CryoFit fitting systems meet or exceed high performance aircraft fitting requirements, including AS85421, AS85720, AS18280, ISO7169 and OEM specifications.

The accuracy of a CryoFit installation is easily verified. A quick visual inspection ensures that the couplings have been properly positioned.

The CryoFit fitting systems have an outstanding record of over 39 years of leak free performance in the demanding aerospace industry. Their permanent, live crimp action creates a metal to metal seal that is often stronger than the tubing it joins.

Expanded couplings have an insidediameter slightly larger than the tube

outside diameter

As the coupling warms and recoversit swagers on the tubing generating a

highly reliable metal to metal seal

COUPLINGS AND COMPATIBLES - CRYOFIT

CryoFit Couplings

CryoFit Compatable

www.aerofit.com9

NOTES:

1. RECOVERED DIMENSIONS ARE FOR A FREELY RECOVERED COUPLING I.E., NOT INSTALLED ON TUBING.

2. MATERIAL: TINEL ALLOY

3. COUPLING IS INTENDED FOR USE IN FLUID SYSTEMS WITH OPERATING PRESSURE UP TO 2000 PSI.

4. PART NUMBER EXAMPLE:

5. DRY FILM LUBRICANT ON TAIL ONLY

6. ALL DIMENSIONS ARE IN INCHES.

7. COUPLINGS SHALL BE PERMANENTLY AND LEGIBLY MARKED WITH MANUFACTURERS IDENTIFICA-TION, PART NUMBER AND LOT NUMBER.

2000 PSI CRYOFIT COUPLINGS2PHS111 COUPLING

2PHS111-20 1.250 1.259 1.517 2.322

2PHS111-24 1.500 1.510 1.724 2.500

C +.010

RECOVERED

BRECOVERED

(MAX)

A EXPANDED

(MIN)TUBE SIZE PART NUMBER

SIZE CODE, TUBE SIZE IN .062 INCREMENTS

BASIC PART NUMBER

2PHS111 – 24

C

A B

www.aerofit.com10

NOTES:



3. COUPLING IS INTENDED FOR USE IN FLUID SYSTEMS WITH OPERATING PRESSURE UP TO 14 MPa (2000 PSI).



6. ALL DIMENSIONS ARE IN MILLIMETERS.


14 MPa (2000 PSI) METRIC CRYOFIT COUPLINGSM2PHS111 METRIC COUPLING

SIZE CODE, TUBE SIZEBASIC PART NUMBER

M2PHS111 – 12

C +.030

RECOVERED

NOMINALWEIGHT

(GRAMS)

BRECOVERED

(MAX)

A EXPANDED


M2PHS111-08 8 8.15 10.4 22.3 3.8

M2PHS111-12 12 12.2 14.4 29.5 6.9

M2PHS111-16 16 16.2 19.0 36.9 14

M2PHS111-18 18 18.22 21.4 40.7 20

M2PHS111-22 22 22.23 26.1 48.3 35

M2PHS111-28 28 28.23 33.1 59.5 69

C

A B

www.aerofit.com11


C RECOVERED

NOMINALWEIGHT

(GRAMS)

BRECOVERED

(MAX)

A EXPANDED


3PHS111-04 .250 .255 .350 .971 / .991 .009

3PHS111-06 .375 .381 .492 1.292 / 1.312 .020

3PHS111-08 .500 .508 .649 1.594 / 1.614 .043

3PHS111-10 .625 .633 .814 1.897 / 1.917 .081

3PHS111-12 .750 .759 .971 2.205 / 2.225 .133

3PHS111-16 1.00 1.009 1.293 2.835 / 2.855 .302

3PHS111-20 1.250 1.259 1.505 2.496 / 2.516 .280

3PHS111-24 1.500 1.510 1.705 2.674 / 2.694 .290

NOTES:




4.PART NUMBER EXAMPLE:



7. COUPLINGS SHALL BE PERMANENTLY AND LEGIBLY MARKED WITH MANUFACTURERS IDENTIFICA-TION, PART NUMBER AND LOT NUMBER


BASIC PART NUMBER

3PHS111 – 08

C

A B

www.aerofit.com12

NOTES:









C RECOVERED

NOMINALWEIGHT

(GRAMS)

BRECOVERED

(MAX)

A EXPANDED


4PHS111-04 .250 .255 .345 .687 / .707 .005

4PHS111-06 .375 .381 .533 .937 / .958 .018

4PHS111-08 .500 .508 .664 1.178 / 1.198 .031

4PHS111-10 .625 .633 .815 1.426 / 1.446 .057

4PHS111-12 .750 .759 .961 1.678 / 1.698 .087

4PHS111-14 .875 .884 1.118 1.920 / 1.960 .139

4PHS111-16 1.00 1.009 1.275 2.170 / 2.210 .208

4PHS111-20 1.250 1.259 1.589 2.700 / 2.740 .397


BASIC PART NUMBER

4PHS111 – 08

C

A B

www.aerofit.com13


C +.010

RECOVERED

NOMINALWEIGHT

(GRAMS)

BRECOVERED

(MAX)

A EXPANDED


5PHS111-04 .250 .255 .345 .709 .006

5PHS111-06 .375 .381 .505 .962 .016

5PHS111-08 .500 .508 .670 1.216 .035

5PHS111-10 .625 .633 .836 1.473 .066

5PHS111-12 .750 .759 1.003 1.739 .112

5PHS111-16 1.00 1.009 1.334 2.272 .259

NOTES:









BASIC PART NUMBER

3PHS111 – 08

C

A B

www.aerofit.com14

XPHS112-10

BASIC NUMBER

TUBE SIZE PORT #1 &(.062 INCREMENTS)

2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS112-10-08

BASIC NUMBER

TUBE SIZE PORT #(.062 INCREMENTS)

TUBE SIZE PORT #1(.062 INCREMENTS)

2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS113-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS113-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS114-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS114-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS144-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS144-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS119-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

CRYOFIT COMPATIBLES PERMANENT FITTINGSSTRAIGHT

XPHS 112

XPHS113

XPHS144

XPHS114

XPHS119

ADAPTER, BULKHEAD

SEALING

ADAPTER, BULKHEAD

NON SEALING UNJF THREAD

ADAPTER, BULKHEAD

(THICK) SEALING

ADAPTER, BULKHEAD


UNION NA

Port #1

Port #1

Port #1

Port #1

Port #1

Port #2

Port #2

Port #2

Port #2

Port #2

PART NUMBER EXAMPLE PART NUMBER PICTURE DESCRIPTION NON REDUCER EXAMPLE EXPANDER OR REDUCER

www.aerofit.com15

XPHS124-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS124-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS128-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS123-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS128

ADAPTER, BULKHEADSEALING,

FLANGED HEX

ADAPTER, BULKHEAD,

BLANK, SEALING,

FLANGED HEX

NON REDUCER

NA

XPHS124

Port #1

Port #1

Port #2

Port #2

XPHS123

PLUG NA

NA

Port #1


www.aerofit.com16

XPHS211-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS211-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS212-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS212-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS213-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS215-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS214-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS213-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS214 10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS215-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

CRYOFIT COMPATIBLES PERMANENT FITTINGSELBOW

XPHS211

XPHS212

XPHS213

XPHS214

XPHS215

ELBOW, 90˚

ELBOW, 45˚

ELBOW, 90˚, BULKHEAD

SEALING


SEALING



Port #2

Port #2

Port #2

Port #2

Port #2

Port #1

Port #1

Port #1

Port #1

Port #1


www.aerofit.com17

XPHS216-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS216-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS236-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS236-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS228-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS228-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS238-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS238-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS216

XPHS238

XPHS236

XPHS 228

ELBOW, 45˚, BULKHEAD NON SEALING UNJF

THREAD


THREAD


SEALING


THREAD

Port #2

Port #2

Port #2

Port #2

Port #1

Port #1

Port #1

Port #1


www.aerofit.com18

CRYOFIT COMPATIBLES PERMANENT FITTINGSTEE & CROSS

XPHS311-10

BASIC NUMBER

TUBE SIZE PORT #2 & #3(.062 INCREMENTS)

2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS311-10-08-10

BASIC NUMBER


TUBE SIZE PORT #2(.062 INCREMENTS)TUBE SIZE PORT #1(.062 INCREMENTS)

2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS312-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS312-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS313-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS313-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS314-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS314-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS344-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS344-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS311

XPHS312

XPHS313

XPHS314

XPHS344

TEE

TEE BULKHEAD, SEALING ON

RUN

TEE BULKHEAD, SEALING ON SIDE BRANCH

TEE BULKHEAD ON RUN NON SEALING UNJF

THREAD

TEE BULKHEAD ON RUN NON SEALING UNJF

THREAD

Port #2

Port #2

Port #2

Port #2

Port #2

Port #3

Port #3

Port #3

Port #3

Port #3

Port #1

Port #1

Port #1

Port #1

Port #1


www.aerofit.com19

XPHSC1-10

BASIC NUMBER

TUBE SIZE PORT #1, #2 & #3(.062 INCREMENTS)

2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHSC1-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS315-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS315-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS345-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS345-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHSC1

XPHS345

CROSS

Port #2

Port #3

Port #4

Port #1

XPHS315

TEE BULHEAD ON SIDE

BRANCH NON SEALING UNJF

THREAD

TEE BULHEAD ON SIDE

BRANCH NON SEALING UNJF

THREAD

Port #2

Port #2

Port #3

Port #3

Port #1

Port #1


www.aerofit.com20

CRYOFIT COMPATIBLES BEAMSEAL FITTINGSSTRAIGHT

XPHS115-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS115-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS143-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS143-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS122-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS122-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS129-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS129-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS130-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS130-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS115

XPHS143

XPHS122

XHPS129

XPHS130

ADAPTER MALE BEAMSEAL BULKHEAD

ADAPTER MALE BEAMSEAL

ADAPTER MALE BEAMSEAL TO

SEALING WITH FLANGED HEX

ADAPTER MALE BEAMSEAL BULKHEAD

SEALING

ADAPTER MALE BEAMSEAL

THICK BULK-HEAD SEALING

Port #2

Port #2

Port #2

Port #2

Port #2

Port #1

Port #1

Port #1

Port #1

Port #1


www.aerofit.com21

XPHS134-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS134-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS134

ADAPTER AS-SEMBLY FEMALE

BEAMSEAL

Port #2

Port #1


www.aerofit.com22

CRYOFIT COMPATIBLES BEAMSEAL FITTINGSELBOW

XPHS217-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS217-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS218-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS218-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS219-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS219-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS220-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS220-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS221-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS221-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS217

XPHS218

XPHS219

XPHS220

XPHS221

ELBOW 90˚ AS-SEMBLY FEMALE

BEAMSEAL

ELBOW 90˚ MALE BEAMSEAL

BULKHEAD


BEAMSEAL

ELBOW 45˚

MALE BEAMSEAL BULKHEAD


BEAMSEAL

Port #2

Port #2

Port #2

Port #2

Port #2

Port #1

Port #1

Port #1

Port #1

Port #1


www.aerofit.com23

XPHS222-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS222-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS229-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS229-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI


XPHS222

XPHS229


BULKHEAD


THICK BULKHEAD

Port #2

Port #2

Port #1

Port #1

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CRYOFIT COMPATIBLES BEAMSEAL FITTINGSTEE

XPHS317-10

BASIC NUMBER

TUBE SIZE PORT #1,#2 & #3(.062 INCREMENTS)

2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS317-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS324-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS324-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS348-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS348-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS349-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS349-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS326-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS326-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS317

XPHS324

XPHS348

XPHS349

XPHS326

TEE BULKHEAD MALE

BEAMSEAL ON SIDE BRANCH

TEE BULKHEAD MALE BEAMSEAL

ON RUN

TEE MALE BEAMSEAL

ON SIDE

TEE MALE BEAMSEAL

ON SIDE AND RUN

TEE BULKHEAD FEMALE


Port #2

Port #2

Port #2

Port #2

Port #2

Port #3

Port #3

Port #3

Port #3

Port #3

Port #1

Port #1

Port #1

Port #1

Port #1


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XPHS327-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS327-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS332-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS332-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS318-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS318-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS318

Port #2

Port #3

Port #1

XPHS327

XPHS332

TEE BULKHEAD FEMALE

BEAMSEAL ON RUN

TEE BULKHEAD MALE


TEE BULKHEAD MALE


Port #2

Port #2

Port #3

Port #3

Port #1

Port #1


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CRYOFIT COMPATIBLES FLARELESS FITTINGSSTRAIGHT

XPHS116-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS116-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS117-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS117-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS151-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS151-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS126-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS126-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS142-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS142-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS116

XPHS151

XPHS117

XPHS142

XPHS126

ADAPTER MALE FLARELESS BULKHEAD

ADAPTER MALE FLARELESS BULKHEAD

SEALING

ADAPTER MALE FLARELESS

ADAPTER MALE FLARELESSBULKHEAD

ADAPTER FEMALE

FLARELESS

Port #2

Port #2

Port #2

Port #2

Port #2

Port #1

Port #1

Port #1

Port #1

Port #1


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CRYOFIT COMPATIBLES FLARELESS FITTINGSELBOW

XPHS223-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS223-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS224-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS224-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS206-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS206-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS225-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS225-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS230-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS230-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS223

XPHS224

XPHS206

XPHS225

XPHS230

ELBOW 90˚ FEMALE

FLARELESS

ELBOW 90˚ MALE FLARELESS

BULKHEAD


THICK BULKHEAD

ELBOW 45˚ FEMALE

FLARELESS


BULKHEAD

Port #2

Port #2

Port #2

Port #2

Port #2

Port #1

Port #1

Port #1

Port #1

Port #1


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XPHS231-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS231-10-08

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS231


EXPANDER OR REDUCER

Port #2

Port #1


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CRYOFIT COMPATIBLES FLARELESS FITTINGSTEE

XPHS320-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS320-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS325-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS325-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS343-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS343-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS328-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS328-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS320

XPHS325

XPHS343

XPHS328

TEE FEMALE FLARELESS ON SIDE BRANCH

TEE MALE BULKHEAD ON

RUN FLARELESS ON SIDE BRANCH

TEE MALE BULKHEAD ON

RUN FLARELESS ON SIDE BRANCH

TEE FEMALE FLARELESS ON

RUN

Port #2

Port #2

Port #2

Port #2

Port #3

Port #3

Port #3

Port #3

Port #1

Port #1

Port #1

Port #1


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XPHS329-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS329-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS330-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS330-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS333-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS333-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS334-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS334-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS341-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS341-10-08-10

BASIC NUMBER



2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS329

XPHS330

XPHS333

XPHS334

XPHS341

TEE MALE FLARELESS

BULKHEAD ON RUN

TEE MALE FLARELESS ON SIDE BRANCH

TEE MALE FLARELESS

BULKHEAD ON SIDE BRANCH

TEE MALE FLARELESS ON

RUN

TEE FEMALE AND MALE

FLARELESS ON RUN

Port #2

Port #2

Port #2

Port #2

Port #2

Port #1

Port #1

Port #1

Port #1

Port #1

Port #3

Port #3

Port #3

Port #3

Port #3


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CRYOFIT COMPATIBLES FLARED FITTINGSSTRAIGHT

XPHS121-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS121-10-08

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS133-10-08

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS133-10

BASIC NUMBER


2=2000 PSI3=3000 PSI4=4000 PSI5=5000 PSI

XPHS121

XPHS133

ADAPTER MALE FLARED

ADAPTER MALE FLARED

BULKHEAD

Port #2

Port #2

Port #1

Port #1


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Installation CRYOFIT COUPLING AND CROYFIT CAMPATIBLE FITTING SHAPES

I. INTRODUCTIONCryoFit couplings are used to permanently join hydraulic and pneumatic tubing. A one piece union, the CryoFit coupling is made with an alloy called Tinel that has shape memory properties. The couplings are shipped and stored in liquid nitrogen prior to installation. Upon receipt, the CryoFit coupling will have an inside diameter which is larger than the outside diameter of the tubes to be joined. When the coupling is removed from liquid nitrogen, slipped over the two tube ends and allowed to warm to room temperature, it will shrink to an inside diameter which is smaller than the outside diameter of the tubes. Compression of the tubes will occur and a permanent connection will result.

