Design studies of rocket engine cooling structures for fatigue experiments

Fassin, Marek; Kowollik, D.; Wulfinghoff, Stephan; Reese, Stefanie; Haupt, Matthias

doi:10.1007/s00419-016-1160-6

Cited by 12 publications

(8 citation statements)

References 22 publications

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“…While the slope of this deformation profile strongly depended on the thermal loads, i.e., temperature level and temperature gradients, the critical deformation which occurs in case of failure was not affected. For lifetime prediction, the temperature determined from the conjugate heat transfer (CHT) served as input for a series of quasi-static mechanical analyses, in which a newly developed visco-plastic damage model was utilized [45,46]. During the numerical analysis of the deformation process, it was found that the damage initially spread diagonally from the cooling channel corner to the hot gas wall and eventually merged into a macroscopic failure zone.…”

Section: Thermal Barrier Coatings and Component Life Predictionmentioning

confidence: 99%

Collaborative Research for Future Space Transportation Systems

Haidn

Adams

Radespiel

et al. 2020

Notes on Numerical Fluid Mechanics and Multidisciplinary Design

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This chapter book summarizes the major achievements of the five topical focus areas, Structural Cooling, Aft-Body Flows, Combustion Chamber, Thrust Nozzle, and Thrust-Chamber Assembly of the Collaborative Research Center (Sonderforschungsbereich) Transregio 40. Obviously, only sample highlights of each of the more than twenty individual projects can be given here and thus the interested reader is invited to read their reports which again are only a summary of the entire achievements and much more information can be found in the referenced publications. The structural cooling focus area included results from experimental as well as numerical research on transpiration cooling of thrust chamber structures as well as film cooling supersonic nozzles. The topics of the aft-body flow group reached from studies of classical flow separation to interaction of rocket plumes with nozzle structures for sub-, trans-, and supersonic conditions both experimentally and numerically. Combustion instabilities, boundary layer heat transfer, injection, mixing and combustion under real gas conditions and in particular the investigation of the impact of trans-critical conditions on propellant jet disintegration and the behavior under trans-critical conditions were the subjects dealt with in the combustion chamber focus area. The thrust nozzle group worked on thermal barrier coatings and life prediction methods, investigated cooling channel flows and paid special attention to the clarification and description of fluid-structure-interaction phenomena I nozzle flows. The main emphasis of the focal area thrust-chamber assembly was combustion and heat transfer investigated in various model combustors, on dual-bell nozzle phenomena and on the definition and design of three demonstrations for which the individual projects have contributed according to their research field.

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Section: Thermal Barrier Coatings and Component Life Predictionmentioning

confidence: 99%

Collaborative Research for Future Space Transportation Systems

Haidn

Adams

Radespiel

et al. 2020

Notes on Numerical Fluid Mechanics and Multidisciplinary Design

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“…The design process of the fatigue experiment is explained in [6]. Table 1 shows a comparison of the load conditions of test campaigns B-K.…”

Section: Experimental Set-upmentioning

confidence: 99%

“…(a) Fatigue segment cut view (Reprinted by permission from Springer Nature[6]), cut position marked as A-A inFig. 1(b)(b) Fatigue specimen top view with flow directions and measurement positions (Reprinted by permission from Felix Hötte[9] …”

mentioning

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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“…3.2), in which a viscoplastic damage model (see e.g. Kowollik et al [16] and Fassin et al [10]) is utilized. The Finite Element (FE) model with corresponding boundary conditions used for the thermal and mechanical analyses is illustrated in Fig.…”

Section: Lifetime Predictionmentioning

confidence: 99%

“…To this end, a viscoplastic damage model presented in former works (see e.g. Kowollik et al [16] or Fassin et al [10]) is utilized which accounts for nonlinear kinematic and isotropic hardening, respectively. Furthermore, rate-dependence of Perzyna type and Lemaitre type ductile damage are incorporated into the model.…”

Section: Quasi-static Mechanical Analysismentioning

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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Design studies of rocket engine cooling structures for fatigue experiments

Cited by 12 publications

References 22 publications

Collaborative Research for Future Space Transportation Systems

Collaborative Research for Future Space Transportation Systems

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

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

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