Sub-Topic: AIAA LRE Course AIAA Short Course on Liquid Rocket Engines Liquid Rocket Engine Testing and Exhibit Tuscon, Arizona July 13-14, 2005 Joint Propulsion Conference st Dr. Shamim Rahman 41 NASA John C. Stennis Space Center, MS RELEASED - Printed documents may be obsolete; validate prior to use. 2 AIAA LRE Course g Tools, Operations, Processes, quid Rocket Engine Testing Section Outline Continued on Next Page … – RDT&E, Evolutionary Technology, – ELV Propulsion Shuttle, Apollo, – Upper Stage (Sea-level and Altitude) Boost, – LOX/LH, LOX/RP, Other development Infrastructure • and Motivation for Testing Objectives • Representative LRE Test Campaigns • Overview of Test Facilities for Liquid Rocket Engines • Statistics (historical) of Li • Project Enablers: Engineerin Test RELEASED - Printed documents may be obsolete; validate prior to use. 3 AIAA LRE Course ulsion Test Alliance Continued from Previous Page … Section Outline (cont.) – Commercial Test Sites – Test Sites University – National Rocket Prop • Summary • BACKUP MATERIAL •(CPIA) Test Capability Non-NASA RELEASED - Printed documents may be obsolete; validate prior to use. 4 AIAA LRE Course FOR LRE TESTING FOR LRE TESTING OBJECTIVES & MOTIVATION OBJECTIVES & MOTIVATION RELEASED - Printed documents may be obsolete; validate prior to use. 5 AIAA LRE Course reduce risk to the to meet performance ponent that may be with the new unit. If the unit s to a new configuration, Acceptance testing is intended to: ne acceptance testing, but it may not ion and flight hardware, s, processes, materials, and workmanship, work and test cycles, valent unit-level acceptance testing). ngine LRU is a com ch deliverable item ch deliverable item onstrate capability, and to ce test firing of the engine tests) are conducted to: ng as part of its acceptance test, then the replacement unit d acceptance program, including test techniques, procedures, ted, as required, to: e fabrication of qualificat accommodate multiple re proven concepts and technique certification e the acceptability of ea h level serves to reduce risk for engi e conceptual phase to the operational phase, ing process, and acceptance program produce hardware/software that meet Key Terms adequately reduce flight risk. (An e ent failures due to latent defects in part ee workmanship in manufacturing. identify early in their problems design evolution so that any required corrective test on an engine, or should undergo equi and acceptance test procedures, velopment tests are conduc tests (also commonly known as testing is required to achieve design maturity, dem tests are conducted to demonstrat equipment, instrumentation, and software. removed and replaced by a new unit, without requiring reacceptan being replaced was included in an engine acceptance test firi either should be subjected to such a specification requirements with adequate margin to simulate the engine environments adequately. actions can be taken prior to starting formal qualification testing. – In addition, the qualification tests should validate the planne Generally qualification follows completion of the development test program. – acceptance Component testing at the benc Many components require engine hot fire to – Validate new design concepts or the application of – that Demonstrate the design, manufactur – to precipitate incipi screen items Stress –– and validate Develop qualification development testing is to An objective of or concerns Investigate problems that arise after successful qualification, –– in the Assist evolution of designs from th – design changes, Validate the risk Reduce involved in committing designs to th qualification program. De Development Qualification Acceptance specification and demonstrate error-fr • • • RELEASED - Printed documents may be obsolete; validate prior to use. 6 AIAA LRE Course , RL-60, MB-60 Objectives of Liquid Propulsion Testing – devices (turbomachinery, chambers, ignitors), e.g. RS-84 Combustion – Advanced technology demonstrators – J-2 S, XRS-2200 SSME – etc. RL-10, J-2, F-1, SSME, RS-68, –RS-68, – SSME Block Upgrades – thrust chamber LR-89 • Development Component • Prototype Engine Development • Flight Engine Qualification, Certification • Flight Engine Acceptance • Major Engine Upgrades • Re-development and Re-Use Potential Some examples of each are listed RELEASED - Printed documents may be obsolete; validate prior to use. 7 Flight Stage Flight Engine Acceptance Test Acceptance Test AIAA LRE Course DATA Qual. Test DATA Flight Stage DATA Flight Engine Qual./Cert. Test Dev. Test Flight Engine DATA DATA Engine Test Engine “Battleship” Typical Sequence of Testing Full Scale thrust chambers, (pumps, preburners, (pumps, Powerheads, nozzles) Component Test Component Subscale • An On-going process of risk reduction (components, engines, stages) thrust chambers) (pumps, preburners, (pumps, Component Test Component RELEASED - Printed documents may be obsolete; validate prior to use. 8 Make It Low Cost,” presented It Low Cost,” Make AIAA LRE Course portation Meeting, 25-27 July1995. Meeting, portation George, D.; “Chemical Propulsion: How To Propulsion: George, D.; “Chemical Trans Space Reusable at Highly Historical Full Scale Development Cost Distribution Testing Cost / Total for Propulsion RELEASED - Printed documents may be obsolete; validate prior to use. 9 AIAA LRE Course Engines,” AIAA Paper No. 2001-3985. ngines,” AIAA Paper No. 2001-0749. 