CryoFit couplings should be removed from their storage containers and installed only by personnel who have been properly trained in the handling of liquid nitrogen and CryoFit couplings. Please see Section D for stor-age, handling and safety of liquid nitrogen.

II. INSTALLATION TOOLSCryoFit couplings are installed using simple tools. The function of each tool is described as follows:

1) CRYOFIT INSTALLATION PACKAGE (Figure 1): An outer shell sur-rounding each coupling enables the installer to grasp the coupling during installation and also insulates the coupling during installation, thereby extending the installation time. Once installed the package is removed and discarded.

2) TEST COUPLING (Figure 2): Used to: a) Ensure proper tube alignment b) Check the gap between the tube ends c) Check the O.D. of the tube for proper size

3) TUBE CHILLER (Figure 3): A felt lined clamp used to cool the tube prior to installing the coupling, extending installation time for difficult or awkward installations.

Figure 3TUBE CHILLER

Figure 1CRYOFIT

COUPLING ININSTALLATION

PACKAGE

Figure 2TEST COUPLING

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4) MARKING GAUGE (Figure 4): Used with pen to apply the installation mark (witness mark) on each tube.

5) INSTALLATION STOP (Figure 5): O-ring or “U-shaped” plastic snap on clamp (used on tubes), to aid in positioning the coupling properly.

6) MARKING PEN: Used with the marking gauge to establish the installation mark on the tubes prior to installation. Use a low chloride level pen such as the Panduit #PFX-0.

7) WORK BOX (Figure 6): A small insulated container used to transport couplings from the storage area to the work area.

8) GLOVES: Used to handle tools that have been chilled in liquid nitrogen.

9) SPRAY CHILLER BOTTLE (Figure 7): An alternative method for chilling the tube. It performs the same function as the tube chiller.

10) TONGS (Figure 8): Instrument used to transfer and remove couplings and installation package assemblies from workbox.

Figure 4MARKING GAUGE

Figure 5INSTALLATION STOP

Snap-on Fixture O-ring

Figure 6WORKBOX

Figure 7CRYOGUN

Figure 8TONGS

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III. PREPARATION FOR INSTALLATIONEnsure the couplings have been stored properly and the tubes are properly prepared. If a coupling shrinks before being installed on a tube, it should be returned for re-expansion.

III(a) INSPECTION OF COUPLING INSIDE DIAMETER (I.D.) If there is reason to believe that a coupling has been warmed (perhaps because of a low liquid nitrogen level in the dewar or previous removal from liquid nitrogen), its I.D. can be checked as follows:

1) Obtain a length of the same size tubing as the coupling, approximately 6 inches long.

2) Cool the end of the tube in liquid nitrogen until boiling stops.

3) Being careful to keep the coupling in the liquid nitrogen, insert the tube into the coupling. The tube should easily slip through the entire bore of the coupling.

4) If the tube cannot pass through the coupling, the coupling should be removed from stock and returned for re-expansion.

III(b) TUBE PREPARATION The following steps will ensure that the tube is properly prepared for the coupling installation. This procedure describes the replacement of existing tube sections as well as new installations on the aircraft.

1) Mark the tube at the point where cuts must be made to remove the damaged section. Generally, a length of straight tube equal to the coupling length must remain after the damaged section is removed.

2) Cut the tube at the marks, using a roller type cutter to avoid generating chips which could contaminate the system. Deburr the tube ends.

3) Cut and deburr a splice tube to replace the damaged section which has been removed. The splice tube should butt against the remaining tube ends if possible. A maximum gap of .120 inch between the tube ends is permissible.

4) Inspect all tube ends to be sure they are free of burrs and conform to any applicable specifications.

5) Tubing within 1/2 coupling length of the end should be free of deep scratches. If necessary, scratches can be removed by polishing with 400 grit or finer abrasive in the circumferential direction.

IV. INSTALLATION PROCESSThe processes for installing couplings, elbows, tees and fittings are similar. With fittings, some steps are re-peated.

IV(a) TUBE TO TUBE INSTALLATION1) Obtain the proper CryoFit couplings and installation tools.

2) Clean and dry any hydraulic fluid from the tube ends which might interfere with marking the tubes.

3) Slip a test coupling over the tube ends to ensure that the tubes are round and free from burrs. The test coupling should slide freely.

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4) Position the test coupling so that both tubes are visible in the coupling window. The tubes should be butted together if possible; however, if both tubes are visible, the gap is deemed acceptable (less than .120” or 3mm).

5) Several methods are available for marking the tube to insure the proper positioning of the coupling. Two methods of tube marking will be discussed. The first method uses a marking gauge and a pen to mark a band on each tube at the proper distance from the end. Place the marking gauge over the tube end. Using the marking pen, color the tube in the rectangular slot in the marking gauge. Repeat the process on the other tube (Figure 8).

FIGURE 8

When you do not have a marking gauge, the tubes can be pre-marked with an installation band by measuring the distance from the end of the tube. In this method the installation band is marked around each tube at the proper distance from the end (See Figure 9).

FIGURE 9TUBE INSTALLATION BAND LOCATION

MARKING GAUGE

INSTALLATION MARK

MARKING PEN

BALOCATION BAND

TubeSize

2PHS111 3PHS111 4PHS111 5PHS111

A Min B Max A Min B Max A Min B Max A Min B Max Tube Tube Tube Tube Tube Tube Tube Tube Insertion Insertion Insertion Insertion Insertion Insertion Insertion Insertion (inch) (inch) (inch) (inch) (inch) (inch) (inch) (inch)

1/4 0.487 0.607 0.34 0.67 0.289 0.409 0.294 0.414 3/8 0.613 0.733 0.501 0.801 0.414 0.534 0.421 0.54 1/2 0.665 0.785 0.652 0.952 0.533 0.653 0.547 0.667 5/8 0.81 0.93 0.804 1.104 0.656 0.776 0.675 0.795 3/4 0.94 1.06 0.958 1.258 0.78 0.9 0.806 0.926 7/8 1.09 1.21 0.905 1.025 1 1.25 1.37 1.273 1.573 1.029 1.149 1.075 1.195 1-1/4 1.53 1.65 1.103 1.403 1.294 1.414 1.1 1.221-1/2 1.27 1.39 1.192 1.492 1.185 1.308 1.185 1.305

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6) To aid in positioning the coupling, place an installation stop in the middle of the mark. Check the location by positioning the test coupling so that it is butted against the stop. Both tube ends should be visible in the window and the test coupling should cover approximately half the installation mark on each tube (Figure 10). Adjust the tubes and installation stops if necessary. Remove the test coupling.

FIGURE 10

7) Tube chiller use is optional but, recommended for sizes 04 through 08 and for aluminum tubing. Place cooled tube chiller over the tube to be joined (Figure 11). Remove the chiller after 20-30 seconds. As an alternative, spray the tubes with liquid nitrogen using the Spray Chiller Bottle. Spray the tubes (1-1/2) coupling length on both tubes) for 20 to 30 seconds. Placing the CryoFit coupling in contact with a tube which has not been pre-chilled with liquid nitrogen may initiate premature warming and shrinkage of the coupling.

FIGURE 11

8) The following steps should be performed sequentially and without delay:a) Cool the tubes to be joined and remove the chiller if used.b) Using cooled tongs, remove the CryoFit installation package from the liquid nitrogen and grasp the

package between the thumb and forefinger.c) Deflect the tube without the installation stop to allow the coupling to be slipped over the end.d) Slip the coupling onto the tube, realign the tubes and slide the coupling against the installation stop

(Figure 12).FIGURE 12

INSTALLATION MARK

INSTALLATION STOP

TUBE CHILLER

INSTALLATION STOP

CRYOFIT COUPLING ININSTALLATION PACKAGE

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e) Check to see that the coupling is against the installation stop and that the deflected tube has been inserted into the coupling to the installation marks (Figure 13).

FIGURE 13GOOD INSTALLATION

f) Allow the coupling to warm and shrink onto the tube. Remove the CryoFit installation package and the

installation stop.

g) Verify that both ends of the coupling lie within the installation marks on both tubes (Figure 13). If one or both ends do not touch the installation marks, the installation is incorrect and must be removed.

IV(b) INSTALLATION OF FITTING TO TUBE:

Tees, elbows, and other fittings are installed by connecting each leg of the fitting to a tube with a CryoFit cou-pling. The installation procedure is similar to that used in connecting two tubes.

1) Obtain the proper CryoFit couplings, installation packages, fittings, and installation tools. With the fitting in position, the gap between the fitting legs and the adjoining tubing must be less than .120 inches or 3mm. The test coupling should be used to ensure this gap. Refer to Section IV (a), Step 4.

2) On all fitting legs to be joined, slip an O-ring over each fitting leg and place in the center of the etched installation band (Figure 14).

FIGURE 14

3) Position the fitting so that all legs are aligned with the tubing. Slip a test coupling over each fitting leg. The test coupling should slide freely. With the test coupling butted against the O-ring, the fitting leg and tub-ing ends must be visible in the test coupling window and the opposite end of the test coupling must fall

INSTALLATION MARKS

O-RING

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within the installation mark on the tubes. Adjust the tubes and O-rings if necessary (Figure 15). Remove the test coupling from one leg.

FIGURE 15

4) Using one or more tube chillers, cool the tube and one leg of the fitting. Leave the remaining test couplings in position on the other leg(s) to ensure proper positioning. Additionally, the spray chiller bottle can also be used to cool the leg and tubing.

5) The following steps should be performed sequentially without delay:

a) Remove the tube chiller(s), if used, from the leg to be joined.

b) Remove the CryoFit installation package from liquid nitrogen with pre cooled tongs and grasp the package between thumb and forefinger.

c) Deflect the tube and slip the coupling over the tube.

d) Realign the tube. Slide the coupling against the O-ring on the fitting leg (Figure 16).

FIGURE 16

e) Check to ensure that the coupling has been properly positioned against the O-ring, and that the tube has been inserted into the coupling to the installation mark. Also be certain that the remaining fitting legs are in proper alignment; adjust if required (Figure 17).

FITTING LEG AND TUBEEND MUST BE VISIBLEIN EACH WINDOW

TEST COUPLING

CRYOFIT COUPLING ININSTALLATION PACKAGE

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FIGURE 17GOOD INSTALLATION

f) Allow the coupling to warm and shrink into position. Remove the CryoFit installation package and O-ring.

6) If the inspection of the coupling indicates that the coupling is not properly installed, then the fitting must be replaced.

