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Liquid & Solid Propulsion Overview
Dr. Richard CohnChief, Liquid Engines Branch
Propulsion DirectorateAir Force Research Laboratory
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2
Space and Missile R&D Building Block Process
6.1 6.2 6.3
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Joint government and industry effort focused on developing affordable technologies for revolutionary, reusable and/or rapid response military global reach capability, sustainable strategic
missiles, long life or increased maneuverability spacecraft capability and high performance tactical missile capability
SMV/SOVSMV/SOV
Air-to-Air MissilesAir-to-Air Missiles
High Energy High Energy Upper StagesUpper Stages
ELVsELVs ICBMsICBMs
SLBMsSLBMs SatellitesSatellites
Micro-SatellitesMicro-Satellites
Integrated High Payoff Rocket Propulsion Technology (IHPRPT)
Ground/SurfaceGround/SurfaceLaunched MissilesLaunched Missiles
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4
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%
IHPRPT Goals
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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
Solid Motor
Technology development is critical to sustaining strategic system capability and
affordability
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• 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
Solid Performance Technology
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7
• 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
M&S Technology
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• 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
Aging and Surveillance Technology
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9
AFRL Edwards Rocket Site: LiquidRocket Technology Development
Air Force Programs
Air Force Proposed
Other Programs
X-33
XRS-2200
AFRL HC
Boost
On-Demand Launch(RBS)
Space Vector 1
AFRL Aerospike Tech
AFRL Thrust Cell Program
Military Space Plane & SOV
AFRL IPD
Concept Engine
AFRL XLR-129
SpaceShuttle
SSME
X-15
AFRL XLR-99
RL-10
Centaur Upper Stage
CL-400 Suntan
DC-X
J2X
RS 68- A/B ARES
Four Decades of Leadership in Rocket Engine TechnologyNot STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number
Increasing Reusability
Rapid turn 4 hrs
100X lower ops cost
Vehicle reliability
All Wx availability
• 4X Sortie Airframe4X Sortie Airframe
• 5X Sortie Propulsion 5X Sortie Propulsion & Systems& Systems
Rapid turn 24 hrs
10X lower ops cost
Vehicle reliability
All Wx availability
• 2X Sortie Airframe
• 2.5X Sortie Propulsion & Systems
Rapid turn 48 hrs
3X lower ops cost
Vehicle reliability
All Wx availability
• High Sortie Airframe
• High Sortie Propulsion & Systems
Far TermMid TermNear Term
BASELINEEELV, Shuttle,Aircraft Ops
Responsive Space AccessTime Phased Plans
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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)
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Drive Towards Model Driven Development
• 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
Test Driven Development
(TDD)
Model Driven Development
(MDD)
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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 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
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
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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
Models & design tools applicable to other Liquid Boost & OTV Applications
- Range of Thrust - Range of Propellants - Range of Engine CyclesNot STINFO Approved. Distribution A – Public release, unlimited distribution. Release Number
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Vision Engine
TRL 3
Subscale / Rig TestingTRL 4
Component Testing
Integrated Demo Testing
TRL 5
TRL 5
Component TRL – Red
System TRL - Purple
Hydrocarbon Boost Developing LOx/RP staged combustion Technology
Mondalloy – High Strength
Ox-Compatible MaterialNot 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
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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
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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
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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
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