TRR 40: Technological Foundations for the Design of Thermally and Mechanically Highly Loaded Components of Future Space Transportation Systems
Mechanical and Industrial Engineering
Materials Science and Engineering
Mathematics
Final Report Abstract
The TRR 40 has been established in 2008 as a transregional research consortium of leading German Universities and DLR research centers in aeronautical and astronautical research with a focus on enabling technologies for future generations of space-transportation or launcher systems. Partnering up with ArianeGroup, TRR 40 has served to ensure Europe’s independent access to space. Only such a capability ensures political and economic independence of EU member states whose industries and security to a significant extent rely on usage and exploitation of the near-earth orbit, and whose scientific interests lie in Earth and planetary exploration. Future generations of space-transportation systems will offer a variety of launch capabilities and different levels of reusability. They will rely on chemical propulsion systems as primary engines, as this type of propulsion for the foreseeable future offers the best compromise between development and production cost, and efficiency. In particular, civil launches and human space flight rely on liquid-propellant technologies. Competitiveness with launcher producers from the U.S.A., Russia, and Asia requires further development of technologies on all sectors in terms of cost, efficiency, reliability, and environmental compatibility. The particularly high complexity and extreme thermal and mechanical loads of chemical propulsion engines call for intensive fundamental research as prerequisite for radical improvements and innovative technical solutions. Critical, thermally and mechanically highly loaded components of space transportation systems with chemical propulsion engines can be differentiated according to their functionality and primary physical interactions. Throughout TRR 40 we differentiate the following categories: combustion chamber, nozzle, aft-body flows, and structure cooling. Aft-body flows and structure cooling are characterized by the interaction of thrust-chamber components. They are essential for the efficient and safe operation of space transportation systems. Combustion chamber and nozzle offer the highest potential for increasing overall efficiency. All components are coupled through strong interactions, however, such that design optimization or innovative design solutions of a single component cannot be successful without taking into account its interaction with all other components. Thus, it is not sensible to consider individual components separately from others. Such a procedure would imply gross negligence of important parameters and dependencies and would invalidate the results. The technological challenges of the individual components and the need for an integrated treatment of the propulsion system lead naturally to the five Project Areas as substructure of the TRR 40: Project Area A: Structure Cooling, Project Area B: Aft-body flows, Project Area C: Combustion Chamber, Project Area D: Nozzle, Project Area K: Thrust Chamber. Project Area K represents the application backbone jointly with the industrial TRR 40 partner ArianeGroup. The thrust chamber system consists of the combustion chamber (Project Area C) and the nozzle (Project Area D) as the main hardware components. Operational components of the thrust chamber are structure cooling (Project Area A) and aerodynamic integration into the aft body (Project Area B). Among Project Area K projects are those that define and operate simplified or generic representations of thrust-chamber hardware components. Moreover, a synergizing subproject has been contributed and fully funded by ArianeGroup that maintains the TRR 40 reference thrust chamber as virtual demonstrator. The reference thrust chamber has been defined in three versions of full-scale thrustchambers, fully represented by the ArianeGroup design-simulation environment. It has served as virtual technology testbed where the impact of TRR 40 technological innovations on thrust chamber components have been tested virtually and qualified. Moreover, state-of-the-art research simulation methods, developed by TRR 40, have been used to identify weak links of the design simulation environment and to assess the gain in prediction accuracy offered by the incorporation of such modern simulation methods into the simulation environment. The nozzle and its interactions are subject of Project Area D. Such interactions are determined by the combustion chamber, which is subject of Project Area C. The effects of heat transfer on combustion chamber and nozzle operation and on cooling have been investigated in Project Area A. Exterior loads on the nozzle are the result of exhaust-plume interaction with the exterior flow, constituted the research focus of Project Area B. Scientific core subject of all Project Areas is the multi-disciplinary investigation of nonlinearly coupled thermomechanical systems. Model development is based on experimental findings and validation by detailed numerical simulations. This is the backbone of all projects within each Project Area and for their interaction across Project Areas. Across its three funding periods, the TRR 40 has derived new technologies that have led to less costly, more reliable and more efficient thrust-chamber concepts, and improved design prediction tools.