V. CRYOFIT COUPLINGS AND CORRESPONDING INSTALLATION TOOLS

3PHS111 Series CryoFit Couplings

COUPLING TOUCHES ORCOVERS INSTALLATIONBAND ON LEG

Tube Coupling Test Marking Tube Chiller Installation Size Part Coupling Gauge Part Number Stop -OD Number Part Number Part Number Part Number


1/4 3PHS111-04 TC3PHS111-04 MG3PHS111-04 910415-01 SC4/5PHS111-043/8 3PHS111-06 TC3PHS111-06 MG3PHS111-06 910415-01 SC4/5PHS111-061/2 3PHS111-08 TC3PHS111-08 MG3PHS111-08 910415-01 SC4/5PHS111-085/8 3PHS111-10 TC3PHS111-10 MG3PHS111-10 910415-02 SC4/5PHS111-103/4 3PHS111-12 TC3PHS111-12 MG3PHS111-12 910415-02 SC4/5PHS111-127/8 3PHS111-14 TC3PHS111-14 MG3PHS111-14 910415-02 SC4/5PHS111-141 3PHS111-16 TC3PHS111-16 MG3PHS111-16 910415-02 SC4/5PHS111-161 1/4 3PHS111-20 TC3PHS111-20 MG3PHS111-20 910415-03 SC4/5PHS111-20

1/4 4PHS111-04 TC4PHS111-04 MG4PHS111-04 910415-01 SC4/5PHS111-043/8 4PHS111-06 TC4PHS111-06 MG4PHS111-06 910415-01 SC4/5PHS111-061/2 4PHS111-08 TC4PHS111-08 MG4PHS111-08 910415-01 SC4/5PHS111-085/8 4PHS111-10 TC4PHS111-10 MG4PHS111-10 910415-02 SC4/5PHS111-103/4 4PHS111-12 TC4PHS111-12 MG4PHS111-12 910415-02 SC4/5PHS111-127/8 4PHS111-14 TC4PHS111-14 MG4PHS111-14 910415-02 SC4/5PHS111-141 4PHS111-16 TC4PHS111-16 MG4PHS111-16 910415-02 SC4/5PHS111-161 1/4 4PHS111-20 TC4PHS111-20 MG4PHS111-20 910415-03 SC4/5PHS111-201 1/4 2PHS111-20 TC2PHS111-20 MG2PHS111-20 910415-03 1 1/2 2PHS111-24 TC2PHS111-24 MG2PHS111-24 910415-03 SC4/5PHS111-24


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M4PHS111 Series CryoFit Couplings


5 M4PHS111-05 TCM4PHS111-05 MGM4PHS111-04 910415-01 SCM4PHS111-056 M4PHS111-06 TCM4PHS111-06 MGM4PHS111-06 910415-01 SCM4PHS111-068 M2PHS111-08 TCM2PHS111-08 MGM2PHS111-08 910415-01 SCM2PHS111-0810 M4PHS111-10 TCM4PHS111-10 MGM4PHS111-10 910415-01 SCM4PHS111-1012 M2PHS111-12 TCM2PHS111-12 MGM2PHS111-12 910415-01 SCM2PHS111-1214 M4PHS111-14 TCM4PHS111-14 MGM4PHS111-14 910415-01 SCM4PHS111-1416 M2PHS111-16 TCM2PHS111-16 MGM2PHS111-16 910415-02 SCM2PHS111-1618 M2PHS111-18 TCM2PHS111-18 MGM2PHS111-18 910415-02 SCM4PHS111-1820 M4PHS111-20 TCM4PHS111-20 MGM4PHS111-20 910415-02 SSCM4PHS11-2022 M2PHS111-22 TCM2PHS111-22 MGM2PHS111-22 910415-02 SCM2PHS111-2228 M2PHS111-28 TCM2PHS111-28 MGM2PHS111-28 910415-02 SCM2PHS111-28

1/4 5PHS111-04 TC5PHS111-04 MG5PHS111-04 910415-01 SC4/5PHS111-043/8 5PHS111-06 TC5PHS111-06 MG5PHS111-06 910415-01 SC4/5PHS111-061/2 5PHS111-08 TC5PHS111-08 MG5PHS111-08 910415-01 SC4/5PHS111-085/8 5PHS111-10 TC5PHS111-10 MG5PHS111-10 910415-02 SC4/5PHS111-103/4 5PHS111-12 TC5PHS111-12 MG5PHS111-12 910415-02 SC4/5PHS111-127/8 5PHS111-14 TC5PHS111-14 MG5PHS111-14 910415-02 SC4/5PHS111-141 5PHS111-16 TC5PHS111-16 MG5PHS111-16 910415-02 SC4/5PHS111-161 1/4 2PHS111-20 TC2PHS111-20 MG2PHS111-20 910415-03 SC4/5PHS111-20

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Design Guide CRYOFIT PRODUCTS 1.0 Introduction

Good design practices, common to all tubing systems, should be followed when using CryoFit fittings. The use of these couplings will allow lines to be spaced closer together while still maintaining the nec-essary access for installations.

2.0 Installation Clearance

In designing a tube system using CryoFit couplings, the assembly technique must be considered to assure that sufficient space is provided for coupling installation. It is this installation clearance which limits the spacing of adjacent hydraulic lines and components. The CryoFit system often allows a closer spacing than alternate methods. The spacing and clearances noted in this document are the minimums recommended for standard CryoFit installations.

2.1 Radial Clearance

The clearance required between CryoFit coupling installations is determined by the clearance required for removal of the installation package. The required clearance between two parallel tubes is listed in Figure 1.

FIGURE 1MINIMUM TUBE SPACING

Figure 2 shows the CryoFit coupling in the installation package. Sufficient clearance must be provided in or-der to remove the installation package after the coupling is installed.

FIGURE 2INSTALLATION PACKAGE CLEARANCE

A

TUBESIZE

1/4”3/8”1/2”5/8”3/4”7/8”

1”1-1/4”1-1/2”

.255

.337

.382

.441

.488

.550

.610

.725

.934

AMINIMUM

(IN)

A

A

A B

COUPLING

PACKAGE

DASHNUMBER A B B B BA A A

4 0.981 0.564 0.691 0.5486 1.302 0.714 0.94 0.7468 1.604 0.88 0.178 0.88410 1.907 1.054 1.424 1.04912 2.215 0.22 1.674 1.19614 1.924 1.36616 2.845 1.56 2.172 1.53420 2.506 1.784 2.697 1.86224 2.684

1.8191.935

2.3032.479 1.996

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2.2Axial Clearance

The amount of axial clearance and straight unobstructed tube required will vary with coupling size and the installation technique employed.

Proper installation requires that a length of tube equal to 1/2 the coupling length be inserted in each end of the coupling. The coupling can be positioned either by axially moving the tube to allow access or by deflecting the tube.

2.2.1 Axial Tube Movement

In this installation technique, one tube is pulled back axially to allow the installation of the coupling. The coupling is slipped into place on the second tube and the first tube is then inserted into the cou-pling (See Figures 3A and 3B). This method requires the minimum amount of straight tube, 1/2 the coupling length, but requires axial tube movement.

FIGURE 3AAXIAL INSTALLATION CLEARANCE

AXIAL TUBE MOVEMENT

T1 T2

T1 T2

T1 T2

Where axial tube movement is allowable, the required length of straight tube is equal to 1/2 of the coupling length.

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FIGURE 3BAXIAL INSTALLATION CLEARANCE

AXIAL TUBE MOVEMENT

T1 T2

T1 T2

T1 T2

NOTE: The area from the end of T1 to the obstruction should be equal to the length of the coupling.

2.2.2 Tube DeflectionAs an alternate to moving the tube axially the tube may be deflected to one side. The coupling is then slipped over the deflected tube. The tube is repositioned and the coupling is slipped into place (See Figure 4). This method eliminates the need for axial tube movement, but requires a full cou-pling length of unobstructed tube on one end.

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FIGURE 4AXIAL INSTALLATION CLEARANCE

TUBE DEFLECTION

1.T1 is fixed. T2 cannot be moved axially, but can be deflected as shown.

2. The length of straight tube (B) required on T2 would be equal to the coupling length. The length of straight tube (A) required on T1 would be equal to 1/2 the coupling length.

NOTE: Coupling may be positioned immediately adjacent to the bend radius.

T2

T2

B

T1

T1

T1

T2

BA

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TUBE APPLICATION SPECIFICATIONS

2PHS111 3AL-2.5V CWSR AMS 20 1 1/4 0.045 Titanium 4944 24 1 1/2 0.054 EN3120 8 8mm .5mm 3AL-2.5V CWSR 12 12mm .5mm Titanium 16 16mm .6mm M2PHS111 22 22mm .8mm 28 28mm 1.0mm 18/10 CrN, CRES BSI T72- 8 8mm .5mm T73 18 18mm .6mm 4 1/4 0.02 6 3/8 0.028 3PHS111 304 1/8H CRES Mil-T- 8 1/2 0.035 6845 10 7/16 0.049 12 3/4 0.058 16 1 0.065 4 1/4 0.018 .016-.018 6 3/8 0.019 .019-.028 8 1/2 0.022 .022-.035 3AL-2.5V CWSR AMS 10 7/16 0.023 .023-.044 Titanium 4944 12 3/4 0.027 .027-.052 14 9/16 0.032 .032-.061 16 1 0.036 .036-.071 20 1 1/4 0.045 .045-.087 24 1 1/2 0.054 4 1/4 0.054 6 3/8 0.016 8 1/2 0.02 4PHS111 21-6-9 CRES AMS 10 7/16 0.026 5561 12 3/4 0.033 14 9/16 0.039 16 1 0.052 20 1 1/4 0.054 4 1/4 0.028 .020-.035 6 3/8 0.028 .028-.049 6061-T6 Mil-T- 8 1/2 0.035 .028-.065 Aluminum 7081 10 7/16 0.035 .035-.065 12 3/4 0.035 0.049 16 1 0.065 4 1/4 0.035 6 3/8 0.035 5052-T0 8 1/2 .035-.049 Aluminum 10 7/16 .035-.049 12 3/4 0.049 16 1 0.065

Basic Tube Tube Tube CryoFit Part Tube Material Spec. Dash Dia Number No.

Tube Wall Thickness 1000 2000 3000 4000 5000 psi psi psi psi psi

Temp.Range

-65˚ Fthru

275˚ F

-54˚ C thru

135˚ C

-65˚ Fthru

275˚ F

-65˚ Fthru

275˚ F

Separable End Fittings

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Introduction:

The CryOlive and CryoFlare sleeves and corresponding nuts come preasem-bled in a plastic installation package. This assembly has many functions. It acts as an installation tool, inspection gauge, dust cap, and protective cov-er for the tube end. Accurate placement of the assembly is automatically ensured and provides for correct tube position equal to that of internally swaged flareless and flared sleeves. Because the installer needs no tools, SMA fittings assemble with equal ease in the shop or on the aircraft.

At installation, this assembly is removed from liquid nitrogen, slipped onto the end of the tube, and allowed to warm from its cryogenic storage temperature. In seconds, the shape memory CryOlive (flareless) and CryoFlare (flared) end fittings shrink and crimp down on the tube with tremendous radial force, producing a leak proof metal to metal seal between the tube and sleeve. The plastic installation package acts as an installation tool, inspection gauge, dust cap and protective cover for the tube end.

The time required for both training and product installation is a small fraction of that needed for internally or externally swaged sleeves. Regardless of the installer’s skill level, installation is accomplished in a few seconds. CryOlive (flareless) and CryoFlare (flared) end fitting assemblies are installed by hand. No capital expenditure is required.

After installation, a visual inspection is all that is needed. The inspector has only to look at the end of the as-sembly to determine that the tube is visible in the inspection window (CryOlive) or that the tube is at the stop (CryoFlare) to determine that the installation is correct.

The CryOlive (flareless) and CryoFlare (flared) end fittings use the same shape memory technology as the CryoFit fitting system, which has a service record of more than 25 years in the aerospace industry with no re-ported inservice failures. During qualification, CryOlive (flareless) and CryoFlare (flared) end fittings met or exceeded the requirements in AS18280 and other demanding aircraft manufacturers’ requirements.

SEPARABLE END FITTINGS - CRYOLIVE (FLARELESS) AND CRYOFLARE (FLARED)

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a. DASH “V” AFTER BASIC PART NUMBER INDICATES ASSEMBLY WITH CARBON STEEL NUT

b. LETTER “J” AFTER BASIC PART NUMBER INDICATES ASSEMBLY WITH 304 CRES CORROSION RESISTANT STEEL NUT

c. LETTER “W” AFTER BASIC PART NUMBER INDICATES ASSEMBLY WITH 7075-T73 ALUMINUM ALLOY NUT

d. LETTER “T” AFTER BASIC PART NUMBER INDICATES ASSEMBLY WITH TITANIUM NUT.

NOTES:1. MATERIAL: SLEEVE TINEL HEAT RECOVERABLE, SHAPE MEMORY ALLOY NUT “V“ 15-5PH CRES PER AMS5659 “J” 304 CRES PER QQ-S-763 “W” 7075-T73 PER QQ-A-225/9 “T” 6AL-4V PER AMS4928

PACKAGE RED TRANSLUCENT POLYCARBONATE

2. FINISH: SLEEVE DRY FILM LUBRICANT ON TAIL NUT “V“ CADMIUM PLATE PER QQ-P-416 TYPE II, CLASS 2 “J” PASSIVATE PLUS DRY FILM LUBRICANT PER MIL-L-46010, TYPE 1 ON INTERNAL SURFACES “W” ANODIZE PER MIL-A-8625 TYPE II, CLASS 1 PLUS DRY FILM LUBRICANT PER MIL-L-46010, TYPE 1 ON INTERNAL SURFACES “T” FLUORIDE PHOSPHATE COATED PER AMS2486 PLUS DRY FILM LUBRICANT PER MIL-L-46010, TYPE 1 ON INTERNAL SURFACES PACKAGE NONE


LOCKWIRE HOLE CODEBASIC PART NUMBERMATERIAL CODE LETTER

921721 W 08 L

3000 PSI CRYOLIVE ASSEMBLY (FLARELESS)921721: CRYOLIVE SLEEVE, INSTALLATION PACKAGE AND NUT

Part Number Example:

CT

A

B

E

HEX

HEX

TUBE INSERTIONINSPECTION WINDOW

TUBE PROTRUSIONFROM END OF SLEEVE,INSTALLED

TUBE

(3D BEND RAD)

CRYOLIVE ASSEMBLY“AS SHIPPED” CONDITION

“AS INSTALLED” STRAIGHT LENGTH OF TUBEWITH 3D BEND

THREAD

NUT

SLEEVE

AMBER TRANSLUCENT PACKAGE(NUT)

(PKG) DF

PART TUBE (A) (B) (C) (D) (E) (F) T (THREAD PER MIL-S NUMBER SIZE +/- .010 MIN -8879CLASS-3B) 921721( )04 .250 1.221 .562 .500 .093 .214 1.23 7/16-20 921721( )06 .375 1.309 .688 .625 .112 .230 1.27 9/16-18 921721( )08 .500 1.393 .875 .812 .101 .285 1.31 3/4-16 921721( )10 .625 1.677 1.000 .938 .183 .330 1.51 7/8-14 921721( )12 .750 1.872 1.250 1.125 .177 .330 1.63 1 1/16-12 921721( )16 1.000 2.240 1.500 1.375 .211 .392 1.82 1 5/16-12 921721( )20 1.250 2.571 1.875 1.688 .243 .395 1.99 1 5/8-12 921721( )24 1.500 2.759 2.125 1.938 .289 .465 2.36 1 7/8-12

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a. LETTER “T” AFTER BASIC PART NUMBER INDICATES ASSEMBLY WITH TITANIUM NUT.

