Hot-fire Tests Research Articles

Investigation of Dual-Vortical-Flow Hybrid Rocket Engine without Flame Holding Mechanism

A 250 kgf thrust hybrid rocket engine was designed, tested, and verified in this work. Due to the injection and flow pattern of this engine, this engine was named dual-vortical-flow engine. This propulsion system uses N2O as oxidizer and HDPE as fuel. This engine was numerically investigated using a CFD tool that can handle reacting flow with finite-rate chemistry and coupled with the real-fluid model. The engine was further verified via a hot-fire test for 12 s. The ground Isp of the engine was 232 s and 221 s for numerical and hot-fire tests, respectively. An oscillation frequency with an order of 100 Hz was observed in both numerical and hot-fire tests with less than 5% of pressure oscillation. Swirling pattern on the fuel surface was also observed in both numerical and hot-fire test, which proves that this swirling dual-vortical-flow engine works exactly as designed. The averaged regression rate of the fuel surface was found to be 0.6~0.8 mm/s at the surface of disk walls and 1.5~1.7 mm/s at the surface of central core of the fuel grain.

Space Launch System Core-Stage Rocket Engine Development for Shock-Tunnel Testing

The NASA Space Launch System vehicle is composed of four RS-25 liquid oxygen and hydrogen rocket engines in the core stage and two five-segment solid rocket boosters. Because of the complex nature of rocket plume-induced flows within the launch vehicle base during ascent and new vehicle configuration, subscale shock-tunnel propulsive testing was performed to reduce base environment uncertainty and lower vehicle design risk. The major testing challenges are that the shock-tunnel facility test duration spans only 30–160 ms and that similar engine development efforts for shock-tunnel testing have not been accomplished in years. As a result, various numerical models have been developed to design a 2% subscale Space Launch System core-stage gaseous oxygen and hydrogen rocket engine. Static hot-fire tests were conducted in the CUBRC Large Energy National Shock II facility at sea-level conditions to ascertain the combustion dynamics, engine performance, plume flowfield, and operational sensitivity. The model propulsion system satisfied all the design considerations, showed similar performance characteristics to the full-scale RS-25 propulsion system, confirmed minimal to no erosion of hardware, and demonstrated good agreement with numerical design predictions. High-speed video imaging showed that the model core-stage engine plumes have similar shock structure behavior and flow physics to the flight RS-25 engines. As described in this paper, novel engineering design and analyses methods, new engine materials, and cutting-edge diagnostic techniques showed that the subscale Space Launch System core-stage rocket engine satisfied all flow physics similarity parameters needed for high-fidelity short-duration base heating studies.

Experimental and numerical studies of ammonium dinitramide based liquid propellant combustion in space thruster

In this paper, the combustion process of liquid propellant ammonium dinitramide (ADN)-methanol aqueous solution in a small space thruster is investigated experimentally and numerically. The phase Doppler anemometer measurement is used to investigate the injection process and the results are used as the liquid boundary condition in the simulation to minimize uncertainties. Hot fire tests have also been operated to estimate the performance of the thruster. To simulate the complicated processes in the thruster, a modified multi-component droplet model is employed to simulate the evaporation process considering the interaction between the liquid droplet and the porous media. A non-equilibrium model for the porous media is used to describe the heat transfer in the catalyst bed. A reduced chemical mechanism containing 18 species and 40 reactions is used to simulate the reactions of gas-phase ADN and methanol. The results show that the decomposition of ADN and the oxidization of methanol do not happen synchronously in the chamber. The decomposition of ADN takes place near the inlet while methanol is oxidized downstream of the porous media. The establishment of pressure in the thruster depends on the evaporation and reaction processes and the temperature changes relatively slowly because the porous media increases the thermal inertia of the whole system.

Green hypergolic combination: Diethylenetriamine-based fuel and hydrogen peroxide

The present research dealt with the concept of green hypergolic combination to replace the toxic hypergolic combinations. Hydrogen peroxide was selected as a green oxidizer. A novel recipe for the non-toxic hypergolic fuel (Stock 3) was suggested. Sodium borohydride was blended into the mixture of energetic hydrocarbon solvents as an ignition source for hypergolic ignition. The main ingredient of the mixture was diethylenetriamine. By mixing some amount of tetrahydrofuran with diethylenetriamine, the mixture became more flammable and volatile. The mixture of Stock 3 fuel remained stable for four months in the lab scale storability test. Through a simple drop test, the hypergolicity of the green hypergolic combination was verified. Comparing to the toxic hypergolic combination MMH/NTO as the reference, the theoretical performance of the green hypergolic combination would be achieved about 96.7% of the equilibrium specific impulse and about 105.7% of the density specific impulse. The applicability of the green hypergolic combination was successfully confirmed through the static hot-fire tests using 500N scale hypergolic thruster.

