CMC Rocket Thrust Chamber Technology Status and Perspectives M. - - PowerPoint PPT Presentation

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CMC Rocket Thrust Chamber Technology Status and Perspectives M. - - PowerPoint PPT Presentation

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DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 Chart 1 CMC Rocket Thrust Chamber Technology Status and Perspectives M. Ortelt, H. Hald,

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SLIDE 1

Knowledge for Tomorrow

CMC Rocket Thrust Chamber Technology Status and Perspectives

  • M. Ortelt, H. Hald, D. Koch

markus.ortelt@dlr.de German Aerospace Center (DLR) Institute of Structures and Design AIRBUS DS – Space Systems - 6th R&T DAYS, Paris, 19.11.2015, Session 3, WG2 Technologies for Future Liquid Propulsion

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 1

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SLIDE 2

Outline

  • Conceptional aspects of the transpiration cooled CMC TCA
  • Development status
  • Structural components
  • Materials
  • Test data
  • Some future perspectives for CMC in space propulsion components
  • Summary & outlook

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 2

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SLIDE 3

CMC thrust chamber – Design concept

Transpiration cooled CMC thrust chamber – design principle

  • Decoupling of single components – no bonding
  • Decoupling of mechanical and thermal loads
  • Specific hybrid interface technologies
  • Selective inner liner design

Features

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 3

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SLIDE 4
  • Standard CFD systems (FLUENT, CFX, …) are constructive (pure flow coupling)
  • Ongoing tool-development for ‚structure-flow-coupling‘ (TAU)
  • Investigations on materials out-flow homogeneity

Functional aspects

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 4

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SLIDE 5

System analysis of transpiration cooling

0% 2% 4% 6% 8% 10% 12% 1 10 100 1000 10000 100000

Coolant ratio [‐] Vacuum thrust [kN] Tw = 800 K

dc = 50 mm dc = 100 mm dc = 200 mm dc = 440 mm dc = 1000 mm 0% 2% 4% 6% 8% 10% 12% 1 10 100 1000 10000 100000

Coolant ratio [‐] Vacuum thrust [kN] Tw = 1200 K

dc = 50 mm dc = 100 mm dc = 200 mm dc = 440 mm dc = 1000 mm

  • Comparison of chamber size (scaling)
  • 50 mm chamber demonstration
  • O/F = 5.5 (injector)
  • Contraction ratio 6.25
  • Characteristic chamber length l*=1.84 m
  • 7 % coolant ratio
  • Damage free operation
  • Amount of coolant depends on
  • Hotgas conditions, As, T
  • D + p  required coolant ratio
  • Further coolant ratio reduction potential
  • Chamber length can be shortened

 High operational efficiency predicted

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 5

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SLIDE 6

Processes for Manufacturing of Nonoxide CMC

C, SiC fibers in C, SiC, SiC(N) matrix

Polymer Infiltration and Pyrolysis (PIP) Liquid Silicon Infiltration (LSI) Combi-Process (PIP+LSI, CVI+LSI) Chemical Vapor Infiltration (CVI) Focus at DLR Stuttgart

preform (e.g. fabrics, filament winding) fiber-coating if necessary infiltration (e.g. RTM) with C-precursor pyrolysis (inert atmosphere)  carbon matrix finishing siliconisation (inert gas, T>1420°C, Si+CSiC)  stoichiometric SiC-matrix preform (e.g. fabrics, filament winding) fibrer coating infiltration (e.g. RTM) with Si-precursor (e.g. polysilazane) pyrolysis (inert atmosphere, T~1000°C, e.g. polysilazane  SiCN-matrix) finishing 3-6 times to decrease porosity

PIP

intermediate machining joining

Koch et al., DLR Werkstoffkoll. 2013

LSI

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 6

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SLIDE 7

Processing of Ceramic Matrix Composites (DLR-ST, BT)

  • Autoclave

30 bar, 350 °C

  • Warm Press 350°C
  • RTM 300°C
  • Pyrolysis, LSI, 2000°C
  • Machining Center

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 7

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SLIDE 8

Thrust chamber – potential CMC derivatives

Initial C/C model material LOX-sensitive! Other derivatives damage free after efficiently cooled and non-cooled operation: Oxipol AvA-Z-ISC C/SiCN C/C (CVI) 10 35 18 7 2.3 2.6 1.6 1.6 Density kg/cm3 Open porosity  [%] (porosity + permeability kd / kf adaptable by manufacturing process)

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 8

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SLIDE 9

CMC thrust chamber – Components

Co-axial injector

Applied injector systems for cyl. 50 mm

Porous metal injector Porous CMC injector Elements of

  • xide

CMC for the LOX injection Integrated ‚BlackEngine‘ demonstrator, cyl. 50 mm C/C-SiC face-plate Inner liner segment

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 9

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SLIDE 10

CMC thrust chamber – mechanical interfaces

Characteristic hybrid interface types

Bolt interface for CFRP-metal joining Load-de-coupling double-shell nozzle extension with keyed joint elements for CMC-metal joining

