Future Space-Transport-System Components under High Thermal and Mechanical Loads: Results from the DFG Collaborative Research Center TRR40

Preface
Contents
Collaborative Research for Future Space Transportation Systems
1 Introduction
2 Research Area A: Structural Cooling
2.1 Transpiration Cooled Ceramic Structures
2.2 Supersonic Film Cooling
2.3 Damping Performance of Resonators
3 Research Area B: Aft-Body Flows
3.1 Nozzle Flow Separation Studies
3.2 Interaction of Rocket Plume and External Flow
3.3 Modeling of Buffeting
4 Research Area C: Combustion Chamber
4.1 Dynamic Processes in Trans-Critical Jets
4.2 Injection, Mixing and Combustion Under Real-Gas Conditions
4.3 Boundary Layer Heat Transfer Modelling
4.4 Combustion Stability of Rocket Engines
5 Research Area D: Thrust Nozzle
5.1 Thermal Barrier Coatings and Component Life Prediction
5.2 Cooling Channel Flows
5.3 Fluid Structure Interaction
6 Research Area K: Thrust-Chamber Assembly
6.1 Combustion and Heat Transfer
6.2 Dual Bell Nozzle
6.3 Thrust-Chamber Demonstrators
7 Central Research and Education Support
References
Structural Cooling
A Coupled Two-Domain Approach for Transpiration Cooling
1 Motivation
2 Mathematical Modeling
2.1 Hot Gas Domain
2.2 Porous Medium Domain
2.3 Coupling Conditions
3 Numerical Methods
4 Numerical Results
4.1 Non-uniform Injection into a Subsonic Hot Gas Channel Flow
4.2 Uniform Injection into a Supersonic Nozzle Flow
5 Conclusion
References
Innovative Cooling for Rocket Combustion Chambers
1 Introduction
2 Experimental Setup
2.1 Stacked Transpiration Cooling Specimen
2.2 Hot Gas Channel and Measurement Setup
3 Numerical Setup
4 Results and Interpretation of the Serial Transpiration Cooling Experiment
5 Summary and Outlook
References
Film Cooling in Rocket Nozzles
1 Motivation
2 Film Cooling Theory
2.1 Film Cooling Efficiency
2.2 Film Cooling Model
3 Experimental Setup
3.1 Test Facility
4 Results Conical Nozzle
4.1 Reference Flow
4.2 Parametric Study
4.3 Correlation
5 Results Dual-Bell Nozzle
5.1 Experiments Without Film Cooling
5.2 Experiments with Film Cooling
6 Conclusion
References
Numerical Simulation of Film Cooling in Supersonic Flow
1 Introduction
2 Flow Configuration
2.1 Film Cooling
3 Numerical Method
4 Results
4.1 Influence of Coolant Mass Flow Rate
4.2 Influence of Coolant Mach Number
4.3 Influence of the Upstream Wall Temperature
4.4 Lip-Thickness Influence
4.5 Influence of the Coolant Velocity Profile
4.6 Correlation of Data
5 Conclusions and Outlook
References
Heat Transfer in Pulsating Flow and Its Impact on Temperature Distribution and Damping Performance of Acoustic Resonators
1 Introduction and Placement in SFB
2 Impact of Temperature Inhomogeneities on Damping Performance
3 Impact of Acoustic Oscillations on Heat Transfer
3.1 Wall Normal Heat Transfer
3.2 Longitudinal Heat Transfer
4 Summary and Conclusions
References
Aft-Body Flows
Effects of a Launcher's External Flow on a Dual-Bell Nozzle Flow
1 Introduction
2 Experimental Setup
2.1 BFS Model
2.2 Measurement Techniques
3 Results
3.1 Steady-State Sea Level Mode
3.2 Steady-State Altitude Mode
3.3 Transition
4 Summary and Conclusions
References
Interaction of Wake and Propulsive Jet Flow of a Generic Space Launcher
1 Introduction
2 Experimental and Numerical Setup
2.1 Geometry and Test Cases
2.2 Experimental Setup
2.3 Numerical Setup
3 Results
3.1 Passive Flow Control on TIC Configuration
3.2 Analysis of Dual-Bell Transition—Effect of Reynolds Number
