Mechanically locking, high vibration resistant fuel line connectors and hydraulic fittings to improve flight line maintenance times on the B-1 and B-2 by eliminating the need for safety wire

This Phase I feasibility study is to develop a mechanically locking, high vibration resistant and reusable fastening solution for aircraft fuel connectors and hydraulic fittings (without the need for safety wire) for critical fluid conveyance system applications on the B-1 and B-2 aircraft and ground support equipment. The proposed technology with its positive locking mechanism will provide for zero leak connections even when applied in high pressure, high vibration, and high temperature environments. The ease of application and reversible/reusable property of the technology will improve flight line maintenance times on the B-1 and B-2 aircrafts.  Fuel line connectors and hydraulic fittings are used in critical fluid conveyance systems of an aircraft, such as fuel systems, landing gear systems, wheel brakes, thrust reverser actuation systems, and wing routing actuations, etc. The fittings applied in these critical applications are commonly exposed to high vibration and high temperature that could result in failure of the fitting joint, and thus the performance of the critical system itself.  Currently, the connectors and fittings applied in critical aircraft systems are fastened and safety-wired to reduce their chance of loosening due to rigorous vibration and inconsistent pressure of fluids. The manual installation of safety wire is very labor-intensive and therefore costly. A mechanic can typically safety-wire 10 fasteners per hour at an hourly labor rate of $150. Hence, there is an imminent need to develop a high vibration resistant and high-pressure fluid connector that is easy to install and that can remain locked and provide for secure fluid connections when exposed to extreme vibration.  Enduralock, in collaboration with an offshore well completions company, has previously developed the first mechanically locking, high vibration-high temperature resistant fastening solution for 17000 PSI gas fitting that in vibration testing, in accordance with National Aerospace Standard (NAS), survived 10x the aerospace requirement for a self-locking nut, proving its reliability in establishing a secure and reliable connection for the fluid lines. The fastening technology was designed to be installed with standard tools for ease of application and the fastening mechanism is fully reversible/reusable in maintenance. On the assembly line, approximately over 300 of Enduralock’s high vibration resistant fasteners could be installed in an hour compared to 10 fasteners that can be safety wired during the same time. Thus, integration of Enduralock’s locking technology in aircraft fuel connectors and hydraulic fittings that are currently safety wired will result in improvement of both the reliability of the connectors in high vibration environments and the flight line maintenance times on the assembly line for the B-1 and B-2 aircrafts.