Low-Mass, Low-Leakage Cryogenic Dual-Motion Valve Development

Project Objective

Utilize an eccentric cam mechanism that will allow the development of a low-leakage valve similar to the performance of heritage poppet valves within a smaller form factor.  

Project Description

As NASA programs are planning on utilizing cryogenic propellants on longer duration missions in the future, reducing leakage through propellant isolation valves is becoming a critical technology gap to overcome. MSFC ER14 (Valves, Actuators, and Ducts Design and Development Branch) has previously developed low-leakage valves within a poppet style architecture with an inherently compliant sealing mechanism with testing success. While the performance of these valves was likely adequate for long-duration missions, the form factor of the valve designs left some performance to be desired (reduced volume and mass). The Low-Mass, Low-Leakage Cryogenic Dual-Motion Valve Development is aiming to maintain the inherently compliant sealing mechanism in conjunction with a smaller and lighter form factor valve body. This will reduce launch mass of a spacecraft and still maintain low-leakage performance.

Project Results and Conclusions

The development of low-leakage cryogenic valves is critical to the success of future long-duration missions that must be able to store propellent for significant periods of time. MSFC ER14 (Valves, Actuators, and Ducts Design and Development Branch) has previously developed a low-leakage concept that utilizes a "floating" poppet design that has 5 degrees of freedom. The multiple degrees of freedom results in a poppet that is tolerant of inherent imperfections within a valve build. Initial testing of the low-leakage valves was successful, with test articles displaying leakage rates 1-2 order of magnitude less than current commercial-off-the-shelf options.

A limitation within traditionally stroked poppet designs is that it results in a fairly large and heavy valve. Within the architecture of a long-duration mission, it is likely that a low-leakage valve would be within the mass of the spacecraft for the full mission duration; thus, any additional mass required to create a low-leakage valve is close to a 1:1 loss of payload mass. Through this project, ER14 will develop a compact, dual-motion, Low-Mass, Low-Leakage valve. Through the enabling technology of a low-profile floating ball poppet, in conjunction with a shuttle-era-based dual-motion eccentric cam mechanism, ER14 developed a valve with low-leakage performance within a valve similar in mass and volume to a much more compact butterfly valve. Currently, this designed valve is still in fabrication, with testing expected to take place later in 2025. Initial piece part fabrication is underway, with clutch refinement in work.

This technology will enable potentially up to hundreds of pound-mass additional payload on future long-duration missions to the Moon, Mars, and beyond.

The objective of this project is to develop a low-leakage valve that is an order of magnitude lighter than current State-of-the-Art Low-Leakage valves, while maintaining or improving upon the same low-leakage performance. The primary STMD Gap ID this project fulfills is Gap #461, Minimizing cryogenic fluid commodity loss through valve leakage is critical in reducing boil-off. This project is transformative. Low-leakage valves with acceptable leakage rates do exist, but they are larger and heavier than desired. Through this funded work, high-performance low-leakage rates will be pursued within a significantly (order of magnitude) lighter valve design. This mission pull for this technology will come within the Moon to Mars transition. Ultimately, low-leakage cryogenic valves will be required for a long-duration Mars mission, and any mass saved on vehicle components allows for additional payload mass to Mars.

This is early/mid-stage (TRL 3) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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