Assembly & Test Services

Extensive In-House Capabilities

Extensive In-House Capabilities to Meet Your Precision Assembly and Demanding Testing Requirements

Assembly and Test receives a complete kit for each component/system package – all the necessary parts to produce the final product.  The package includes assembly drawings, procedures, inspection criteria, in-process testing, and final acceptance test procedures.  Special hardware assembled at Marotta Controls occurs in the 1,000 square foot Class 7 Clean Room.  This Clean Room is monitored and controlled in accordance with ISO-14644-1.

The majority of components/systems produced by Marotta Controls are “active control products” requiring 100% final acceptance testing.  To achieve that requirement, Marotta Controls maintains a complete on-site high-performance test capability including:

  • Pneumatic up to 25,000 psig, and up to 20,000 SCFM @ 6,000 psig
  • Hydraulic up to 10,000 psig, and up to 25 GPM @ 6,000 psig
  • Hydrostatic up to 40,000 psig
  • Vacuum down to 1 x 10-4 TORR
  • Thermal Altitude to 100,000 ft at -70°C to +200°C
  • Metrology including Moisture to .01ppm and COto .02 ppm/volume
  • Environmental – vibration, contamination, thermal, shock, explosion, altitude, humidity, sub-sea, salt spray, life cycle and more.

Our extensive on-site capabilities and efficient methods yield very competitive rates. 

For more information regarding Marotta’s Assembly and Testing Services, please contact us or review the items below.

Pneumatic
  • High Pressure – High Flow:   Gaseous nitrogen is supplied from a liquid nitrogen storage tank through a heat exchanger and compressors.  The storage capacity of 55 cubic feet at a maximum pressure of 6,500 psig.  This facility can produce short duration flow rates of 20,000 SCFM at 6,000 psig.
  • High Pressure – Intermediate Flow:  The high pressure, intermediate flow test area contains 20 individual 250 SCFM high pressure pneumatic test stands, each stand capable of pressure to 6,000 psig.

Special Fluids

Marotta Controls has the capability and facilities to conduct testing of components and systems that require performance evaluations outside the realm of standard fluids.  Fluids used include:

  • Helium
  • Nitrogen
  • Ammonia
  • Freon
  • Hydrogen
  • Skydrol
  • Oxygen
  • Isopropyl Alcohol
  • Hydrogen Peroxide

Hydraulic Testing

High Pressure – High Flow: The high pressure, high flow facility contains four units with the following capabilities:

  • Flow rates of 25 GPM at 5,000 psig MIL-H-83282 and 5606
  • Short duration pressures to 10,000 psig of chlorotrifluoroethylene (CTFE) and MIL-H-6083 or 5606 hydraulic fluid
  • Flow rates of 30 GPM at 6,000 psi Skydrol LD-4
  • Flow rates of 30 GPM at 1,500 psi of Lube Oil, MIL-PRF-23699

Hydrostatic Testing

Marotta Controls designed and developed its own hydrostatic test facility.  This unique facility can test components and systems using gaseous nitrogen or helium at pressure up to 40,000 psig.  This unit is enclosed, yet permits full operational control and visual assessment through bullet-proof glass viewing windows.


Vacuum Testing

Components and systems can be tested in Marotta’s vacuum test facility to 1 x 10-4 TORR.


High & Low Temperature Chambers

High and low temperature tests are performed using  a variety of environmental chambers ranging in size from 1 ft3 to 30 ft3.  The normal operating range of the chambers is -100°F to 400°F.  These chambers are used for in-house development, acceptance testing, and qualification testing to customer specifications and requirements.


Clean Room

Marotta Controls’ facility boasts a 1,000 sq. ft. Class 10,000 Clean Room in accordance with FED-STD 209.  Six Flow Benches (Class 100) with flow hoods, in accordance with FED-STD 209.


