DE102014100345B4 - Method for producing a thrust chamber device, thrust chamber device and rocket engine - Google Patents

Abstract

In order to provide a method for producing a thrust chamber device by means of which a stable and at the same time lightweight thrust chamber device can be produced, it is proposed that the method for producing a thrust chamber device comprises: providing a base body in the form of solid material; Removing material of the base body to produce an outer shape of an inner layer of the thrust chamber device; Providing the inner layer of the thrust chamber device with a reinforcement layer surrounding the inner layer and removing material from the base body to produce an inner shape of the inner layer of the thrust chamber device.

Description

The present invention relates to a method of manufacturing a thrust chamber device.

Thrust chamber devices are used in particular in engines, for example rocket engines, use.

Such thrust chamber devices may, for example, comprise a combustion chamber device or be part of a combustion chamber device. Such combustion chamber devices and methods for producing such combustion chamber devices are known for example from US Pat DE 10 2010 043 336 A1 known.

The DE 197 30 674 A1 discloses a combustion chamber and a method for producing a combustion chamber, wherein the combustion chamber comprises an outer sheath of a fiber-ceramic material and an inner sheath of a fiber-ceramic material or of graphite.

The DE 691 05 464 T2 discloses a method for producing a combustion chamber wall in which a plurality of metallic bands are brought into a predetermined shape and welded together.

The present invention has for its object to provide a method for producing a thrust chamber device, by means of which a stable and at the same time easy Schubkammervorrichtung can be produced.

This object is achieved by a method according to claim 1.

Characterized in that the outer shape of the inner layer of the thrust chamber device is preferably made independent of the inner shape of the inner layer of the thrust chamber device and also the inner layer is provided with a reinforcing layer surrounding the inner layer, the inner layer may have a low material thickness and yet be made stable ,

The inner layer is preferably the layer delimiting a combustion space and / or a nozzle space.

The outer shape is to be understood as meaning the shaping in the region of an outer side (outer surface) of the inner layer facing away from a combustion space and / or nozzle space.

Under the production of the inner mold is the shaping in the region of the combustion chamber and / or nozzle chamber facing inside (inner surface) to understand the inner layer.

Preferably, in the method for producing a thrust chamber device, the base body is first provided in the form of solid material. Subsequently, the material of the base body for producing an outer shape of the inner layer of the thrust chamber device is preferably removed. Following this, the inner layer of the thrust chamber device is preferably provided with a reinforcing layer surrounding the inner layer. Following this, preferably material of the base body is removed to produce the inner shape of the inner layer of the thrust chamber device.

The method steps described above can be carried out immediately after one another. However, it can also be provided that one or more further method steps are carried out between the method steps.

To produce the outer shape of the inner layer of the thrust chamber device, the material of the base body is preferably removed from an outer side of the base body.

To produce the inner shape of the inner layer, the base body is preferably hollowed out. In particular, material of the base body is removed on an inner side.

It can be provided that the material of the base body is removed by machining, in particular for producing the outer mold and / or the inner mold.

By machining, drilling, turning, filing, milling, planing, rasping, broaching, reaming, sawing, scraping, pushing, whirling, sliding sawing, honing, lifting loops, lobes, grinding and / or blasting are preferably to be understood here.

It may be favorable if the inner layer of the push chamber device is treated after the outer shape has been produced and / or after the inner shape has been produced in a solidification method and / or in a conversion method, for example in a sintering method.

In one embodiment of the invention it is provided that the base body is provided by layers of solid material plate elements.

The base body may, for example, comprise a green body material or be formed from a green body material.

In particular, a green body material is to be understood as meaning a material which is provided in an initial state, treated in the initial state for influencing the shape and then aftertreated for changing the material properties, in particular for converting the material, for example by sintering.

It may be favorable if the reinforcing layer is wound onto the inner layer of the thrust chamber device or onto a separate core.

In particular, the reinforcing ply is wound onto the inner layer of the pusher chamber device or onto a separate core before the inner shape of the inner ply is made.

The reinforcing layer preferably comprises a fiber-reinforced material or is formed from a fiber-reinforced material.

