5. Test Facilities

Imprint: Deutsches Zentrum für Luft- und Raumfahrt e.V. Institut für Raumfahrtantriebe Im Langen Grund 74239 Hardthausen Germany Phone:+49 6298 28 0 Fax: +49 6298 112 Institute of Space Propulsion Institut für Raumfahrtantriebe Status Report 2011 Status Report 2011 Preamble means that special storage, handling and transportation facilities are a pre-requisite on the In the course of the last five decades, the site in site. Lampoldshausen has played an integral part in the The space company EADS Astrium also has a European space flight program. Together with its division on the premises. A number of other partners in the aerospace industry; the European companies and institutes also make use of the site’s Space Agency, national agencies, research services and test benches, thus contributing to a organizations and universities, the team in close-knit and beneficial alliance. These include the Lampoldshausen makes an essential contribution to European Space Agency (ESA), the French space the development of European rocket propulsion agency Centre National d’Études et de Recherches systems and assures the continuous success of Spatiales (CNES), and the Société Nationale European operational launchers. A very close co- d’Études et de Constructions de Moteurs d’Aviation operation exists since 1959 with the major French (Snecma). organisations involved in space propulsion and the Ariane programs. This co-operation is vital to the In recent years, DLR Lampoldshausen has developed success of current and future European launcher into a modern service provider now covering all development projects. stages of the testing process from the provision of test benches and the operation of engines to the Lampoldshausen has been the main German recording and transmission of measurement data to development and testing site for all European liquid the client. fuel rocket engines ranging from attitude control engines (> 0.5 N) and apogee engines (>200 N) to With its engineering and operations departments large liquid hydrogen main stage engines (>1300 on the one hand and the research departments on KN) such as Ariane´s main stage engine - the the other hand the Institute is a unique place which Vulcain 2. delivers results from the early stages of a development project all the way to qualification of At present and in the near future Lampoldshausen the final product: a certified rocket engine. is dedicated to supporting Europe’s Ariane 5 ME program: the development of the new upper stage The German Space Strategy, published on 1st with the 180 kN, re-ignitable engine Vinci. This December 2010, emphasizes that Lampoldshausen engine is tested on the P4 test bed. High-altitude is the pillar which supports Germany’s efforts to testing represents a major core competence in guarantee access to space with the Ariane launcher Lampoldshausen. family. Lampoldshausen’s unique high altitude facilities ensure that Germany’s duties within the DLR Lampoldshausen is home of the Institute of European Launcher Community, namely systems Space Propulsion, one of the most important space responsibility for the old and new Ariane upper research facilities. Management of the site was stages, will be fulfilled. integrated into the Institute in October 2008, which comprises six key departments: Test Facilities, All critical components and operating procedures Engineering, Rocket Propulsion, Propellants, for the new upper stage engine, which goes by the Technology and Safety & Quality. name of Vinci, will be developed and tested in Lampoldshausen. In line with the German Space In view of the fact that potentially hazardous fa- Strategy, DLR has defined specific research and cilities are operated on the site, safety management development targets ranging from system analysis plays a key role in the Institute. A safety office, site of the engines, thrust chambers, nozzles, security unit, site fire brigade, and medical service combustion, fuel management, ignition - ensure the safety and protection of employees, particularly under vacuum conditions, cryo- facilities, and the environment alike during research technology, all the way to testing, verification and and testing operations. The Safety & Quality validation and thus qualification of the rocket department is responsible for acquiring operating engines on the different test benches under settings licences from the relevant authorities and characteristic of those found during launch and maintaining infrastructure on the site. A well- space flight. organised infrastructure of assembly halls, work- shops, pump stations, sewage treatment plant, It is well known that over the next few decades all oxygen and hydrogen tanks, petrol station, and launch vehicles will use chemical rocket engines. vehicle garages ensures smooth, trouble-free The key technology is combustion, and it is well operation. The use of a variety of fuels and oxidisers understood in the scientific community that the Institute of Space Propulsion Preamble Status Report 2011 control and management of the exceptionally high The Technology Transfer Centre (TTZ), a power densities in rocket combustors is of peak conglomerate of different regional business importance. The governing equations which are associations and DLR Lampoldshausen, works to used to model the multiple complex interacting improve networking among regional companies processes in combustion chambers are highly non- that are active in the field of science and industry. linear and therefore extremely difficult to solve. Clear synergies in the fields of environment, health While the application of computational fluid and safety, combustion, ignition, fuel management, dynamics CFD and other improved modelling cryo-technology and systems engineering exist and techniques in areas of compressor and turbine present opportunities for partnerships within and development paved the way to keeping expensive outside of the space propulsion business. testing at a minimum, the control of combustion The DLR Institute for Space Propulsion in phenomena is still based purely on empiricism. Lampoldshausen draws on competence and Combustion modelling is currently only used to experience to deliver qualified test results to support the understanding of combustion chamber national and European decision makers to support phenomena, like heat transfer or combustion the DLR mission: instabilities, but up to now only semi-empirical methods have been used to design components like injectors, swirlers or the complete layout of a Knowledge for Tomorrow! combustion chamber. The only possibility to tune the chemical combustion process is still solely by extensive testing in an environment of total quality control. This still holds for component tests on single injector elements as well as complete rocket engines with power head and nozzle. The Institute of Space Propulsion guarantees the maintenance of an infrastructure to develop and meet the requirements of today’s and tomorrow’s rocket engines. All of Lampoldshausen’s research and development programs directly support European rocket engine development programs. In addition to the unique features of high altitude testing and cryogenic technology for the qualification and development of space propulsion systems, DLR Lampoldshausen develops and manages the application of storable and gel propellants. The Institute co-ordinates the scientific and technical activities of the German Gel Technology Program. Prof. Dr.-Ing. Stefan Schlechtriem The training of space engineers and scientists plays a major role in ensuring reliable, long lasting German Aerospace Center support of European engine development Director Institute of Space Propulsion programs. Since 2005 DLR Lampoldshausen has Im Langen Grund addressed this with the DLR_School_Lab, a Lampoldshausen laboratory for young people where promising 74239 Hardthausen young scientists conduct experiments under the Germany guidance of experienced scientists and engineers. As a next step the DLR Campus Lampoldshausen will be established to ensure the education and training also of bachelor, master and Ph.D. students with the aim of developing the DLR_Campus Lampoldshausen into one of the main sources of qualified personnel for the German space industry. Preamble Institute of Space Propulsion Status Report 2011 CONTENTS 1. Research and Technology 1.1 Engine Cycle Analysis ...........................................................................................................8 1.2 Propellants ...........................................................................................................................9 1.3 Propellant Injection ........................................................................................................... 13 1.4 Start Transients and Ignition ............................................................................................. 18 1.5 Combustion and Stability .................................................................................................. 21 1.6 Heat Transfer and Cooling ................................................................................................ 25 1.7 Lifetime Assessment ......................................................................................................... 28 1.8 Combustion Chamber Technology .................................................................................... 35 1.9 Nozzles ............................................................................................................................. 37 1.10

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