1985 1990 1995 2000 2005 r LOX/Kerosene Liquid Rocket Completion Year Completion for Hydrogen Oxygen Rocket E Development Programs Kerosene Booster Engines StageKerosene Engines Upper H2 Booster Engines H2 Upper Stage Engines Survey of LOX/RP and LOX/LH Engine 1955 1960 1965 1970 1975 1980 8 6 4 2 0 14 12 10 Years for Development and Qualification and Development for Years • Emdee, J., “A Survey of Development fo Test Programs • Emdee, J., “A Survey of Development Test Programs RELEASED - Printed documents may be obsolete; validate prior to use. 10 AIAA LRE Course Engines,” AIAA Paper No. 2001-3985. Kerosene Booster Engines H2 Booster Engines H2 Upper Stage Engines ngines,” AIAA Paper No. 2001-0749. r LOX/Kerosene Liquid Rocket Test Firings for Hydrogen Oxygen Rocket E Effect on Engine Flight Success Rate 0 500 1,000 1,500 2,000 2,500 3,000 98% 96% 94% 92% 90% 88% 86% 84% 82% 80% 100% Success Rate Success • Emdee, J., “A Survey of Development fo Test Programs • Emdee, J., “A Survey of Development Test Programs RELEASED - Printed documents may be obsolete; validate prior to use. 11 AIAA LRE Course REPRESENTATIVE TEST CAMPAIGNS REPRESENTATIVE TEST CAMPAIGNS RELEASED - Printed documents may be obsolete; validate prior to use. 12 AIAA LRE Course Vehicle Component Turbopump Space Shuttle (External Tank) Main Engine Space Shuttle Components, Engines, Stages Self Contained Transfer Systems Contained Engine Self Propellant Systems on Stand Transfer Systems Facility Emulates Engine Parameters High Pressures High Flowrates Extremely Fast Controls Test Facility Challenges – • • • • • • • • • Complex More Complexity More Complexity – – – Stage/Vehicle Testing Engine Testing Component Testing • • • RELEASED - Printed documents may be obsolete; validate prior to use. 13 5 6 N/A 2809 10 Klbf LMDE (Lander) 149,000 s Saturn V (Apollo 11,12,14-17) (Apollo 3 AIAA LRE Course i/w 707 (U/S) 15 Klbf 71,000 s RL-10A-3 Various RL-10A-1 Upgraded to 6 ~15 J-2 (i/w) 1730 (U/S) in-work in-work 250 Klbf 120,000 s Saturn V For many of above: the For many of locations variety at a performed was testing 3 188 5 - 6 (i/w) 6,810 s (Boost) RS-68 700 Klbf Delta IV **11,000 s 8 ~15 F-1 2805 (Boost) 30,000 s 1.5 Mlbf 250,000 s Saturn V 9 726 113 (Boost) Shuttle SSME 500 Klbf 110,000 s (& counting) ~750,000 s* A Survey of Test Engine Campaigns • 2001-0749. No. Paper AIAA Engines,” Rocket Oxygen • Hydrogen for Test Programs Development of “A Survey J., Emdee, 2001-3985. No. Paper AIAA Rocket Engines,” Liquid • LOX/Kerosene for Test Programs Development of “A Survey J., Emdee, 67-521. No. Paper AIAA Module,” Lunar the for Engine Descent G. et al., “The Elverum, First Flight First First Flight *SSME Flight Seconds (~150,000 s) not counted s) (~150,000 Flight Seconds *SSME **RS-68Pre-flight Seconds (in-work):s total ~19500 s at (~11000 SSC) Thrust Years of Devt. Hot-Fire Test Seconds Hot-Fire After Tests Prior to Hot-Fire First Flight Vehicle Missions Flown Hot-Fire Test Seconds Hot-Fire Prior to RELEASED - Printed documents may be obsolete; validate prior to use. 14 Rate Rate Flight Flight Success Success Success Success Seconds Seconds y Firings Firings AIAA LRE Course Qualification Qualification Development onl Development Engines Engines including stage firings stage including including stage firings including stage Total Development and Total Development and Seconds Seconds y (LOX/LH) ngines,” AIAA Paper No. 2001-0749. Firings Firings Qualification Qualification Engines onl Development Engines including stage firings stage including including stage firings Seconds Seconds Firings Firings Development Development Engines Engines for Hydrogen Oxygen Rocket E including stage stage firings including including stage firings Seconds Seconds Firings Firings Feasibility Feasibility Engines Engines cellation. Datacellation. purposes only for comparative included 520 0 0 0 16+ 627 77,135 4+ 99 33,118 20+ 726 110,253 99.7% Burn Time Burn Time (secs) (secs) 0 flight st Life Life secs) secs) Engine Engine (firings / / (firings (firings / Testing to Enhance Reliability Time from from Time Time from from Time Qualification Qualification