NOTES:1. MATERIAL: SLEEVE TINEL HEAT RECOVERABLE, SHAPE MEMORY ALLOY NUT “T” 6AL-4V PER AMS4928 PACKAGE RED TRANSLUCENT POLYCARBONATE

2. FINISH: SLEEVE DRY FILM LUBRICANT ON TAIL NUT “T” FLUORIDE PHOSPHATE COATED PER AMS2486 PLUS DRY FILM LUBRICANT PER MIL-L-46010, TYPE 1 ON INTERNAL SURFACES

PACKAGE NONE


BASIC PART NUMBERMATERIAL CODE LETTER

921504 T 08

4000 PSI CRYOLIVE ASSEMBLY (FLARELESS)921504T: CRYOLIVE SLEEVE, INSTALLATION PACKAGE NUT


PART TUBE (A) (B) (C) (D) (E) T (THREAD PER NUMBER SIZE +/- .020 MIN MIL-8-8879) 921504T04 1/4 1.221 .562 .500 .030 1.23 .4375-20 UNJF-3B 921504T06 3/8 1.349 .688 .625 .030 1.31 .5625-18 UNJF-3B 921504T08 1/2 1.453 .875 .812 .030 1.37 .7500-16 UNJF-3B 921504T10 5/8 1.677 1.000 .938 .100 1.51 .8750-14 UNJF-3B 921504T12 3/4 1.872 1.250 1.125 .120 1.63 1.0625-12 UNJ-3B 921504T14 7/8 2.017 1.375 1.250 .140 1.68 1.1875-12 UNJ-3B 921504T16 1 2.240 1.500 1.375 .160 1.86 1.3125-12 UNJ-3B 921504T20 1 1/4 2.571 1.875 1.688 .200 1.99 1.6250-12 UNJ-3B 921504T24 1 1/2 2.759 2.125 1.938 .250 2.36 1.8750-12 UNJ-3B

CT

A

BHEX (NUT)

HEX (CAP)

TUBE INSERTIONINSPECTION WINDOW

TUBE PROTRUSION

TUBE

(3D BEND RAD)

CRYOLIVE ASSEMBLY“AS SHIPPED” CONDITION

“AS INSTALLED” STRAIGHT LENGTH OF TUBEWITH 3D BEND

THREAD

NUT

SLEEVE

REDTRANSLUCENTPACKAGE D

E

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NOTES:1. MATERIAL: UNION TINEL HEAT RECOVERABLE, SHAPE MEMORY ALLOY PACKAGE TRANSLUCENT POLYCARBONATE

2. FINISH: UNION - DRY FILM LUBRICANT ON TAIL PACKAGE - NONE

TUBE SIZE IN .062 INCREMENTS BASIC PART NUMBER

921895 08

3000 PSI LIGHTWEIGHT UNION ASSEMBLY (MALE FLARELESS)921895: LIGHTWEIGHT UNION AND INSTALLATION PACKAGE


TUBE A EST. PART NUMBER SIZE EXPANDED B D T THREAD PER MIL-S-8879 WT. LBS. (MIN)

T

A

B HEX

FITTING END PERMS33514, STYLE EEXCEPT HEX ANDTUBE STOP THREAD

TUBE

LIGHTWEIGHTUNION

TRANSLUCENTCAP PACKAGE

D

921895-04 .250 .239 .370 .810 .4375-20 UNJF .009 921895-06 .375 .359 .495 .992 .5625-18 UNJF .020 921895-08 .500 .478 .683 1.244 .7500-16 UNJF .043 921895-10 .625 .598 .808 1.469 .8750-14 UNJF .080 921895-12 .750 .717 .995 1.695 1.0625-12 UNJF .132 921895-16 1.000 .956 1.308 2.026 1.3125-12 UNJ-3A .300

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a. LETTER “J” AFTER BASIC PART NUMBER INDICATES ASSEMBLY WITH 304 CRES CORROSION RESISTANT STEEL NUT

b. LETTER “W” AFTER BASIC PART NUMBER INDICATES ASSEMBLY WITH 7075-T73 ALUMINUM ALLOY NUT

NOTES:1. MATERIAL: SLEEVE TINEL HEAT RECOVERABLE, SHAPE MEMORY ALLOY NUT “J” 304 CRES PER QQ-S-763 “W” 7075-T73 PER QQ-A-225/9 CAP PACKAGE RED TRANSLUCENT POLYCARBONATE

2. FINISH: SLEEVE DRY FILM LUBRICANT ON TAIL NUT “J” PASSIVATE PLUS DRY FILM LUBRICANT PER MIL-L-46010, TYPE 1 ON INTERNAL SURFACES “W” ANODIZE PER MIL-A-8625 TYPE II, CLASS 1 PLUS DRY FILM LUBRICANT PER MIL-L-46010, TYPE 1 ON INTERNAL SURFACES CAP PACKAGE - NONE


BASIC PART NUMBERMATERIAL CODE LETTER

921883 W 08

3000 PSI CRYOFLARE ASSEMBLY (FLARED)921883: CRYOFLARE SLEEVE, INSTALLATION PACKAGE AND NUT


PART NUMBER TUBE SIZE B C F THREAD PER AS8879 MIN 921883( )04 .250 .562 1.238 1.23 .4375-20 UNJF 921883( )06 .375 .688 1.483 1.27 .5625-18 UNJF 921883( )08 .500 .875 1.718 1.31 .7500-16 UNJF 921883( )10 .625 1.000 1.941 1.51 .8750-14 UNJF 921883( )12 .725 1.250 2.207 1.63 1.0625-12 UNJF

TA

A

C B HEX

“AS INSTALLED” MINIMUM STRAIGHT LENGTH OF TUBEWITH 3D BEND

CRYOFLARE ASSEMBLY“AS SHIPPED” CONDITION

TUBE

(3D BEND RAD)

NUT SLEEVE

THREAD

BLUE TRANSLUCENTCAP PACKAGE

HINGE DETAILVARIES WITHSIZE

SECTION A-A

F

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Installation CRYOLIVE AND CRYOFLARE PRODUCTS I. IntroductionCryOlive and CryoFlare shape memory alloy sleeves and coupling nuts are components of a flareless fluid fitting connection. The sleeves are installed on the ends of tubes and permit the tubes to be connected to tees, elbows, unions, etc., with ends machined per military standards AS33514 and AS33515.

CryOlive and CryoFlare sleeves are manufactured from Tinel shape memory alloy. The ID of the sleeve is ma-chined somewhat smaller than the OD of the tube it will be installed upon. After fabrication, the sleeve is cooled to cryogenic temperatures, -320ºF, in liquid nitrogen (LN2). When cooled, the shape memory alloy undergoes a transformation from a high strength, austenitic phase to a relatively low strength, martensitic phase. While in the cooled, low strength phase, the sleeve is “expanded” to an inside diameter slightly larger than the OD of the tube it is to be installed upon. When the sleeve is removed from LN2 and allowed to warm, the austenite to martensite transformation is reversed, and the sleeve “recovers” to its pre expanded, or as machined, diameter and its high strength state. This transformation and expansion process can be repeated if the sleeve has “recov-ered” prior to installation.

To install the sleeve on a tube, the sleeve is removed from the LN2 and immediately slipped over the end of the tube and allowed to warm up and recover. The tube OD, being larger than the ID that the sleeve wants to revert to, constrains the sleeve’s recovery. During constrained recovery the alloy develops considerable force and ef-fectively “self swages” the sleeve permanently onto the tube.

The sleeve and coupling nut come pre assembled in a disposable molded installation package (Figure 1). As-semblies are shipped and stored in liquid nitrogen and are removed from LN2 just prior to installation.

Figure 1

CRYOLIVEASSEMBLY

CRYOFLAREASSEMBLY

CryOlive and CryoFlare assemblies should be removed from their storage containers and installed only by personnel who have been properly trained in the handling of liquid nitrogen and installation of CryOlive and CryoFlare sleeves. Please see Section D for safety and handling of liquid nitrogen.

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II. Installation ToolsCryOlive and CryoFlare sleeves are installed by using simple tools purchased direct or through our stocking distributors. The function of each tool is described below.

1. TONGS: Instrument used to transfer and remove assemblies from insulated workbox. Product Descrip-tion: AT911067-01.

2. WORK BOX: A small insulated box used to transport assemblies from the storage area (see Logistics sec-tion) to the work area. Product Description: WB910825-01

3. GLOVES: Thin, well insulated gloves, which are used when handling assemblies that have been stored in liquid nitrogen. They must NOT, under any circumstances, be immersed in liquid nitrogen. Product Description: OE Glove Liner- (S-M-L)

4. Safety Glasses: Safety glasses with side shields should be used at all times.

III. INSPECTION OF SLEEVE I.D. If there is reason to believe that the sleeve within the assembly has recovered (such as from a low liquid nitro-gen level in the storage dewar), its inside diameter can be checked as follows:

1. Obtain a length of the appropriate size tubing approximately 6” long.

2. Cool the tube end in liquid nitrogen (work box) until the boiling stops.

3. Being careful to keep the assembly in liquid nitrogen, insert the cooled tube onto the assembly. The tube should bottom out against the assembly end (CryOlive) or the stop (CryoFlare). This can be checked by viewing the end of the tube through the inspection window of the package. If the tube cannot be inserted into the assembly and through the sleeve, the assembly should be removed from stock. Return the sleeve for reexpansion. A nominal fee is charged for this service.

IV. Installation ProcessNOTE: CryOlive and CryoFlare assemblies should be installed only by properly trained personnel.

1. Obtain the proper CryOlive or CryoFlare assemblies from inventory. Refer to the application table for assem-bly description.

2. Ensure that the tubes are round and free from burrs and meet dimensional specifications.

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3. Clean and dry end of tube, if necessary, by wiping with a clean rag or cloth.

4. Put on gloves. NOTE: Do not put gloved hand in liquid nitrogen.

5. Using tongs, remove the assembly from the liquid nitrogen and allow the excess liquid nitrogen to run off.

6. Grasp the assembly with gloved hand. Without delay, slip it over the tube end and push until the tube end is firmly seated against end stop inside the plastic installation package. The tube must bottom out against the assembly end (CryOlive)(Figure 4) or tube stop (CryoFlare).

7. The package is designed to provide the proper tube insertion. To do so the tube must be fully bottomed against the inside end of the package. For CryOlive the tube end should be visible in the slot (inspection win-dow) and should butt against the inside end of the package (Figure 2). For CryoFlare the tube must bottom on the tube stop. You may leave plastic installation package on tube end to protect sleeve and act as a dust cover until ready to mate with fitting.

Figure 2

8. To remove the plastic installation package, unscrew the nut and remove the plastic package.

Figure 3

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9. Tube protrusion and other installation related dimensions are found in the Specification Control Drawings.

V. TUBE APPLICATION SPECIFICATIONSTorque the CryOlive or CryoFlare nut to the value listed in the following tables.

Basic SMA Tube Tube Tube Wall Installation Torque System Temperature Assembly Part Tube Material Specification Size Thickness Operating Range Number Inch Lbs Nm Pressure

921721 OR921883

-65° F thru275° F

-65° F thru275° F

-65° F thru275° F

-65° F thru275° F

-65° F thru275° F

-65° F thru275° F

304 1/8H CRES

21-6-9 CRES

6061-T6ALUMINUM

3AL-2.5V CWSRTITANIUM



921721J OR921883J

921721W OR921883W

921721T

921504

MIL-T-6845

AMS 5561

MIL-T-7081

AMS 4944

AMS 4944

AMS 4944921504

4 0.020 135-145 15.3-16.4 3000 psi 6 0.028 215-245 24.3-27.7 3000 psi 8 0.035 470-510 53.1-57.6 3000 psi 10 0.042 610-680 68.9-76.8 3000 psi 12 0.058 810-945 91.5-106.8 3000 psi 16 0.065 1,140-1,260 128.8-142.4 3000 psi 4 0.016 135-145 15.3-16.4 3000 psi 6 0.020 215-245 24.3-27.7 3000 psi 8 0.026 470-510 53.1-57.6 3000 psi 10 0.033 610-680 68.9-76.8 3000 psi 12 0.039 810-945 91.5-106.8 3000 psi 16 0.052 1,140-1,260 128.8-142.4 3000 psi 4 0.028 135-145 15.3-16.4 1500 psi 6 0.028 215-245 24.3-27.7 1500 psi 8 0.035 470-510 53.1-57.6 1500 psi 10 0.035 610-680 68.9-76.8 1500 psi 12 0.035 810-945 91.5-106.8 1500 psi 16 0.065 1,140-1,260 128.8-142.4 1500 psi 20 0.035 1,520-1,680 171.7-189.8 500 psi 24 0.035 1,900-2,100 214.7-237.3 500 psi 4 0.016 135-145 15.3-16.4 3000 psi 6 0.019 215-245 24.3-27.7 3000 psi 8 0.026 470-510 53.1-57.6 3000 psi 10 0.032 610-680 68.9-76.8 3000 psi 12 0.039 810-945 91.5-106.8 3000 psi 16 0.051 1,140-1,260 128.8-142.4 3000 psi 4 0.020 135-145 15.3-16.4 4000 psi 6 0.019 215-245 24.3-27.7 4000 psi 8 0.019 470-510 53.1-57.6 4000 psi 10 0.032 610-680 68.9-76.8 4000 psi 12 0.039 810-945 91.5-106.8 4000 psi 14 0.045 985-1,090 111.3-123.3 4000 psi 16 0.051 1,140-1,260 128.8-142.4 4000 psi 6 0.020 215-245 24.3-27.7 2000 psi 8 0.020 470-510 53.1-57.6 2000 psi 10 0.023 610-680 68.9-76.8 2000 psi 12 0.027 810-945 91.5-106.8 2000 psi 14 0.032 985-1,090 111.3-123.3 2000 psi 16 0.036 1,140-1,260 128.8-142.4 2000 psi 20 0.045 1,520-1,680 171.7-189.8 2000 psi 24 0.032 1,900-2,100 214.7-237.3 150 psi 24 0.054 1,900-2,100 214.7-237.3 2000 psi

Logistics(Liquid Nitrogen Handling And Storage)

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Liquid Nitrogen Storage & Handling

1. IntroductionShape Memory Alloy (SMA) fittings are used to permanently join sections of tubing and are stored in liquid nitrogen until just before installation. When received, the fittings have an inside diameter which is larger than the outside diameter of the tubes they will be installed onto. If removed from the liquid nitrogen and allowed to warm, the couplings will shrink so that the inside diameter will be smaller than the tube outside diameter. If the coupling is slipped over the tube/fitting ends before it warms, the fittings will shrink and swage onto the tube or fitting.