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 10

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SLIDE 11

Thrust chamber - hot gas verification (LOX/LH2; LOX/GH2)

120 s, pc = 55 bar, LOX / LH2 operation,  = 15 %

Structure tests P8 Efficiency test P6.1 2012

20 s, pc = 55 bar, LOX / GH2 (120 K),  = 9 % Demonstration of the integrated CMC TCA

P6.1 firing test Dec 2013

P8 (2005) LOX / LH2, 65  70 bar 52 s, 5  6 kg/s, τ = 4.2 % 90 bar tests Vulcain contour cyl. 50 mm Contraction 6.25 cyl. 50 mm Vulcain contour cyl. 80 mm Component tests P8, 2008 cyl. 50 mm C/C damages near injector! C/C damage free CMCs damage free CMCs damage free

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 11

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SLIDE 12

Thrust chamber – pressure loads during hot-run

Segmented chamber module

Adequate pressure drops at 8 % C/C porosity!

cyl. 50 mm

Inner liner: Initial model material C/C O/F = 5.5

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 12

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SLIDE 13

200 400 600 800 1000 1200 1400 1600 1800 10 20 30 40

Temperature [K] Time [s]

U_T_1_8 [K] U_T_2_8 [K] U_T_3_8 [K] U_T_4_8 [K] U_T_1_9 [K] U_T_2_9 [K] U_T_3_9 [K] U_T_4_9 [K]

Nominal hotrun-sequence O/F = 5.5;  = 6.72 %; pc  55 bar

Thrust chamber – thermal loads during hot-run

Cooling turned off O/F = 2.0

  • Max. Tsurface  1800 K
  • 750 /

{

P6.1, 2012 cyl. 50 mm

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 13

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SLIDE 14

CMC injector (‚Cone Injector‘)

Features, goals, results Mechanical design Flow design

Start-up Steady state Channel morphology Demonstrator LH2O/GN2 Spray test Design principle

0,05 0,1 0,15 0,2 0,25 0,3 ‐6000 ‐1000 4000 9000 14000 M‐GH2‐COOL [kg/s] M‐GH2‐INJ [kg/s] M‐LOX‐INJ [kg/s]

DLR ‐ Cone Injector test campaign 'IZ2' ‐ MASS FLOW CURVES

Time [s] 10 20 30 40 50 60 ‐6000 ‐1000 4000 9000 14000 P_I_GH1 [bar] P_I_GH2 [bar] P_I_GH3 [bar] P_I_LOX [bar] U_P_IGN [bar] Time [s]

DLR ‐ Cone injector test campaign 'IZ2' ‐ PRESSURE CURVES

Initially successful hotruns, P6.1, Dec 2013

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 14

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SLIDE 15

Hyperboloid chamber contour – Orbital propulsion size

Comparison referred to typical 500 N class

Hyperboloid geometry Numerical comparison

at similar performance

Hyperboloid chamber design Perfectly combined with ‚cone injector‘ technology

  • Advantages for
  • film cooling
  • transpiration cooling
  • Composite affine structure manufacturing (winding technique)

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 15

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SLIDE 16

Hyperboloid chamber contour – Comparison VINCI size

Including insert Without insert

Dynamic viscosity

Heat flux Performance

Contour Mass flow Total heat flux Specific heat flux [kg/s] [MW] [MW/m2] Classical 43 16 55 Hyperboloid without insert 42 16 56 Hyperboloid including insert 43 27 52

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 16

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SLIDE 17

Future potential - Preburner

Application principle (oxide CMCs for ox-rich systems)

  • Standard injector technology

concerning …

  • functional design
  • mixture ratio
  • Propellant overhead injected

through chamber wall

  • Long life and light weight

structures, similar to CMC thrust chamber design Features

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 17

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SLIDE 18

Further activities

  • ALM / SLM technology for injector systems
  • CMC components for hybrid propulsion systems
  • Paraffin / N2O: Hybrid thruster
  • CMC thrust chamber for an ADN orbital propulsion system
  • Investigations on alternative propellants for CMC high performance thrust chamber application
  • LOX / LCH4
  • LOX / kerosene

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 18

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SLIDE 19

Summary

  • The transpiration cooled CMC thrust chamber principle could be demonstrated successfully
  • a simplified and de-coupled design principle has been proven
  • no critical material degradation under efficient operation, considering scaling aspects
  • mechanically safe structures
  • First firing tests of the ceramic ‚cone injector‘ concept successful and promising
  • Adequate hybrid mechanical interfaces demonstrated
  • New hyperboloid thrust chamber contour numerically validated
  • CMC application potential for ADN thruster (orbital propulsion)
  • CMCs principally interesting for hybrid propulsion systems
  • Preburner application (in particular ox-rich)
  • Up-coming SLM technology
  • Alternative propellants

Outlook

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 19

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SLIDE 20

Thank you for your attention!

DLR-ST-IBT > M. Ortelt / H. Hald / D. Koch > Presentation > AIRBUS DS – Space Systems - 6th R&T DAYS > Paris > France, 19.11.2015 • Chart 20