Experimental characterization of the cycling thermo-mechanical behavior of a reusable LOX-LNG regeneratively cooled thrust chamber

This paper presents the numerical life prediction of the Huracan LOX/LNG rocket engine’s thrust chamber assembly developed as part of the Nyx Moon vehicle by The Exploration Company. The results are validated by means of an experimental test campaign conducted to evaluate the cycling thermo-mechanical performance of the hardware at the German Aerospace Center (DLR) in Lampoldshausen, with support from the European Space Agency (ESA). A deep material characterization of the Additive Manufactured heat tread Inocnel718 involved in the thrust chamber has been used to finely calibrate nonlinear hardening models. High temperature low cycle fatigue and high temperature tensile tests are utilized to calibrate hardening models involved in the material constitutive numerical models responsible for the life prediction of the hardware. Experimental data have been involved to validate the thermal boundary conditions. Results highlight the benefits of using additive manufacturing nickel-based alloys for combustion chambers and thermal barrier coating. Usage factors related to ratcheting and low cycle fatigue have been involved for life prediction to investigate the failure modes in the regenerative cooling channels.