hypersonic flight and (re)-entry in germany – overview...

17th AIAA International Space Planes and Hypersonic Systems and Technologies Conference11 – 14 April 2011The Grand Hyatt San Francisco, San Francisco, USA

Hypersonic Flight and (Re)-Entry in Germany – Overview and Selected Projects

Klaus Hannemann

German Aerospace Center, DLRInstitute of Aerodynamics and Flow Technology

37073 Göttingen, Germany

Institutions involved in Hypersonic Flight and (Re) EntryTools and Tool DevelopmentSelected Applications, Research Activities, Projects

Outline

German AerospaceCenter, DLR

BraunschweigBremenGöttingenKölnStuttgartLampoldshausenOberpfaffenhofen

IndustriesEADS AstriumMT AerospaceOHBHTG, HSTLFKBayern ChemieIABGKayser ThredeTALIS ENTERPRISEGmbHAstos SolutionsGmbHAerospace InnovationGmbH

UniversitiesRWTH Aachen UniversityUniversität StuttgartTechnische Universität MünchenUniversität der Bundeswehr MünchenTechnische Universität BraunschweigTechnische UniversitätBerlin

Institutions involved in Hypersonic Flight and (Re)-Entry

Tools and Tool Development:

Flight Experiment

NumericsGround Based Testing

HEG, DLR Göttingen

Cold hypersonic facilitiesArc heated tunnels for qualification of hot structure componentsShock tunnels for re-entry aerothermodynamics, hypersonic flight and scramjet propulsionAerodynamics in rarefied gas environmentConnected tube facilities for dual mode ram-/scramjet combustionThermo-mechanical component testing

H2K, DLR Köln

Ground Based Testing

Screw Compressor

CombustionChamber

Heater 1

Auxiliary Air SupplyAir Dryer

Heater 2

Heater 0

Supersonic combustion test facility, ITLR Stuttgart

Arc-heated wind tunnels L2K and L3K, DLR Köln

Trisonic Test Section TMK, DLR Köln

Ground Based Testing

Hypersonic shock tunnel TH2, Shock WaveLaboratory, RWTH Aachen

Low density facilities VXG, DLR Göttingen

Aerodynamic design and multi-disciplinary-optimization toolsCFD including multidisciplinary coupling (structure mechanics, flight mechanics, combustion, chemsitry …)CFD for continuum and free molecular regimeSystem analysisAtmospheric re-entry includingaerothermal break-up

SCARAB (spacecraft atmospheric re-entry and aerothermal break-up), HTG

Numerical Methods

TAU code, DLR

SHEFEX I (flight: 2005), DLRSHEFEX II (flight scheduled: 2011), DLRSHEFEX III (project in preparation), DLREXPERT (flight scheduled: 2011), ESA withGerman participationHIFiRE flight program, cooperation AFRL / DLRSCRAMSPACE I, The University of Queensland,DLR member of international consortium

Flight Testing

SHEFEX I launch, DLR

EXPERT (European eXPErimentalRe-entry Testbed), ESA SHEFEX III aerothermodynamics

study, DLR

Measurement techniques

Hardware manufacturing

- Flow diagnostics in wind tunnels- Flight instrumentation

- CMC materials for hot structures (nose caps, body flaps, …)

Measurement Techniques, Hardware Manufacturing

EXPERT payload 6, DLR Köln

IXV in H2K, DLR Köln

EXPERT nose cap, DLR StuttgartEXPERT flap, MT Aerospace

Selected Applications, Research Activities, Projects

EC co-funded research projects- LAPCAT II- ATLLAS II- FAST20XX

DFG funded Graduate School 1095/2ESA flight experiment EXPERTHayabusa re-entry radiation measurementsBL Transition study on HIFiRE I configurationDLR SHEFEX II flight experiment

EC - co funded Projects LAPCAT II, ATTLAS II, FAST20XX

General Objectives:Assessing the potential of high-speed cruisers and high-altitude suborbital vehicles independently within EuropeIdentification, development and acquisition of critical technologies, know-how and disciplinesLaying out a basis for a core of experts and researchers involved in the development of the above technologies within Europe

Three complementary projects (coordinated by ESA) were initiated studying alternative concepts fulfilling different goals and objectives

