Synopsis
The NASA Engineering and Safety Center was requested to assess the aerospace valve industrial base and NASA’s acquisition practices due to some recent valve failures experienced across multiple NASA programs and projects. A three-pronged approach was utilized for this assessment. First, questionnaires were distributed to various NASA programs and projects across multiple centers to identify valve suppliers they utilize, issues experienced with those suppliers, and perspectives on NASA’s design, construction, and test requirements. Next, valve vendor data from a 2017 Department of Commerce survey of the broader propulsion industry base was analyzed for specific issues impacting the valve companies that participated. Finally, targeted valve vendors were sent questionnaires to obtain feedback on supply issues they face regarding NASA’s acquisition practices or valve design requirements.
Based on the survey data and subject matter expert review, although problems were noted with a few aerospace valve suppliers, the industry overall does not appear to be declining. In fact, newer entrants and suppliers unfamiliar with aerospace seem to be prospering. Financial data for the valve suppliers participating in the Department of Commerce survey showed general growth, not decline. The recent valve-related issues experienced on NASA programs are likely attributable to multiple factors. First, NASA currently has an unusually high number of programs underway concurrently needing large quantities of challenging, unique valve designs developed, qualified, manufactured, and properly applied in a compressed timeframe. Coupled with other aerospace industry demands, this may have overwhelmed some valve suppliers. Additionally, several newer aerospace entrants are now supplying valves to NASA and may be undergoing initial difficulties establishing design experience and manufacturing processes to meet NASA’s specifications.
Overall, the assessment team concluded the aerospace valve supplier base appears to be expanding versus contracting. The data collected by the Department of Commerce’s thorough propulsion industry survey was determined to be an excellent resource for future component-specific assessments if erosion concerns arise. The team also found the multiple tiers of separation between valve vendors and NASA program management frequently observed can impede effective communication and problem resolution. Additionally, system integrators with sole ownership of valve-related issues may not be transparent with NASA about problems. Finally, conflicting perspectives on the value of acceptance vibration testing as a valve workmanship screening method were noted between NASA and vendors.