Publications
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Grilli, M., Schmid, J., Hickel, S., and Adams, N.
(See online at https://doi.org/10.1017/jfm.2012.37) - (2012), "Numerical study of the subsonic base flow with a side support", in Fu et al. (eds): Progress in Hybrid RANS-LES Modelling. Notes on Numerical Fluid Mechanics and Multidisciplinary Design, 117, pp. 427-437
You, Y., Osswald, K., Lüdeke, H., and Hannemann, V.
(See online at https://doi.org/10.1007/978-3-642-31818-4_37) - (2014), "Numerical simulation of transpiration cooling through porous material", International Journal for Numerical Methods in Fluids, 76, pp. 331–365
Dahmen, W., Gotzen, T., Müller, S., and Rom, M.
(See online at https://doi.org/10.1002/fld.3935) - (2015), "Analysis of pressure perturbation sources on a generic space launcher after-body in supersonic flow using zonal RANS/LES and dynamic mode decomposition", Physics of Fluids, 7, 016103
Statnikov, V., Sayadi, T., Meinke, M., Schmid, P., and Schröder, W.
(See online at https://doi.org/10.1063/1.4906219) - (2015), "Heat transfer in reacting cooling films: Influence and validation of combustion modeling in numerical simulations", Journal of Turbomachinery, 137(8), 081003
Pohl S., Frank G., and Pfitzner M.
(See online at https://doi.org/10.1115/1.4029350) - (2015), "Influence of cooling-gas properties on film-cooling effectiveness in supersonic flow", Journal of Spacecraft and Rockets 52(5), pp.1443-1455
Keller, M., Kloker, M.J., and Olivier, H.
(See online at https://doi.org/10.2514/1.A33203) - (2015), "Mapping the Influence of Acoustic Resonators on Rocket Engine Combustion Stability". Journal of Propulsion and Power 31, pp. 1159–1166
Förner, K., Cárdenas Miranda, A., and Polifke, W.
(See online at https://doi.org/10.2514/1.B35660) - (2015), "Numerical boundary layer investigations of transpiration-cooled turbulent channel flow", International Journal of Heat and Mass Transfer, 86, pp. 90-100
Dahmen, W., Müller, S., Rom, M., Schweikert, S., Selzer, M., and von Wolfersdorf, J.
(See online at https://doi.org/10.1016/j.ijheatmasstransfer.2015.02.075) - (2015), "The flow field in a high aspect ratio cooling duct without and with one heated wall", Experiments in Fluids, 56(12), pp. 1-13
Rochlitz, H., Scholz, P., and Fuchs, T.
(See online at https://doi.org/10.1007/s00348-015-2071-y) - (2016), "Design studies of rocket engine cooling structures for fatigue experiments", Archive of Applied Mechanics, 86(12), pp. 2063-2093
Fassin, M., Kowollik, D., Wulfinghoff, S., Reese, S., and Haupt, M.
(See online at https://doi.org/10.1007/s00419-016-1160-6) - (2016), "Direct numerical simulation of foreign-gas film cooling in supersonic boundary-layer flow", AIAA Journal 55(1), pp. 99-111
Keller, M., and Kloker, M.J.
(See online at https://doi.org/10.2514/1.J055115) - (2016), "Experiments on the Interaction of a Fast-Moving Shock with an Elastic Panel", AIAA Journal, 54(2), pp. 670-678
Daub, D., Willems, S., and Gülhan, A.
(See online at https://doi.org/10.2514/1.J054233) - (2016), "Injector-driven combustion instabilities in a hydrogen/oxygen rocket combustor", Journal of Propulsion and Power, 32(3), pp. 560-573
Gröning, S., Hardi, J. S., Suslov, D., and Oschwald, M.
(See online at https://doi.org/10.2514/1.B35768) - (2016), "Large-eddy simulation of nitrogen injection at trans- and supercritical conditions", Physics of Fluids, 28(1), 0151026
Müller H., Niedermeier C.A., Matheis J., Pfitzner M., and Hickel S.
