Key points of the article
- The collaboration between Mascherpa and Skyward Experimental Rocketry was established to address a critical issue in liquid propellant engines, where ethanol dissolved traditional greases used in valves.
- The cold flow test demonstrated the effectiveness of Molykote HP 300 grease in ensuring smooth openings even after multiple cycles and in the presence of aggressive solvents.
- Choosing the right grease allowed for the elimination of intermediate maintenance, improving the repeatability and efficiency of the tests.
- Mascherpa provided specialized technical consulting, supporting the team in selecting the most suitable lubricant for high chemical reactivity environments.
- This experience confirms that even a single component, if designed and chosen correctly, can become strategic for the overall performance of a propulsion system.
In liquid propellant engines, even the friction of a valve can compromise the entire ignition sequence. It is precisely from these types of technical needs that the collaboration between Skyward Experimental Rocketry and Mascherpa arises, within the NEXT initiative. In this case, Mascherpa experts, together with the Skyward team, tested a high-performance valve grease in the field.
During the cold flow tests, Skyward tested the behavior of valves in contact with ethanol, a highly aggressive fluid that, in previous tests, had dissolved traditional greases, making the system unstable. The solution came with the introduction of Molykote HP 300 grease, designed for extreme environments and resistant to solvents.
The Technical Problem: Ethanol and Performance Losses
During the static tests of the previous rocket, Skyward observed a critical anomaly: after the first opening, ethanol had completely dissolved the grease, making the valve jerky and not smooth. This type of friction risks compromising:
- The efficiency of the injection system
- The synchronization between multiple valves
- The safety of the engine during ignition
In a bipropellant system, where milliseconds of delay can make the difference between nominal ignition and hard start, lubrication is a fundamental element.
The Solution: Molykote HP 300 in Cold Flow Tests
To solve the problem, Mascherpa proposed the use of grease Molykote HP 300, a lubricant specifically formulated for valve applications in hostile environments, such as those in aerospace. Its main properties include:
- Chemical resistance to ethanol and other photosolvent fluids
- Thermal stability even under intense thermal shocks
- Compatibility with metals and alloys typical of cryogenic valves
- Low initial friction coefficient maintained even after multiple cycles
During the cold flow tests, the valve grease showed stable behavior for over four consecutive opening cycles, without the need for relubrication. The system was reassembled and subjected to functional tests, with positive results: smooth movement, no blockage, and time and resource savings thanks to the elimination of maintenance breaks.
Why the Cold Flow Test is Such a Rigorous Proving Ground
The cold flow tests are designed to simulate the real operating conditions of the propulsion system, without ignition. This means:
- Testing pressure, temperature, and dynamic cycles on valves and injectors
- Observing the interaction between fluid and materials
- Validating lubricant solutions in real conditions
Passing these tests represents a fundamental preliminary operational certification, especially in view of the subsequent hot fire tests, where the system will be subjected to much greater stress.
From Workshop to Rocket: a Real Application of Molykote Grease
The work carried out in synergy by Skyward Experimental Rocketry and Mascherpa represents an exemplary case of engineering applied to the most extreme conditions. It was not simply a matter of replacing a lubricant, but of responding precisely to a concrete technical challenge, capable of compromising the entire test sequence. The introduction of Molykote HP 300 valve grease transformed an operational bottleneck into a strength: the team was able to eliminate long maintenance breaks between tests, avoiding the need to disassemble, relubricate, and reassemble the system every time ethanol removed the previously used grease.
This solution significantly improved the repeatability and efficiency of bench tests, helping to create a test environment closer to real flight operating conditions. In a sector where precision and reliability are not just requirements but preconditions for safety and performance, even a seemingly simple modification can have a structural impact.
With the choice of Molykote HP 300, Mascherpa also provided comprehensive technical consulting, based on experience, knowledge of materials, and a deep understanding of valve dynamics in high chemical reactivity environments. A targeted intervention that helped strengthen the entire system.
Conclusion
In the aerospace world, performance is not only measured in thrust or speed but also in the ability of each component to work optimally, without compromise. The collaboration between Skyward and Mascherpa demonstrates that even a simple valve grease, if chosen correctly, can become a strategic element for mission success.
Do you have a high-criticality project or need to face extreme conditions in valves, actuators, or propulsion systems? Contact the Mascherpa experts to receive personalized consulting and find the most suitable lubricant solution for your case. Whether you operate in aerospace, defense, or high-tech industry, we are ready to support you.
