COBRA Main Engine ProjNAS8-01108

AIAA/IAF Symposiumon Future RLV's

12 April 2002

Jim SnoddySteve Sides

P&W-Aerojet Propulsion Associates

(A Joint Venture)

https://ntrs.nasa.gov/search.jsp?R=20020085154 2018-06-10T23:42:00+00:00Z

COBRA MAIN ENGINE PROJECT TEAM NAS8-01108/01083PRATT & WHITNEY- AEROJET PROPULSION ASSOCIATES Generation RLV

IEngineSystemsManager

KathyKynard/UP30

(256)544-7439721-26-22

NASAProjectManagerlCOTR721.26-20

JimSnoddr/UP30

(256)5444972Cell 256)651-3700

ResidentOffice t

@WestPalmBeach

BillPoweWUP30

(561)796-6132Cell(561)236-1560

LeadSystemEngineer /

TomByrd/UP30 1(256)544-7147

I

AssistantProjectManager

RandyForsythe/UP30

(256)544-2456

ProjectOfficeSupport

I °

L_ManagementSupportAssistance

AmyrebeccaShockley/Inlinity

(256)544.4997

m

mmm mm am aim i l

PowerheadManager I

EricTepool/UP30

(256)544-3196721-26.23

Contractor Project ManagerRick Bachtel/Pratt

(561) 796-9O67a

AJ_istant Project ManagerSteve Sides/Pratt(561) 796-2611

|Deputy Preject Manager

Dick Johnaon/Aerojet(916) 355-4622

|Chief Engineer

Tom Kmiec/Pratt(561)796.4059

IDeputy Chief Engineer ]

Scott Sieger/Aerojet I(916) 355-3353

I

] Pratt Regional Manager IHuntsville/Vie Giuliano

(256) 721-2422

I....._ IAerojet Director Space Propulsion

ThrustChamberAssemblyManager[ [ Huntsville/Carla Bossard

MikeShadoan/UP30 [ [ (256)837-3982

(256)544-5276 |

721-26.24 I

12 April 02 2

ROADMAP - NRA 8-27 THROUGH NRA 8-30.A.N_n_RFYON_n Generation RLV

SSME StudiesXLR129

RL10 FamilyTitian Propulsion

ALS/NLSDC-X, DC-XA

SSME-AT

X-33 ActivityIHPRPT

EELVSMV/SOV

InternationalSTAS 3B Results

2010

Operational.,2GRLV -"

r

NRA 8-27 Vehicle PrimesBoeing

Lockheed Martin

Kelly AerospaceOrbital Sciences

Space AccessAndrews Space

2005-2010

2GRLV

FSD Program

Initial

2GRLV Engine Options

DBFRSC

DBFFSC

SBFRSC

SBORSC

SPLTEX

SBFRGG

Phase II

2003-2005

ContinuedRisk Reduction

Prototype Engine TestFSD SRR

ContractNAS8-00168

Phase I

2001.2003

NRA 8-30

Cycle I Base &Option

NRA 8-30 'Cycle 1'Candidates

SBFRSC

SBORSC

SPLTEX

NR/_8-3oContract

NAS8-011 O8

NRA 8-30 'Cycle 1'

SBFRSC -COBRA

SPLTEX-RLX

DBFRSC - Dual Burner Fuel Rich Staged Combustion (H2/O2)

DBFFSC - Dual Burner Full Flow Staged Combustion (H2/O2)

SBFRSC - Single Burner Fuel Rich Staged Combustion (H2/O2)

SBORSC - Single Burner Oxidizer Rich Stage Combustion (RP/O2)

SPLTEX - Split Expander (H2/O2)

SBFRGG - Single Burner Fuel Rich Gas Generator (H2/O2)

12 April 02 3

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LOV Per Million Flights (No Technology Considerations)

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COBRA PROTO-TYPE ENGINE APPROACHENABLES MISSION SUCCESS Generation RLV

• Requirements

- Propulsion Systems Requirement Document (PSRD) Traceable to the SynthesizedArchitecture Requirements (SAR) and both are Full Scale Development (FSD)

Requirements

• COBRA Engine Requirements Traceable to PSRD

- COBRA Engine System Proceeding to Configuration Control

,, SRR Conducted

,, PDR Conducted

,, Powerhead Test in Option II

,, CDR end of Option II

• Design and Development Approach

- COBRA Engine System Integrates Risk Reduction Technologies with Engine Cycle

- COBRA Engine System Design Fidelity Enables

• Engine System Relevant Environments Characterization

• Risk Reduction Technology Demonstration in a Relevant Environment

• Engine Reliability Demonstration to Allow Traceability to FSD

• Engine Operation & Maintenance Demonstration to Allow Traceability to FSD

• Engine Manufacturing Demonstration

• Engine Performance Verification at Thrust Level Representative for a Wide Scale

12 April 02

Design Process & Control are FSD Applicable (e.g., EEE Parts, Fracture Control, Ops

Concept) 5

COBRA PROVIDES QUICK, LOW COST DEMO OFCYCLF AN_D TECHNOLOGIES °°-"°°_

Program PDR(_Milestones

800K

" COBRA

ine W/,=

40K

Cycle II and Phase

12 April 02 6

COBRA CYCLE I RISK REDUCTION SUPPORTSTECHNOLOGY NEEDS FOR 2GRLV °--"°°_

Co-Optimized Booster for Reusable Applications

2nd Gen RLV Focus

• Crew and vehicle safety

• Reliability• Operability• Maintainability• Low payload cost

Ill=,,._

2nd Gen RLV _p_

Architectures SupportedDerived shuttle

• Evolved shuttle• TSTO

Cycle I Risk Reduction

• Systems engineering• EHMS architecture/safety sensor)