(See online at https://doi.org/10.1063/1.4937948) - (2017), "Investigation of the heat transfer coefficient in a transpiration film cooling with chemical reactions", International Journal of Heat and Mass Transfer, 113, pp. 755-763
Frank G., and Pfitzner M.
(See online at https://doi.org/10.1016/j.ijheatmasstransfer.2017.05.103) - (2017), "Linear stability assessment of a cryogenic rocket engine", International Journal of Spray and Combustion Dynamics, 9(4), pp. 277-298
Schulze, M., and Sattelmayer, T.
(See online at https://doi.org/10.1177/1756827717695281) - (2017), "Numerical modelling of transpiration-cooled turbulent channel flow with comparison to experimental data", Journal of Thermophysics and Heat Transfer, 32(3), pp. 713-735
Munk, D., Selzer, M., Böhrk, H., Schweikert, S., and Vio, G.
(See online at https://doi.org/10.2514/1.T5266) - (2017), "Propulsive jet simulation with air and helium in launcher wake flows", CEAS Space Journal, 9, pp. 195–209
Stephan, S., and Radespiel, R.
(See online at https://doi.org/10.1007/s12567-016-0142-4) - (2017), "Unsteady effects of strong shockwave/boundary-layer interaction at high Reynolds number", Journal of Fluid Mechanics, 823, pp. 617-657
Pasquariello. V., Hickel, S., and Adams, N.
(See online at https://doi.org/10.1017/jfm.2017.308) - (2018), "A quantitative speed of sound database for multi-component jet mixing at high pressure", Fuel, 233, pp. 918-925
Baab, S., Steinhausen, C., Lamanna, G., Weigand, B., and Förster, F.J.
(See online at https://doi.org/10.1016/j.fuel.2017.12.080) - (2018), "Efficient thermo-chemistry tabulation for non-premixed combustion at high-pressure conditions", Flow, Turbulence and Combustion, 101(3), pp.821-850
Zips J., Müller H., and Pfitzner M.
(See online at https://doi.org/10.1007/s10494-018-9932-4) - (2018), "Inverse heat transfer method applied to capacitive cooled rocket thrust chambers", International Journal of Heat and Mass Transfer, 131, pp. 150-166
Perakis, N., and Haidn, O.J.
(See online at https://doi.org/10.1016/J.ijheatmasstransfer.2018.11.048) - (2018), "Passive flow control for reduced load dynamics aft of a backward-facing step", AIAA Journal, 57, pp. 1-12
Bolgar, I., Scharnowski, S., and Kähler, C. J.
(See online at https://doi.org/10.2514/1.J057274) - (2018), "Temperature dependent mechanical properties of metallic HVOF coatings", Surface and Coatings Technology, 349, pp. 32-36
Fiedler, T., Sinning, H.-R., Rösler, J., and Bäker, M.
(See online at https://doi.org/10.1016/j.surfcoat.2018.05.062) - (2018), "The effect of the Mach number on a turbulent backward-facing step flow", Flow, Turbulence and Combustion, 101, pp. 1-28
Bolgar, I., Scharnowski, S., and Kähler, C. J.
(See online at https://doi.org/10.1007/s10494-018-9921-7) - (2019), "A new metallic thermal barrier coating system for rocket engines: Failure mechanisms and design guidelines", Journal of Thermal Spray Technology, 28, pp. 1402-1419
Fiedler, T., Rösler, J., and Bäker, M.
(See online at https://doi.org/10.1007/s11666-019-00900-1) - (2019), "Active control of a Dual-Bell nozzle operation mode transition by film cooling and mixture ratio variation", Journal of Propulsion and Power, 36(1)
Schneider, D., Stark, R., Génin, C., Kostyrkin, K., and Oschwald, M.
(See online at https://doi.org/10.2514/1.B37299) - (2019), "Design of a film cooled dual-bell nozzle", Acta Astronautica, 158, pp. 342-350
Stark, R., and Génin, C.