2. Shipping and Storage ContainersCryoFit unions and separable fittings called CryOlive (flareless) and CryoFlare (flared) fittings are shipped and stored in special insulated liquid nitrogen containers called dewars or are stored for longer periods of time in freezers. Dewars and freezers are available from Aerofit, Inc. or their distributors. The size of the dewar or freezer is dependent on the quantities of fittings to be shipped and/or stored.

A dewar functions like a thermos bottle by controlling the boil off or evaporation of liquid nitrogen (LN2) and thus maintaining the inside temperature of the vessel at a relatively constant -320° F. The smaller the neck of the dewar, the slower the evaporation process and the longer a constant temperature will be maintained. It is important to note that replacing the neckcore into the dewar after loading/removing SMA products is vital in helping to control LN2 evaporation. Required servicing intervals are delineated in the manufacturer’s literature for each dewar type/design.

If frost is noted on the outside of the dewar at any time, transfer the SMA parts to another container and re-move the dewar from use. Frost indicates that the vacuum has been broken and it will no longer maintain LN2 per its design and usage specification.

If the dewar shows no sign of frost on the exterior, it only needs regular servicing of LN2 to maintain the SMA parts in their expanded state. Shape Memory Alloy parts are to be submerged in liquid nitrogen until removed for installation.

If the dewar has a large mouth and neck, it is possible to see the LN2 and determine its depth. If the dewar has a small mouth and neck, the quantity/depth of the liquid nitrogen can be determined by observing the condensation on the outside of the parts canisters when removed from the dewar.

NOTE: if the neckcore of the dewar is removed and it is determined that only a minimal amount of liquid nitrogen or vapor is left in the dewar, immediately replenish the liquid nitrogen. In most cases, the parts will remain in their expanded state, but they should be checked before installation is begun.

Liquid DewarThis unit is suitable as a shipping container and for short term storage. Liquid nitrogen level must be checked every few days and topped off if necessary. Least economical shipping container due to weight.

LOGISTICS – SMA FLUID FITTING SYSTEM

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Vapor Dewar

This unit is excellent as a shipping container or for medium term storage. This style Dewar has a liner which absorbs liquid nitrogen and inhibits evaporation. In this condition parts will remain cold for up to two weeks and reduces the shipping weight. When both the liner and storage chamber are full of liquid nitrogen SMA parts can be stored for up to a month without topping off.

Freezer SystemThis unit is superior for long term storage. Features include temperature con-trol and monitoring alarm system, easy access to stored product, automatic liquid nitrogen fill and auto clear of fog for improved part identification and determining the quantity of stored products.

3. Packing for Shipment

For shipment, SMA fittings are packaged in canister tubes in the small dewars or half trays in the large dewars. For shipping, the dewar is attached to a special pallet designed to prevent it from being tipped over. Each canister or half tray is tagged to identify parts in canister or tray.

4. Receiving Procedure

The shipment and storage in liquid nitrogen means that it is unlikely to be practical for SMA fittings to be checked at receiving. The Release Note/Certificate of Conformity on the outside of the container may be removed by receiving so that the quantities may be ‘booked-in’ and the document passed on to QA. The containers must be forwarded unopened to the user department.

2

Vapor Dewar This unit is excellent as a shipping container or for medium term storage. This style Dewar has a liner which absorbs liquid nitrogen and inhibits evaporation. In this condition parts will remain cold for up to two weeks and reduces the shipping weight. When both the liner and storage chamber are full of liquid nitrogen SMA parts can be stored for up to a month without topping off.

Freezer System This unit is superior for long term storage. Features include temperature control and monitoring alarm system, easy access to stored product, automatic liquid ni-trogen fill and auto clear of fog for improved part identification and determining the quantity of stored products.

3. Packing for Shipment For shipment, SMA fittings are packaged in canister tubes in the small dewars or half-trays in the large de-wars. For shipping, the dewar is attached to a special pallet designed to prevent it from being tipped over. Each canister or half tray is tagged to identify parts in canister or tray.

4. Receiving Procedure The shipment and storage in liquid nitrogen means that it is unlikely to be practical for SMA fittings to be checked at receiving. The Release Note / Certificate of Conformity on the outside of the container may be removed by receiving so that the quantities may be ‘booked-in’ and the document passed on to QA. The con-tainers must be forwarded unopened to the user department.

Outer Protective Ship-ping Cover

Dewar

Freezer

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Half TrayCanister Tube

Locking tab

FoamPlug

6 or moreinternalcanisters

Double wallwith insulationand vacuum

Base configured tohold canisters

Hinged Lid

Large DewarSmall Dewar

DewarOuter Protective Shipping Cover

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When received by stores or the user department, the liquid nitrogen level in the dewar should be checked. If the level has dropped, it should be replenished. On receipt, by stores or the user department, the liquid nitrogen level in the dewar should be checked and topped off at regular intervals thereafter.

5. Transfer of FittingsThe transfer of fittings from the shipping dewar to the storage dewar should be made as quickly as possible.

Transfer from a Half TrayTransfer from a half tray is accomplished by moving the half tray to a shallow insulated foam tray filled with liquid nitrogen.

1) Fill the storage dewar with liquid nitrogen.2) Fill the storage half tray or inventory control system drawer with liquid

nitrogen.3) Fill the foam tray with approximately 3” of liquid nitrogen.4) Remove the shipping half tray from the shipping dewar and place in the

foam tray.5) Select the proper tools and cool.6) Using the proper tool, transfer the fittings from the shipping half tray to

the storage container one at a time.7) It is desirable to verify and record the quantity of fittings received at this

time.8) After completing the transfer, return the storage half tray or drawer to the

storage dewar or freezer.

Transfer of couplings from dewar canister to work box1) Fill the work box with approximately 3” of liquid nitrogen.2) Remove the canister tube from the dewar and remove any wad-

ding (sometimes inserted to ensure couplings remain in canisters during transit)

3) Position the canister over the work box and tip it so the couplings slide into the work box.

Transfer of couplings from Work Box to the canisterTo return couplings from work box (as for example after verifica-tion)

1) Top up the work box with liquid nitrogen if necessary & stand the canister in the work box.

2) Cool the tongs.3) Pick up the couplings with the tongs and transfer them into the

canister 4) Ensure liquid nitrogen level is sufficient to cover the couplings at

all times.5) Return the canister to the dewar (tip the canister slightly so that

it engages the slot in the base of the dewar).

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6. StorageSMA fittings can be stored in liquid nitrogen indefinitely. The storage containers are unpressurized and are therefore refilled by simply pouring liquid nitrogen directly into the container.

• Pouring should be done slowly, especially when pouring into empty vessels at ambient temperature to minimize thermal shock to components

• Care should be exercised when adding liquid nitrogen from a pressurized source directly to a con-tainer which contains SMA fittings. There is a small risk that a pressurized ‘stream’ from a hose in the base of the container could push small size parts out of the canisters and into the main body of the container.

7. SMA Fitting Recovery CheckIf there is reason to believe that a coupling has been warmed (such as from a low liquid nitrogen level in the dewar), its inside diameter can be checked as follows:

1) Obtain a length of the same size tubing as the coupling, ap-proximately 6 inches long.

2) Cool the end of the tube in liquid nitrogen until boiling stops. Point the upper end of the tube away from the face and body as small diameter tube will create a ‘fountain’ effect as it cools.

3) Being careful to keep the coupling in the liquid nitro-gen, insert the tube into the coupling. 4) The tube should easily slip through the entire bore of the CryoFit fitting 5) If the tube cannot pass through the fitting, the fitting should be removed from stock and returned to the sup-plier for reexpansion.

8. SMA Fitting reexpansionSMA fittings which have been allowed to warm prematurely may be returned to the supplier for reexpansion. SMA fittings should be carefully packaged so as to prevent damage (especially to the coating on the extremi-ties) before return. Before reexpansion the couplings are carefully examined for damage, restenciled with a unique reexpansion batch number and issued with a new Certificate of Conformity. The cost of this process is approximately 30% of the cost of a new SMA fitting, however transport and set up costs mean that it may be uneconomic to reexpand batches of less than 100 couplings (or 50 on larger sizes).

Fountain Effect

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9. Liquid Nitrogen SafetyThe following precautions are provided to assist the user of SMA fittings in developing adequate safety stan-dards for use of liquid nitrogen. They are intended as guidelines only and should not be considered binding recommendations. The safe handling of liquid nitrogen and cryogenically cooled components is the user’s responsibility.

1) Liquid nitrogen will displace oxygen in confined spaces. Its volume expansion from liquid to gas at standard conditions is 696 to 1. Evaporation of large amounts of liquid nitrogen in unventilated or confined spaces may cause suffocation. Therefore, working areas should be provided with adequate ventilation.

2) Liquid nitrogen at -320° F (-196°C) can cause frostbite or “burn” if it is in contact with the skin for more than a few seconds. Brief contact with the liquid due to accidental splashing will not cause harm. Care must be taken to avoid trapping spilled liquid nitrogen against the skin. Wear loose fitting clothing. Pants should be long enough to cover the tops of the shoes.

3) Thermal Gloves recommended by Aerofit, Inc. are to be used when handling tooling and SMA fit-tings which have been cooled by liquid nitrogen. Gloves should not be directly submerged in liquid nitrogen.

4) Eye damage can result from splashed liquid nitrogen: suitable eye protection should be worn (Safety Glasses or Goggles).

5) Do not come into contact with areas of tools, couplings or materials which have been cooled by liq-uid nitrogen, as they can also cause frostbite.

6) Bulk transfer of liquid nitrogen should be performed only by trained personnel.7) Small quantities of liquid nitrogen must be poured slowly to avoid splashing, thermal shock and rapid

build up of pressure.

Emergency Action if a liquid nitrogen spill occurs:1) Remain clear of the spilled liquid. Allow it to evaporate as a result of shop ventilation.2) Immediately remove any clothing or shoes which have been soaked with liquid nitrogen; flush skin

with lukewarm water and seek immediate medical attention if burned.3) In case of eye contact, flush with water and get immediate medical attention.4) In case of asphyxiation and loss of consciousness move person to ventilated area and seek immediate

medical attention.

General Information

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Warranty of Couplings and FittingsAerofit, Inc. warrants that CryoFit couplings, compatible fittings, CryOlive flareless, CryoFlare flared end fittings, and tooling will be free from defects in design, material, and workmanship. Should any SMA fitting, coupling or tool fail in service, it will be replaced by Aerofit, Inc. at no cost.

Warranty Terms and Conditions

• Proper storage, handling and installation are required, as shown in Aerofit, Inc. published document

• Couplings must be installed on qualified and certified tube material, OD, and wall thickness combinations, or on Aerofit, Inc. supplied or approved CryoFit compatible fittings

• Failures attributable to designs, modifications, and repairs that are not consistent with accepted design prac-tice are not covered under this warranty.

• This warranty is not assignable to third parties (except the US Government) without the prior written con-sent of Aerofit, Inc.

• The cost of repairs is not covered under this warranty.

GENERAL INFORMATION

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GENERAL INFORMATIONAIRCRAFT MANUFACTURER APPROVALS

Manufacturer (Partner

Companies in Parentheses)

Cryofit CryOlive CryoFlareLight

Weight Union same tube

materials as

CryOlive

Titanium 3AL-2.5V

Titanium 3AL-2.5V

Aluminum 6061-T6 5052-0

Aluminum 6061-T6 5052-0

Aluminum 6061-T6 5052-0

CRES 21.6.9

304-1/8H 321

CRES 21.6.9

304-1/8H 321

CRES 21.6.9

304-1/8H 321

BOEING

727, 737, 747, 757, 767, 777, 787

3PHS111 921721T- 921721J- 921721W-

DC-9, DC-10, MD-80, MD-11

4PHS 4PHS

4PHS

921721T 921721J

X-36 Remotely Piloted Vehicle

C-17 (Northrop Grumman)

4PHS111 921853

Canard Rotary Wing 4PHS

747 Airborne Laser 4PHS

LOCKHEED MARTINF16 (Block 60) 3PHS111

BOMBARDIERdeHavilland Dash 7,

Q200, Q300 3PHS111 3PHS111 921883- 921883W

deHavilland Dash 8 3PHS111 3PHS111 921883- 921883W

Canadair Challenger 3PHS111 3PHS111

Canadair Regional Jet 3PHS111

AIRBUSA300, A310, A318,

A319, A320, A321 A330, A340, A350, A380

3PHS111 3PHS111Refer TDD (Technical Design Directive)

921721T 921721J 921721W 921895

A380

DASSAULTFalcon Jet 3PHS111 3PHS111 NTO Status

GULFSTREAM (Northrop Grumman)GV 3PHS111 3PHS111 3PHS111 921721T 921895GIV 3PHS111 3PHS111 3PHS111

MARSHALL AEROSPACEL1011 3PHS111

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materials as

CryOlive

Titanium 3AL-2.5V

Titanium 3AL-2.5V

Aluminum 6061-T6 5052-0

Aluminum 6061-T6 5052-0

Aluminum 6061-T6 5052-0

CRES 21.6.9

304-1/8H 321

CRES 21.6.9

304-1/8H 321

CRES 21.6.9

304-1/8H 321

RAYTHEONKing Air 4PHS 4PHS

Premier 1 4PHS111 4PHS111 921721T- 921895Hawker Horizon

(FHI) 4PHS111 4PHS111 921721T- 921895

BELL HELICOPTERUH-1 921721T- 921721J- 921721W

V-22 (Boeing) 5PHS111 921721TB609 (Agusta) 921721T-

CESSNACitation X Proto-type 4PHS111 4PHS111 921721T 921721W

Model 650 4PHS1114PHS111

4PHS1114PHS111

921721T921721T

921721W921721WModel 750

SAAB340

20004PHS4PHS

NORDAM Thrust Reversers for:

Citation 550/560Lear 45

Hawker Horizon

921721T 921721J

921721T 921721JU.S. DEPT of DEFENSE

C-17 (Douglas) 4PHS111F-14

(Northrop Grumman) 3PHS

T-1 (Lockheed Martin) 3PHS1

B-1B (Rockwell) 4PHSV-22 (Bell/Boeing)T-45 (BAE/Boeing)

767-AWACS (Boeing)

5PHS111M4PHS111

4PHS 4PHS707 JSTARS

(Lockheed Martin)C-5 (Lockheed Martin)

4PHS

4PHS

F-22 (Boeing)CP Ti 6.4 and Inc-onel 625

F16 (Lockheed Martin)

3PHS111

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materials as

CryOlive

Titanium 3AL-2.5V

Titanium 3AL-2.5V

Aluminum 6061-T6 5052-0

Aluminum 6061-T6 5052-0

Aluminum 6061-T6 5052-0

CRES 21.6.9

304-1/8H 321

CRES 21.6.9

304-1/8H 321

CRES 21.6.9

304-1/8H 321

NON U.S. GOVERNMENT

Taiwan IDF (Lockheed Martin) 4PHS 4PHS

Harrier GR5/GR7 /T10 (BAe)

4PHS111

Eurofighter Ty-phoon(EADS, Bae,

Alenia)

M2PHS111 M4PHS111

The following table is intended to summarize the historical qualification and technical development of the cur-rent CryoFit couplings series.