For example, it can be provided that a first material of the reinforcing layer comprises fibers or consists of fibers which are wound onto the inner layer of the push chamber device or onto a separate core. Another material of the reinforcing layer is preferably an infiltrating material, for example a matrix material, by means of which, in particular, interstices between the fibers are filled up in order to provide a fiber-reinforced material.

The reinforcing layer may be subjected to or otherwise post-treated after the application of the fibers and the filling of interstices of the fibers with a conversion process, for example a sintering process.

The inner layer of the thrust chamber device preferably surrounds a combustion space and / or a nozzle space of the thrust chamber device.

In particular, it can be provided that the inner layer of the thrust chamber device comes into direct contact with hot operating gases of the thrust chamber device when using the thrust chamber device.

Alternatively, it may be provided that the inner layer of the thrust chamber device is protected by a coating from direct contact with the hot operating gases during operation of the thrust chamber device.

In one embodiment of the invention it can be provided that at least one placeholder element is arranged on the inner layer before providing the inner layer of the thrust chamber device with a reinforcing layer surrounding the inner layer.

It can be provided that the at least one placeholder element is removed, in particular after the inner layer has been provided with the reinforcement layer surrounding the inner layer.

Preferably, a distance and / or a cavity between the inner layer and the reinforcing layer is formed by means of the at least one placeholder element.

The placeholder element is this applied in particular on an outer side of the inner layer and then surrounded when providing the inner layer with the reinforcing layer with the reinforcing layer.

It may be favorable if the at least one placeholder element is removed after the completion, during the completion and / or through the completion of the inner layer and / or the reinforcement layer.

In particular, it can be provided that the at least one placeholder element is burned, vaporized or otherwise dissolved during a sintering step in the production of the push chamber device.

By means of the at least one placeholder element is preferably formed a fluid channel for a fluid, in particular fuel, oxidizer and / or inert gas.

In particular, at least one fluid channel is formed by a cavity, which is created by removing the at least one placeholder element.

Alternatively or additionally, it may be provided that at least one fluid channel is or will be formed by a recess and / or recess, for example a pocket, of the base body.

It may be favorable if the inner layer and / or the reinforcing layer is provided on an inner side and / or on an outer side with a protective layer.

Such a protective layer may in particular be a chemical protective layer, a heat protection layer and / or a layer for sealing the inner layer and / or the reinforcing layer, that is to say a layer for protection against an undesired fluid passage.

In one embodiment of the invention, it is provided that the solid material of the base body is provided as an open-pore material or that the material of the base body is open-pored during the completion of Schubkammervorrichtung.

As a result, the inner layer is preferably fluid-permeable, in particular for a fluid, for example for fuel, for oxidant and / or for another fluid, preferably an inert gas, in particular helium.

In particular, this can be made possible in that on an outer side of the inner layer, in particular between the inner layer and the reinforcing layer, for example, through the fluid channels, a fluid is supplied, the fluid then preferably through the inner layer through the combustion chamber and / or the nozzle chamber is supplied.

The fluid may in particular be fuel and / or oxidizer. However, it can also be provided that the fluid is or comprises an inert gas. For example, helium, which is preferably carried for tank depression, may be supplied as fluid to produce an inert protective film.

The present invention further relates to a thrust chamber device obtainable by a method according to the invention.

The thrust chamber device according to the invention preferably has one or more of the features and / or advantages described in connection with the method according to the invention.

The thrust chamber device according to the invention is particularly suitable for use in a rocket engine.

The present invention therefore also relates to a rocket engine comprising a thrust chamber device according to the invention.

The rocket engine according to the invention preferably has one or more of the features and / or advantages described in connection with the method according to the invention and / or the thrust chamber device according to the invention.

Furthermore, the method according to the invention, the thrust chamber device according to the invention and / or the rocket engine according to the invention can have one or more of the features and / or advantages described below:
Preferably, by means of the method according to the invention, thin-walled mechanically and thermally stable structures can be produced simply and cost-efficiently.

A contouring of the inner layer is preferably carried out by processing solid material.

A reinforcing layer surrounding the inner layer is preferably produced by winding and in situ silicization.

Between the inner layer and the reinforcing layer preferably discretized film layer (spacer elements) are introduced.

The thrust chamber device according to the invention is particularly suitable for use in small engines, which are operated for example at a combustion chamber pressure of less than 20 bar. Such small engines are operated in particular only in a vacuum and therefore supplied only via the tank pressure and without turbopumps with fuel and oxygen (pressure-pumped engine cycle).

