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Lowcost life assessment of liquid rocket engines by replacing full-scale engine tests with TMF panel tests

Kringe, Pascal and Riccius, Jörg and Oschwald, Michael (2020) Lowcost life assessment of liquid rocket engines by replacing full-scale engine tests with TMF panel tests. Journal of the British Interplanetary Society, 73 (5), pp. 154-162. British Interplanetary Society. ISSN 0007-084X.

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Official URL: https://www.jbis.org.uk/preview/2020.73.154.jpg

Abstract

Liquid rocket engines are still key components of many space transportation systems. The combustion chamber of the engine itself is one of the most critical parts as it has to withstand severe temperatures, extreme temperature gradients and high pressures. Reusability and therefore cyclic loading can lead to failure due to rupture of the cooling channelsin the inner liner of the combustion chamber. Those failures are induced by a progressing failure mechanism called doghouse effect. The doghouse effect causes thinning of the cooling channels until rupture. For the development of new engines numerical methods are used. In order to save costs for obtaining experimental data to validate numerical analysis methods, a Thermo-Mechanical Fatigue (TMF) test bench was set up at the Lampoldshausen site of German Aerospace Center (DLR) to reduce the need for expensive full scale rocket engine tests. The test bench uses so-called thermomechanical fatigue panels representing a small section of the geometry (5 - 7 cooling channels) of the hot gas wall. To simulate the heat load, a diode laser can provide thermal loading with heat fluxes up to q = 25 MW/m² applied to an area of 10 mm x 34 mm. Supercritical Nitrogen at a temperature of T = 160 K and a pressure of p = 50 bar serves as coolant. The laser is cyclically powered on for typically 200 s until rupture is visible. The heat distribution on the laser-loaded surface of the TMF panel is measured with an infrared camera. The fatigue life is assessed by counting the number of laser cycles. With this method the appropriateness and response of different copper based alloys can be predicted for different use-cases like liquid core stage engines, liquid booster engines or liquid upper stage engines regarding thermomechanical fatigue by utilizing a cost-saving alternative to full scale rocket engine tests. This paper presents the detailed capabilities and potential of the TMF panel test bench at DLR Lampoldshausen as well as the recent results of a TMF panel made of CuCrZr alloy.

Item URL in elib:https://elib.dlr.de/138646/
Document Type:Article
Additional Information:First published by the British Interplanetary Society https://www.jbis.org.uk/preview/2020.73.154.jpg
Title:Lowcost life assessment of liquid rocket engines by replacing full-scale engine tests with TMF panel tests
Authors:
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Kringe, PascalUNSPECIFIEDhttps://orcid.org/0000-0003-2866-8419UNSPECIFIED
Riccius, JörgUNSPECIFIEDhttps://orcid.org/0000-0002-5935-874XUNSPECIFIED
Oschwald, MichaelUNSPECIFIEDhttps://orcid.org/0000-0002-9579-9825UNSPECIFIED
Date:2020
Journal or Publication Title:Journal of the British Interplanetary Society
Refereed publication:Yes
Open Access:Yes
Gold Open Access:No
In SCOPUS:Yes
In ISI Web of Science:No
Volume:73
Page Range:pp. 154-162
Publisher:British Interplanetary Society
ISSN:0007-084X
Status:Published
Keywords:Thermo-Mechanical-Fatigue, TMF panel test, Liquid Rocket Engine, Doghouse Effect
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Space
HGF - Program Themes:Space Transportation
DLR - Research area:Raumfahrt
DLR - Program:R RP - Space Transportation
DLR - Research theme (Project):R - Reusable Space Systems and Propulsion Technology
Location: Lampoldshausen
Institutes and Institutions:Institute of Space Propulsion > Rocket Propulsion
Deposited By: Hanke, Michaela
Deposited On:01 Dec 2020 07:48
Last Modified:12 Jan 2021 07:52

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