Lightweight, Low-Power Cryogenic Valve for Orbital Propellant Management

Orbital refueling of cryogenic propellants is a key enabling technology that will extend the usable life of spacecraft around Earth and facilitate the next generation of advanced exploration missions. Propellant management on orbit requires advanced propellant tanks, liquid acquisition devices, propellant transfer pumps, space-rated valves, and other subcomponents compatible with common propellants and designed for use at cryogenic temperatures. We propose to help meet this need by developing a space-rated valve for cryogenic propellants. Our valve uses a floating seal to provide low flow restriction without the bulky housing typically required of valves with large orifices. In Phase I, we completed detailed design of the valve and preliminary design of the actuator, fabricated a prototype valve, and made flow and leakage measurements to demonstrate compliance with NASA requirements. Our Phase I testing showed our valve offers higher flow capacity in a smaller, lighter package compared with commercial alternatives. In Phase II, we will update our valve design using lessons learned, integrate it with our space-rated actuator, and conduct valve testing under representative operating conditions (in a vacuum environment at cryogenic temperatures). At the end of Phase II, we will have a complete valve assembly with demonstrated performance, ready for spaceflight qualification and mission use. Cryogenic propellant production, transport, and storage are critical for future space missions which call for spacecraft to refuel in orbit. Many technologies are critical to meet this need. Cryogenic valves in particular are a crucial technology, as they play a key role in almost all cryogenic fluid management applications. Existing valves use metallic seats to seal cryogens and rely on thick, heavy valve bodies to accommodate large sealing forces without deforming. Creare’s innovative six Degree of Freedom floating seal valve combines a self‑aligning seal design with pressure-balancing bellows to create a lightweight, reliable valve seal that overcomes limitations of traditional valve technologies and provides minimal restriction (high Cv) for a given line size. In Phase I we proved feasibility of our floating seal valve through design, analysis, prototype assembly, and testing. Results show we meet or exceed NASA requirements for (1) external leakage, (2) internal leakage, (3) flow restriction (Cv), (4) operating pressure, and (5) cycle life, all in a small, lightweight package. We will continue to develop our floating seal cryogenic valve technology, building on our successful Phase I proof-of-concept testing to provide NASA with a design tailored to their requirements. Key technical objectives for our valve development include:   Design for Cryogenic Operation. Choose materials and construction methods to enable operation with key cryogenic propellants including hydrogen, oxygen, and methane. High Cv for Efficient Propellant Transfer. Use CFD modeling and scaled Phase I test data to ensure our valve design meets NASA’s requirement for low valve Cv, and verify through water flow testing. Low-Leakage Internal and External Seals. Leverage Phase I test data to design our valve’s floating seal to exceed NASA’s internal leakage requirements. Continue to use hermetic construction methods to exceed external leakage requirements. Verify both through measurement. Lightweight, Low-Power Design for Spaceflight Applications. Design our valve and actuator explicitly for use in orbital CFM applications with materials and construction methods chosen to reduce mass and leverage spaceflight heritage. We will deliver two prototype valve and actuator assemblies to NASA for testing in their facilities at the end of the contract.

Our cryogenic valve is intended to operate in propellant depots located on orbit, as well as spacecraft designed to interface with these depots. We expect NASA will leverage our valve in both systems. Although designed for use in space, it is possible our valves will also become a part of ground-based cryogenic fuel production, storage, and transfer facilities supporting the SLS and other launch systems. Commercial aerospace companies are actively pursuing orbital propellant management systems to realize economic advantages of refueling on orbit. Our valve will be an attractive component for spacecraft and fuel depot subsystems, especially if they seek to share a common interface with NASA systems. It may also be used in ground-based propellant management systems to support launch operations.

This is early/mid-stage (TRL 4) — 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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