By suitable selection of the material of the inner layer and / or by a suitable coating of the inner layer, preferably a high permissible wall temperature can be achieved, whereby the mass flow requirement of a film cooling can be reduced and the efficiency of the engine can be increased.

The use of expensive refractory metals, for example titanium alloys, for the production of the inner layer and / or the reinforcing layer is preferably avoided.

Preferably, in the thrust chamber device according to the invention a delamination of fibers in the inner contour, in particular in the inner layer, can be prevented, in particular due to the provision of the base body for producing the inner layer in the form of solid material.

By providing a base body in the form of solid material and the independent shaping of the outer shape and the inner shape of the inner layer, a gradation of the material thickness can be made possible in a simple way.

Preferably, a layer construction for providing the inner layer and a winding construction for providing the reinforcing layer are combined with respective minimum wall thicknesses.

The reinforcing layer preferably serves to receive mechanical loads.

The inner layer is preferably used to absorb the thermochemical loads.

In particular, due to an inner layer construction, preferably the radial heat transfer, that is, the heat transfer device perpendicular to the flow direction of the thrust chamber device is increased. Delamination problems of the winding construction can be thereby defused preferably.

A required amount of coolant for a cooling film on an inner surface of the inner layer can on the one hand by a staggered film layer (fluid channels) and the localized supply of fluid and / or on the other hand by the use of high temperature resistant materials for the production of the inner layer and / or coating the inner layer can be minimized.

Carbon-fiber-reinforced materials, for example C / C or C / C-SiC, can be used in particular as high-temperature-resistant materials.

The inner layer preferably has a graded and / or varying material thickness in the axial direction, that is to say along the flow direction of the thrust chamber device.

Instead of producing the reinforcing layer on the inner layer, the reinforcing layer can also be produced separately on a core.

The production of the reinforcing layer essentially corresponds to the production of the reinforcing layer described in connection with the production on the inner layer.

It may be advantageous if the reinforcing layer substantially completely surrounds the inner layer in the region of the combustion chamber and / or the nozzle chamber.

In particular, it can be provided that the reinforcing layer essentially completely covers the inner layer in the axial direction, that is to say perpendicular to the flow direction within the thrust chamber device.

The thrust chamber device is preferably a component or preferably forms part of a radiation-cooled engine, which as a secondary cooling can have a transpiration cooling and / or film cooling.

The connection between the inner layer and the outer layer is preferably a positive and / or cohesive connection.

Preferably, no additional connecting elements are required for connecting the inner layer to the reinforcing layer.

An engine provided with the thrust chamber device according to the invention is particularly suitable as a so-called apogee engine or as a landing gear, for example during a moon landing. The thrust chamber device is thus particularly suitable for so-called "in-space" applications.

Particularly in the finished state of the thrust chamber device, this preferably comprises only two components, namely the inner layer and the reinforcing layer, which preferably both extend from an inlet opening to an outlet opening and thus surround a combustion chamber and a nozzle chamber in the axial direction, in particular substantially completely ,

Further preferred features and / or advantages of the invention are the subject of the following description and the drawings of exemplary embodiments.

In the drawings show:

1 a schematic sectional view of a Schubkammervorrichtung, which comprises an inner layer and a reinforcing layer surrounding the inner layer;

2 a schematic longitudinal section through a base body for producing the inner layer, wherein an outer shape of the inner layer has already been prepared;

3 one of the 2 corresponding schematic representation of the base body, wherein the base body has been provided with placeholder elements;

4 one of the 2 corresponding schematic representation of the base body, wherein the base body and the placeholder elements arranged thereon have been surrounded by a reinforcing layer;

5 one of the 2 corresponding schematic representation of the formed from the base body inner layer and the reinforcing layer, wherein the inner layer of the inner layer was prepared to complete the inner layer and wherein the placeholder elements have been removed to provide fluid channels between the reinforcing layer and the inner layer;

6 to 8th the 2 to 4 corresponding representations of an alternative embodiment for the production of Schubkammervorrichtung, wherein initially provided a core and with the spacer elements and the reinforcing layer is provided, wherein subsequently the core is replaced by the base body for the preparation of the inner layer and finally the inner layer is completed by producing the inner shape of the inner layer;

9 one of the 6 corresponding representation of the reinforcing layer and the introduced after removal of the core base body for the preparation of the inner layer;

10 a schematic representation of fluid channels of the thrust chamber device;

11 an enlarged view of a placeholder element and surrounding the placeholder element reinforcing layer for the preparation of the fluid channels; and

12 an enlarged view of a fluid channel, which is bounded by the reinforcing layer and the inner layer.