EC - co funded Projects LAPCAT II, ATTLAS II Cruisers up to antipodal range; flight speeds from Mach 3 to 8

Hydrocarbon Hydrogen

4.54.5

5.05.03.53.5

6.06.08.08.0

8.08.0

8.08.0

German Contributions (EADS-Astrium, DLR, Universität Stuttgart):System analysis (M8 vehicle, airbreathing engine cycle analysis)Nose-to-tail aerothermodynamics (CFD and ground based testing)Hypersonic intake aerothermodynamicsSupersonic combustion experiments in connected tube and free-jet facilitiesAir-turbo-rocket gas generator combustion experiments and CFD modelingPenetration, mixing and supersonic combustion modelingNOx reduction and environmental chemistry modeling

LAPCAT II (Long-Term Advanced Propulsion Concepts and Technologies II)

Mid-term review was successfully performed in March 2011

HyShot II in HEG, DLR GöttingenLAPCAT II small scale M8 configuration; to be tested in H2K and TMK, DLR Köln

and HEG, DLR GöttingenGeneric ram-/scramjet combustor,

ITLR Stuttgart

Detailed design of Mach 5-6 vehicle (general structural and thermal protection layout, structural sizing, vehicle optimization (MDO))Durability of metallic materials at high thermal and structural loads (titanium matrix composites characterization, aero thermal ground testing)Durability of non-metallic materials at high thermal and structural loads (CMC material samples for characterization: SiC/SiC, and WHIPOX, anti-oxidation coatings)Mechanical integration technologies for structures and materialsCombustor and material integration (durability of non-metallic liners, fuel injectors, cooling techniques)Aero-thermal-structural loads at high-speed (unsteady SWBLI loadings on control surfaces, intermittency based transition modeling)

ATLLAS II (Aerodynamic and Thermal Load Interactions with Lightweight Advanced Materials for High Speed Flight II)

Kick-off scheduled for May 2011

German Contributions (EADS-Innovation Work, DLR, UniversitätStuttgart):

FAST20XX (Future High-Altitude High-Speed Transport 20XX) Suborbital flights (100km and higher); consideration of two vehicle concepts

Low Energy Concept:Low Range

High Energy Concept:Large Range

Space vehicle launched from an airplane; low-energy ballistic flight using hybrid propulsion (based on EADS Astrium RLV demonstrator Phoenix)

Vertically launched two-stage rocket space vehicle; identification of the conditions and constraints experienced during high-energy suborbital ultra-fast transport

Space Liner, DLR Bremen

German Contributions (DLR, Aerospace Innovation GmbH, AstosSolutions GmbH, TU Berlin, EADS Astrium):

System analysis for DLR Space Liner concept; trajectory optimizationAnalysis of ground operation and launch facilitiesGuidance, navigation & control technologiesGeneration of experimental data base on dynamic stability derivatives and lateral stability, aerodynamic data base consolidationControl of laminar turbulent boundary layer transitionAerodynamics in rarefied flowAscent and descent trajectory calculationsTranspiration cooling technology using porous CMC materials and structures (sample manufacturing, ground verification)Consideration of metallic / composite airframe technologies; subsystem technologies and designDefinition and modeling of hybrid rocket motor; design, manufacturing and ground test of scaled hybrid motorMedical issues of human suborbital space flight

FAST20XX (Future High-Altitude High-Speed Transport 20XX)

German Contributions (DLR, Universität Stuttgart, HTG, MT Aerospace):

EXPERT (European eXPErimental Re-entry Testbed), ESA

Scientific Payloads

P/L #01 FADS Flush Air Data SystemP/L #02 PYREX Nose HeatingP/L #03 PHLUX Catalysis P/L #04 Natural transition P/L #05 Roughness induced

transitionP/L #06 SWBLI onto FlapsP/L #07 SWBLI ahead of FlapsP/L #08 Flap HeatingP/L #10 RESPECT Shock-layer

chemistry through spectrometryP/L #11 Nose-TPS Step JunctionP/L #12 Base FlowP/L #13 SFS - Skin Friction SensorsP/L #15 Flying Winglet - Sharp Hot Structure “SHS”P/L #18 Inter-metallic TPS Flight Experiment