Product Series

Year Qualified

System Operating Pressure

Tubing Type Background OEM Qualifications

User Qualifications

4PHS111 1985 4000 psi

First fitting made from Tinel Alloy AHS, designed using Finite Element Analysis. About 35% shorter and lighter than 4P0 counterpart, but with longer recovery

time. Allowable installation gap is 0.120”. Developed and qualified for the B-2 and

Northrop ATF.

Northrop, Boeing Military, Vought,

McDonnell Douglas, Hughes

Space & Com-munications, GE

Satellites

U.S Navy, U.S Air Force,

Royal Air Force (Harrier)

2PHS111 1985 2000 psi Ti-3Al-2.5V

Ti-3Al-2.5V

Ti-3Al-2.5V

Made from Tinel Alloy AHS. Roughly 35% shorter and lighter than 4P0 counter-

part, but with longer recovery time. Allowable installation gap is 0.120”.

Used in conjunction with 4PHS system.

Northrop, Boeing Military, Vought,

McDonnell Douglas, Hughes

Space & Com-munications, GE

Satellites

U.S Navy, U.S Air Force

M4PHS111 1986

4000 psi Ti-3Al-2.5V Made from Tinel Alloy AHS. Allowable installation gap is 0.120” (3 mm). Metric coupling developed and qualified for the T-45 Goshawk and now selected for the

Eurofighter Typhoon.

BAe, McDonnell

Douglas3000 psi BS T72-T73

U.S. Navy

U.S. Navy

U.S. Navy

M2PHS111 1986 1000 psi BS T72-T73Made from Tinel Alloy AHS. Allowable

installation gap is 0.120” (3 mm). Metric coupling developed for use in conjunction

with the M4PHS111 system.

BAe, McDonnell

Douglas

5PHS111 19875000 psi

Made from Tinel Alloy AHS. Allowable installation gap is 0.120”. Developed and qualified for the Bell/Boeing V-22 and the

McDonnell Douglas A-12.

Northrop, McDonnell

Douglas, Bell Helicopter, Boeing

Helicopter

3PHS111 1995

3000 psi Ti-3Al-2.5V Made from Tinel Alloy AHS. Allowable instal-lation gap is 0.300”. Originally qualified to ISO 7169 for Airbus as a direct replacement for Rynglok and Permaswage. Designed to be the single coupling for commercial air-

craft original installation and repair.

Airbus Industrie,

Air France, United Airlines

3000 psi 21-6-9 Boeing, deHavilland

3000 psi 304-1/81000 psi 6061-T6

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CompanyProduct

Series and Sizes

Tube Types Propellant Tests Performed Results Space Vehicle

Applications

All mechanical test results deemed acceptable. CryoFit couplings not affected by hydrazine and no trace of titanium or nickel found in hydrazine after test.

All mechanical test results deemed acceptable. No untoward effects were noted during the metallurgi-cal evaluation of CryoFit sleeves after propellant exposure.

Unknown

Unknown

UHF/F2;Brasilsat;GMS-5, MSAT E-1PANAMSAT K-1

Pegasus and GPS programs.(Sub-contract for Lockheed Martin)

Globalstar 2Teledesic

Undetermined

CryoFit couplings met all require-ments of use with liquid propulsion systems with the propellants listed. Service with xenon gas qualified by similarity to helium. Recommend-ed as an alternative to welding or flareless tube coupling where high strength, high reliability and ease of installation are important factors.In 1999 Hughes reported an ag-gregate 800 problem-free years in space for the CryoFit couplings on their spacecraft.

All tests completed satisfactorily. DASA noted (as had GE) that Xylan lubricant on CryoFit extremities was soluble in hydrazine. No risk of contamination of propellant inside tubes because lubricant is external to coupling ‘teeth’.

MMS reported leak rate of less than 10-9 cc/s for a 4PHS111-04 joining 2 Ti-3Al-2.5V tubes filled with helium at 387 bar (≈ poros-ity of tube)

All tests completed satisfactorilyLeak and burst tests successful even on samples where assembly had been deliberately bent. Tests concluded when tube burst at 23,500 psi

All tests completed satisfactorily

Lockheed Missiles & Space Company

General Electric Astro Space

4P021113/8”

Ti-3Al-2.5V

Hughes Space & Communica-tions

4PHS1111/4”, 3/8”

Ti-3Al-2.5V

DASA Space (Daimler-Benz Aerospace Raumfahrt Infrastruc-ture)

4PHS111 &921721 (Cryolive) 3/8”

Ti-3Al-2.5V

Matra-Mar-coni Space (UK)(Now As-trium)

4PHS1111/4”, 3/8”

Ti -3Al-2.5VTi-6Al-4VCP Ti, SS304

Boeing Space & Defence Group

4P02111 ¼” 304 1/8 Hard321

Primex Aerospace Company

5PHS111 ¼” Ti 6Al-4V304 1/8 Hard

4P021111/4”, 1/2”, 3/4”

304CRES joined to: Ti-3Al-2.5V, 304CRES, 2021Al

N2H4

N2H4MON-3

Unknown but included propellant compatibility

MON-3 per MIL-P-26539; Monomethyl-hydrazine per MIL-P-27404; Hydrazine per MIL-P-26536; Helium per MIL-P-27407

Gas Leak; Propellant compatibility; Burst pres-sure; Impulse;Thermal cycle; Flex; Metallograph-ic analysis

Hydrazine Hydrazine compatibil-ity, gas leak, proof pressure, further quali-fication tests planned.

Hydrazine Gas Leak

Hydrazine Vibration, Thermal Cycle, 4X operating pressure

Hydrazine Proof PressureMass Spectrom-eter Leak test, Bending, Vibra-tion, Torsion, Burst, Adjacent Weld

Tensile strength, Burst, Gas Leak, Vibration, Contamination, Hydrazine compatibility

Unknown (but see entry under Primex Aerospace below)

GENERAL INFORMATION

CryoFit® Couplings for Space Vehicle Plumbing SystemsCryoFit couplings have been used in Space Vehicle applications dating back to the mid-1970s. They have been qualified by Lockheed Missiles & Space Company (1974), General Electric Astro Space (1991) and Hughes Space & Communications (1994). CryoFit couplings have also been evaluated for space vehicle applications in the UK, Japan and Germany and by Boeing Defense & Space Group. All testing has been conducted at the expense of the companies and test reports are considered proprietary. This fact sheet is intended to summarise the conclusions of those reports and such details as are known about any ongoing testing.

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CompanyProduct

Series and Sizes

Tube Types Propellant Tests Performed Results Space Vehicle

Applications

GHe leak rate less than 1x 10-7cc/ sec even when installed coupling below martensitic transformation temperature.

Unknown Unknown

XMM

Mars Rover Landing Vehicle

Satisfactory - approved for propel-lant tank repair.

NASA, JFK Space Center

Ishikawa-jima Harima Heavy Indus-tries

4PO2111 3/8” & 1/2”

Commercial Stainless Steel

ESA/Dornier /Fiat BPD/Dowty Aero-space

JPL Pasadena

NASA – God-dard Space Center

Surrey Satel-lite Technolo-gies Ltd

4PHS111 1/4”

4PHS111

4PHS111

3PHS111 ¼” & 3/8”

Ti-3Al-2.5V

Unknown

Unknown

T1-3Al-2.5V & CRES

Unknown

Unknown

Unknown

Unknown

Thermal Cycling

Not communicated

Not communicated

Tests completed satisfactorily

3PHS111 ½” 304 1/8 Hard

Undetermined

Undetermined Unknown

Hydrazine Leak Test (Dowty) Vibration with Thermal Cycle superimposed (ESA)

Negative Pressure, Low temperature leak tests

Unknown

GENERAL INFORMATION

CryoFit® Couplings for Space Vehicle Plumbing Systems

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GENERAL INFORMATIONMeasurements of Electrical Resistance measured across assembled 3PHS111 coupling

Tube Size

Tube Size

CRES 21-6-9 Ti-3AL-2.5V

Test No. Test No.Measured Resistance Measured ResistanceBAC5117

limit milliohms

BAC5117 limit

milliohmsmilliohms milliohmsavg avg

4

6

8

10

12

16

20

24

4

6

8

10

12

16

20

24

15906 2.6 15907 2.35 15940 2.65 15946 2.65 15833 2.1 15840 2.1 15846 1.9 15847 1.96 15856 2 15869 2.11 15939 1.55 15951 1.61 15953 1.63 15954 1.63 15958 1.74 15852 2.1 15857 1.6 15870 1.2 15871 1.18 15881 1.26 15884 1.33 15849 1.1 15911 1.08 15925 1.03 15926 1.05 15964 0.9 15969 0.94 15989 0.85 15995 0.86 15996 0.86 16229 1.73 16230 1.78 16231 1.65 16232 1.7 16236 1.69 16237 1.73 16238 1.95 16239 1.9

15908 3.7 15910 3.27 15930 3.45 15931 3.6 15832 2.46 15838 2.9 15845 2.68 15865 3.2 15866 3.25 15876 3.4 15936 2.35 15950 2.35 15965 2.34 15972 2.22

15842 1.62 15874 2.08 15875 1.9 15886 1.8

15848 1.56 15928 1.6 15929 1.68 15942 1.6 15850 1.36 15863 1.35 15970 1.4 15984 1.3 15990 0.58

2.56 12

2.03 8

1.63 5

1.45 3

1.07

0.88

1.72

1.82

3.51 12

2.98 8

2.32 5

1.85 3

1.61

1.2

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Tube SizeTest No.

Measured Resistance BAC5117 limit milliohms

milliohms avg

Al. Alloy 6061-T6

4

6

8

10

12

16

20

24

15912 2.37

15916 2.17

15917 1.84

15918 1.66 15841 2.15 15867 1.44 15868 2.2 15878 2.72 15880 1.69 15882 1.27 15883 2.38 15927 0.63 15938 0.54 15959 0.4 15960 0.68 15971 0.75 15843 0.38 15873 0.48 15877 0.36 15885 1.06 15887 0.46 15897 0.38 15921 0.43 15922 0.37 15923 0.38 15862 0.61 15909 0.44 15935 0.36 15952 0.27 15851 0.4 15991 0.71 16014 0.28

16243 0.23 16244 0.4 16245 1.64 16246 0.17 16247 0.71

2.01

1.98 1.3

0.6 0.95

0.48 0.75

0.42

0.46

0.63

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CryoFit CryOlive and Lightweight Union

InstalledInstalledTube Size

Tube only (control)Tube only (control)

Comparative Measurements of Electrical Resistance measured across assembled CryoFit couplings and CryOlive /Lightweight Union connections

-4 1.8 2.63 2.7 2.74

-6 0.95 1.32 1.08 1.42

-8 0.95 1.36 0.96 1.9

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GENERAL INFORMATIONCorrosion Resistance of TiNi Alloys

TiNi alloys in natural atmospheres and waters are generally more corrosion resistant than 316 stainless steel but not as resistant as pure titanium. A passive oxide/nitride surface film is the basis of the corrosion resistance of these three materials. Specific environments can cause the passive film on TiNi to break down , opening the al-loy to attack. The accumulated experience with TiNi will be presented as corrosion by atmospheres, by waters, by organic chemicals, by inorganic chemicals or by biological environments.

Corrosion by AtmospheresPolished TiNi remains shiny in air from ambient temperatures up to about 100ºC at which temperature the oxide/nitride surface layer slowly thickens giving the interference colors. Up to about 700ºC, a tight, thin, blue-black oxide/nitride film protects the TiNi. Above 700ºC, the layer thickens into a more porous brown and yellow scale. No absorption of oxygen into the alloy or internal oxidation occurs, thus TiNi behaves more like stainless steel at elevated temperatures than like titanium alloys.

If TiNi at ambient temperature is impinged by pure oxygen gas at progressively higher pressures, flashes and sustained burning begin above 150 psi absolute. By 500 psia, 16 out of 20 tests produced flashes and burn-ing.

When TiNi is heated to 700ºC in pure nitrogen at atmospheric pressure a beautiful gold-colored, somewhat brittle, surface layer forms.

The interaction between hydrogen and TiNi is sensitive to hydrogen concentration, pressure, and temperature. TiNi remains ductile after having been heated to 750ºC in hydrogen gas at atmospheric pressure , then returned to room temperature. However, TiNi exposed to hydrogen gas at 360ºC becomes brittle and crumbly. If nascent hydrogen is charged into TiNi, a brittle surface layer forms and thickens with time. This will be discussed in more detail in the “waters” section. Also, if TiNi tensile samples are elongated while surrounded by hydrogen gas at 7,000 psi, brittle failure occurs; immediately upon reducing the pressure to one atmosphere, the failure mode is again ductile.

The presence of gaseous hydrogen fluoride in damp air at ambient temperatures has caused surface etching and stress corrosion cracking in bare TiNi couplings. Condensation was occurring on the couplings, however, so this should probably be considered as attack by hydrofluoric acid.