3.3 Analysis of Dual-Bell Transition—Influence of Afterbody Geometry
4 Summary
References
Rocket Wake Flow Interaction Testing in the Hot Plume Testing Facility (HPTF) Cologne
1 Introduction
2 The Hot Plume Testing Facility (HPTF)
2.1 Vertical Wind Tunnel Cologne (VMK)
2.2 GH2/GO2 Supply Facility
3 Characterization of HPTF for Wind Tunnel Testing
3.1 HPTF Characterization Test Setup
3.2 HPTF Characterization Test Results
4 Cold and Hot Plume Interaction Testing
4.1 GH2/GO2 Wind Tunnel Model
4.2 Test Program and Test Conditions
4.3 Wind Tunnel Test Results
5 Conclusions
References
Numerical Analysis of the Turbulent Wake for a Generic Space Launcher with a Dual-Bell Nozzle
1 Introduction
2 Computational Approach
2.1 Geometry and Flow Conditions
2.2 Zonal RANS/LES Flow Solver
2.3 Computational Mesh
3 Results
3.1 Supersonic Configuration
3.2 Transonic Configuration
4 Conclusions
References
Numerical Investigation of Space Launch Vehicle Base Flows with Hot Plumes
1 Introduction
2 Numerical Method and Setup
3 Results of Thermal Flow Structure Coupling
4 Investigation of Aft-Body Flow Fields
5 Conclusions and Outlook
References
Combustion Chamber
On the Consideration of Diffusive Fluxes Within High-Pressure Injections
1 Introduction
2 Phenomenological Considerations on Mixing Jets
3 Numerical Consideration and Thermodynamic Modeling
3.1 Thermodynamic Modeling
4 Numerical Results: LES of N-Hexane/Nitrogen Jet
5 Conclusions
References
Numerical Investigation of Injection, Mixing and Combustion in Rocket Engines Under High-Pressure Conditions
1 Introduction
2 Physical and Mathematical Modeling
2.1 Governing Equations
2.2 Numerical Flow Solver
2.3 Thermodynamic Modeling
2.4 Combustion Modeling
3 Results and Discussion
3.1 Thermodynamics
3.2 Combustion
4 Conclusion
References
Large-Eddy Simulations for the Wall Heat Flux Prediction of a Film-Cooled Single-Element Combustion Chamber
1 Introduction
2 Governing Equations and Numerical Procedure
3 Test Case
3.1 Combustion Chamber Test Cases
3.2 Roughness Test Cases
4 Results
4.1 Combustion Chamber Results
4.2 Roughness Results
5 Conclusions
References
Calculation of the Thermoacoustic Stability of a Main Stage Thrust Chamber Demonstrator
1 Introduction
2 Test Case
3 Stability Assessment Procedure
3.1 Perturbation Analysis
3.2 Mean Flow
3.3 Flame Response
3.4 External Components and Design Adaption
4 Numerical Setup
4.1 Eigensolution Study
4.2 Single Flame
5 Results
5.1 Dome Acoustics
5.2 Coupled Acoustics
5.3 Stability Behavior
6 Conclusions
References
Experimental Investigation of Injection-Coupled High-Frequency Combustion Instabilities
1 Introduction
1.1 Summary of Previous Investigations
2 Experimental Technique
2.1 Experimental Setup
2.2 Methodology
3 Results and Discussion
3.1 Mean Flame Images
3.2 Dynamic Characteristics
3.3 LOX Core Dynamic Response to Excited Injector Eigenmodes
3.4 Damping Device to Reduce Risk of Injection-Coupled Instabilities
4 Summary and Conclusions
References
Thrust Nozzle
Pseudo-transient 3D Conjugate Heat Transfer Simulation and Lifetime Prediction of a Rocket Combustion Chamber
1 Introduction
2 Conjugate Heat Transfer Simulation
2.1 Computational Model
2.2 Results and Validation
3 Lifetime Prediction
3.1 Transient Thermal Analysis
3.2 Quasi-static Mechanical Analysis
4 Conclusion
References
Lifetime Experiments of Regeneratively Cooled Rocket Combustion Chambers and PIV Measurements in a High Aspect Ratio Cooling Duct
1 Introduction
2 Fatigue Experiment
2.1 Experimental Set-Up
2.2 Load Conditions
