Brian D. Reed

Engineering Issues of Iridium Coated Rhenium Rockets

Abstract The key to the performance and lifetime of radiation-cooled rockets is the chamber temperature capability. Temperature limitations (1370°C) of current state-of-art chamber materials force the use of film cooling, which degrades rocket performance and imposes plume contamination from unburned fuel. A material system composed of a rhenium (Re) substrate and an iridium (Ir) coating has demonstrated operation, for long lifetimes (hours), at higher temperatures (2200°C). The added thermal margin afforded by iridium-coated rhenium (Ir/Re) allows the virtual elimination of film cooling, leading to higher performance and cleaner spacecraft environments. In the course of developing Ir/Re rockets for flight use, some engineering issues have arisen concerning Ir/Re rocket fabrication processes, critical Re mechanical properties, Re joining methods, and Ir/Re life-limiting mechanisms. Government- and industry-sponsored efforts are addressing these concerns.

Near-Net Shape Powder Metallurgy Rhenium Thruster

This paper describes the development of a method to produce a near-net shape (NNS) powder metallurgy (PM) rhenium combustion chamber of the size 445 N (100 lbf) used in a high performance liquid apogee engine. These engines are used in low earth Orbit and geostationary orbit for satellite positioning systems. The developments in near-net shape powder metallurgy rhenium combustion chambers reported in this paper will reduce manufacturing cost of the rhenium chambers by 25 percent, and reduce the manufacturing time by 30 to 40 percent. The quantity of rhenium metal powder used to produce a rhenium chamber is reduced by approximately 70 percent and the subsequent reduction in machining schedule and costs is nearly 50 percent.

Hydrogen/oxygen auxiliary propulsion technology

A survey is provided of hydrogen/oxygen (H/O) auxiliary propulsion system (APS) concepts and low thrust H/O rocket technology. A review of H/O APS studies performed for the Space Shuttle, Space Tug, Space Station Freedom, and Advanced Manned Launch System programs is given. The survey also includes a review of low thrust H/O rocket technology programs, covering liquid H/O and gaseous H/O thrusters, ranging from 6600 N (1500 lbf) to 440 mN (0.1 lbf) thrust. Ignition concepts for H/O thrusters and high temperature, oxidation resistant chamber materials are also reviewed.

Rhenium mechanical properties and joining technology

Iridium-coated rhenium (Ir/Re) provides thermal margin for high performance and long life radiation cooled rockets. Two issues that have arisen in the development of flight Ir/Re engines are the sparsity of rhenium (Re) mechanical property data (particularly at high temperatures) required for engineering design, and the inability to directly electron beam weld Re chambers to C103 nozzle skirts. To address these issues, a Re mechanical property database is being established and techniques for creating Re/C103 transition joints are being investigated. This paper discusses the tensile testing results of powder metallurgy Re samples at temperatures from 1370 to 2090 C. Also discussed is the evaluation of Re/C103 transition pieces joined by both, explosive and diffusion bonding. Finally, the evaluation of full size Re transition pieces, joined by inertia welding, as well as explosive and diffusion bonding, is detailed.

Experimental and analytical comparison of flowfields in a 110 N (25 lbf) H2/O2 rocket

A gaseous hydrogen/gaseous oxygen 110 N (25 lbf) rocket has been examined through the RPLUS code using the full Navier-Stokes equations with finite-rate chemistry. Performance tests were conducted on the rocket in an altitude test facility. Preliminary parametric analyses have been performed for a range of mixture ratios and fuel film cooling percentages. It is shown that the computed values of specific impulse and characteristic exhaust velocity follow the trend of the experimental data. Specific impulse computed by the code is lower than the comparable test values by about two to three percent. The computed characteristic exhaust velocity values are lower than the comparable test values by three to four percent. Thrust coefficients computed by the code are found to be within two percent of the measured values. It is concluded that the discrepancy between computed and experimental performance values could not be attributed to experimental uncertainty.

Rocket-in-a-Duct Performance Analysis

An axisymmetric, 110 N class, rocket configured with a free expansion between the rocket nozzle and a surrounding duct was tested in an altitude simulation facility. The propellants were gaseous hydrogen and gaseous oxygen and the hardware consisted of a heat sink type copper rocket firing through copper ducts of various diameters and lengths. A secondary flow of nitrogen was introduced at the blind end of the duct to mix with the primary rocket mass flow in the duct. This flow was in the range of 0 to10% of the primary massflow and its effect on nozzle performance was measured. The random measurement errors on thrust and massflow were within +/1%. One dimensional equilibrium calculations were used to establish the possible theoretical performance of these rocket-in-a-duct nozzles. Although the scale of these tests was small, they simulated the relevant flow expansion physics at a modest experimental cost. Test results indicated that lower performance was obtained at higher free expansion area ratios and longer ducts, while, higher performance was obtained with the addition of secondary flow. There was a discernable peak in specific impulse efficiency at 4% secondary flow. The small scale of these tests resulted in low performance efficiencies, but prior numerical modeling of larger rocket-in-a-duct engines predicted performance that was comparable to that of optimized rocket nozzles. This remains to be proven in large-scale, rocket-in-a-duct tests.