Industry: Aerospace
Testing Application: Extended Temperature Range Thermal Cycling for High-Density Steel Alloy Valve Components
A prominent company in the aerospace sector approached Associated Environmental Systems (AES) in need of a custom, high-performance liquid nitrogen (LN2) cooled floor-style test chamber to validate structural integrity and performance across extreme thermal profiles. The challenge? The client needed to achieve precise 5–9°F/min part ramp rates and batch testing uniformity across heavy steel alloy components (up to 38 lbs), while requiring extreme temperatures ranging down to cryogenic levels (-292°F), strict 5V TTL I/O integration, and a custom footprint that integrates with existing 480V/20A lab infrastructure.
The AES Solution
AES engineered the ZBD-108 Custom Liquid Cooled Oven Test Chamber, a floor-style, liquid nitrogen-cooled system built to meet the unique demands of the application.
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Vertical Airflow Plenum Architecture: Features an engineered floor-and-ceiling plenum system providing uniform vertical airflow to eliminate part-to-part thermal deviations and Out-of-Tolerance (OOT) conditions during multi-unit batch testing.
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Extended Cryogenic Thermal Range: Delivers rapid thermal conditioning from -292°F to 450°F (-180°C to 232°C) with controlled IEC ramp rates up to 8°C/min, utilizing hard-plumbed VJ LN2 injection to hit aggressive part ramp targets.
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AESONE CONNECT Integration: Powered by a Watlow F4T controller with cascade product control, supporting 9–15 auxiliary T-type thermocouples and AESONE CONNECT® software integration for seamless data logging and remote monitoring.
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Custom Hardware & I/O Adaptation: Configured with two 4-inch side pass-through ports, a 37-pin SUB-D connector driving 5-bit 5V TTL triggers directly from the F4T, and single-floor stands with swivel brake casters for lab mobility.
Crafting Your Perfect Test Set-Up
This solution was custom-engineered to meet aerospace component testing demands in batch thermal profiling and cryogenic cycling. By combining targeted vertical airflow, ultra-low LN2 cooling capabilities, and specialized digital I/O integration, AES delivered a chamber system that seamlessly integrates into existing 480V 3-phase lab drops, eliminates batch temperature variance, and accelerates qualification cycles under strict aerospace standards.
This project highlights AES’s commitment to designing advanced, customized test solutions that help engineers push boundaries—supporting innovation in the aerospace sector and beyond.