Corrosion by WaterTinel is not attacked by fresh water. Even in pressurized boiling water (PBW) at 300°C for eleven months, Tinel gained only 15% as much weight as Zircaloy-2. The same sort of PBW at 340°C and 20 ml / kg H2 causes little damage. Water at 360°C with 100 ml H2 / kg causes Tinel to crumble to dust; the diffraction pattern of the dust shows only the presence of TiH2 and Ti2Ni. Tinel resists attack while immersed in flowing sea water. However, in stagnant sea water as in crevices, the protective film can break down, resulting in pitting. Tunneling corrosion can occur when Tinel is exposed to a marine environment which cycles from salt mist in the cool of the day to evaporation during the heat of the day. Small, residue-free pits form on the weather surface while branching tunnels penetrate into the bulk of the metal (tunneling corrosion has been reported in austenitic stainless steel under similar conditions). This same type of corrosion occurs when the salinity exceeds twice that of sea water and the pH drops below two. Addition of sodium hydrochloride to sea water causes the same phenomenon. Salt spray tests are often used as an accelerated indication of longer term corrosion resistance. Tinel passes these tests. In one case CryoFit coupling assemblies were subjected to a six-day cyclic test in 5% salt plus sulphur dioxide spray. All assemblies passed the test. A year later one of the unwashed assemblies was found to have cracked. Sectioning revealed that tunneling occurred throughout the coupling, starting from the inside where electrolyte had been trapped between the coupling and the tube.

Special effects have resulted from electrical currents and saline solutions. A cycling plus-minus 5 volt applied to Tinel in a 150-ohm saline solution caused grain boundary cracking within 150 days. Also, when Tinel was

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made the cathode in a cell with a saline electrolyte and a voltage which caused hydrolysis of the water, the Tinel was charged with nascent hydrogen. For several days after removal from the cell, chips of Tinel would forcibly pop off the surface, especially at corners.

Products for Demanding Marine and Industrial ApplicationsSMA Fittings for marine and industrial use provide an innovative means to permanently join pipes and tubes in critical high-performance systems. SMA Fitting’s reliable performance and reduced installation cost make it superior to welding or brazing methods for both original construction and maintenance in a variety of applica-tions.

Typical marine applications for SMA Fittings include hydraulic, compressed air, fire fighting, and gauge line systems. SMA Fittings are used in over 20 different ship classes, including the DDG-51, CG-47, and LHD-1 classes.

SMA Fittings are also used in both nuclear and fossil fuel electric power generating plants for feed water, control, and discharge systems.

Corrosion by Organic ChemicalsAcetic acid, CH3COOH, attacks Tinel at a modest rate of one to three mils per year (mpy) over the temperature range 30°C to the boiling point and the concentration range 50% to 99.5%. The attack is fastest at the lowest concentration at the highest temperature and at the highest concentration at the lower temperature. Seventy per cent acetic acid with 0.1% formic acid, HCOOH, attacks at the same rate as 70% acetic acid: 0.3 mpy.

A study reported 5 mpy attack rate in 0.5M oxalic acid, H2C2O4, at 50°C.

Methanol, CH3OH, has a mixed history. A steel pipeline on the bottom of the North Sea was used to deliver methanol as an anti-freeze to gas wells. An undersea repair was made to the line using a Tinel coupling which served without problems for several years. A similar installation on a new drilling platform off Scotland leaked within hours after being filled with methanol. This occurred again with several methanol line couplings under Lake Erie. Tunneling of a type similar to that found with special marine exposure situations was the cause. Low concentrations of water and halides in methanol cause attack on titanium alloys, whereas pure methanol or more contaminated methanol does not. Perhaps this is true for Tinel, too.

A 15% solution of iodine in polyvinyl pyridine at 37°C and at 60°C caused severe cracking of Tinel couplings within one month.

Tinel was not attacked after three months in a urea, CO(NH2)2, solution at 100°C.

The hydraulic fluids, Skydrol 500 and Aerosafe 2300, at 125°C and 135°C, respectively, for 20 hours caused no attack on Tinel couplings. This preliminary observation has been corroborated by many years of satisfactory Tinel service aboard aircraft.

Corrosion by Inorganic ChemicalsTinel has been exposed to a number of different inorganic chemicals singly or in combinations and mostly as aqueous solutions. The observations will be presented in alphabetical order:

Aluminum nitrate at 6.2M concentration and 50°C attacked Tinel at a fraction of a mil per year. However, 0.3M A1 (NO3)3 + 0.6M HF + 12M HNO3 attacked at 1300 mpy.

At 50°C, 6.2M ammonium thiocyanate, NH4SCN did not attack Tinel.

Boron trifluoride plus hydrogen fluoride dissolved in water condensate on CryoFit couplings attacked at 20 to 40 mpy in a pitting mode and led to stress corrosion cracking.

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Bromine dissolved in methanol can chemically polish Tinel.

Tinel has been exposed to liquid cadmium with no ill effects.

Calcium hypochlorite at 70°C attacked at 15 mpy.

Chromic acid at 10% concentration and 70°C attacked at 1 mpy; 50%, at 2 mpy. One percent chromic acid plus five per cent hydrochloric acid attacked at 18.5 mpy. Chromic acid at 6.8% plus 1.5% ferric chloride plus 9% hydrochloric acid attacked at 2,200 mpy. Half a per cent chromic acid plus 5% sulfuric acid attacked at 1 mpy.

Copper chloride at 70°C attacked at 215 mpy.

Ferric chloride at 8% concentration and 70°C attacked at 350 mpy. 1.5% ferric chloride +2.5% HCl attacked at 110 mpy; +5% HCl, at 120 mpy; +10% HCl, dissolved the Tinel!

The attack of hydrochloric acid on Tinel has a strong dependence on temperature, acid concentration, and the specific alloy composition. With 3% HCl at 100°C and a range of alloy compositions, the rate of attack was as low as 14 mpy and as high as 129; with 5% HCl the rate was from 14 to 1,667 mpy. At room temperature with 7M HCl, Tinel “A” lost from 9,000 to 18,000 mpy. Preliminary results indicate that gaseous HCl can cause stressed CryoFit couplings to fail within minutes. Curiously, equal parts of concentrated hydrochloric acid, concentrated nitric acid, and water at room temperature remove the heavy scale from hot worked Tinel without noticeable attack of the alloy.

Combinations of hydrofluoric acid, nitric acid, and water give some of the most useful solutions for chemical surface treatment of Tinel. Descaling, metallographic etching, and chemical polishing at various rates can be achieved by adjusting the ratios. One part of 40% HF, one part concentrated HNO3, and two and a half parts of concentrated H2SO4 also brightens Tinel.

Hydrazine did not attack Tinel “A” in a 49-day test at 85°F. A 16-week test at 70°F also caused no attack.

Nitric acid is more aggressive toward Tinel than toward austenitic stainless steel. At 30°C, 10% HNO3 attacked Tinel at 1 mpy; 60%, at 10 mpy; 5% HNO3 at its boiling point attacked at 80 mpy. In another test at 50°C, 3M HNO3 attacked at 11.5 mpy, 7.5M at 29 mpy; and 12M, at 30.5 mpy. Red fuming nitric acid at room tempera-ture caused extensive weight loss and pitting of Tinel within 48 hours.

The combination of 7.5M nitric acid with 0.02M sulfuric acid caused just 9 mpy attack on a Tinel coupon. However, a Tinel coupling on a 304 stainless steel tube lost 29 mpy, whereas the stainless steel lost none.

Nitrogen tetroxide, N2O4, caused no attack of Tinel during a 49-day exposure at 85°C.

Attack by phosphoric acid is a strong function of concentration and temperature. At 30°C, 5% H3PO4 attacks Tinel at 0.5 mpy; for 50% H3PO4 at the boiling point the rate is 2,300 mpy. A CryoFit coupling im-mersed in 105 weight per cent H3PO4 at 400°F “completely dissolved within 48 hours”.

Potassium hydroxide does not seem to attack Tinel. Seven hundred twenty hours exposure to 6M KOH at 50°C caused no loss of Tinel.

A CryoFit coupling joining two 304 stainless steel tubes was pressurized with helium. The assembly was im-mersed in liquid sodium at 482°C for 30 minutes, then returned to room temperature. On the sixth cycle the assembly leaked. The failure was attributed to creep; attack of the Tinel was not reported.

Sodium hydroxide at 20% concentration and 30°C attacks TiNi at 0.4 mpy; at the boiling point, 1.6 mpy.

Binary TiNi is attacked by 5 wt. sulfuric acid at 100°C at 8,200 mpy; by 10 wt. %, at 14,300 mpy. For highly alloyed TiNi, 1% sulfuric acid at 30°C attacks at 0.4 mpy; concentrated sulfuric, at 84 mpy. At its boiling point, 0.1 % sulfuric acid attacks highly alloyed TiNi at 0.3 mpy; 5% sulfuric acid, at 460 mpy. At 50°C, 0.3M sulfuric acid attacks Tinel at 3 mpy; 3.0M, at 670 mpy.

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Oxygen CompatibilitySMA products manufactured from Tinel have been found to be compatible with oxygen system applications due to their geometry and passive protective oxide layer

We have carefully researched the topic and concluded that there is no reasonable possibility of this occurring. Consider the following:

1. Spontaneous combustion of highly reactive materials is known -- fires from zirconium machining chips caused serious damage and injuries in the 1960’s at the Bettis Atomic Power Labs in West Mifflin, PA; and explosions involving aluminium powder are certainly common -- in fact, the self combustion of aluminium provides the fuel for the space shuttle booster rockets. NiTi is indeed highly reactive, but far less so than is pure titanium or aluminium. We have done a careful search of the literature on NiTi and found no published or verifiable evidence of self-combustion with oxygen. The only reference to the effects of NiTi in oxygen is an obscure letter written from the NASA Marshall Flight Center to Raychem in 1971. It was found that an unidentified NiTi alloy sustained some reaction in gaseous and liquid oxygen above 150 psia. However, it must be noted that neither the alloy, the test conditions or sample configurations were documented. If NASA conducted the tests according to the ASTM test method, which involves the use of dropped weights, to obtain these results, then there would seem to be absolutely no correlation to your fluid fittings applications.

2. All known combustion events of similar materials have involved forms such as fine powders or machining chips, where the surface area to volume ratios are very high. The products you use, however, are bulk prod-ucts and have nowhere near the surface area to volume ratio required to self-combust. Roughly speaking, the ratio in a -6 CryOlive (3/8” I.D.) is about 10,000 times lower than that which would be found in a fine powder. Very fine sheet and wire products would have a higher propensity to combust than would the CryO-live, but still would be considered safe by any measure. Keep in mind, sheets of 0.1mm thicknesses and wires of 0.02mm diameter have been in use for some time without adverse observations.

Note that it is possible for shapes to have very fine burrs, depending upon manufacturing methods. Fine burrs are candidates for combustion, but would not trigger a general combustion event. Combustion de-burring is, in fact, a common and harmless production method used with stainless steels and like materials.

3. Combustion can only happen in the absence of a passive oxide layer. Aluminium powder, for example, is explosive after atomization in high purity helium, but not after atomization in air. Aluminium tubing is com-monly used upon aircraft even though aluminium is the most reactive metal known -- many more times so than is nickel-titanium. Safety, in this case, is provided by the passive oxide layer formed by nature itself dur-ing the processing of the tubing. Nickel-titanium is well known to have such a protective layer. New metal is exposed by machining but the oxide layer is immediately reformed due to exposure to coolant water and air. Moreover, your finished products are heat treated which eliminates all chance that parts go unprotected.

4. Combustion of NiTi is known in one particular case: if elemental ingredients are pressed together in the absence of oxygen, then heated rapidly and adiabatically to 720°C, they can “combust”. That is, they will chemically combine in an exothermic manner, heating specimens beyond their melting points. This, clearly, is completely irrelevant to your situation since you use pre-alloyed material. We mention this simply because there are literature references to such “combustion synthesis” methods which might tend to mislead people into believing this is a problem with the alloy in general.”

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GENERAL INFORMATIONSeal, Hold and FlexSeal, hold, and flex are the essential tasks that any flareless sleeve must perform, in addition to properly mating with the flareless fitting end. Sealing in this context refers to the sleeve-to-tube juncture. Holding refers to the sleeve’s ability to withstand various operating loads, i.e. tension and torsion. Flex refers to the sleeve’s ability to withstand flexural loads. To aid understanding of how CryOlive sleeves work, Figure 7 identifies the regions of the sleeve responsible for the various tasks it must perform.

Figure 7

TASK REGIONS OF A CRYOLIVE SLEEVE

Sealing: CryOlive SleevesThe tube-to-sleeve seal occurs at the teeth, and is a pressure boundary. No leakage is allowed. A robust seal is essential. Sealing is a task at which CryOlive sleeves excel because of shape-memory. To understand the role shape-memory plays in sealing, it is useful to examine the stress-strain curves for the sleeve and the tube during installation (constrained recovery). These are shown in Figures 8a and 8b respectively.

SEAL (TEETH)

HOLD (BODY)

FLEX(TAIL)MATE

(NOSE)

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In Figure 8a, sleeve contact with the tube begins at point 5. In Figure 8b sleeve contact with the tube begins at point 1. After contact, stress builds rapidly in both the sleeve and the tube. Looking at the tube stress/strain curve, the tube begins to yield and continues to yield until equilibrium is reached between the tube and the sleeve. At this point recovery ceases. It is very important to note that when recovery ceases there is no let-off, or springback in either the tube or the sleeve, and that the final stress in each remains high. The remaining high interfacial pressure between the tube and the sleeve is the paramount feature of the CryOlive SMA sleeve. It is this interfacial pressure, transmitted primarily through the teeth, which creates and sustains the metal-to-metal seal between the tube and the sleeve.

Sealing: MS 21922 Flareless SleevesSealing with MS 21922 sleeves is accomplished quite differently. Figure 9 shows a detail of the MS 21922 sleeve before and after installation. MS 21922 sleeves are often called “bite-type” sleeves. When the sleeve is installed on the tube, the nut (or pre-setter) pushes the sleeve towards the end of the tube and the nose of the sleeve is forced into the tube by the conical taper of the fitting end. The small, sharp, case-hardened cutting edge on the inside surface of the nose digs or “bites” into the tube surface and throws up a burr, hence the term “bite-type” sleeve. The bite is where the sleeve-to-tube seal occurs.

Figure 9MS 21922 SLEEVE DETAIL

MS 21922 sleeves work satisfactorily on soft steel and aluminum tubes but don’t work well on harder tube ma-terials, (21-6-9 CRES and 3AL-2.5V titanium, for example) as they can’t bite into them with a high degree of consistency and reliability.

