Abstract: A bulkhead fitting assembly that includes a tube, a mounting flange attachable to a bulkhead, a thermal shell joining the mounting flange and the tube and having a portion spaced away from the tube forming an air pocket between the tube and the thermal shell, a plurality of mounting studs extending from the mounting flange away from the thermal shell, and a plurality of bushings positioned between the mounting studs and the bulkhead. The plurality of bushings are each shaped to complete a current path from the tube to the plurality of mounting studs, from the plurality of mounting studs to the plurality of bushings, and from the plurality of bushings to the bulkhead. Nuts are threaded on the studs to secure the fitting assembly by sandwiching the bulkhead between the mounting flange and the bushings, which are retained by the nuts.

Abstract: A method of sealing an opening in a bulkhead with a fitting assembly having a tube, a mounting flange, a thermal shell, an adapter, a bushing, and a jam nut may include inserting the tube through the opening; placing the mounting flange against the bulkhead, the mounting flange attached to the thermal shell, the thermal shell attached to the tube, and the mounting flange attached to the adapter so that the adapter extends away from the mounting flange and from the thermal shell through the opening; forming an air pocket by spacing a portion of the thermal shell away from the tube; placing the bushing on the adapter; and tightening the jam nut on the adapter to sandwich the bulkhead between the mounting flange and the bushing to form a seal between the mounting flange and the bushing to seal the opening.

Abstract: A method of making a bulkhead fitting assembly may include joining a tube to a thermal shell of a mounting flange, the mounting flange shaped to be attached to a bulkhead and including an adapter; forming the thermal shell to have a portion spaced away from the tube to form an air pocket between the tube and the thermal shell adjacent the mounting flange; and placing a bushing on the adapter such that the bushing completes a current path from the tube to the adapter, from the adapter to the bushing, and from the bushing to the bulkhead.

Abstract: A bulkhead fitting assembly may include a tube; a mounting flange attachable to a bulkhead; a thermal shell joining the mounting flange and the tube and having a portion spaced away from the tube forming an air pocket between the tube and the thermal shell; a plurality of mounting studs extending from the mounting flange away from the thermal shell; a plurality of bushings positioned between the mounting studs and the bulkhead, the plurality of bushings each shaped to complete a current path from the tube to the plurality of mounting studs, from the plurality of mounting studs to the plurality of bushings, and from the plurality of bushings to the bulkhead; and a plurality of nuts received on the adapter to lock the fitting assembly in place by sandwiching the bulkhead between the mounting flange and the nuts, wherein the nuts are in engagement with the bushings.

Abstract: A method of sealing an opening in a bulkhead with a fitting assembly having a tube, a mounting flange, a thermal shell, an adapter, a bushing, and a jam nut may include inserting the tube through the opening; placing the mounting flange against the bulkhead, the mounting flange attached to the thermal shell, the thermal shell attached to the tube, and the mounting flange attached to the adapter so that the adapter extends away from the mounting flange and from the thermal shell through the opening; forming an air pocket by spacing a portion of the thermal shell away from the tube; placing the bushing on the adapter; and tightening the jam nut on the adapter to sandwich the bulkhead between the mounting flange and the bushing to form a seal between the mounting flange and the bushing to seal the opening.

Abstract: A method of making a bulkhead fitting assembly may include joining a tube to a thermal shell of a mounting flange, the mounting flange shaped to be attached to a bulkhead and including an adapter; forming the thermal shell to have a portion spaced away from the tube to form an air pocket between the tube and the thermal shell adjacent the mounting flange; and placing a bushing on the adapter such that the bushing completes a current path from the tube to the adapter, from the adapter to the bushing, and from the bushing to the bulkhead.

Abstract: A bulkhead fitting assembly may include a tube, a mounting flange, and a thermal shell joining the mounting flange and the tube; the thermal shell may consist of a thin barrier and form an air gap between the tube and the mounting flange.

Abstract: Disclosed herein is a method and apparatus for providing a bulkhead fitting assembly useful for aircraft, watercraft, spacecraft, architectural, or industrial applications. The assembly provides a mechanical barrier against fluid transfer from a wet side to a dry side of a bulkhead and allows electrical conduction through or from the bulkhead. The assembly includes a thermal shell for reducing heat transfer from a tube to the bulkhead.