Supporting Space Flight History with the Space Launch System
Supporting Space Flight History with the Space Launch System
Technetics Group is a proud supplier to NASA, Boeing and Aerojet Rocketdyne, and proved instrumental in working with these organizations on the development of NASA’s Space Launch System (SLS).
The SLS is an advanced, heavy-lift launch vehicle that will send astronauts into deep space and open up the possibility for missions to neighboring planets. The program is enabling humans to travel further into space than ever before and paving the way for new scientific discoveries and knowledge that was once out of reach.
Technetics has worked closely with program design teams for critical applications for the Core Stage and Upper Stage on the SLS. Specifically, a number of precision sealing solutions and fluid management components were needed for Aerojet Rocketdyne’s RS-25 and RL10 engines to ensure the integrity of the overall system. By working closely with engineers at Boeing and Aerojet Rocketdyne, the Technetics team designed, tested, and implemented custom solutions to solve the critical sealing needs within the engines. Within the Core Stage on the RS-25 engines as well as the Upper Stage on the RL10 engines, solutions included custom metal seals, NAFLEX and K-Port seals, carbon face seals, BELFAB® edge-welded metal bellows, and accumulators.
Because of the ongoing commitment Technetics has to Boeing and Aerojet Rocketdyne, both organizations have recognized Technetics for their excellent supplier contribution to the SLS program.
Boeing representatives held a supplier recognition presentation for the Technetics team members, citing outstanding performance in providing hydraulic accumulators and reservoirs for the Thrust Vector Control hydraulic system located within the Core Stage of the rocket. Technetics was one of the first suppliers on the program to have provided all Flight 1 requirements and subsystem test units.
Aerojet Rocketdyne also recognized Technetics and stated that Technetics “has gone above and beyond to produce quality hardware and support aggressive schedules” and that “Technetics efforts and those of Technetics employees have not gone unnoticed.” To express their appreciation, Aerojet Rocketdyne representatives visited the Technetics Deland, FL facility to present an appreciation letter for the contributions Technetics made in support of Aerojet Rocketdyne’s RS-25 High-Pressure Turbomachinery team.
The SLS program is ongoing, and Technetics continues to work closely alongside the teams at NASA, Boeing, and Aerojet Rocketdyne to develop custom-engineered sealing and component solutions that provide safety, performance, and reliability while subjected to the harsh environments of deep space. Technetics is honored to be a part of the history-making SLS program and is eagerly awaiting upcoming launches.
CUSTOMIZED HELICOFLEX® PROVIDES THE IDEAL SEAL
Alternate Energy Solutions, a division of downhole plug manufacturer Thru-Tubing Systems, required a solution to seal caustic gasses on expired wells for a customer in the South Pacific. They reached out to Technetics Group looking for a metal seal solution.
Technetics Provides Optimal Sealing Solution at Berkley Lab
As a part of its Advanced Light Source Upgrade, Berkley Lab needed a sealing solution for its accumulator ring. After being invited to conduct a metal seal educational presentation, Technetics received the Accumulator Ring BPM application from Berkley Lab.
Technetics Provides Optimal Sealing Solution
Technetics Provides Optimal Sealing Solution
Why Technetics HELICOFLEX® Delta seal was the perfect match for Berkley National Laboratory
The Advanced Light Source is a research facility at Lawrence Berkley National Laboratory (Berkley Lab) working to advance science through its synchrotron light source capabilities. As a part of its Advanced Light Source Upgrade, Berkley Lab needed a sealing solution for its accumulator ring. The upgrade called for a UHV sealing solution appropriate for a synchrotron, with a seal located at the Beam Position Monitor (BPM) housing. The specifications for the application included a leak rate of 1×10-9 cc/sec He atm and temperatures of 25ºC operating and 180ºC bake-out for 1 hour each startup. Furthermore, Berkley Lab required 4 seals for each of the 72 assemblies of the seal, for a total of 288 seals needed for the initial startup of this application.
Due to the existing relationship between Berkley Lab and Technetics Group as well as Technetics’ involvement for several years in the Advanced Light Source “Kicker Box” assembly, the expertise and industry experience of Technetics was trusted for this application. After being invited to conduct a metal seal educational presentation, Technetics received the Accumulator Ring BPM application from Berkley Lab.