CUTTING EDGE

PRE-INSTALLED INSTALLED

Sleeve Contacts Tube

1 15

26 f

3

4

Sleeve Contacts Tube

Tube Yields

TUBESLEEVE

f

Figure 8a Figure 8b

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Holding: CryOlive SleevesAs previously stated, holding refers to the sleeve’s ability to withstand all of the various operating loads, i.e. ten-sile and torsional loads caused by fluid pressure, structural flexing, and vibration. With CryOlive sleeves, there are two mechanisms doing the holding: mechanical interference and friction. Mechanical interference is cre-ated as the sleeve swages the tube into a drawing-die configuration. The interfacial pressure, or radial loading, between the sleeve and the tube creates friction forces which oppose axial and torsional loads.

Holding and sealing are both aided by tooth “bite”. The sleeve’s teeth concentrate the recovery forces and actu-ally indent the surface of the tube as the sleeve recovers. This creates additional mechanical interference between the sleeve and the tube and enhances the tensile load carrying ability of the sleeve. Figure 10 contains a cutaway view of a CryOlive sleeve installed on tube.

Figure 10INSTALLED CRYOLIVE SLEEVE

Empirical and analytical study of the interaction between the tube and the teeth has led to thorough under-standing of the tooth geometry and spacing needed to produce the optimum drawing-die configuration. State-of-the-art finite element analysis involving plastic deformation analysis with slide lines was employed to opti-mize the configuration of the teeth for optimum “bite”.

The sealing and holding ability of CryOlive sleeves are both entirely dependent on the sleeve’s ability to swage the tube. With this in mind, many who are unfamiliar with shape-memory technology feel compelled to ask, “Will the sleeve always swage the tube enough?”, and the converse, “Can the sleeve swage the tube too much?”

Holding: MS 21922 Flareless SleeveWith MS 21922 sleeves there are also two mechanisms providing holding ability. There is mechanical inter-ference resulting from the deformation that takes place when the sleeve is set, and there is the “bite” that was described in the discussion of sealing. As mentioned previously, the bite isn’t good on hard tubes.

Taking these questions one at a time, the answer to the first question is yes, the sleeve will always swage the tube sufficiently. Two things are required for proper swaging: sufficient force, and sufficient motion. As was men-tioned early on, the alloy can develop hoop stress upwards of 60 KSI (412 MPa) during constrained recovery. This ability is an inherent property of the alloy, and is a function of alloy composition and processing. Consistent alloy exhibits consistent shape-memory behavior. Alloy production, processes, controls, and quality checks are utilized to assure consistent material. Determination of the force required to swage a tube of a given material, strength, and stiffness is relatively straightforward, and burst performance requirements, typically 4X, dictate the amount of swaging necessary to meet the requirements. Conventional calculations are then employed to determine the cross sectional thickness of alloy required to do the job. In general, ensuring sufficient swaging involves 1) balancing the stress the shape-memory alloy can produce with the force required to swage a given tube via sleeve cross section, and 2) sizing the sleeve’s as-machined ID so as to effectively use the available shape-memory motion.

As mentioned earlier, CryOlive sleeves were designed to be used with most common aerospace tubing: 6061-T6 aluminum, 304 1/8 hard CRES, 21-6-9 CRES, 3Al-2.5V CWSR titanium, etc. As far as tube swaging is con-cerned, the sleeve’s cross section and ID are sized such that even at their worst-case tolerance extremes, i.e. the

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minimum cross-section and the maximum tooth ID, the sleeve has enough stored energy and motion to swage the strongest, stiffest tube, i.e. 4000 psi rated CWSR titanium tube per AMS4944, with the tube in its least favor-able condition, i.e. minimum OD, maximum wall, and maximum yield strength.

The following example illustrates how a sleeve is sized so as to swage properly under adverse tolerance stack-ups. A size -20 shape-memory alloy sleeve is used in this example.

Tube OD: 1.249-1.254Machined Sleeve ID: 1.186-1.192EXPANDED SLEEVE ID1. Max Tube Diameter: 1.2542. Min. Clearance at Installation: +.0053. Required Min Expanded Sleeve ID: 1.259

REQUIRED SLEEVE MOTION4. Min Required Tube Swaging (2%): 1.249 X .02 = .0255. Unresolved Sleeve Recovery (2%): 1.192 X .02 = .0246. Tube Tolerance: 1.254 - 1.249 = .0057. Installation Clearance: 1.259 - 1.254 = .0058. Necessary Sleeve Motion: 4 + 5 + 6 +7 = .059

EXCESS MOTION 9. Min. Available Sleeve Motion: 1.259 - 1.190 = .06910. Necessary Sleeve Motion: -.05911. Excess Available Motion: .010

Dimensions in inches.

Note the following about the preceding exercise:

2% swaging is a nominal figure considered by Aerofit, Inc. engineers to provide good “holding” ability. Note that 2% swaging is based on the minimum OD tube and is therefore conservative. 2% unresolved recovery refers to the difference between the as-machined, or free-recovered, sleeve ID and the as-installed ID. 2% is a nominal figure considered by Aerofit, Inc. engineers to provide good sealing ability. Note that 2% unresolved is based on the max machined sleeve ID, and is also conservative.

Excess available motion (.010 in this example) and the unresolved recovery ensure that the sleeve will always swage the tube sufficiently.

A size -20 sleeve is used as an example here but the situation is typical. There is excess available motion for all sizes of sleeves.

Moving now to the second question, “Can the sleeve swage the tube too much?” The answer is no, but this an-swer requires some qualification. The sleeve can only recover to its original, as-machined size. This can only occur if there is little or no resistance from the tube or no tube at all.

Low-strength, low stiffness tubes are not ideally suited to CryOlive installations, nor to any other flareless design, for that matter. Consider 1.000 x .020 wall, 5052-0 aluminum tube, for example. This is a very low strength, low stiffness tube. This tubing would present little resistance to the swaging force of a CryOlive sleeve. The sleeve would recover virtually all the way to its as-machined ID resulting in very little unresolved recovery. The benefits of the “live crimp” action that results from unresolved recovery are lost in this situation.

Other questions that have been raised with regard to swaging are, “Is it possible for the nose to swage so much as to lose its ability to mate with the MS fitting end?”, and, “Can the sleeve body swage to the point where it would not have adequate contact with the shoulder of the coupling-nut?”. The answer on both accounts is no. These possibilities were addressed in the sleeve design by configuring the nose so that it is incapable of swaging upon recovery, and by ensuring there was adequate overlap of the nut and sleeve shoulders after recovery.

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Flexing: CryOlive SleevesReferring to Figure 7, note the tail region of the sleeve. The tail is responsible for flexure performance. The tail bleeds off bending stresses encountered by the tube. Firm, uniform contact between the tube and the tail is required to effectively transfer the stresses from the tube to the sleeve. Here the interfacial pressure of the shape-memory effect is tailored via tail geometry to provide gradual, uniform support of the tube. In addition the ID of the tail is coated with a solid film lubricant to combat fretting between the sleeve and the tube. Flex-ural endurance of CryOlive shape-memory sleeves is often limited by the flexural endurance of the tube. 4000 psi rated CryOlive sleeves, for example, were qualified on 3Al-2.5V titanium tubing in flexure with a minimum of ten million cycles at 20,750 psi minimum dynamic bending stress. No other 4000 psi rated separable fit-ting is qualified at this stress in every size. Figure 11 and Figure 12 display CryOlive sleeve flexure results from qualification testing on 4000 and 3000 psi rated CWSR titanium tube, respectively. CryOlive sleeves meet the flexure requirements of AS18280.

Figure 114000 PSI QUALIFICATION FLEXURE TEST RESULTS

CRYOLIVE SLEEVES ON4000 PSI CWSR TITANIUM TUBE

CYCLES

50000

40000

30000

20000

10000

0

RUNOUT BEYOND10,000,000 CYCLES

-4 test halted; no failure-6 test halted; no failure-6-8 test halted; no failure

3 4 5 6 7 8

STRE

SS (

PSI)

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Mating: CryOlive Sleeves vs. MS 21922 SleevesWhen mated, the contacting surfaces of a flareless sleeve and flareless fitting end form a pressure boundary. Proper mating is essential. To hold pressure, the surfaces must contact uniformly and be held together firmly.

The sleeves and fittings are machined within certain tolerances. Proper mating must occur for any combination of permissible tolerance conditions of both the mating parts. Flareless connections are required by AS18280 to be capable of eight repeated assemblies.

Proper mating must be established each time the joint is reassembled. In actual usage, reassembly may involve replacement of the fitting, in which case the sleeve may encounter a fitting end that is likely to be in a slightly different tolerance condition than its predecessor. So proper mating must occur 1) for any permissible toler-ance condition of both parts, 2) with repeated assembly, and 3) if components are interchanged. To accomplish this, the design and/or the components need to have some “give” in them. MS sleeves and CryOlive sleeves both provide the necessary “give”, but differ in one key aspect: MS sleeves do not have positive stop whereas CryOlive sleeves do.

Because they have no positive stop, MS sleeves are susceptible to problems resulting from over torquing. Torqu-ing beyond the prescribed limits forces the MS sleeve deeper and deeper into the conical taper of the fitting end and results in deformation of the sleeve. The deformation can cause leakage or if the over torquing is severe the sleeve can actually buckle. In either case the deformation interferes with proper mating upon reassembly with the same fitting or a different fitting.

CryOlive sleeves are not susceptible to over torquing. The shoulder on the sleeve butts against the end of the fitting as the joint is torqued up and thus limits the penetration of the nose into the fitting end, even if the joint is overtorqued.

Figure 123000 PSI QUALIFICATION FLEXURE TEST RESULTS

CRYOLIVE SLEEVES ON3000 PSI CWSR TITANIUM TUBE

CYCLES

50000

40000

30000

20000

10000

0

RUNOUT BEYOND10,000,000 CYCLES

-4 test halted; no failure-4

-6 test halted; no failure

-8 test halted; no failure

-6

-8

3 4 5 6 7 8

STRE

SS (

PSI)

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GENERAL INFORMATIONCommon Questions

If I let a coupling recover (shrink), can I put it back in liquid nitrogen to re-expand it?No, it must be returned to the distributor for re-expansion. But make sure that it is returned, because the ability to re-expand couplings ensures that the investment in the product is not lost if it recovers for whatever reason. Do not throw away/dispose of recovered couplings!

If I let a coupling recover on a tube without it being properly positioned, can I remove the coupling by putting it back in liquid nitrogen?No, once the coupling shrinks on a tube, the only way to remove it is to cut it off the tube.

If the joint is cooled below the transformation temperature of the alloy, will the coupling fail?No, the coupling will become relatively weaker at cryogenic temperatures, but will not fail. Recall that the only way a coupling can be expanded at low temperatures is by mechanical force, as in the mandrel used in the man-ufacturing process. The low temperature itself will not cause the coupling to expand. Indeed NASA have tested couplings at -320ºF (-196ºC) and recorded Helium leak rates of less than 10-5 cc/sec.

Is there a corrosion problem between the coupling (which contains titanium) and aluminum tubing?No. Even though titanium and aluminum are at opposite ends of the galvanic scale, testing and thirty years of experience of using the alloy on aluminum have shown that corrosion problems do not readily occur. The key is properly protected aluminum tube. Corrosion problems on unprotected aluminum tube will occur with any coupling, not just SMA products!

How long do I have till the coupling recovers?The complete answer is it depends on the size of the coupling which translates into the mass of the metal. The tube material can also influence recovery with aluminum transferring temperature the quickest and titanium transferring temperature the slowest. But on the average, you should have about 30 seconds to install a coupling prior to recovery. This time can be increased by cooling the tube prior to installation.

What is the shelf life of the couplings in storage?Unlimited - provided the liquid nitrogen in the storage vessel is kept refilled.

Are there Shape Memory Alloy tees and elbows too?Because of the limitations of the expansion process ( the final stage of manufacturing of all Shape Memory Al-loy couplings ) it is not possible to have tees and elbows made from Shape Memory Alloy - they would in any case be somewhat complex to install. However, Aerofit offers a wide range of CryoFit-compatible tees, elbows, crosses, bulkhead fittings, in both permanent connection styles and with threaded interface to some ports for connection to Flared, Flareless and Beamseal systems. These compatible fittings are generally made from Ti-6Al-4V alloy for maximum strength and lowest weight and come ready marked and prepared for use with the rel-evant CryoFit couplings. They are fully qualified to the relevant industry or in-house specifications for use with CryoFit couplings.

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Can CryoFit, Cryolive and CryoFlare be used for Battle Damage Repair? Absolutely, CryoFit can often provide the quickest and most effective permanent repair to any damage, whether in a military or civilian context. It has the crucial advantage over all other systems of requiring much less disas-sembly of surrounding components.

CryOlive and CryoFlare are even simpler to install and can be used to provide the mating interface for a tempo-rary repair with a flexible hose.

Can they be installed while wearing NBC (Nuclear, Biological, Chemical Warfare) Protective Equipment?Yes, the simplicity of the installation process means that CryoFit, CryoFlare and CryOlive are ideal for installa-tions where vision and manual dexterity are impaired. As an added benefit the standard NATO issue inner and outer glove combination can also be used for short periods with Liquid Nitrogen without any additional protec-tion.

Are CryoFit and CryOlive joints electrically conductive? Do they meet requirements for Lightning Strike?Yes, Tinel has a resistivity of 100 x 10-6 ohm-cm. The resistance of assembled CryoFit joints is only very slightly higher than for tube of an equivalent material, size and length. Both CryoFit and the separable CryOlive/Light-weight Union joint easily meet the requirements of BAC5117.

QA Summary• A coupling which has warmed up cannot be re-expanded by re-immersion in liquid nitrogen.

• It is impossible to install a coupling on to a tube assembly unless it is in the expanded (as-delivered) condition.

• This characteristic acts as fail-safe: a coupling which has not been expanded, or which has been allowed to warm prematurely, cannot be installed.

• The characteristics of shape-memory-alloy are such that a correctly installed coupling will not leak.

• Only a visual inspection of the position of the coupling with respect to the installation witness marks is required.

• Additional examination by radiography or endoscope provides no additional information and is of no value.

Aerofit, Inc. APT Laboratory

1425 South Acacia AvenueFullerton, California,92831 USA

www.aerofit.comwww.aptlab.com

Documents

Shape Memory Alloy (SMA) Fluid Fitting System · Shape Memory Alloy (SMA) Fluid Fitting System Product Handbook & Engineering Data