Identical or functionally equivalent elements are provided with the same reference numerals in all figures.

An in 1 shown as a whole with 100 designated Schubkammervorrichtung is for example part of a rocket engine 102 for driving a rocket (not shown) or other spacecraft.

The thrust chamber device 100 includes in particular a combustion chamber device 104 of the rocket engine 102 and a nozzle device 106 , which with respect to a flow direction 108 in the combustion chamber device 104 burned fuel and oxidizer downstream of the combustor device 104 followed.

The combustion chamber device 104 includes in particular a combustion chamber 110 , which of the Schubkammervorrichtung 100 is surrounded.

The nozzle device 106 in particular comprises a nozzle space 112 , which of the Schubkammervorrichtung 100 is surrounded.

The thrust chamber device 100 is preferably formed multi-layered.

For example, the thrust chamber device comprises 100 an inner situation 114 which the combustion chamber 110 and / or the nozzle space 112 is arranged facing.

Furthermore, the thrust chamber device comprises 100 for example, a reinforcing layer 116 which the inner situation 114 surrounds and thus on a the combustion chamber 110 and the nozzle space 112 opposite side of the inner layer 114 is arranged.

The reinforcement layer 116 forms in particular a sheath 118 the inner situation 114 ,

The thrust chamber device 100 preferably has one with respect to the flow direction 108 upstream inlet port 120 and one with respect to the flow direction 108 downstream outlet opening 122 on.

Through the inlet opening 120 In particular, fuel and oxidizer are introduced into the thrust chamber device 100 initiated.

The fuel and / or the oxidizer or exhaust gas generated therefrom leave the thrust chamber device 100 through the outlet 122 ,

The inner situation 114 forms in particular an inner wall 124 during operation of the thrust chamber device 100 could come into contact with hot gas.

The inner wall 124 must therefore be thermally stable.

The inner situation 114 For this purpose, it can be provided, for example, with a coating, in particular a heat protection layer.

Furthermore, it can be provided that the inner layer 114 at least partially or completely fluid-permeable, so that by passing a fluid through the inner layer 114 , in particular by supplying fluid to the combustion chamber 110 and / or the nozzle space 112 , a coolant film on the inner layer 114 can be formed, creating a thermal load on the inner layer 114 can be reduced.

For supplying such a fluid, in particular fuel and / or oxygen, to the inner layer 114 , in particular at one of the combustion chamber 110 and / or the nozzle space 112 opposite outside 126 the inner situation 114 includes the thrust chamber device 100 preferably a plurality of fluid channels 128 ,

The fluid channels 128 are between the inner situation 114 and the reinforcement layer 116 arranged and / or trained.

The thrust chamber device described above 100 can be prepared, for example, as follows:
Like that 2 to 5 it can be seen, the inner layer 114 for example, be made of a solid material.

For this purpose, a base body 130 provided in the form of solid material and initially on an outside 126 edited, in particular machined.

The base body 130 is shaped so that an outer shape 132 the inner situation 114 is produced (see 2 ).

For example, in that portion of the inner layer 114 , which later the combustion chamber 110 Surround in a next step placeholder elements 134 on the base body 130 arranged.

In particular, the placeholder elements become 134 on an outside 126 the inner situation 114 arranged (see 3 ).

Following this, the reinforcing layer 116 produced.

The reinforcement layer 116 For example, by wrapping the base body 130 including the placeholder elements arranged thereon 134 made with a fibrous material and then infiltrated by the same.

The reinforcement layer 116 thus surrounds the inner situation 114 on the outside 126 and at the same time covers the placeholder elements 134 from.

For example, during the completion of the reinforcement layer 116 in a sintering step, the placeholder elements become 134 removed, in particular evaporated or burned.