DLR Stuttgart,HTG, IRS Stuttgart

IRS Stuttgart

IRS Stuttgart

DLR Köln

HTG

EXPERT (European eXPErimental Re-entry Testbed), ESAScientific Payloads 6, 7 and 8

payload 7,CIRA (Italy),SWBLIahead of flap

payload 6, DLR Köln,flap and cavity instrumentation

payload 8, RUAG/ETH (Switzerland),infrared camera to measure the flap rear surface temperature

Hardware of payload 6

Study of BL Transition on the HIFiRE I Configuration in HEG

JAXA cone model- 7° half-angle cone- nose radii 2.25 mm and 5 mm- length 1100 mm- equipped with thermocouples and

pressure transducers

Second mode instability- Predicted by means of stability calculations

using the DLR code NOLOT- Confirmed by measurements in HEG using

fast PCB 132A37 pressure transducers- Confirmed by high speed Schlieren

visualization

DLR Project IMENS-3C and DLR-JAXA cooperative Task: High Enthalpy Aerothermodynamics

DLR Flight Experiment SHEFEX II

Suborbital flightRocket system VS 40 (brasilian)Controlled hypersonic flightMass approx. 400 kgVelocity app. M = 11Re-entry duration 50 sPassenger experiments (EADS ASTRIUM,MT-Aerospace, IRS (Universität Stuttgart),AFRL)


Köln-Porz

Stuttgart

Oberpfaffenhofen

Braunschweig

Göttingen

Bremen

Involved DLR sites and institutes:

Bremen:Mission analysis, navigation technology, avionicsBraunschweig:Aerodynamic vehicle layout, fairing structure, parachute control system, aerodynamic flight controlGöttingen:Hypersonic wind tunnel testsKöln: Flight instrumentation and hypersonic wind tunnel tests, MHD-System, oxide based TPSStuttgart:Program coordination, vehicle design, TPS and hot structures Oberpfaffenhofen:Rocket design, subsystems, RCS-control, operation

Institute of Structures and Design

Institute of Aerodynamics and Flow TechnologyInstitute of Flight Systems

Institute of Space Systems

Institute of Materials Research

Mobile Rocket Base


9 TPS systems1 actively cooled segment4 „Hot“ antennas

Hybrid navigation system

Instrumentation: TC, heatflux, pressure,

pyrometer (app. 150 gauges), 2 cameras,

COMPARE (IRS)

New ablative fin

Aerodynamic control

Hybrid CMC/metallic canards


C/SiC (MT-Aerospace)13B72 TS in PRS sensor115B5C/SiC (Astrium)13B3SiC-Tex (Astrium)13B1

1A71A51A31A1

Massive C/C-SiC nose (FADS)83A0

RemarkPYRPRSTSTile

Instrumentation Section A - B

TS : Sheath thermocouple type SPRS : Pressure port for pressure measurementPYR : Pyrometer measurement


Instrumentation Section C - E

WHIPOX (DLR)3D6

SPFI (Astrium)3D2

ACTIVE reference2 TS in PRS sensor

Panel113E7Panel113E5Panel113E3Metal-TPS (Astrium)6E1

113D7

113D5113D3

113D119C7132C5

ACTIVE Experiment211C313C1

RemarkHFPRSTKTSTile

TS : Sheath thermocouple type S TK : Sheath thermocouple type KPRS : Pressure port for pressure measurement HF :Heat flux sensor (VATELL HFM)


Camera location

Possible camera system

Instrumentation of fin section

Canards

Fins

Cameras will be embedded in a separate small finHigh temperature insulation and a quartz window will be used to thermally isolate the cameraTwo cameras looking forward will be installed; one camera will be focused on the canards, the other one (with a wide angle lens) will be able to see the front edges of the fins and the horizon

DLR Flight Experiment SHEFEX II current Status

All hardware and experiments availableFinal acceptance tests in July 2011Pre-campaign at Andoya rocket range in June 2011Start of campaign and system assembly at Andoya Rocket range in August 2011Opening of launch window September 12th, 2011

ANDOYA rocket range Proposed trajectory and impact region

Thank You!

hypersonic flight and (re)-entry in germany – overview...

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