2.3 Load Phases
2.4 Deformations and Lifetime
3 Cooling Channel Measurements
3.1 Test Setup
3.2 Light Sheet Alignment
3.3 Window Size Analysis
3.4 Particle Shift
4 Conclusions
References
Mechanical Integrity of Thermal Barrier Coatings: Coating Development and Micromechanics
1 Introduction
2 Methods
2.1 Coating Process
2.2 Arc Heated Hypersonic Wind Tunnel
2.3 Subscale Combustion Chamber
3 Coating Design for a Large Scale Combustion Chamber
3.1 Mechanical Loads
3.2 Crack Propagation
4 Validation Tests
4.1 Arc Heated Hypersonic Wind Tunnel
4.2 Subscale Combustion Chamber
5 Conclusions
References
Assessment of RANS Turbulence Models for Straight Cooling Ducts: Secondary Flow and Strong Property Variation Effects
1 Introduction
2 High Aspect Ratio Cooling Duct
2.1 Equation System and Numerical Model
2.2 Simulation Setup
2.3 Flow and Temperature Field
3 Channel Flow with Strong Property Variations
3.1 Equation System and Numerical Model
3.2 Simulation Setup
3.3 Flow and Temperature Field
4 Summary and Conclusion
References
Experiments on Aerothermal Supersonic Fluid-Structure Interaction
1 Introduction
1.1 FSI and SWBLI
1.2 High Temperature FSI
2 Experiments on Aerothermoelastic FSI with SWBLI
2.1 Wind Tunnel H2K
2.2 Wind Tunnel Model and Instrumentation
2.3 Properties of the Elastic Panel
2.4 Experimental Results
3 Experiments on High Temperature FSI with Plastic Deformation
3.1 Arc-Heated Wind Tunnel L3K
3.2 Wind Tunnel Model and Instrumentation
3.3 Experimental Results
4 Conclusion
References
Numerical Modelling of Fluid-Structure Interaction for Thermal Buckling in Hypersonic Flow
1 Introduction
2 Fluid-Structure Interaction
3 Structural Model
3.1 Thermal Analysis
3.2 Structural Analysis
4 Fluid Model
5 Results
5.1 Solid
5.2 Fluid
6 Conclusion
References
Thrust-Chamber Assembly
Experimental and Numerical Investigation of CH4/O2 Rocket Combustors
1 Introduction
2 Description of the Test Case
3 Inverse Heat Transfer Method
3.1 Direct Solver
3.2 Optimization Method
3.3 Applying the Heat Flux on the Boundary
3.4 Modeling the Cooling Channels
4 Experimental Results
4.1 Experimental Azimuthal Heat Flux Profiles
4.2 Comparison with Calorimetric Method
5 Numerical Simulation
5.1 Computational Setup
5.2 Temperature and Heat Release
5.3 Axial Heat Flux Results
5.4 Azimuthal Heat Flux Results
6 Conclusions
References
Rocket Combustion Chamber Simulations Using High-Order Methods
1 Introduction
2 Numerical Method
2.1 Governing Equations
2.2 Numerical Solver
2.3 Cell Interface Value Reconstruction
3 Combustion Chamber Simulations
3.1 Multi-injector Combustion Chamber
3.2 PennState Preburner Combustor
3.3 Single Injector Combustion Chamber (BKC)
4 Conclusions
References
Dual-Bell Nozzle Design
1 Introduction
1.1 Method of Design
1.2 Parameters of Influence
2 Optimization Studies
3 Film Cooling
3.1 Dual-Bell Nozzle Film Cooling
3.2 Film Cooling Study in Shock Tunnel
4 Wake Flow with Dual-Bell Nozzle
4.1 Flow Fluctuation Experiment
4.2 Interaction Between Afterbody and Dual-Bell Nozzle Flow
5 Conclusion
References
Definition and Evaluation of Advanced Rocket Thrust Chamber Demonstrator Concepts
1 Introduction
2 Virtual Thrust Chamber Demonstrators
2.1 TCD1—Overview and Cooperation
2.2 TCD2—Overview and Cooperation
2.3 TCD3—Overview and Cooperation
3 Numerical Investigation of the Thrust Chamber Demonstrators
3.1 Design Validation of the TCDs
3.2 Design Variation of TCD1
3.3 3D Conjugate Heat Transfer Investigation of TCD1
4 Conclusion and Outlook
References