Experimental lifetime study of regeneratively cooled rocket chamber walls

Hötte, Felix; Sethe, Christoph von; Fiedler, Torben; Haupt, Matthias; Haidn, Oskar; Rohdenburg, Michael

doi:10.1016/j.ijfatigue.2020.105649

Cited by 16 publications

(11 citation statements)

References 14 publications

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“…The fatigue experiment can be used for validation of numerical simulations regarding heat transfer and lifetime (e.g. [5,17]) PIV measurements have been made in a generic high aspect ratio cooling duct. The results were analyzed well in terms of different parameters affecting the PIV measurements.…”

Section: Discussionmentioning

confidence: 99%

Lifetime Experiments of Regeneratively Cooled Rocket Combustion Chambers and PIV Measurements in a High Aspect Ratio Cooling Duct

Hötte

Günther

Sethe

et al. 2020

Notes on Numerical Fluid Mechanics and Multidisciplinary Design

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This paper aims at experimental investigations of the life limiting mechanisms of regeneratively cooled rocket combustion chambers, especially the so called doghouse effect. In this paper the set up of a cyclic thermo-mechanical fatigue experiment and its results are shown. This experiment has an actively cooled fatigue specimen that is mounted downstream of a subscale GOX-GCH$$_{\text {4}}$$ combustion chamber with rectangular cross section. The specimen is loaded cyclically and inspected after each cycle. The effects of roughness, the use of thermal barrier coatings, the length of the hot gas phase, the oxygen/fuel ratio and the hot gas pressure are shown. In a second experiment the flow in a generic high aspect ratio cooling duct is measured with the Particle Image Velocimetry (PIV) to characterize the basic flow. The main focus of the analysis is on the different recording and processing parameters of the PIV method. Based on this analysis a laser pulse interval and the window size for auto correlation is chosen. Also the repeatability of the measurements is demonstrated. These results are the starting point for future measurements on the roughness effect on heat transfer and pressure loss in a high aspect ratio cooling duct.

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Section: Discussionmentioning

confidence: 99%

Lifetime Experiments of Regeneratively Cooled Rocket Combustion Chambers and PIV Measurements in a High Aspect Ratio Cooling Duct

Hötte

Günther

Sethe

et al. 2020

Notes on Numerical Fluid Mechanics and Multidisciplinary Design

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“…To validate these assumptions, the coating system was tested in a subscale combustion chamber. The results from the whole test campaign including also many tests with uncoated test panels are also to be published in [9]; in the following, the coated specimen is investigated in more detail.…”

Section: Subscale Combustion Chambermentioning

confidence: 99%

“…Since a coating in an as-sprayed condition showed poor adhesion in preliminary tests and delaminated within one cycle [9], the experiments were carried out on a diffusion heat treated coating. As expected, vertical cracks could be observed in the coating after the first cycle.…”

Section: Subscale Combustion Chambermentioning

confidence: 99%

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Mechanical Integrity of Thermal Barrier Coatings: Coating Development and Micromechanics

Fiedler

Rösler

Bäker

et al. 2020

Notes on Numerical Fluid Mechanics and Multidisciplinary Design

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To protect the copper liners of liquid-fuel rocket combustion chambers, a thermal barrier coating can be applied. Previously, a new metallic coating system was developed, consisting of a NiCuCrAl bond-coat and a Rene 80 top-coat, applied with high velocity oxyfuel spray (HVOF). The coatings are tested in laser cycling experiments to develop a detailed failure model, and critical loads for coating failure were defined. In this work, a coating system is designed for a generic engine to demonstrate the benefits of TBCs in rocket engines, and the mechanical loads and possible coating failure are analysed. Finally, the coatings are tested in a hypersonic wind tunnel with surface temperatures of 1350 K and above, where no coating failure was observed. Furthermore, cyclic experiments with a subscale combustion chamber were carried out. With a diffusion heat treatment, no large-scale coating delamination was observed, but the coating cracked vertically due to large cooling-induced stresses. These cracks are inevitable in rocket engines due to the very large thermal-strain differences between hot coating and cooled substrate. It is supposed that the cracks can be tolerated in rocket-engine application.

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“…The Transregio 40 subproject D9's fatigue experiment (see [13,14]) is used as reference configuration. It serves as a basis for extensive measurements which are further used for validation.…”

Section: Introductionmentioning

confidence: 99%

Pseudo-transient 3D Conjugate Heat Transfer Simulation and Lifetime Prediction of a Rocket Combustion Chamber

Barfusz

Hötte

Reese

et al. 2020

Notes on Numerical Fluid Mechanics and Multidisciplinary Design

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Rocket engine nozzle structures typically fail after a few engine cycles due to the extreme thermomechanical loading near the nozzle throat. In order to obtain an accurate lifetime prediction and to increase the lifetime, a detailed understanding of the thermomechanical behavior and the acting loads is indispensable. The first part is devoted to a thermally coupled simulation (conjugate heat transfer) of a fatigue experiment. The simulation contains a thermal FEM model of the fatigue specimen structure, RANS simulations of nine cooling channel flows and a Flamelet-based RANS simulation of the hot gas flow. A pseudo-transient, implicit Dirichlet–Neumann scheme is utilized for the partitioned coupling. A comparison with the experiment shows a good agreement between the nodal temperatures and their corresponding thermocouple measurements. The second part consists of the lifetime prediction of the fatigue experiment utilizing a sequentially coupled thermomechanical analysis scheme. First, a transient thermal analysis is carried out to obtain the temperature field within the fatigue specimen. Afterwards, the computed temperature serves as input for a series of quasi-static mechanical analyses, in which a viscoplastic damage model is utilized. The evolution and progression of the damage variable within the regions of interest are thoroughly discussed. A comparison between simulation and experiment shows that the results are in good agreement. The crucial failure mode (doghouse effect) is captured very well.

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Experimental lifetime study of regeneratively cooled rocket chamber walls

Cited by 16 publications

References 14 publications

Lifetime Experiments of Regeneratively Cooled Rocket Combustion Chambers and PIV Measurements in a High Aspect Ratio Cooling Duct

Lifetime Experiments of Regeneratively Cooled Rocket Combustion Chambers and PIV Measurements in a High Aspect Ratio Cooling Duct

Mechanical Integrity of Thermal Barrier Coatings: Coating Development and Micromechanics

Pseudo-transient 3D Conjugate Heat Transfer Simulation and Lifetime Prediction of a Rocket Combustion Chamber

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