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Liquid & Solid Propulsion Overview

Liquid & Solid Propulsion Overview. Dr. Richard Cohn Chief, Liquid Engines Branch Propulsion Directorate Air Force Research Laboratory Richard.Cohn@edwards.af.mil 661-275-5198. Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number.

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Liquid & Solid Propulsion Overview

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  1. Liquid & Solid Propulsion Overview Dr. Richard Cohn Chief, Liquid Engines Branch Propulsion Directorate Air Force Research Laboratory Richard.Cohn@edwards.af.mil 661-275-5198 Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  2. Space and Missile R&D Building Block Process 6.3 6.1 6.2 Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  3. Integrated High Payoff Rocket Propulsion Technology (IHPRPT) Joint government and industry effort focused on developing affordable technologies for revolutionary, reusable and/or rapidresponsemilitary global reach capability, sustainablestrategic missiles, long life or increased maneuverabilityspacecraft capability and high performance tactical missile capability ELVs ICBMs Micro-Satellites SLBMs Satellites High Energy Upper Stages SMV/SOV Ground/Surface Launched Missiles Air-to-Air Missiles Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  4. IHPRPT Goals • Boost and Orbit Transfer Propulsion Near Mid Far • Improve ISP (sec) 14 21 26 • Improve Thrust to Weight (Liquids) 30% 60% 100% • Improve Mass Fraction (Solids) 15% 25% 35% • Mean Time Between Removal (Missions) 20 40 100 • Reduce Stage Failure Rate 25% 50% 75% • Reduce Hardware Costs 15% 25% 35% • Reduce Support Costs 15% 25% 35% • Spacecraft Propulsion • Improve Itot/Mass (wet) (Electrostatic/Electromagnetic) 20%/200% 35%/500% 75%/1250% • Improve Isp (Bipropellant/Solar Thermal) 5%/10% 10%/15% 20%/20% • Improve Density-Isp (Monopropellant) 30% 50% 70% • Improve Mass Fraction (Solar Thermal) 15% 25% 35% • Tactical Propulsion • Improve Delivered Energy 3% 7% 15% • Improve Mass Fraction (Without TVC/Throttling) 2% 5% 10% • Improve Mass Fraction (With TVC/Throttling) 10% 20% 30% Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  5. Solid Motor • Technology development for the warfighter • Increase performance at reduced cost • Improve tools to reduce life cycle cost and enable increased capability • Aging and Surveillance • Sustain industry technology development Technology development is critical to sustaining strategic system capability and affordability Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  6. Solid Performance Technology • Inert Components • High strength composite case • Low erosion / non-eroding nozzle • Low erosion insulation • Energetic components • Increased energy/low sensitivity ingredients • High performance 1.3HC propellant • Technology demonstration • Delivered performance of integrated components • Demonstration of IHPRPT goal compliance Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  7. M&S Technology • Performance • Multi-phase computational fluid dynamics • Combustion of metallized propellants • Ignition transient including erosive burning • Thermostructual • Multi-phase heat transfer • Material ablation, erosion, and burnback geometry • Fluid Thermal Structural Interaction • Coupled solutions • Model verification and validation Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  8. Aging and Surveillance Technology • Service life prediction technology • Assessment of critical defects • Propellant damage model development • Environmental effects on material life • Integrated motor life management • Integrated sensor/data/analysis system • Smart sensor technology • Long term data warehousing • Automated non-destructive evaluation Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  9. AFRL Edwards Rocket Site: LiquidRocket Technology Development DC-X X-33 AFRL IPD X-15 AFRL Thrust Cell Program SSME AFRL XLR-129 RS 68- A/B Military Space Plane & SOV ARES On-Demand Launch (RBS) Air Force Programs Air Force Proposed Other Programs Centaur Upper Stage Space Vector 1 J2X Concept Engine AFRL HC Boost Space Shuttle XRS-2200 RL-10 CL-400 Suntan AFRL XLR-99 AFRL Aerospike Tech Four Decades of Leadership in Rocket Engine Technology Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  10. Responsive Space AccessTime Phased Plans Increasing Reusability • Rapid turn 48 hrs • 3X lower ops cost • Vehicle reliability • All Wx availability • High Sortie Airframe • High Sortie Propulsion & Systems • Rapid turn 24 hrs • 10X lower ops cost • Vehicle reliability • All Wx availability • 2X Sortie Airframe • 2.5X Sortie Propulsion & Systems • Rapid turn 4 hrs • 100X lower ops cost • Vehicle reliability • All Wx availability • 4X Sortie Airframe • 5X Sortie Propulsion & Systems BASELINE EELV, Shuttle, Aircraft Ops Near Term Mid Term Far Term Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  11. Liquid Rocket • Drive towards Modeling and Simulation • Rocket Engine Development Programs • IPD (LOx/LH2 Booster) • USET (LOx/LH2 Upper Stage) • Hydrocarbon Boost (LOx/RP-2 Booster) • 3GRB (LOx/LCH4 