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AEROSPIKE ENGINE FOR SSTO September 9 th 2014

AEROSPIKE ENGINE FOR SSTO September 9 th 2014. Christopher J. Caddock Dr. Anurag Purwar Dr. Sotirios Mamalis Subrat Jain. Introduction.

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AEROSPIKE ENGINE FOR SSTO September 9 th 2014

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  1. AEROSPIKE ENGINE FOR SSTOSeptember 9th 2014 Christopher J. Caddock Dr. AnuragPurwar Dr. Sotirios Mamalis Subrat Jain

  2. Introduction • Goal: To design an aerospike rocket engine that will be more efficient than a conventional rocket engine and would make Single Stage To Flight a possibility. • Research: Study of basics of aerospike engines, comparison with the conventional rocket engine, the scope of the aerospike engine in space transportation, understanding the performance, identify the manufacturing & design aspect of the aerospike engines, testing requirements and laying the theoretical foundation for the aerospike engine development. • First Step: Literature survey of the aerospike engine for finding out the constraints, drawbacks, limitations, possibility, scope, and requirements for the development of aerospike engine.

  3. Rocket Engine • It is an engine which propels the rocket by a reaction force. • The reaction (thrust) is produced by expelling the mass i.e. the combustion gases. • One of the most important part of the rocket engine is the nozzle, which produces the maximum thrust. The function of nozzle is to expand and accelerate the combustion gases. References – [1],[2]

  4. Rocket Engine – Nozzle Types Fig 1. Types of Rocket Nozzle. Out of which, the Bell nozzle (modification of Cone nozzle) is most common. Spike (or Plug) is in research to testing phase mostly and Expansion Deflection (E-D), Radial Flow (R-F) and Horizontal Flow (H-F) have found very limited to no use. [3]

  5. Common Rocket Engine Nozzle • The conventional nozzle is a bell shaped nozzle, which is used over in almost all of the rocket engines. • The thrust is transferred through the nozzle boundary. • The bell nozzle is tailored for an optimum altitude, where its efficiency will be maximum. • For orbital spaceflights, with bell shaped nozzle the flight is multi-staged. At Po Ae References – [4]

  6. Important Technical Terms • Thrust coefficient – Indicates the amount of thrust produced. • Thrust coefficient efficiency (or Nozzle efficiency) – Ratio of experimental /actual thrust coefficient to ideal thrust coefficient (without losses) of a nozzle. • NPR, Nozzle Pressure Ratio (or Pressure ratio, PR) – Signifies altitude. Higher the NPR, higher the altitude. • Complete expansion altitude / NPR – It is the altitude at which the efficiency of a nozzle is 100%. The design altitude of nozzle. • Area ratio (or Expansion ratio) – Ratio of area of the exit (spike) to throat area (of thruster) • Total thrust = Pressure on spike wall + Momentum thrust through propellant exit + Pressure on base. • Interchangeable terms: • Aerospike / Plug nozzle. • Conical / Bell / Conventional nozzle. • Primary nozzles / Modules / Thrust chamber / Combustion chamber / Cell nozzle / Thrusters / Thrust cells.

  7. Aerospike Engines Fig 2. Truncated annular Aerospike nozzle [5] Fig 3. Full spike annular nozzle [7] Fig 1. Linear Aerospike nozzle Fig 4. A linear Aerospike can be explained as an inside-out bell nozzle [6]

  8. Aerospike Engines • Type of plug nozzle, having a center body called spike at center. • Unlike bell nozzle, the exiting gases are not contained in outer boundary. • Truncated spike. • The exhaust gas is in direct contact with atmosphere without outer boundaries. • Transfers the maximum thrust to the inner body. • Also called altitude compensating nozzle. • Performance losses due to truncation is countered by providing secondary flow into the base region, explains the reason ‘aero’-’spike’ for the name. • Two types – Linear and Annular (Toroidal). References – [8]

  9. Comparison with Bell Nozzle Rockets • Aerospike engines perform better at lower altitudes. Fig 1. Bell nozzle altitude variation showing losses due to overexpansion and underexpansion [9] Fig 2. Aerospike nozzle altitude variation without losses due to overexpansion and underexpansion [9]

  10. Comparison with Bell Nozzle Rockets • Thrust vectoring [10] Variable area ratio. Obtaining the different area ratios at different altitudes. • This graph shows that variable area ratio produces the maximum amount of thrust. [11] Area ratio = 15. Average thrust performance. Area ratio = 33. Better thrust at higher altitude, but poor thrust at lower altitudes due to higher overexpansion. Area ratio = 15. Better thrust performance at lower altitude but poor performance at higher altitude due to high underexpansion. Thrust coefficient vs. altitude

  11. Comparison With Bell Nozzle • CFD analysis • Efficiency range: • Tile shaped Aerospike – 93%-100%, • Bell nozzle – 66%-100% Fig 2. CFD analysis showing better Nozzle efficiency of Aerospike engines [13] Fig 1.Better Thrust Coefficient of Aerospike for the same expansion ratio [12] Fig 3. Better Specific impulse for Aerospike compared to Bell nozzle [14]

  12. Base Bleed / Secondary Flow Effect • Base-bleed (or Secondary flow) – An exhaust flow provided from the base of a truncated nozzle to counter the vacuum formed at the truncated base area. • Base bleed is generally 1-2% of the primary flow. • NDPbase = • Higher the NDPbase, better the performance. With base-bleed Without base-bleed Fig 1. Performance improvement through base-bleed in Aerospike engine.[15]