The HELICOFLEX® DELTA seal was identified as an optimal solution for this application. It incorporates two small ridges, or “Deltas,” on the face of the seal. The high-contact stress in the seal track makes the HELICOFLEX® DELTA seal an excellent choice for ultra-high vacuum applications that require ultra-low Helium leak rates. After the prototype order was received and pump down testing successfully completed, Technetics received additional prototype orders with the expectation of MRO demands every 2 years.
SLS Case Study
SLS Case Study
Technetics Group is a proud supplier to NASA, Boeing and Aerojet Rocketdyne, and proved instrumental in working with these organizations on the development of NASA’s Space Launch System (SLS).
Qualiseal® – Circumferential Seal Application: Military Aircraft
Circumferential Seal Application: Military Aircraft
The control valve in a military aircraft had a controlled gap circumferential seal with a carbon steel composite ring assembly. High wear and carbon ring deterioration resulted in shortened seal life.
Operating Conditions
- High temperature (1,125°F)
- Pressure (660 psid)
Determining Cause and Failure Modes
- High-temperature carbon grade oxidizing due to high temperature
Technetics Qualiseal® Technologies Solution
- Designed a controlled gap circumferential seal utilizing a solid silicon carbide ring, improving temperature rating up to 2,500°F
- Silicon carbide ring increased seal pressure rating based on FEA generated stress distribution
Qualiseal® – Mating Ring Solution: Hydraulic Pump
Mating Ring Solution: Hydraulic Pump
An aerospace OEM historically purchased an inexpensive mating ring to pair with a precision carbon face seal in a hydraulic pump. The supplier was capable of achieving flatness to 6 HLB. The buyer was satisfied because the mating ring met the design requirements at a low cost.
Operating Process
- After receiving the mating rings, the OEM inspected 100% of them using a laser interferometer to ensure sufficient flatness.
- 80% of the mating rings needed to be re-lapped and re-inspected before they could be used even though they were built to spec.
- The total cost of the final product was significantly greater than the amount on the purchase order
Technetics Qualiseal® Technologies Solution
- Technetics Qualiseal® Technologies manufactured mating rings to a standard above the customer’s design requirements, achieving flatness to 3 HLB or better.
- Inspected utilizing QT’s laser interferometer and delivered ready-to-use products to the customer.
- The customer recognized savings in the “total cost” of the product and also reduced the required inspection staff by two.
Qualiseal® – Contacting Face Seal Application: Aircraft Engine
Contacting Face Seal Application: Aircraft Engine
The main shaft in a commercial aircraft engine had an existing carbon face seal experiencing high leakage and seal failures.
Operating Conditions
- High speed (51,000 rpm)
- Gearbox oil (MIL-R-23699)
- 20 psid
Determining Cause and Failure Modes
- Technetics Qualiseal® Technology FEA model indicated significant face tapering and waviness in the two-piece seal nose design
- The existing design also enabled anti-rotation wear, causing the part to hang up and further contribute to the significant leakage
Technetics Qualiseal® Technology Solution
- Designed a new carbon face seal with a mono-block seal nose design
- Integral anti-rotation heat treated to high hardness for wear resistance
- Final design solution required NO COST INCREASE over the original product
Qualiseal® – Metal Bellows Seal Application: Fuel Pump
Metal Bellows Seal Application: Fuel Pump
Background
The pump for a commercial aircraft had an existing carbon face seal experiencing high leakage and seal failures. Technetics Qualiseal® Technology was employed to find a solution.
Operating Conditions
- High speed (27,000 rpm)
- Dry running (no lubrication)
- 12.5 psid
Determining Cause and Failure Modes
- Seal testing and Qualiseal® Technology FEA model indicated temperatures up to 650°F
- Current secondary seal taking a set due to high temperature
- Possible carbon resin exudation due to high temperature
Technetics Qualiseal® Technology Solution
- Designed a metal bellows seal assembly with a high-temperature carbon grade
- Sealed application and satisfied extreme temperature requirements
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