Aerospace Components
Components for aircraft and spacecraft- Chem-tronics fabricates components
for Aerojet, Allison, Boeing, General Electric, Lockheed Martin,
Pratt&Whitney, Rocketdyne, Rolls-Royce, and many
others. We specialize in lightweight Unistructure(tm)
and Unisandwich(tm) chemically-milled titanium and aluminum alloy parts for
engines, airframe structures, and launch vehicles. We can build parts to your
specifications or work with you to design the components you need.
Component Product
Types:
·Rings, Cases, and
Modules
·Ducts and Compressor Cases
·Avionics Enclosures
·Exhaust Nozzles and
Structures
·Doors, Keels, and Bulkheads
·Sandwich Structures
·Space Systems
·Complex Weldments
·Pressure Vessels
 Rings,
Cases & Modules
Chem-tronics pioneered the use
of roll-formed and welded aluminum extrusions to reduce the cost of cases for large
commercial aircraft engines. To the newest generation of fan and containment cases we have
applied the weight saving benefits of Unistructure(tm) technology. Our Unistructure
stiffened designs save over 100 pounds per unit over a structurally equivalent single
shell design. We supply Rolls Royce with a complete Unistructure stiffened fan containment
system for the Trent 800 engine, destined to power the Boeing 777 family of aircraft. This
module assembly consists of a Unistructure stiffened titanium rear fan case and a 2219
aluminum fan containment case, inner V-groove, OGV assemblies, plus composite honeycomb
panels bonded in place and Kevlar wrapping on the containment case. Chem-tronics
participated in the design and concurrent engineering of the Trent 800 module, helping to
make the Trent 800 engine a lighter overall power system. |
 Ducts and Compressor Cases
Unistructure
has been applied with great success to jet engine bypass fan and augmenter ducts for
military aircraft that operate in a high vibration environment with high internal pressure
loads. Unistructure ducts are easily inspected and avoid the problems of delamination or
stress cracking due to their integral unitized design. Each assembly parts count is
greatly reduced when compared to equivalent composite or monocoque assemblies. Comparisons
of Unistructure components show them to be both lighter and less costly than equivalent
honeycomb construction. The Allison AE 2100/3007 high-pressure compressor case weighed 50
pounds (22.7kg) as a machined casting. With Unistructure plus the use of vacuum brazing to
incorporate the bleed air manifold and guide vane bosses, both weight and cost were
reduced over 20%. This product now weighs less than 40 pounds (18.14kg). Designers
considering a Unistructure product can use this rule of thumb: a Unistructure design can
approach the light-weight of composites for 10% less cost. Compared to a skin/stringer
equivalent, a Unistructure design will typically weigh 25% to 40% less. |
 Avionics Enclosures
In the early '90s Chem-tronics
designed a 3/4 ATR box as light as the latest composites, which could be produced
competitively with standard aluminum enclosures. The resultant 7.5 lb. (3.4kg) electron
beam welded aluminum Unistructure stiffened box that met MIL-I-85508 vibration and shock
criteria. This technology is also applied to reduce weight on automated test equipment
such as this transit case, which saved 12 pounds (5.44kg) for our customer. |
 Exhaust Nozzles and Structures
Chem-tronics has
been building exhaust structures from difficult-to-work-with alloys for many years. Some
examples include the J58 Diffuser for the SR-71 Blackbird (inconel 718), fuel nozzles for
the C-5 A&B aircraft, an afterburner segment in inconel 625, TF-39/L2500 engine fuel
nozzles in inconel 718, and others. We worked closely with both General Electric and Pratt
& Whitney to concurrently engineer vectoring exhaust nozzle transition structures for
YF-22 and YF-23 aircraft. Currently we manufacture the F119 vectoring exhaust nozzle
transition duct made from a Beta titanium alloy for the F-22 aircraft. We are also
building launch vehicle nozzles from columbium and inconel 718 for Aerojet, Pratt &
Whitney, and Rocketdyne in our vertically integrated facilities. |
 Doors, Keels, and Bulkheads
Our first use of Unistructure on a flat
fabrication in production was the Ti 6Al-4V bulkhead ("firewall") for the
Rolls-Royce RB211-535 E4. The firewall is lightweight, stiff, and replaces an expensive
skin and stringer fabrication. Unistructure has demonstrated weight and cost savings in
numerous airframe structure trade studies and competitions, comparing favorably with
alternative fabrication methods such as SPF truss structures, honeycomb, sheet/stringer
constructions, and selected composites. The high parts counts associated with composites
(fasteners, stringers, stiffeners, rivets, etc.) are eliminated with Chem-tronics unitized
designs. Additionally, our patented hot creep forming process produces complex contoured
panel segments with very little thinning, excellent surface finish and dimensional