The reinforcement layer 116 Retains the form that they use with the existing placeholder elements 134 exhibited.

In those places where previously the placeholder elements 134 were arranged, thus channels, namely the fluid channels 128 , educated.

Especially after completion of the reinforcement layer 116 , in particular, when the reinforcing layer 116 the desired stability and rigidity to reinforce the inner layer 114 has, becomes an inner shape 136 the inner situation 114 produced.

The base body 130 is hollowed out for this purpose, so that the areas are created, which in the assembled state of the rocket engine 102 the combustion chamber 110 and the nozzle space 112 form.

The inner situation 114 can due to the already made reinforcement by means of the reinforcing layer 116 Here are made very thin and yet very stable.

If necessary, the inner situation 114 be subjected to further treatment steps, in particular the heat resistance, the chemical resistance, the stability and / or the rigidity of the inner layer 114 continue to increase.

In the finished state (see 5 ) of the thrust chamber device 100 Then there is a very stable, yet very thin-walled and thus easy Schubkammervorrichtung 100 in front.

It may be particularly advantageous if for the provision of the base body 130 a cylinder is made of a fibrous ceramic material or a fibrous ceramic green body material. The cylinder axis is then preferably transverse to fiber planes of the base body 130 ,

The solid material can be sorted. However, provision may also be made for different material variants to be combined with one another in layers, in particular even fiber-level, for the fiber plane.

In particular, if for the production of the reinforcing layer 116 a silicating process is provided, it can be provided that the inner layer 114 after production of the outer shape 132 is sealed with a protective layer (not shown), for example, resin or wax. An undesirable silicization of the material of the inner layer 114 This can preferably be prevented.

The reinforcement layer 116 can be produced in particular by wet laying, in particular winding or braiding.

The reinforcement layer 116 is preferably fluid-tight after its completion.

In particular, a thermal barrier coating (thermal barrier coating, TBC) can provide additional protection of the inner layer 114 be provided.

In the 6 to 9 is an alternative way of producing the thrust chamber device 100 displayed.

With this possibility is a core 138 provided, which is for example formed as a metal core and has an outer shape, which the outer shape 132 the inner situation 114 equivalent.

The core 138 is particularly formed in two parts, wherein the two parts of the core 138 in the area of a bottleneck 140 the thrust chamber device 100 which the combustion chamber 110 from the nozzle space 112 separated, juxtaposed and interconnected.

As in particular the 7 and 8th it can be seen, the fluid channels 128 and the reinforcement layer 116 in this possibility for the production of Schubkammervorrichtung 100 directly to the core 138 applied by first placing the placeholder elements 134 at the core 138 are arranged and then the reinforcing layer 116 will be produced.

After completion of the reinforcement layer 116 and thereby removing the placeholder elements 134 becomes the core 138 away. In particular, the two parts of the core 138 in opposite directions parallel to the flow direction 108 extending directions from the reinforcement layer 116 pulled out.

Then the base body becomes 130 , which has already been edited so that this is the outer shape 132 the inner situation 114 in one of the reinforcing ply 116 surrounded interior 142 brought in.

The base body 130 can be initially formed in two parts.

The two parts, which in particular at the bottleneck 140 adjacent to each other, then still need to be interconnected.

In a further step after the introduction of the base body 130 in the interior 142 the reinforcement layer 116 becomes the base body 130 (further) hollowed out to the inner mold 136 the inner situation 114 manufacture.

If necessary, after further processing steps for the conversion and / or solidification of the inner layer 114 will eventually be in the 1 and 5 illustrated Schubkammervorrichtung 100 receive.

In the 10 to 12 are schematic representations illustrating the fluid channels 128 shown.

10 shows the Schubkammervorrichtung 100 in a schematic side view.

In particular, will be off 10 it can be seen that by means of the fluid channels 128 by suitable design of the same a desired fluid to arbitrary locations of the thrust chamber device 100 feedable and finally by the inner situation 114 through into the combustion chamber 110 and / or the nozzle space 112 can be introduced.

The thrust chamber device 100 can thus have a highly efficient cooling adapted to individual applications.

In addition, the Schubkammervorrichtung 100 be particularly lightweight and stable when the outer shape 132 the inner situation 114 the thrust chamber device 100 , the inner shape 136 the inner situation 114 the thrust chamber device 100 and the reinforcement layer 116 the thrust chamber device 100 are made essentially independently of each other.