(See online at https://doi.org/10.1016/j.actaastro.2018.05.056) - (2019), "Experimental investigations of film cooling in a conical nozzle under rocket-engine-like flow conditions", AIAA Journal, 57(3), pp.1172-1183
Ludescher, S., and Olivier, H.
(See online at https://doi.org/10.2514/1.J057486) - (2019), "Gradient-extended anisotropic brittle damage modeling using a second order damage tensor – Theory, implementation and numerical examples", International Journal of Solids and Structures, 167, pp. 93-126
Fassin, M., Eggersmann, R., Wulfinghoff, S., and Reese, S.
(See online at https://doi.org/10.1016/j.ijsolstr.2019.02.009) - (2019), "Heat flux evaluation in a multi-element CH4/O2 rocket combustor using an inverse heat transfer method", International Journal of Heat and Mass Transfer, 142
Perakis, N., Strauß, J., and Haidn, O.J.
(See online at https://doi.org/10.1016/j.ijheatmasstransfer.2019.07.075) - (2019), "Heat transfer and combustion simulation of a 7-Element GOX/GCH4 rocket combustor", Journal of Propulsion and Power, 35(6), pp. 1080-1097
Perakis, N., Rahn, D., Haidn, O.J., and Eiringhaus, D.
(See online at https://doi.org/10.2514/1.B37402) - (2019), "Injector-driven flame dynamics in a high-pressure multi-element oxygen-hydrogen rocket thrust chamber", Journal of Propulsion and Power, 35(3), pp. 632-644
Armbruster, W., Hardi, J. S., Suslov, D., and Oschwald, M.
(See online at https://doi.org/10.2514/1.B37406) - (2019), "Large eddy simulation of enhanced heat transfer in pulsatile turbulent channel flow". International Journal of Heat and Mass Transfer 144, pp. 118585
Van Buren, S., Cárdenas Miranda, A., and Polifke, W.
(See online at https://doi.org/10.1016/j.ijheatmasstransfer.2019.118585) - (2019), "Numerical investigation of jet-wake interaction for a dual-bell nozzle" Flow, Turbulence and Combustion, 104, pp. 553-578
Loosen, S., Meinke, M., and Schröder, W.
(See online at https://doi.org/10.1007/s10494-019-00056-6) - (2019), "On the use of tabulated equations of state for multi-phase simulations in the homogeneous equilibrium limit", Shock Waves, 29, pp. 769-793
Föll, F., Hitz, T., Müller, C., Munz, C.-D., and Dumbser, M.
(See online at https://doi.org/10.1007/s00193-019-00896-1) - (2019): "On the subsonic near-wake of a space launcher configuration with exhaust jet", Experiments in Fluids, 60, 165
Saile, D., Kühl, V., and Gülhan, A.
(See online at https://doi.org/10.1007/s00348-019-2801-7) - (2020), "Investigation of structured and unstructured grid topology and resolution dependence for scale-resolving simulations of axisymmetric detaching-reattaching shear layers", in Hoarau et al. (eds): Progress in Hybrid RANS-LES Modelling. Notes on Numerical Fluid Mechanics and Multidisciplinary Design, 143, pp. 169-179
Schumann, J.-E., Hannemann V., and Hannemann K.
(See online at https://doi.org/10.1007/978-3-030-27607-2_13) - (2020), and Rohdenburg, M., "Experimental lifetime study of regeneratively cooled rocket chamber walls", International Journal of Fatigue, 138, 105649
Hötte, F., von Sethe, C., Fiedler, T., Haupt, M.C., Haidn, O.J.
(See online at https://doi.org/10.1016/j.ijfatigue.2020.105649) - (2020): Future Space-Transport-System Components under High Thermal and Mechanical Loads: Results from the DFG Collaborative Research Center TRR40. Notes on Numerical Fluid Mechanics and Multidisciplinary Design, 146
Adams, N., Schröder, W., Radespiel, R., Haidn, O, Sattelmayer, T., Stemmer, C., and Weigand, B. (eds.)
(See online at https://doi.org/10.1007/978-3-030-53847-7)
