Challenges in Cryogenic Rocket Engine Development

CHALLENGES IN CRYOGENIC DEVELOPMENT

PRESENT & THE FUTURE

Presentation by

NK GUPTAProject Director, C25

LPSC-ISRO, Trivandrum

Twentieth National ConferenceNew Delhi

April 10-11, 2006

SATELLITE

C25

L110 (ES)

S200(2 Nos)

GSLV MARK III VEHICLE

Fig 1. STAGE FLOW DIAGRAM

Fig 2. ENGINE OPERATING CYCLES

Expander Cycle Staged combustion Cycle GG Cycle

PERFORMANCE COMPARISON OF VARIOUS CYCLES (Comb. Chamber Pc=60Ksc, MR=6.4, AR=200)

217215-#Incr. P/L from GG Cycle (Kg)

33.4633.3534.87Thrust/weight Ratio

604606587Engine Weight (Kg)

20.21220.21220.468Engine Thrust (T)

5.8725.8725.441Engine Mixture Ratio

459.45459.45453.39Engine lsp. (s)

15512999LH2 Pump Outlet Pr. (Ksc)

Expander Cycle

Staged Combustion

Cycle

Gas Generator Cycle

Fig 1. ENGINE / SUBSYSTEMS

GAS GENERATOR

LOX TURBOPUMP

LH2 TURBOPUMP

INTEGRATED TURBOPUMP

THRUST CHAMBER

FLUID COMPONENTS

INTEGRATED ENGINE (SL)

Fig 3 STAGES OF COPPER CONVERGENT INNER SHELL DEEP DRAWING

2

5

STAGES OF COPPER DIVERGENT INNER SHELL DEEP DRAWING

1

3

3 4

Combustion chamber helical channel milling

C20 INJECTOR BODY

GAS GENERATOR

Fig 6. IGNITORS FOR CRYO ENGINES

1

2

110

17

54

3

4

EBW

EBW

Electric igniterPyrogen igniter

GG

INJECTION VALVES

LH2

EXHAUST GAS DUCT

LOX

GG WITH FEED CIRCUIT FOR TESTING

CE20 GAS GENERATOR MOUNTED AT TEST BED

Fig 5. GG HOT TEST SEQUENCE

OPEN Tf+0.2

OPEN Tf+2.5

OPEN Tf+1.5

HELIUM PURGE VALVE

LH2 VENT VALVE (HVV1)

LOX VENT VALVE (OVV1)

LOX VENT VALVE (OVV2)

LH2 INJECTION VALVE(HIV1)

LH2 INJECTION VALVE(HIV2)

IGNITER

LOX INJECTION VALVE(OIV1) LOX INJECTION VALVE(OIV2)

ToOPEN To-20

Tf =To + 50 s

OPEN To

CLOSE To+ 1.5 CLOSE Tf+10

CLOSE To-3

ON To+0.2 To+ 2.7

OPEN To+0.3 CLOSE Tf

CLOSE To-3.3

CLOSE To-6.5

CLOSE To-10

CLOSE Tf + 2.5

OPEN To+ 1.5 CLOSE Tf + 1

OPEN To+ 2.7 CLOSE Tf - 4

CLOSE To-5

Fig 7. PERFORMANCE OF GG IN HOT TEST

3 0

4 0

3 7 .8 +

s)

G G 0 2 H T 0 2 T E S T

CE20 GAS GENERATOR HOT TEST VIDEO FOOTAGE

Fig 8 CE20 ENGINE- TURBINES ARRANGEMENT

LH2 TURBINELOX TURBINE

TURBINE EXHAUST NOZZLE

Fig 4. DOUBLE LAYERED RING

SINTERED BRONZE SEALRING

DETAILS OF DOUBLE LAYERED RING

Major specifications :Property External layer Internal layer

• Composition Cu-10%Sn Cu-10%Sn-5%BN• Porosity(%) 30 Max. 20-35• Hardness(BHN) 50 Min. 35 Max• Bending strength 250 min(MPa) 100 min (MPa) • UTS 150 min. (MPa) 50 min (MPa)

