Development of Long-Lifetime Pulsed Gas Valves for Pulsed Electric Thrusters
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NASA is developing a new launch vehicle, called the Space Launch System (SLS), which is intended on taking humans out of low earth orbit to destinations including the moon, asteroids, and Mars. The propulsion system for the core stage of this vehicle includes four RS-25 Liquid Hydrogen/Oxygen rocket engines. These engines are upgraded versions of the Space Shuttle Main Engines (SSME); the upgrades include higher power levels and affordability enhancements. As with any new vehicle, the Main Propulsion System (MPS), which include the feedlines and ancillary hardware connecting the engines to the fuel and oxidizer tanks, had to be redesigned (figure 1 - export clearance in progress), as the previous MPS for the SSME's was inherently part of the Space Shuttle System, which had a completely different overall configuration.
A unique single degree-of-freedom approximation technique has been developed to enable rapid application of a temporally-defined multi-spectral semi-narrow-band loading for generation of realistic stress/cycle values compared to a resonant analysis. The technique uses the harmonic analysis at resonance of a high-fidelity finite element model to produce a transfer function, which is then used to calibrate the response of the SDOF model. A standard numerical ordinary differential equation solver is then used to obtain the temporal response, and its histogram is used in a fatigue/fracture model. This technique is related to other SDOF methods used widely in industry, such as Miles' Equation and the Shock Response Spectra, but it is unique in that it produces a realistic time history of the response. The most obvious error in the process, which is the effect of closely-spaced modes, was also assessed using the parallel application of several SDOF models, and the error is shown to be small. The application of this unique and tractable reduced-order methodology has enabled the SLS program to avoid substantial cost and schedule penalties if a redesign or change of material were required. It has also enabled quick analysis of a number of other structures undergoing the same or similar excitation fields, and quick assessment when the excitation and structural configuration has been altered due to design changes in the system.
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The proposed design for the light duty diesel is an in-line four cylinder spark assisted diesel engine mounted transversely in the front of the vehicle. The engine has a one piece cylinder head, with one intake valve and one exhaust valve per cylinder. A flat topped piston is used with a cylindrical combustion chamber recessed into the cylinder head directly under the exhaust valve. A single ceramic insert is cast into the cylinder head to insulate both the combustion chamber and the exhaust port. A similar ceramic insert is cast into the head to insulate the intake port. A ceramic faceplate is pressed into the combustion face of the head to insulate the face of the head from hot combustion gas. The valve seats are machined directly into the ceramic faceplate for the intake valve and into the ceramic exhaust pot insert for the exhaust valve. Additional ceramic applications in the head are the use of ceramic valve guides and ceramic insulated valves. The ceramic valve guides are press fit into the head and are used for increased wear resistance. The ceramic insulated valves are conventional valves with the valve faces plasma spray coated with ceramic for insulation.
An intake valve arrangement for positively controlling the opening and closing of the poppet valve in a hot gas cylinder in a hydrazine powered engine is described. The poppet valve is operated by the piston and gas pressure only. The poppet valve uses a pneumatic spring which holds the poppet valve against the piston while the valve is opened and closed. To accomplish this, a poppet valve is slidably mounted in a pneumatic spring chamber which reaches a pressure approaching the gas supply pressure and, during the opening of the valve, the spring chamber retains enough pressure to hold the poppet valve onto the piston. In addition, the bottom of the poppet valve can have a suction cup type configuration to hold the poppet valve on the piston during the down stroke.
Microvalves containing silicone-rubber seals actuated by heating and cooling of paraffin have been proposed for development as integral components of microfluidic systems. In comparison with other microvalves actuated by various means (electrostatic, electromagnetic, piezoelectric, pneumatic, and others), the proposed valves (1) would contain simpler structures that could be fabricated at lower cost and (2) could be actuated by simpler (and thus less expensive) control systems. Each valve according to the proposal would include a flow channel bounded on one side by a flat surface and on the other side by a curved surface defined by an arched-cross-section, elastic seal made of silicone rubber [polydimethylsilane (PDMS)]. The seal would be sized and shaped so that the elasticity of the PDMS would hold the channel open except when the seal was pressed down onto the flat surface to close the channel. The principle of actuation would exploit the fact that upon melting or freezing, the volume of a typical paraffin increases or decreases, respectively, by about 15 percent. In a valve according to the proposal, the seal face opposite that of the channel would be in contact with a piston-like plug of paraffin. In the case of a valve designed to be normally open at ambient temperature, one would use a paraffin having a melting temperature above ambient. The seal would be pushed against the flat surface to close the channel by heating the paraffin above its melting temperature. In the case of a valve designed to be normally closed at ambient temperature, one would use a paraffin having a melting temperature below ambient. The seal would be allowed to spring away from the flat surface to open the channel by cooling the paraffin below its melting temperature. The availability of paraffins that have melting temperatures from 70 to +80 C should make it possible to develop a variety of normally closed and normally open valves. The figure depicts examples of prototype normally open and normally closed valves according to the proposal. In each valve, an arch cross section defining a channel having dimensions of the order of tens of micrometers would be formed in a silicone-rubber sheet about 40 m thick. The silicone rubber sheet would be hermetically sealed to a lower glass plate that would define the sealing surface and to an upper glass plate containing a well. The well would be filled with paraffin and capped with a rigid restraining layer of epoxy. In the normally open valve, the paraffin would have a melting temperature above ambient (e.g., 40 C) and the wall of the well would be coated with a layer of titanium that would serve as an electric heater. In the normally closed valve, the paraffin would have a melting temperature below ambient (e.g.-5 C). Instead of a heater in the well, the normally closed valve would include a thermoelectric cooler on top of the epoxy cap.