  13. Development Attempts of Aerospike Engines • The research and testing over Aerospike engines has been going since 1960 by Rocketdyne. • In the 90s, NASA and Lockheed Martin collaborated to create a SSTO RLV using new technologies including aerospike engines. Project name was X-33. Engine was named XRS-2200. • But it was cancelled in 2001 before it could take off. • California State University, Long Beach and Garvey Spacecraft Corp. successfully conducted a flight test of a liquid-propellant powered aerospike engine in the Mojave Desert in Sept 2003. • Researchers from Dryden, the Air Force Flight Test Center and blacksky Corp., Carlsbad, Calif., tested the aerospike rocket concept during two successful flights in 2004. • NASA Dryden Flight Research Center, the U.S. Air Force and Blacksky Corporation together tested a scaled version of solid-fueled aerospike engine.[7] Fig 1. XRS-2200 Linear Aerospike engine tested and created by NASA and Lockheed Martin Fig 1. Small Annular Aerospike engine tested at California State University, Long Beach References – [4]

  14. Major Issues • Composite cryogenic tank • Flight instabilities • Excess weight • Lack of flight test data • One of the main issues with aerospike feasibility is, the lack of validation of computational methods for predicting the performance. [22] • General obstacles in aerospike are weight and cooling.[23] • Complex manufacturing especially of the ramp, propellant tank and combustion chambers. [22] [24] • Million dollars investment. [25] Fig 1. A picture depicting the failure of Liquid Propellant Tank. [20] Other References – [18], [19]

  15. Advantages • Improved thrust performance and fuel efficiency at low altitudes. • Smaller size for specific thrust. • Lesser fuel consumption. • Possible single-stage-to-orbit vehicle due to altitude compensation characteristic. • Segmented combustion chamber design. • Lower vehicle drag. • Easier thrust vectoring. References – [10], [19], [21]

  16. Summary And Future Work • Preliminary studies shows Aerospike is better than conventional rocket engines. • Aerospike is a preferred option for SSTO. • Future work will include CAD design, CFD simulation, and structural analyses. • Scaled prototype will be developed and tested.

  17. References • http://en.wikipedia.org/wiki/Rocket_engine • http://www.grc.nasa.gov/WWW/k-12/airplane/lrockth.html • http://www.aerospaceweb.org/design/aerospike/shapes.shtml • http://ffden-2.phys.uaf.edu/212_spring2005.web.dir/Tess_Caswell/HowWork.htm • CFD ANALYSIS OF A MULTI-CHAMBER AEROSPIKE ENGINE IN OVER-EXPANDED, SLIPSTREAM CONDITIONS • http://www.csulb.edu/colleges/coe/ae/engr370i/ch10/sect_3-1/bell_shape_to_linear_aerospike.gif • http://www.dfrc.nasa.gov/Gallery/Photo/Aerospike_Rocket/HTML/EC04-0113-146.html • http://www.csulb.edu/colleges/coe/ae/engr370i/ch10/sect_3-1/ • http://www.aerospaceweb.org/design/aerospike/compensation.shtml • http://www.aerospaceweb.org/design/aerospike/x33.shtml • Ruf, J. H. and McConnaughey, P. K. The Plume Physics Behind Aerospike Nozzle Altitude Compensation and Slipstream Effect, AIAA Paper 97-3218, 1997. • Hanumanthrao.K, Ragothaman.S , ArunKumar.B, GiriPrasad.M And V.R.Sanal Kumar; Studies On Fluidic Injection Thrust Vectoring In Aerospike Nozzles; 49th Aiaa Aerospace Sciences Meeting Including The New Horizons Forum And Aerospace Exposition 4 - 7 January 2011, Orlando, Florida. • Niimi, T. ; Mori, H. ; Okabe, K. ; Masai, Y. ; Taniguchi, M.; Analysis Of Flowfield Structures Around Linear Type Aerospike Nozzles Using Lif & Psp; 20th International Congress On Instrumentation In Aerospace Simulation Facilities, 2003. Iciasf '03. • Hartsfield, Carl; Branam, Richard D.; Hall, Joshua; Simmons, Joseph. Aerospike Rockets For Increased Space Launch Capabilities, Air & Space Power Journal, Air Force Institute Of Technology, June 22, 2011. • Gary Letchworht. X-33 Reusable Launch Vehicle Demonstrator, Spaceport And Range, Aiaa. Detailed Report On X-33 Project Parts, Tests And Failures. • Spike fetches first by Jay Levine, Dryden Flight Research Center, X-Press, Volume 46 Issue 5, 2004. • Gary Latchworth, X-33 Reusable launch vehicle demonstrator, spaceport and range, NASA Kennedy Space Center, Florida, American Institute of Aeronautics and Astronautics. • Linear Aerospike Engine – Propulsion for X-33 vehicle, Marshall Space Flight Center, Fact sheet no. FS-2000-09-174-MSFC, August 2000 • http://www.hq.nasa.gov/office/pao/History/x-33/aero_faq.htm • http://en.wikipedia.org/wiki/Lockheed_Martin_X-33

  18. References • Tomita, Takeo, Takahashi, Mamoru, and Onodera, Takuo. Effects of Base Bleed on Thrust Performance of a Linear Aerospike Engine, AIAA Paper 99-2586, 1999. • Besnard. E, Chen. H.H, Muller. T, Garvey. J, “Design, Manufacture and Test of a Plug Nozzle Rocket Engine”, Joint Propulsion Conference, 2002. • Tomita, T. , Kumada N., Ogawara A. "A Conceptual system design study for a Linear Aerospike Engine applied to a future SSTO vehicle” The 48th AIAA/ASME/SAE/ASEE Joint Propulsion Conference and Exhibit, AIAA-2010-7060, 2010. • Lary F.B., Advanced cryogenic rocket engine program Aerospike nozzle concept: materials and processes, Final report, November 1967 • M. Cabbage, Revolutionary spaceship project stumbles Lockheed Martin prototype flirts with scrap pile, The Denver post, March 2000.

  19. Thank you!

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