Thermal-structural analysis for reusable thrust chamber using temperature-dependent CuZr alloy model adapted to cryogenic to elevated temperature

Abstract

The inner liners of reusable regeneratively-cooled thrust chambers endure significant thermal and mechanical loads, resulting in doghouse deformation and even cracks during cyclic operations. To correctly reveal the failure mechanism of the thrust chamber inner liner, this study investigates the material properties for CuZr alloy and develops a temperature-dependent material model spanning from cryogenic to elevated temperatures. Firstly, we experimentally obtain the thermal and mechanical properties of the material in the temperature range from 77 K to 900 K. The experimental data reveal that the material properties vary considerably with temperature. Then, to precisely characterize the mechanical behavior of CuZr alloy under cyclic loading across a wide temperature range, a material model that combines Voce nonlinear isotropic hardening model with Chaboche nonlinear kinematic hardening model is proposed, and temperature-dependent parameters of this model are calibrated and verified. Finally, the developed material model is applied to perform the thermal-structural analysis on a reusable thrust chamber, with the aim of investigating its failure mechanism. The results demonstrate the capability of the developed model to accurately replicate the doghouse deformation of the inner liner and quantitatively capture the ratcheting effect.