In reciprocating aircraft engines, valves play a critical role in controlling combustion timing, engine breathing, and temperature management. Designed to withstand extreme heat and mechanical stress, intake and exhaust valves are engineered from specialized alloys to ensure durability and performance. Proper valve construction and cooling are essential for safe and efficient engine operation.
The fuel/air mixture enters the cylinders through the intake valve ports, and burned gases are expelled through the exhaust valve ports. The valve head opens and seals against these ports to control gas flow. Aircraft engines use conventional poppet-type valves, commonly classified by head shape as mushroom or tulip types. Figure 1 illustrates the various shapes and configurations used in aircraft engines.
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| Figure 1. Various valve types |
Valve Construction
The valves in the cylinders of an aircraft engine are subjected to high temperatures, corrosion, and operating stresses; thus, the metal alloy in the valves must be able to resist all these factors. Because intake valves operate at lower temperatures than exhaust valves, they can be made of chromic-nickel steel. Exhaust valves are usually made of nichrome, silchrome, or cobalt-chromium steel because these materials are much more heat resistant.
The valve head has a ground face that forms a seal against the ground valve seat in the cylinder head when the valve is closed. The face of the valve is usually ground to an angle of either 30° or 45°. In some engines, the intake-valve face is ground to an angle of 30°, and the exhaust-valve face is ground to a 45° angle. Valve faces are often made more durable by the application of a material called stellite. About 1/16 inch of this alloy is welded to the valve face and ground to the correct angle. Stellite is resistant to high-temperature corrosion and also withstands the shock and wear associated with valve operation. Some engine manufacturers use a nichrome facing on the valves. This serves the same purpose as the stellite material.
The valve stem acts as a pilot for the valve head and rides in the valve guide installed in the cylinder head for this purpose. [Figure 2] The valve stem is surface hardened to resist wear. The neck is the part that forms the junction between the head and the stem. The tip of the valve is hardened to withstand the hammering of the valve rocker arm as it opens the valve. A machined groove on the stem near the tip receives the split-ring stem keys.
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| Figure 2. View of valve guide installed on a cylinder head |
These stem keys form a lock ring to hold the valve spring retaining washer in place. [Figure 3]
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| Figure 3. Stem keys forming a lock ring to hold valve spring retaining washers in place |
| Valve Part | Function / Characteristic |
|---|---|
| Head (Tulip/Mushroom) | The surface that seals the intake or exhaust port. The shape affects gas flow efficiency. |
| Face (30° or 45°) | The precision-ground surface that seats against the cylinder. Usually hardened with Stellite. |
| Stem (Solid or Hollow) | Acts as a pilot in the valve guide. Hollow stems often contain metallic sodium for cooling. |
| Tip | The hardened end of the stem that withstands the impact and pressure of the rocker arm. |
| Groove | A machined recessed area near the tip that secures the split-ring keys and spring retainer. |
Some intake and exhaust valve stems are hollow and partially filled with metallic sodium. This material is used because it is an excellent heat conductor. The sodium melts at approximately 208 °F and the reciprocating motion of the valve circulates the liquid sodium, allowing it to carry away heat from the valve head to the valve stem where it is dissipated through the valve guide to the cylinder head and the cooling fins. Thus, the operating temperature of the valve may be reduced as much as 300° to 400 °F. Under no circumstances should a sodium filled valve be cut open or subjected to any operation that may cause it to rupture. Exposure of the sodium in these valves to the outside air results in fire or explosion with possible personal injury.
The most commonly used intake valves have solid stems, and the head is either flat or tulip shaped. Intake valves for low-power engines are usually flat headed. In some engines, the intake valve may be the tulip type and have a smaller stem than the exhaust valve or it may be similar to the exhaust valve but have a solid stem and head. Although these valves are similar, they are not interchangeable since the faces of the valves are constructed of different material. The intake valve usually has a flat milled on the tip to identify it.