The thrust chamber device 100 is then particularly suitable for use as a primarily radiation-cooled rocket combustion chamber (combustion chamber device 104 ) of a rocket engine 102 ,

In addition to the radiation cooling, in particular a transpiration cooling and / or film cooling of the thrust chamber device can be used 100 be provided.

LIST OF REFERENCE NUMBERS

100

Thrust chamber device

102

Rocket engine

104

combustion chamber device

106

nozzle device

108

flow direction

110

combustion chamber

112

nozzle chamber

114

inner situation

116

reinforcing layer

118

jacket

120

inlet port

122

outlet opening

124

inner wall

126

outside

128

fluid channel

130

base body

132

external form

134

Template item

136

interior shape

138

core

140

bottleneck

142

inner space

Claims (15)

Method for producing a thrust chamber device ( 100 ), comprising the following temporally successive process steps: - providing a base body ( 130 ) in the form of solid material; - Removal of material of the base body ( 130 ) for producing an outer mold ( 132 ) of an internal situation ( 114 ) of the thrust chamber device ( 100 ); - providing the internal situation ( 114 ) of the thrust chamber device ( 100 ) with an inner layer ( 114 ) surrounding reinforcing layer ( 116 ); and - removal of material of the base body ( 130 ) for producing an inner mold ( 136 ) of the internal situation ( 114 ) of the thrust chamber device ( 100 ). Method according to claim 1, characterized in that the material of the base body ( 130 ) for producing the outer mold ( 132 ) of the internal situation ( 114 ) and / or for the production of the inner mold ( 136 ) of the internal situation ( 114 ) is removed by machining. Method according to one of claims 1 or 2, characterized in that the inner layer ( 114 ) of the thrust chamber device ( 100 ) after making the outer mold ( 132 ) and / or after producing the inner mold ( 136 ) in a solidification process and / or in a conversion process, for example in a sintering process. Method according to one of claims 1 to 3, characterized in that the base body ( 130 ) is provided by layers of solid material plate elements. Method according to one of claims 1 to 4, characterized in that the base body ( 130 ) comprises a green body material or is formed from a green body material. Method according to one of claims 1 to 5, characterized in that the reinforcing layer ( 116 ) on the internal situation ( 114 ) of the thrust chamber device ( 100 ) or on a separate core ( 138 ) is wound up. Method according to one of claims 1 to 6, characterized in that the inner layer ( 114 ) of the thrust chamber device ( 100 ) a combustion chamber ( 110 ) and / or a nozzle space ( 112 ) of the thrust chamber device ( 100 ) surrounds. Method according to one of claims 1 to 7, characterized in that prior to the provision of the inner layer ( 114 ) of the thrust chamber device ( 100 ) with an inner layer ( 114 ) surrounding reinforcing layer ( 116 ) at least one placeholder element ( 134 ) on the inner layer ( 114 ) is arranged. Method according to claim 8, characterized in that the at least one placeholder element ( 134 ) is removed so that a cavity ( 128 ) between the internal situation ( 114 ) and the reinforcing layer ( 116 ) is formed. Method according to one of claims 8 or 9, characterized in that the at least one placeholder element ( 134 ) after completion, completion and / or completion of the internal situation ( 114 ) and / or the reinforcing layer ( 116 ) Will get removed. Method according to one of claims 8 to 10, characterized in that by means of the at least one placeholder element ( 134 ) a fluid channel ( 128 ) is formed for a fluid, in particular for fuel, oxidizer and / or inert gas. Method according to one of claims 1 to 11, characterized in that the inner layer ( 114 ) and / or the reinforcement layer ( 116 ) on an inner side and / or on an outer side ( 126 ) is provided with a protective layer. Method according to one of claims 1 to 12, characterized in that the solid material of the base body ( 130 ) is provided as an open porous material or that the material of the base body ( 130 ) in the completion of the Schubkammervorrichtung ( 100 ) becomes porous. Thrust chamber device ( 100 ) obtainable by a method according to any one of claims 1 to 13. Rocket engine ( 102 ) comprising a thrust chamber device ( 100 ) according to claim 14.

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