Börner, Michael

Hardi, Justin

Klein, Sebastian

Rees, Andreas

Traudt, Tobias

Institute of Transport Research:Publications

Overview on the DLR M3 Test InfrastructureMichael Börner, Sebastian Klein, Andreas Rees, Tobias Traudt, Justin HardiDLR Institute of Space Propulsion FAR 20222nd International Conference on Flight Vehicles,Aerothermodynamics and Re-entry Missionsand Engineering21.06.2022DLR M3 Test Infrastructure (1)• in service for research and technology development for cryogenic rocket propulsion for more than 30 years• investigation of fundamental processes in rocket combustion chambers and supply systems• propellant conditioning• transient, two phase flows• injection• ignition (sequencing)• combustion dynamicsThe operating conditions correspond to• orbital engines • in individual aspects to launcher engines> FAR 2022 > Michael Börner •  Overview on the DLR M3 Test Infrastructure > 21.06.2022DLR.de  •  Chart 2DLR M3 Test Infrastructure (2)• 3 test positions• M3.1: injection, ignition & combustion dynamics• M3.3: injection, cryogenic flash boiling & atomization• M3.5: cryogenic flows, cryogenic fluid hammer, characterization of fluid mechanical components• technology tests • component tests for turbopumps• injector element characterization• ignition transients with varying background pressures• nozzle plume/ hot gas interaction with structural components (landing gear, heat shields, …) • fluids• liquid oxygen and liquid nitrogen• gaseous H2 or hydrocarbon fuels • feed-line pressures of up to 40 bar> FAR 2022 > Michael Börner •  Overview on the DLR M3 Test Infrastructure > 21.06.2022DLR.de  •  Chart 3M3.1: Ignition and Start Transients Research• Task area (research focus)• Injection• Ignition sequencing• Laser ignition• Flame anchoring• Flammability studies• Material compatibility• Global features and operation conditions• LOX/H2 and LOX/Methane (sub-critical)• optically accessible combustors• chamber diameter up to 60 mm• temperatures:• H2: 200 K to ambient• CH4: ambient• ground ignition conditions• „in space“ conditions• „retro-propulsion“ conditions> FAR 2022 > Michael Börner •  Overview on the DLR M3 Test Infrastructure > 21.06.2022DLR.de  •  Chart 4M3.1: Ignition and Start Transients• Task area (research focus)• Injection• Ignition sequencing• Laser ignition• Flame anchoring• Flammability studies• Material compatibility• Global features and operation conditions• LOX/H2 and LOX/Methane (sub-critical)• optically accessible combustors• chamber diameter up to 60 mm• temperatures:• H2: 200 K to ambient• CH4: ambient• ground ignition conditions• „in space“ conditions• „retro-propulsion“ conditions> FAR 2022 > Michael Börner •  Overview on the DLR M3 Test Infrastructure > 21.06.2022DLR.de  •  Chart 5Stable atomizationSelf-pulsating atomizationSource: Bee (2021), Design and experimental comparison of swirl coaxial and shear coaxial injector elements for main combustion chambers of LOX/LNG enginesstable zoneunstable zoneM3.1: Ignition and Start Transients• Task area (research focus)• Injection• Ignition sequencing• Laser ignition• Flame anchoring• Flammability studies• Material compatibility• Global features and operation conditions• LOX/H2 and LOX/Methane (sub-critical)• optically accessible combustors• chamber diameter up to 60 mm• temperatures:• H2: 200 K to ambient• CH4: ambient• ground ignition conditions• „in space“ conditions• „retro-propulsion“ conditions> FAR 2022 > Michael Börner •  Overview on the DLR M3 Test Infrastructure > 21.06.2022DLR.de  •  Chart 6~ 100 mbar~1 bar~2 barSoller et al. (2020)SPC2020-00687OH*SchlierenVisM3.1: Ignition and Start Transients• Task area (research focus)• Injection• Ignition sequencing• Laser ignition• Flame anchoring• Flammability studies• Material compatibility• Global features and operation conditions• LOX/H2 and LOX/Methane (sub-critical)• optically accessible combustors• chamber diameter up to 60 mm• temperatures:• H2: 200 K to ambient• CH4: ambient• ground ignition conditions• „in space“ conditions• „retro-propulsion“ conditions> FAR 2022 > Michael Börner •  Overview on the DLR M3 Test Infrastructure > 21.06.2022DLR.de  •  Chart 7LOX/H2 LOX/CH4We=2192 J=0.47We=7007 J=0.65We=2335 J=0.60We=7963 J=0.56Yang, Cuoco & Oschwald (2007)Börner et al. (2017)M3.1: Ignition and Start Transients• Applied software and diagnostic tools• Simultaneous and same field of view for• High speed schlieren• High speed OH*/CH*• LIBS> FAR 2022 > Michael Börner •  Overview on the DLR M3 Test Infrastructure > 21.06.2022DLR.de  •  Chart 8M3.1: Ignition and Start Transients• Task area (research focus)• Injection• Ignition sequencing• Laser ignition• Flame anchoring• Flammability studies• Material compatibility• Global features and operation conditions• LOX/H2 and LOX/Methane (sub-critical)• optically accessible combustors• chamber diameter up to 60 mm• temperatures:• H2: 200 K to ambient• CH4: ambient• ground ignition conditions• „in space“ conditions• „retro-propulsion“ conditions> FAR 2022 > Michael Börner •  Overview on the DLR M3 Test Infrastructure > 21.06.2022DLR.de  •  Chart 9Bee & Börner (2021)M3.3• injection, cryogenic flash boiling & atomization• cryogenic nitrogen and oxygen• temperatures down to 76 K• vacuum levels around 30 mbar• investigation of cryogenic flash boiling and atomization• optical spray diagnostics> FAR 2022 > Michael Börner •  Overview on the DLR M3 Test Infrastructure > 21.06.2022DLR.de  •  Chart 10Rp = 3,0 Rp = 3,2 Rp = 4,2 Rp = 4,4Rp = 5,5 Rp = 7,0 Rp = 12,7 Rp = 52,3Rees (2020)Connector 1M3.5: Overview> FAR 2022 > Michael Börner •  Overview on the DLR M3 Test Infrastructure > 21.06.2022DLR.de  •  Chart 11Connector 2• Cryogenic Fluid Hammer• Acoustic Cavitation• Flow visualization• Characterization of fluid mechanical components• Benchmarks for numerical codes• etc.Tank 2Tank 1Fast Closing ValveLN2 JacketTanks:• 𝑉 = 80l• 𝑃 = 50 bar• Pressure Control• LN2 jacket isolationWorking fluids:• LN2• LOXMass flow:• 2.8 kg/sValve:• Axial Valve• Closing Time: 18 ms• LN2 bathInterchangeable test sectionCoriolis Flow MeterDLR.de  •  Folie 12M3.5: Fluid hammer test section (example)Pipe length: 9,294 m Pipe inner Diameter: 19 mmSensor Position: S1,S2,S3Tank 1Tank 2Test sectionTestbenchLN2 JacketS2S1S3Tank 1Tank 2LN2 JacketCoriolis Flow Meter> FAR 2022 > Michael Börner •  Overview on the DLR M3 Test Infrastructure > 21.06.2022Fast Closing ValveConnector 1Connector 2M3.5: Fluid hammer test section (example)> FAR 2022 > Michael Börner •  Overview on the DLR M3 Test Infrastructure > 21.06.2022DLR.de  •  Chart 13CompressionwaveRarefactionwaveCavitationFlow stoppage Pressure oscillationsCavitationFluid HammerS3 S1S2Flow stoppage ValvePressure sensorsEnd of 1st period PipeWhy to test at M3?• fast iteration of technology development to increase the TRL➢ early identification of „show-stopper“➢ first step from ideal laboratory environment to „real world“ environment• many tests per test day with access to the test article➢ hardware- and sequence-oriented test matrices• test capacity available on short notice• trained and experienced personnel• support by experienced optical diagnostics group• breadboard hardware available to test individual components➢ save costs: no need to manufacture a complete set of test hardware> FAR 2022 > Michael Börner •  Overview on the DLR M3 Test Infrastructure > 21.06.2022DLR.de  •  Chart 14A test bench to test test bench technology• In 2023 at M3.1: new control and measurment system to test technologies of test benches• full access to all sub-components and routines• topics to be adressed➢ intelligent control➢ photonic technologies➢ robotic technologies➢ (wireless) sensor networks➢ predictive maintenance-> michael.boerner@dlr.de> FAR 2022 > Michael Börner •  Overview on the DLR M3 Test Infrastructure > 21.06.2022DLR.de  •  Chart 15Thank you for your attention!> FAR 2022 > Michael Börner •  Overview on the DLR M3 Test Infrastructure > 21.06.2022DLR.de  •  Chart 16Tank 1Tank 2Test sectionTestbenchStable atomizationSelf-pulsating atomization

Overview on the DLR M3 Test Infrastructure

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Overview on the DLR M3 Test Infrastructure

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Institute of Transport Research:Publications