Canted Slit 형상의 핀틀 인젝터 로켓엔진의 특성길이와 운동량비에 따른 연소성능

본 연구에서는 케로신과 액체산소를 추진제로 사용하는 핀틀 인젝터의 설계/제작이 이루어졌으며, 연소실 특성길이와 운동량비에 따른 특성속도효율을 통해 연소성능을 확인하였다. 연소시험 결과, 핀틀 인젝터의 추진제 분무 특성으로 인한 재순환영역에 의해, 추진제 조합에 따른 특성길이 추천치보다 짧은 영역에서도 최적의 연소성능을 발휘하는 것을 확인하였다. 또한 운동량비가 연소성능에 지대한 영향을 미치나, 추천범위 1.0~1.5 내에서 특성속도효율이 일정하게 나타남을 확인하였다. In this study, a pintle injector rocket engine which uses kerosene and liquid oxygen as propellants was manufactured by collecting basic design data and establishing a design procedure. Combustion performance of the liquid rocket engine was investigated by characteristic velocity efficiency with characteristic length of the combustion chamber and total momentum ratio. As a result of hot fire tests, it showed that the engine had shorter characteristic length comparing to those of other type injectors, which was known as recommended value with the propellant combination. Also, the characteristic velocity efficiency was greatly affected by total momentum ratio and almost constant within 1.0~1.5.

Modular simulation software development for liquid propellant rocket engines based on MATLAB Simulink

Focusing on Liquid Propellant Rocket Engine (LPRE) major components, a steady state modular simulation software has been established in MATLAB Simulink. For integrated system analysis, a new algorithm dependant on engine inlet mass flow rate and pressure is considered. Using the suggested algorithm, it is possible to evaluate engine component operation, similar to the known initial parameters during hot fire test of the engine on stand. As a case study, the reusable Space Shuttle Main Engine (SSME) has been selected and the simulation has been performed to predict engine’s throttled operation at 109 percent of the nominal thrust value. For this purpose the engine actual flow diagram has been converted to 34 numerical modules and the engine has been modelled by solving a total of 101 steady state mathematic equations. The mean error of the simulation results is found to be less than 5% compared with the published SSME data. Using the presented idea and developed modules, it is possible to build up the numerical model and simulate other LPREs.

한국형발사체 7톤 파워팩 시스템 고주파 신호 분석

7톤 엔진 시험 전에 엔진 시동/정격구동/종료 특성을 확인하고자 나로우주센터 터보펌프 실매질 시험설비에서 파워팩 시험을 수행하였다. 가스발생기 연소실의 동압은 0.2 bar이하로 측정되어 연소 불안정을 발생하지 않았고, 터보펌프에 장착된 RPM 및 가속도 센서 신호 분석 결과, 예측 RPM 범위 안에서 파워팩 시험이 안정하게 수행되었다는 것을 확인하였다. The 7tonf-class power pack test at turbopump test facility in Naro space center was performed for confirmations of starting/running/ending operation characteristics before 7tonf rocket engine hot-firing test. The dynamic pressure mounted on a combustion chamber of gas generator is measured under 0.2 bar which does not conditioned to the unstable combustion. The analysis results of RPM and acceleration sensors mounted on the turbopump, the power pack test was performed to the estimated RPM with the stable combustion.

Influence study of flow separation on the nozzle vibration response

In the present paper, the vibration response difference of the upper stage nozzle with higher expansion ratio between ground and altitude simulation hot-firing test is analyzed. It indicates that the acceleration response of the nozzle under ground hot-firing test is much higher than that of the altitude condition. In order to find the essential reason, the experimental and numerical simulation studies of the flow separation are developed by using the test engine nozzle. The experimental data show that the nozzle internal flow occurred flow separation and the divergence cone internal wall pressure pulsation increased significantly downstream from the separation location. The numerical simulation and experimental results indicate that the increase of internal wall pressure and turbulence pulsating pressure are the substantial reason of vibration response increasing aggravatingly during the ground firing test.

