New concept for Rocket engines

Jakob NørgaardProject Manager, Space

Force Technology

Rocket Engine Programs

• Volvo Aero is the worlds largest supplier of combustion chamber and nozzles to commercial launch vehicles

• Volvo Aero is the European centre of excellence for rocket turbines

Viking 4,5 & 6(Ariane 1-4)

Vulcain 1 Vulcain 2 Vinci RL 60

• First succesfull launch on Oct. 30 1997 from Korou

• Take off veight approx 750 ton

• Payload 6-12 ton depending on orbit(Low/high)

• Engines: 2 solid fuel boosters + liquid fuelmain engine (10% of total trust)

• Max power of engine and boosters: 61 miobhp (45 GigaWatt)

Recent milestone: Launch and delivery of Jules Verne, the first of five Automated Transfer Vehicles (ATV) for The International Space Station (ISS).

Ariane5

Engine Nozzle – extreme load and temperatures

Vulcain 2 (Main engine for the Ariane 5)• Dimensions: 2,3 m tall and 2,1 m in

diameter• Weight: approx. 400 kg• 150 ton trust (app. 6 mio bhp)• Fuel consumption: 250 kg/s• Flame temp.: approx. 3000 °C• Exhaust gas velocity app. 4000 m/sec• Coolant: liquid Hydrogen approx. -240 °C• Engine life time: approx. 10 min.Requirements• Low weight, no deformation at extreme

loads, high temperatures and temp. gradients

Engine principles

Design principles in use

Ariane 5• Square formed tubes• Spiral wounded to form the nozzle contour• TIG welded

Space shuttle• Conical tubes• Brazed

Russia• Sandwich design• Vacuum brazing

Concept

A cone made from thin metal sheet is formedto the same shape and placed over the cone with milled channels and subsequently laser welded with a patented method.

M

Objectives:• Decreased lead time• Improved flexibility (a concept easy to adapt to various engines)• Maintain or improve reliability• Reduce cost

Volvo Aero sandwich concept

The sandwich wall and seamtracker principles

The ChallengeWeld kilometres of very thin channel walls, hidden under a cover sheet, with a path accuracy in tens of a millimetre.The system has to work on-line as the nozzle moves during the welding process due to the heat load

X-ray

Process control – adaptive on-line technology

Welding cell• Advanced welding cell needed due to the size of the nozzle and the

demand for flexible solution to handle various designs

Seamtracker welding robot:• Dynamically locate channel wall being processed through the cover

sheet to position laser spot within tenths of millimetres• Dynamically measure distance and adapt and keep laser in focus • Sufficient dynamic characteristics to adapt to nozzle movements

during the welding operation

Master control for the production cell• Laser, Manipulators, Gasses, Safety system• Prepared for on-line NDT and data logging

Layout for production cell developed by Force

Weld cell to support specimen and 6 axes of movementSeamTrackerAdvanced Welding robot

Weld cell simulation

Weld cell 6 axes of movement, positioning of specimen and SeamTracker

Concept and functional elements

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X-ray Scanner

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Motion

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Seamtracker simulation

Seamtracker implementation and testing

Seamtracker Verification - Horizontal Inclination Test - Y TrajectoryTest 20061109-102454

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X Position (mm)

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Vulcain 2/2+WP 4010

Seamtracker Verification - Horizontal Inclination Test - Y TrajectoryTest 20061109-100532

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Vulcain 2/2+WP 4010

Weld cell and process control

Metal deposition

Welding curvature

Seamtracker 2.nd generation

Applied NDT technology: LVP sensor

The Laser Vision Profiling (LVP) sensor has to:- measure weld width and concavity with a high resolution.- be a sensor that is relative independent of surface colour

change and ambient light sources.- be an in-line sensor for production.

Laser triangulation

Applied NDT technology: Digital X-ray

• Off-line method CR

• On-line method DLAT

Computed Radiography Line profile nominel heat input

X-ray with linear array

Data processing, eliminating Human factors

3D Evaluation

• Cross section calculation to make a 3D model of the test block in order to measure: » Weld penetration» Weld misalignment» Channel cross section area» Largest inscribed circle of channel

Automated NDT simulation

Engine test planned late 2009

ESA Technology Transfer Programme

A matter of spin-off

ESA Technology Transfer Programme

Motivation:Historisk har rumfartsaktiviteter bidraget til forretningsskabelse i andre sektorer, således at Return of investment, den såkaldte Spin-off faktor, anslås til at ligge på 4-6(00 procent)!

ESA Improving Daily Life !

ESA Technology Transfer Programme

Accu-boremaskine

Spin-off omfatter forretningsskabelse og øvrige gavnlige afledte effekter som ligger udover aftalte leverancer på space programmer.

Definition

Definitionen er MEGET bred, og der er”rum til fortolkning”

Hvad for eksempel med.....Satellitbaseret kommunikationSatellitbaseret navigationPC

ESA Technology Transfer Programme

• Materiale

• Proces

• Anvendelsesform

• Målemetode

• Hastighed

• Størrelse

• Feeling

..eller blot stærk branding....

Innovationfrom space......in MY company?

ESA Technology Transfer Programme

Reference – Aerospace and Space

Boeing - Proposal for automated inspection of Delta IVDanish Air Force - Quality and Metrology LM-JSF - Affiliated to Danish JSF TeamPratt & Whitney - Specialized Aerospace Services (F-16)Rolls Royce - Engine casingsUnited Space Alliance - Inspection on Solid Rocket Boosters Volvo Aero Corp. - Space nozzles, Engine casings, TurbinesWestland Helicopter - Repair and maintenanceEIMG - R&D projects (VITAL lead by Snecma)Snecma, Space - Negotiations regarding inspection on Ariane enginesESA - Contract 2005-2009 development on Vulcain 2 and 2+

Core competences- Laser welding - Inspection - Sensor and NDE innovation- Material analysis - Testing - 3D Simulation