control. |
 Sandwich
Structures Chem-tronics' Unisandwich(tm) concepts for aerospace components combine
strength and the flexible tailoring options of Unistructure. Unisandwich consists of an
integral rib and skin panel brazed or electron beam welded to a single facesheet. It
offers the options to tailor each product for local or global strength and stiffness by
varying skin thickness, rib geometry, and rib concentrations to maximize weight reduction
and minimize cost. End enclosures and penetration features, which are difficult and costly
to integrate in conventional honeycomb or diffusion bonded sandwich structures, are
integral in Unisandwich. |
 Space Systems
Launch vehicles
and other space applications require increasingly lightweight structures. Chem-tronics
produces the finish machined and chem-milled 10' (3.05m) diameter fuel domes for the Titan
IV launch vehicle. We have the capability to produce similar units that require up to
232" (5.9m) diameter and 110" (2.79m) high turning capabilities. For the Titan
IV we also developed Unistructure stiffened aluminum thrust vector control cowls as an
alternative to a skin/stringer type assembly. The Unistructure design delivers a 20%
savings in weight. We designed a series of lightweight aluminum bearing housings for the
rotational motion control mechanism of the solar arrays on Space Station. Here, too, the
rib and shell designs were based on Unistructure. |
 Complex
Weldments
Chem-tronics has state of the art
weld facilities, which include EB, TIG, and plasma. Our largest EB weld chamber is 10' x
10' x 6' (3.05 x 3.05 x 1.82m), with stationary head and movable tooling. A second large
chamber, 9' x 7' x 5.5' (2.74 x 2.1 x 1.67m), has CNC controls for all axes. A full
complement of non-destructive test facilities is on-site and includes a 16' (4.87m) square
X-ray booth, fluorescent penetrant, and ultrasonic inspection. In addition, Chem-tronics
has a NADCAP certified metallurgical lab on site to support chemical and physical
materials analyses. |
 Pressure Vessels
Durability, fracture-criticality,
close-tolerances, level III NDT: these are all characteristics associated with the
work we do on space-based pressure vessels. Whether for the space shuttle's Power Reactant
Storage Assembly, holding oxygen or hydrogen, or for space station or satellite
applications, the demand for quality documentation, program management, and technical
support has never been greater. Beginning with titanium pressure vessels we built for the
Apollo program in the 1960s, to a large titanium thick-walled vessel used on board a
KC-135, to the 72" (1.82m) long, 5' (1.52m) diameter thin-walled fuel tank we built
from Ti 15-3-3-3, Chem-tronics has the machining, welding, non-destructive testing and
program management capabilities to handle the rigorous nature of this product line. |
See GKN Aerospace Chem-tronics Manufacturing Capabilities
History: Advanced ideas in lightweight structures
A 40-year tradition of innovation
Chem-tronics is a vertically integrated manufacturing company that specializes in fabricating lightweight structures for high performance aerospace applications. Since the company's inception in 1953 we have manufactured products for commercial and military aircraft and space launch vehicle systems.
We pioneered the use of near-net extrusions in jet engines, replacing heavy material demanding forgings. We developed Unistructure(tm), an integrally stiffened, lightweight structure which competes favorably with twin skin honeycomb. Every new military fighter and bomber aircraft jet engine built in America since 1976 has utilized Unistructure bypass ducts. To date, production surpasses over 14,000 units. Aircraft equipped with Unistructure bypass ducts include the F-14, F-15, F-16, F/A-18, F-117, B-1B and B-2 bombers, Gripen, and Eurojet. [Designers- See the advantages of Chem-milled/Unistructure Components]
Experience, gained throughout 40 years of successful business, allows us to move forward with new technical advancements. In 1992 we introduced to the commercial engine manufacturers a new Unistructure high-pressure compressor case which provides lower weight and cost compared to castings. In 1993 we teamed with Rolls Royce in the design, development and production of the Trent 800 Fan Module. Our Unistructure technology became part of this Fan Module.
Each year the aerospace industry is faced with new demands and challenges. Our dedicated expert team of aerospace engineers stands ready to meet these challenges, supported by a team of highly skilled, motivated employees using state of the art manufacturing systems.
One may ask, what's special about Chem-tronics? We believe it is our vision of satisfied customers -- customers who can depend on us to meet their needs -- customers convinced that we are committed to excellence with quality products delivered on time, at fair and reasonable prices.
For more details, please contact the Aerospace Components Sales Department.