Effects of gas temperature on nozzle damping experiments on cold-flow rocket motors

In order to explore the impact of gas temperature on the nozzle damping characteristics of solid rocket motor, numerical simulations were carried out by an experimental motor in Naval Ordnance Test Station of China Lake in California. Using the pulse decay method, different cases were numerically studied via Fluent along with UDF (User Defined Functions). Firstly, mesh sensitivity analysis and monitor position-independent analysis were carried out for the computer code validation. Then, the numerical method was further validated by comparing the calculated results and experimental data. Finally, the effects of gas temperature on the nozzle damping characteristics were studied in this paper. The results indicated that the gas temperature had cooperative effects on the nozzle damping and there had great differences between cold flow and hot fire test. By discussion and analysis, it was found that the changing of mainstream velocity and the natural acoustic frequency resulted from gas temperature were the key factors that affected the nozzle damping, while the alteration of the mean pressure had little effect. Thus, the high pressure condition could be replaced by low pressure to reduce the difficulty of the test. Finally, the relation of the coefficients “alpha” between the cold flow and hot fire was got.

추진제 및 연소 사이클을 고려한 액체로켓 엔진의 신뢰도 예측

액체로켓 엔진의 신뢰도는 설계 추력, 추진제, 연소 사이클, 및 연소시험 시간의 영향을 받는다. 기존 연구에 따르면 신규 개발하는 엔진과 같은 추진제 및 연소 사이클을 가지는 참조 엔진들의 연소시험 자료가 알려져 있다면 참조 엔진들의 설계 추력과 연소시험 시간을 보정하여 신규 엔진의 신뢰도를 예측할 수 있다. 본 연구에서는 신규 개발하는 엔진과 같은 추진제 및 연소 사이클을 가지는 참조 엔진의 자료가 존재하지 않은 경우를 고려하여 두 엔진 사이의 유사성 분석을 통하여 고장률을 보정한 후 신뢰도를 예측하는 방법을 제시하였다. 또한 액체산소/케로신 추진제와 가스 발생기 사이클을 사용하는 한국형 발사체의 1단 엔진을 이용하여 제안된 방법을 예시하였다. It is known that reliability of liquid rocket engines depends on the design thrust, propellant, engine cycle, and hot firing test time. Previously, a method was developed for estimating reliability of a new engine by adjusting the design thrust and hot firing test time of reference engines where reference engines have the same propellant and engine cycle with the new engine. In this paper, we provide a procedure to predict the engine reliability when the new engine and the reference engine have different propellant and engine cycles. The proposed method is illustrated to estimate the engine reliability of the first stage of Korea Space Launch Vehicle II.

Measurements and modelling of wall heat fluxes in rocket combustion chamber with porous injector head

A rocket combustion chamber with a porous injector head, which is a new concept for injecting propellants, is tested. The hot-fire tests are carried out using cryogenic oxygen and hydrogen at the mass ratio of oxidizer to fuel of 6 and at pressure of 80 bar. Pressures, wall temperatures, and wall heat fluxes are measured along the axis of the chamber. The wall heat fluxes are determined by the calorimetric method. The wall heat flux has a maximum at a distance of 50–100 mm from the injector plate. To interpret the experimental results, numerical simulations are performed using the commercial CFD code ANSYS CFX. The turbulent flow is modelled by the Favre-averaged Navier–Stokes equations and the shear-stress transport model. The turbulent combustion is modelled using two different models: the extended eddy-dissipation model and the extended coherent flame model. Results obtained with the different models are compared both with experimental data and with each other. The numerical results agree with the experimental data. The extended eddy-dissipation model gives the very good agreement which is achieved by applying additional parameters (‘Flame Temperature’ and ‘Extinction Temperature’) dependent on the mixture fraction.

