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POLITECNICO DI TORINO Repository ISTITUZIONALE Innovative Model Based Systems Engineering approach for the design of hypersonic transportation systems Original Innovative Model Based Systems Engineering approach for the design of hypersonic transportation systems / Ferretto, Davide. - (2020 Mar 06), pp. 1-466. Availability: This version is available at: 11583/2839867 since: 2020-07-14T10:42:55Z Publisher: Politecnico di Torino Published DOI: Terms of use: Altro tipo di accesso This article is made available under terms and conditions as specified in the corresponding bibliographic description in the repository Publisher copyright (Article begins on next page) 04 August 2020 Doctoral Dissertation Doctoral Program in Aerospace Engineering (32nd Cycle) Innovative Model Based Systems Engineering approach for the design of hypersonic transportation systems By Davide Ferretto Supervisor(s): Prof. Nicole Viola, PhD, Supervisor Prof. Eugenio Brusa, PhD, Co-Supervisor Doctoral Examination Board: Dr. Guillermo Ortega, PhD, Referee, European Space Agency Dr. Marco Marini, PhD, Referee, Centro Italiano Ricerche Aerospaziali Dr. Bayindir Saracoglu, PhD, Board Member, Von Karman Institute for Fluid Dynamics Dr. Victor Fernandez Villace, PhD, Board Member, European Space Agency Prof. Paolo Maggiore, PhD, Board Member, Politecnico di Torino Politecnico di Torino 2020 Declaration I hereby declare that, the contents and organization of this Dissertation* constitute my own original work and do not compromise in any way the rights of third parties, including those relating to the security of personal data. Davide Ferretto 2020 * This Dissertation is presented in partial fulfilment of the requirements for Ph.D. degree in the Doctoral School of Politecnico di Torino (ScuDo). This Dissertation has been carried out in the framework of the Stratospheric Flying Opportunities for High-Speed Propulsion Concepts (STRATOFLY) Project, funded by the European Union’s Horizon 2020 research and innovation programme under grant agreement No 769246. All data and results reported in the manuscript are updated to the submission date. “Stepping out into the universe, (…) we must confront the realities of interstellar travel” (Interstellar, 2014). Acknowledgment PhD career is an exciting and challenging endeavour which cannot be run solo. I would like to take this opportunity to first thank my family, which always supported me in my graduate and post-graduate student career. I would like to heartfelt thank my loving wife for her patience, irreplaceable help and true love, which always allowed me moving forward through the everyday work. I would also like to acknowledge my supervisors for their invaluable suggestions provided and for the opportunities offered during these three years, always encouraging me to invest the best of my capabilities within the research described in this Dissertation. Ultimately, I would like to thank a lot all the colleagues and friends that I have met during my PhD career, which made this experience special and left nice memories in my mind, some of which I will never forget. Abstract The Dissertation proposes a new methodology for conceptual and preliminary design of hypersonic transportation systems. Particularly, after a short introduction on historical studies on hypersonic regimes and projects, the Dissertation presents the overall design methodology, formalized through the Systems and Software Engineering Meta-model (SPEM). Notably, the analysis is focused on the conceptual design and validation of the STRATOFLY MR3 concept, a commercial civil hypersonic cruiser capable to reach Mach 8 along antipodal routes. In details, the presented methodology has been designed to support both the conceptual as well as the preliminary design phases. As far as the conceptual design is concerned, the process starts from the derivation of the mission statement, conceived to mirror the high-level mission objectives, and continues with functional and interface analyses to end up in the vehicle matching analysis and feasibility analysis. In particular, these studies include the definition of mission objectives and requirements, the identification of proper high-level performance indexes, such as required Thrust-to-Weight ratio (T/W) and wing loading, for the different flight phases, as well as a vehicle size assessment in terms of wing surface and internal available volume. For this purposes, an innovative Multiple Matching Chart approach is proposed. Complementary, the preliminary design process for on-board subsystems is described, and specifically applied to the design of the Thermal and Energy Management Subsystem (TEMS) allocated on STRATOFLY MR3 vehicle. Preliminary design methodology includes functional and interface analyses up to component level, performance v and physical characterization of the subsystem and constituent components, with special attention to safety and reliability considerations as well as to design margin policies. Ultimately, the preliminary analysis is completed with a Life Cycle Cost (LCC) assessment including new cost estimation models specifically developed to support the estimation of development, production and operating costs for high-speed vehicles. Contents A century of innovation and beyond .................................................................. 1 1. The challenges of hypersonic flight ................................................................... 6 1.1 An historical perspective ................................................................... 7 1.1.1 From the challenge of sound barrier to the new millennium ......... 7 1.1.2 The future trends towards 2050 .................................................... 17 1.1.3 A general classification to be used as starting point .................... 23 1.2 Hypersonic flight regime at a glance ............................................... 25 1.2.1 Re-entry vehicles .......................................................................... 29 1.2.2 Ascent and re-entry vehicles ........................................................ 30 1.2.3 Cruise and acceleration vehicles .................................................. 31 1.3 Challenges of hypersonic aircraft design ......................................... 32 2. Model-Based aircraft design ............................................................................ 35 2.1 A century of aircraft design ............................................................. 36 2.2 The Systems Engineering ................................................................ 38 2.2.1 Historical notes ............................................................................. 38 2.2.2 Definitions, concepts and pillars .................................................. 40 2.3 Definitions and principles of Model-Based aircraft design ............. 51 3. Case study for a hypersonic cruiser concept .................................................... 57 3.1 A fifteen-years path towards the development of a hypersonic aircraft 58 vii 3.1.1 Long-term Advanced Propulsion Concepts And Technologies (LAPCAT – 2005-2008) ................................................................................. 58 3.1.2 Aerodynamic and Thermal Load interactions with Lightweight Advanced materials for high-Speed flight (ATLLAS – 2006-2009) ............. 60 3.1.3 Long-term Advanced Propulsion Concepts And Technologies II (LAPCAT II – 2008-2013) ............................................................................. 61 3.1.4 Aerodynamic and Thermal Load interactions with Lightweight Advanced materials for high-Speed flight II (ATLLAS II – 2011-2015) ...... 63 3.1.5 High-speed EXperimentAl FLY vehicles (HEXAFLY – 2012- 2014) 64 3.1.6 HIgh speed Key technologies for future Air transport - Research & Innovation cooperation scheme (HIKARI – 2013-2015) ........................... 65 3.1.7 High-speed EXperimentAl FLY vehicles – International (HEXAFLY-International – 2014-2019) ........................................................ 66 3.1.8 STRATOspheric FLYing opportunities for high-speed propulsion concepts (STRATOFLY – 2018-2020) .......................................................... 67 3.2 The STRATOFLY MR3 hypersonic cruiser ................................... 69 3.2.1 STRATOFLY MR3 external layout ............................................. 69 3.2.2 STRATOFLY MR3 internal layout ............................................. 75 3.2.3 STRATOFLY MR3 reference mission concept ........................... 79 4. Model-Based Systems Engineering approach to the conceptual design of hypersonic vehicles .......................................................................................... 80 4.1 Introduction ...................................................................................... 81 4.2 Design methodology and main reference process ........................... 84 4.3 Description of high-level Conceptual Design process ..................... 87 4.4 The Systems Engineering Environment (SEE) ................................ 90 4.5 Discussion on low-level Conceptual Design processes for STRATOFLY MR3 ........................................................................................... 91 4.5.1 Mission Statement Analysis ......................................................... 91 4.5.2 Functional Analysis .................................................................... 102 4.5.3 Interface Analysis ....................................................................... 124 viii 4.5.4 Vehicle matching analysis