• Full-scale 600K preburner• Full-scale 600K main case

• 40K main injector• 40K main chamber• 40K LOX-cooled nozzle section

• LOX and fuel boost pumps

• High pressure turbopumps• Smart valves

• Full-scale nozzle fabrication

• Main LOX valve development

• Lightweight material development• Integrated powerhead testing• Main combustion chamber

• Preburner LOX valve

12 April 02 7

COBRA FEATURES GROUNDED FROMNRA 8-27 STUDY Generation RLV

COBRA Safety

Single prebumer cycle

COBBA ReUsabtii_/0Pera_ili_ _ COBRA Risk Reduction Activities

Powerduct main case

for lightest weightand fewest hot gas

joints

Mature SSME-AT

)umps increase

safety and reduce risk

Main injectorreduces touch labor

and has no partswhich can come loose

Long life Liner

Milled channel

regenerativelycooled nozzle -70:1

adopted from SSME

nozzle upgrade

12 April 02 8

ACHIEVING ENGINE SAFETY

Design for Safety• Single fuel rich preburner• Fail safe powerduct• External heat exchanger• Cool turbine temperatures

Technologies for Safety• Advanced engine health monitoring• Channel wall nozzle• Combustion Device liners pmo_w

N_,=m=

Maturity for Safety• Early hardware testing• Demonstrated technologies• Mature turbomachinery (ATD)

Generation RLV

12 April 02 9

RLX CYCLE I RISK R DUCTION SUPPORTST_CHNOLOGY N_=FDS FOR 2GRLV o..o_,,oo_v

Rocket, Liquid, Expander (RLX) - Split Expander (SPL TEX) Cycle

2nd Gen RLV

• Crew and vehicle safety

• Reliability• Low payload cost• Maintainability

2nd Gen RLV

Architectures Supported

• Orbiter

• TSTO (upper stage)

Cycle I Risk Reduction

• Heat transferenhancementdemonstration

12 April 02 10

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NRA 8-30 TECHNOLOGIES ARE ENABLING TO

2GRLV SAFETY GOALS °'°-"°°_v

Benefit of COBRA Safety Risk Reduction Technologies

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Component technologies System technologies

12 April 02 12

NRA 8-30 CYCLE I TECHNOLOGY ROADMAP Generation RLV

1.4.7 Propulsion1,4,7.1 Project Management1.4.7.2 PropuLsion Systems Eng1.4.7.3 Cobra Engine

1.4.7.3.1.1 Prototype & Risk reduction1.4.7.3.1,1.1 Combustion Devices

1.4.7,3.1.1.1.1 Prebumer1.4.7.3.1.1.1.1.1 Subscale1.4.7.3,1,1.1.1.2 Proto

1.4.7.3.1.1.1.2 Powerball

1.4.7.3.1,1.1.3 Injector1.4.7.3.1.1.1.1.3.1 Unlelement1.4.7.3.1,1.1.1.3.2 SubQcale1.4.7.3.1.1.1.1.3.3 Prototype

1,4,7,3.1.1.1.4 Combustion Chamber1.4.7.3.1.1,1.4.1 Subakcale1.4.7.3,1.1.1.4.2 Prototype1.4.7,3.1.1.1.4.3 Fabrication

1.4.7.3.1.1.1.5 Nozzle1.4.7,3.1,1.1.5.1 Sul:_cale1.4.7,3.1.1.1.5.2 Fabrication1..4.7,3.1.1.1.5.3 Prototype

1.4.7.3,1.1.2 Turbomaehinery1,4.7.3.1.1.2.1 ATD Modification

LOXLH2

1.4.7.3.1.2.2.2 Boost Pumps

1,4.7.3.1.1.2.2,1 LOXComponentPrcto

1.4.7.3.1.1.2.2.2 LH2ComponentProto

1.4.7 3.1.1.3 Controls14.7.3.1.1.3.2 Controller1.4.7.3.1.1.3.3 Actuators

1.4.7.3.1 1,3.4 Valves

1,4,7.3.1.1.4 Externals1,4.7.3.1.1,4,2 Plumbing

1.4.7.3,1.1.5 EHMSProtoComponent

1.4,7.3.1.1.6 Light Weight Matedal Dev1.4.7.3.1.1.6.2 Plumbing & Valves1.4.7.3.1.1.6.3 Chamber Structural Jacket

1,4.7.3.1.1,7 Engine/Subsystem Test1.4.7.3.1.1.7.1 Powerhead Test

1.4.7.3.1.3 MCC Heat Transfer for RLX1.4.7.3.1.3.1 Lab. Dev,1.4.7.3.1.3.2 Subscale Dev/Test1.4.7.3.1.3.3 Full Scale Day

_1_ End of Base End of Option

i ....

U :Ill _

L ; .........._1 _ ........................................

16 Technology Needs

i Proto engine

Subscale

12 April 02 13

COBRA PROGRAMAligns Risk Reduction Data with FSD decisions-Uses Building Block Approa

I

Program milestonesATP RRR11

,I_SRR

Design

RR and comp test

Prototype engine development

Advanced development leadingto FSD

Flight qualification

Certification testing

Life extension engine testing

Technology readiness levels

Proto1

protodesignATP

II I

PDR _:SD CD_ lOG

_F i.ISp Decis_n

FSD ATp

Proto CDR

PH test

RLX MCC HTst

FETT1

1st'

Cert

I

e

12 April 02 14