터빈 매니폴드 모사장치를 이용한 액체로켓엔진 가스발생기 연소시험

개방형 사이클의 액체로켓엔진에서는 추진제 중 일부를 연소시켜 터빈 구동용 가스를 생성시키는 가스발생기가 사용되며, 개방형 사이클 액체로켓엔진의 주요 구성품으로서 가스발생기 자체의 연소성능 및 특성을 파악하기 위한 연소시험이 요구된다. 하지만, 가스발생기에서 생성된 연소가스는 터빈 매니폴드의 터빈 노즐에서 질식이 이루어지기 때문에 가스발생기뿐만 아니라 터빈 매니폴드 내부 부피를 고려해야만 가스발생기의 연소 성능 및 특성, 그리고 음향 특성을 정확히 파악할 수 있다. 따라서, 본 논문에서는 터빈 매니폴드 모사장치를 이용한 가스발생기 연소시험 결과를 기술하고 가스발생기 단독 연소시험 결과를 이용한 특성 예측을 설명한다. A gas generator which generates turbine driving gas by burning a part of propellants is used in an open cycle liquid rocket engine and as a main component of an open cycle liquid rocket engine autonomous hot firing tests are required to investigate the combustion performance and characteristics of the gas generator. However, since the combustion gas generated by a gas generator is choked at the turbine nozzle in the turbine manifold, it is necessary to consider the internal volume of turbine manifold as well as that of the gas generator for correct investigation of the combustion performance, characteristics, and acoustic characteristics of the gas generator. Therefore, in the paper hot firing test results of a gas generator with a turbine manifold simulator are described and characteristic prediction using the autonomous test of a gas generator is explained.

Thermal Shock and Ablation Behavior of Tungsten Nozzle Produced by Plasma Spray Forming and Hot Isostatic Pressing

Tungsten nozzle was produced by plasma spray forming (PSF, relative density of 86 ± 2%) followed by hot isostatic pressing (HIPing, 97 ± 2%) at 2000 °C and 180 MPa for 180 min. Scanning electron microscope, x-ray diffractometer, Archimedes method, Vickers hardness, and tensile tests have been employed to study microstructure, phase composition, density, micro-hardness, and mechanical properties of the parts. Resistance of thermal shock and ablation behavior of W nozzle were investigated by hot-firing test on solid rocket motor (SRM). Comparing with PSF nozzle, less damage was observed for HIPed sample after SRM test. Linear ablation rate of nozzle made by PSF was (0.120 ± 0.048) mm/s, while that after HIPing reduced to (0.0075 ± 0.0025) mm/s. Three types of ablation mechanisms including mechanical erosion, thermophysical erosion, and thermochemical ablation took place during hot-firing test. The order of degree of ablation was nozzle throat > convergence > dilation inside W nozzle.

초대형 유압브레이커 개발

Abstract Development of a extra-large hydraulic breaker, which could be used for a 100 ton-class excavator werecarried out Hot-firing tests were carried out. Before designing a hydraulic breaker, the analysis method to predict theperformance such as impact energy and impact rate were studied. Based on the analysis result, the design and manufacture of a extra-large hydraulic breaker were performed, and the breaker were confirmed to operate successfully. The data of impact energy and impact rate were measured during the operation of the breaker, and werecompared with the analysis result. The analysis result of impact rate anticipated well the test data, but that of impactenergy showed a large difference with the test data. The extra-large hydraulic breaker were successfully developed and the analysis method of impact energy will be updated taking into account friction, hydraulic circuit, etc. Key Words : Analysis Method, Impact Energy, Impact Rate, Hydraulic Breaker 이 논문은 2014년도 충북대학교 학술연구지원사업의 연구비 지원에 의하여 연구되었음

Tunable diode laser absorption spectroscopy measurements of high-pressure ammonium dinitramide combustion

The working processes of the ADN-based liquid thruster are complex, utilizing catalytic decomposition in a catalyst bed and high-pressure combustion in the combustion chamber. The present study examines the experimental performance of high-pressure combustion in an ADN-based liquid thruster. Using the Tunable Diode Laser Absorption Spectroscopy (TDLAS) method, flow parameters such as gas temperature and the characteristic species concentration of CO in the combustion chamber were measured instantaneously under the atmospheric environment. The effects of propellant inlet pressure and the catalyst bed preheated temperature on the combustion process were evaluated. It was found that both an increase in the propellant inlet pressure and an increase in the catalyst bed preheated temperature led to an increase in the gas temperature and a decrease of the CO mole fraction in the combustion chamber. In a hot fire test in the vacuum chamber, the performance of the model thruster under steady operation was tested. The results showed that with the increase of propellant inlet pressure, the combustion chamber pressure and the combustion chamber wall temperature also increase. However, although the increase of the catalyst bed preheated temperature also led to the increase of the combustion chamber wall temperature, the combustion chamber pressure remained nearly constant. These results provide a better understanding of the mechanisms of high-pressure combustion with ADN-based liquid propellants, which is beneficial to the development of green aerospace propulsion techniques.