Present status of Technology :The technology of processing double layered seal rings of all 3 sizes has been established through powder metallurgy route for application in C-25

Bronze Bronze SealringSealring(YMB(YMB--22)22) OD 53 x ID 44 x 11.3

mm

OD 110 x ID 100 x 12

mm

OD 126 x ID 118 x 9.5

mm

CC--25 Turbo Pump25 Turbo Pump

CE20 TP DEVELOPMENT TESTS

A. Cold Flow Tests with water/GN2

1. Pump tests, driven by Electric Motor.

2. Turbine test driven by GN2 absorbed by Dynamometer.

3. Integrated Turbo-pump test with GN2 & water.

B. Tests with Cryo Fluids LN2,LOX,LH2

4. Turbine driven by GN2 & Pump working with LN2.

5. Turbine driven by GG & Pump working with LN2.

6. Turbine driven by GG & Pump working with LH2/ LOX

C. Integrated Turbo-pump Tests

7. GG-LH2TP-LOXTP integrated tests.

LH2 PUMP COLD FLOW TEST

Proto LH2 pump at test bed for testing with water & driven by electric motor

LH2 TURBINE COLD FLOW TEST

Pi = 8.1 bar, Pout =1 bar,Ti = 284K, Flow =1.1 kg/sPR = 8.1 , U/Co = 0.15

LH2 Turbine tested with GN2 at design pressure ratio and low power level. Cd & efficiency as expected. Speed= 8300 rpm

Power= 80 KWCd value = 0.91-0.93Efficiency= 47% at U/Co=0.15

LH2 TURBOPUMP

LOX TURBOPUMP

LOX TP Development tests with LN2

CE20 LOX TP test with GN2-LN2

Speed: 13000 rpmLN2 Flow: 28 lit/secPump Head: 6 MPa

Fig 9. LOX TURBOPUMP TEST DATA WITH LN2

10000

12000

14000

m

LOX TURBOPUMP TEST

LH2 TANK

ITSc

LOX TANK

ENGINE

Fig 10

SPECIFICATIONS OF ENGINE & STAGE

Propellant Combination : LOX/LH2

Total propellant loading : 25790 kg

Operating Cycle : Gas Generator

Thrust, Nominal (Vacuum), kN : 200.7 (±3.0%)

Engine Specific Impulse, s : 443 ± 3

Engine Burn Duration (Nom), s : 550

Chamber Pressure, (Nom), MPa : 6.0

Engine Mixture Ratio : 5.05 (±1.5%)

LOX Flow Rate, kg/s : 38.546

LH2 Flow Rate, kg/s : 7.638

TP speed : 38000 rpm(LH2)

15000 rpm(LOX)

Anti static coatingHeat shield coatingVapour barrier coating

PUF

Adhesive

Tank wall

Fig. 11 CRYO TANK THERMAL INSULATION

Fig 12 Thrust Chamber Test Facility

Thrust Chamber Test Facility

CE20 ENGINE SUBSYSTEM TESTS

SINGLE ELEMENT HOT TESTS

GAS GENERATOR DEVELOPMENT TESTS

TURBO-PUMP BEARING TESTS WITH LN2; LOX/LH2

LOX TP SEAL TESTS WITH LN2 & LOX

LH2 TP SEAL TESTS WITH LN2 & LH2

LOX TURBO-PUMP TESTS GN2 & LN2/LOX; GG & LN2 /LOX

LH2 TURBO-PUMP CRYO TESTS GN2/GG & LN2/LH2

INTEGRATED TURBO-PUMP TEST (Pr Fed / Boot Strap)

SUB SCALE CHAMBER (19 ELEMENT) TEST

INTEGRATED SEA-LEVEL ENGINE TEST