Thermal Altitude Chamber

In 2010 Marotta Controls added a Thermatron Thermal Altitude Chamber.  This chamber is capable of simulating altitude of 100,000 ft.  at temperatures from -100°F to +350°F.  The chamber is 5′ x 2.5′ in size with a LN2 Boost.


Nondestructive Testing

Marotta Controls has in-house capability to perform nondestructive testing in the following categories:

  • Penetrant
  • Fluoroluminescent (black light)

Should requirements dictate, Marotta subcontracts to independent laboratories for specialized nondestructive testing such as:

  • Magnetic Particle
  • Ultrasonic
  • Xray
  • Infrared Spectrophotometer
  • Cryogenic Flows
  • High Vacuum and Thermal Vacuum

Soldering

Soldering is performed in accordance with IPC-J-STD-001 with the Space addendum.  Solder inspection is performed in accordance with IPC-A-610, and NASA STD-8739.3.  All personnel performing solder operations and/or inspections are qualified and certified to the above soldering standards by our in-house certified instructors.


Welding & Similar Processes

Standard welding, as well as sophisticated techniques such as Laser, Electron Beam, and Gas Tungsten Arc Welding (GTAW) beam, are subcontracted to qualified laboratories that meet Marotta Controls’ quality assurance standards.  Most GTAW is performed out of house.  Marotta Controls has the capability to silver solder various subassemblies when required.


Contamination Control

Marotta Controls’ products are used in programs and on systems that require the most stringent standards in contamination control.  Marotta Controls’ contamination control standards and Marotta Controls’ process standards meet or exceed the cleanliness requirements of the industries served (including commercial, military, nuclear and space applications).  Whether the requirement is for gas, liquid, oxygen, or exotic-propellant fuels, Marotta has a documented cleaning, processing and packaging procedure to fit the specificaiton.  marotta has over 200 distinct cleaning procedures on file.


Lapping

In-house capabilities to achieve finishes to ± 1µ.  Flatness to ± 0.000001″.


Corrosion Analysis

Before assembly, all component metal parts are examined visually for evidence of corrosion.  Suspected indications of corrosion are identified for the nature of the deposits, and then removed by standard methods relative to the identified corrosion type.


Passivation

Passivation of stainless steel surfaces are processed in-house to the following procedures:  AMS-QQ-P-35, ASTM-A967, QQ-P-35C and AMS-2700B.


Nonvolatile Residue

Nonvolatile residue are determined by two different types of methods depending on the fluid used for the final rinse.  Grade A isopropyl alcohol, Spec. TT-I-735 is filtered through 0.3 micron membrane used in conjunction with an analytical balance, readable down to 0.01 milligrams, to determine the amount of nonvolatile residues remaining in alcohol final rinse fluid.  DC-190 High Temperature Total Organic Carbon Analyzer is used with deionized water, High Purity, Spec TSC-SPEC-C-20 Grade A filtered through a 0.2 micron memmbrane filter, to determine the amount of nonvolatile residue in parts per million.


Oil Detection

As requested, parts are examined using ultraviolet light.  Oil deposits are detected by the refraction of the fluorescent light from the contaminated areas.


Particulate Contamination

Final cleaning procedures are performed using either a liquid or gas flush.  The resultant liquid or gas content is microscopically examined for quantity, size and distribution of any particulates.

The millipore filtration membrane method is used with particulate counts determined by using magnification intensities up to 100x.


Laboratory Test Support

Marotta Controls uses its own test capability to prove concepts and establish performance criteria.  For some programs, environmental test laboratories are used when systems have size, weight and test requirements that exceed Marotta’s in-house capabilities.  They are also used if Marotta Controls is seeking an independent appraisal.

Laboratories selected by Marotta Controls are inspected, audited and qualified to meet Marotta’s strict standards of performance.  Complete test procedures, including test conduct, instrumentation, records and report requirements are generated by Marotta Controls.  All critical environmental test sequences are witnessed by Marotta Controls assurance personnel.