고도 보정용 듀얼 벨 노즐 개발 동향과 기술 분석

Dual-bell nozzle can overcome the performance losses of the conventional bell-shaped nozzles which induced by off-design operations with either over-expanded or under-expanded exhaust flow and minimize the losses of the specific impulse. In United States, Rocketdyne analyzed thrust characteristics according to the shape of the expansion nozzle and NASA conducted hot firing tests with various altitudes. DLR, which is one of the research institute of the Europe, is carrying out research for the different cases of inflection angle, nozzle length and expansion ratio. MAI of Russia applied the slot nozzle to the expansion region in order to reduce the performance losses. In Asia, both the Japan and the India are researching on the dual-bell nozzle and Mitsubishi cooperation of the Japan registered its patent. In this paper, concepts and performance of dual-bell nozzle, which can compensate altitude, are investigated and trends of current research are summarized. It is necessary for Korea to research on the dual-bell nozzle for lucrative space development.

과설계가 타이탄 로켓엔진의 신뢰도 및 개발비용에 미치는 영향

Engine derating is often considered for reliability benefits because lower power operation reduces its failure probability. To be derated during operation, however, the engine must be initially overdesigned. The engine overdesign is cost effective only if reliability increased from derating is enough to offset the initial increase in the development cost caused from the overdesign. The purpose of this paper is to provide an analytical model to consider a trade-off between the engine overdesign and derating. We use a logistic regression model to explain reliability growth in the number of hot firing tests for a fixed power level. Using the Transcost model with the reliability growth model, we show that 10% overdesign of Titan rocket engine decreases its development cost by about 9% and 23% depending on the reliability requirement. We also point out that such a cost reduction depends on the fuel type a rocket uses.

A Novel Kind of Green Solid Propellant Containing H2O2 Cured at Room Temperature (SPHP)

AbstractA novel kind of green solid propellant containing H2O2 cured at room temperature (SPHP) was prepared by a “two‐steps” method, and its stability, mechanical properties, sensitivity, and combustion behavior were characterized. Stable storage of SPHP can be achieved at room temperature by selecting propellant ingredients with perfect compatibility with H2O2 and the addition of a complex stabilizer into propellant formulation. In addition, the obtained SPHP showed a lower tensile strength and higher elongation compared with conventional solid propellant. The experimental results showed that the sensitivity of SPHP was considerably low, but its combustion efficiency and C* efficiency were really high. The hot firing tests demonstrated the stable and smokeless combustion of SPHP, as well as its combustion behavior within the pressure range of 2–10 MPa was in agreement with Vieille’s law and thus can be represented by r=9.95P0.57.

Fluid–solid coupled simulation of the ignition transient of solid rocket motor

The first period of the solid rocket motor operation is the ignition transient, which involves complex processes and, according to chronological sequence, can be divided into several stages, namely, igniter jet injection, propellant heating and ignition, flame spreading, chamber pressurization and solid propellant deformation. The ignition transient should be comprehensively analyzed because it significantly influences the overall performance of the solid rocket motor. A numerical approach is presented in this paper for simulating the fluid–solid interaction problems in the ignition transient of the solid rocket motor. In the proposed procedure, the time-dependent numerical solutions of the governing equations of internal compressible fluid flow are loosely coupled with those of the geometrical nonlinearity problems to determine the propellant mechanical response and deformation. The well-known Zeldovich–Novozhilov model was employed to model propellant ignition and combustion. The fluid–solid coupling interface data interpolation scheme and coupling instance for different computational agents were also reported. Finally, numerical validation was performed, and the proposed approach was applied to the ignition transient of one laboratory-scale solid rocket motor. For the application, the internal ballistics were obtained from the ground hot firing test, and comparisons were made. Results show that the integrated framework allows us to perform coupled simulations of the propellant ignition, strong unsteady internal fluid flow, and propellant mechanical response in SRMs with satisfactory stability and efficiency and presents a reliable and accurate solution to complex multi-physics problems.

Acoustics associated with liquid rocket propulsion testing

Ground testing of liquid rocket engines is a necessary step towards building reliable launch vehicles. NASA Stennis Space Center has a long history of performing both developmental and certification testing of liquid propulsion systems. During these test programs, the propulsion test article, test stand infrastructure and the surrounding community can all be exposed to significant levels of acoustic energy for extended periods of time. In order to ensure the safety of both personnel and equipment, predictions of these acoustic environments are conducted on a routine basis. This presentation will provide an overview of some recent examples in which acoustic analysis has been performed. Validation of these predictions will be shown by comparing the predictions to acoustic data acquired during small- and full-scale engine hot-fire testing. Applications of semi-empirical and advanced computational techniques will be reviewed for both sea-level and altitude test facilities.