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Investigation of Leakage Observed in AISI 321 Stainless Steel Separation Pyro Valve During Post-Function Acceptance Test

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Abstract

Cryogenic engine of satellite launch vehicle employs separation pyrovalves which are pyrotechnically actuated devices used for opening/closing of the flow of fluids. In the qualification test, pyrovalve withstood the functional test. However, during the post-fire acceptance test, one unit of the separation pyrovalve indicated leakage at 38 bar against specified 170 bar pressure. The leaked actuator diaphragm was investigated for identifying the reason for leakage. Leakage during post-fire acceptance test is attributed to the through-thickness hole formation on the AISI 321 stainless-steel diaphragm. Hole formation in diaphragm is caused by the impingement of molten zirconia from the combustion products of zirconium/potassium perchlorate (ZPP) charge to the diaphragm during firing operation. It was responsible for localized melting of stainless steel. After the formation of through-thickness hole on the diaphragm, the molten mixture got solidified and filled the through hole completely. During the post-fire acceptance test, the molten and solidified mixture got dislodged at 38 bar pneumatic pressure and resulted in leakage. Analysis is validated through thermal modelling and simulation, where observations are found to be matching. Estimation of combustion product required for the formation of through thickness hole of the observed dimension has also been estimated.

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Acknowledgment

The authors wish to place on record their deep sense of gratitude to Ignition Systems and Mechanism Group for referring the problem and providing the specimens for the analysis. The authors are grateful to Director, VSSC, for permitting to publish this work.

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Authors and Affiliations

  1. Vikram Sarabhai Space Centre, Thiruvananthapuram, India

    Sushant K. Manwatkar, K. Jalaja, Rohit Kumar Gupta, Rishi Padmanabhan, Philip George, P. Anoop & M. Mohan

  2. Liquid Propulsion Systems Centre, Thiruvananthapuram, India

    S. V. S. Narayana Murty

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  1. Sushant K. Manwatkar
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  2. K. Jalaja
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  3. Rohit Kumar Gupta
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  7. S. V. S. Narayana Murty
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Correspondence to Sushant K. Manwatkar.

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Manwatkar, S.K., Jalaja, K., Gupta, R.K. et al. Investigation of Leakage Observed in AISI 321 Stainless Steel Separation Pyro Valve During Post-Function Acceptance Test. J Fail. Anal. and Preven. 23, 1789–1802 (2023). https://doi.org/10.1007/s11668-023-01728-2

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  • DOI: https://doi.org/10.1007/s11668-023-01728-2

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