Booster) Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  12. Drive Towards Model Driven Development Test Driven Development (TDD) Model Driven Development (MDD) • There is a need to improve 30-40 year old modeling, simulation, & analysis (MS&A) tools • Existing tools old and empirically based and require hundreds of tests • Industry losing grey beards and thus design and analysis capability • Could not handle new technologies like hydrostatic bearings • Current and future computational capabilities allow use of physics-based tools to supplement testing • Testing drives the cost of rocket programs • Necessary • Need to be smart Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  13. Integrated Powerhead Demo (IPD) • Joint program between AF, NASA, and Industry • Supports sortie-like launch for Operationally Responsive Space (ORS) • Payoffs: • 200 Mission Life (20X improvement) • 100 MTBR • First known full scale demonstration of Full Flow Staged Combustion Cycle in the World! IPD Ground Demonstrator Engine installed in E1 Complex Cell 1 IPD Ground Engine: E1 Test Stand NASA SSC,Test 013TA: Standard Start to 80%PL, 87%PL w/ Short Hold; Test Profile RA, November 10th, 2005 IPD Ground Engine: E1 Test Stand NASA SSC, Test 014TA: Standard Start to 85%PL, (Actual 89%PL) w/ Steady State; Test Profile SA, December 15th, 2005 Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  14. USET Objective • Objective: Develop and demonstrate the next generation Model Driven Design (MDD) tools on an upper stage engine component • Selected Turbopump • Approach: • Link commercial design tools with rocket specific empirical data, rocket specific material & propellant libraries, and user defined functions • Replace targeted legacy design tools with physics based tools • Enable Multi-Disciplinary Models, Time Accurate Solutions & Interconnected Models • Reduced design time, more design iterations • Higher fidelity analysis earlier in process • Multi-disciplinary optimization • Use Tools to design validation turbopump assembly • Validation: provide sealed envelope predictions to compare with test data Models & design tools applicable to other Liquid Boost & OTV Applications - Range of Thrust - Range of Propellants - Range of Engine Cycles Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  15. Hydrocarbon Boost Developing LOx/RP staged combustion Technology Component Testing Subscale / Rig Testing TRL 5 TRL 4 Vision Engine TRL 3 Component TRL – Red System TRL - Purple Mondalloy – High Strength Ox-Compatible Material Integrated Demo Testing TRL 5 Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  16. 3GRB • Advancement of the state of the art • Innovative cycles/ component technologies • Pursue IHPRPT Hydrocarbon Boost Phase III and Operability Goals • Fuel Choice • Rocket Grade Methane MIL-PRF-32207 is the baseline fuel • Methane has high potential as fuel for booster stage rocket engines • Database and experience on pump fed methane engines is lacking in US • AFRL to leverage existing pressure fed activities (NASA) • Develop rocket engine components • Component and/or breadboard validation in laboratory environment • No integrated demonstartion Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  17. Conclusions • AFRL/RZS is developing new technology in liquid and solid propulsion • Mix of Tech Push and Mission Pull • Primary customer is SMC • Focused efforts examining Cryo-Boost, HC Boost, and Upper Stage Rocket Propulsion • Aggressive goals lead to unique vision engines • Tool development is crucial • Developing the critical demonstration programs as well as the key underlying technologies • Mondalloy • Other parts of AFRL working air-breathing concepts Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  18. Comments on Roadmap • Reads like a technology review of propulsion concepts • All work seems to be nearly in parallel • Many technologies have been worked in the past • Fundamental changes that make them more effective? • Combination of new technology and “engineering” development • Some are being worked • For more details on current activities, recommend a non-public release environment Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  19. PWR Vision Engine • Expander-Heat Exchanger Cycle (Ex-Hex) • HEX reduces system pressures • Enables higher Pressure Ratio turbine • Reduces heat required to run cycle • Significantly reduces Turbopump power • Ex-Hex Eliminates Preburner • No moisture / contaminates • Eliminates drying / flushing • Significantly reduces Ground-Ops • Low CH4 Hot Gas Temp • Reduced hot gas system complexity • Benign fluid environment • Improved turbine drive system life • Lower Engine pressures • Existing test facility infrastructure Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

  20. WASK Vision Engine • Staged Combustion Cycle • Low Preburner Gas Temperature Assures Long Life • Modular engine design • Small TCAs Lower Development and Test Costs • Altitude compensating nozzle • Innovative TPA • Eliminated boost pumps • Single shaft Not STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number

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