Hypersonic Flight and (Re)-Entry in Germany ... - HobbySpace

Hypersonic Flight and (Re)-Entry
in Germany – Overview and Selected Projects
Klaus Hannemann
German Aerospace Center, DLR
Institute of Aerodynamics and Flow Technology
37073 Göttingen, Germany
17th AIAA International Space Planes and
Hypersonic Systems and Technologies Conference
11 – 14 April 2011
The Grand Hyatt San Francisco,
San Francisco, USA

Outline
Institutions involved in Hypersonic Flight and (Re) Entry
Tools and Tool Development
Selected Applications, Research Activities, Projects

Institutions involved in Hypersonic Flight and (Re)-Entry
Industries
EADS Astrium
MT Aerospace
OHB
HTG, HST
LFK
Bayern Chemie
IABG
Kayser Threde
TALIS ENTERPRISE
GmbH
Astos Solutions
GmbH
Aerospace Innovation
GmbH
Universities
RWTH Aachen University
Universität Stuttgart
Technische Universität
München
Universität der
Bundeswehr München
Technische Universität
Braunschweig
Technische Universität
Berlin
German Aerospace
Center, DLR
Braunschweig
Bremen
Göttingen
Köln
Stuttgart
Lampoldshausen
Oberpfaffenhofen

Tools and Tool Development:
Ground Based Testing
Flight Experiment
Numerics

Ground Based Testing
Cold hypersonic facilities
Arc heated tunnels for qualification of hot
structure components
Shock tunnels for re-entry
aerothermodynamics, hypersonic flight
and scramjet propulsion
Aerodynamics in rarefied gas environment
Connected tube facilities for dual mode
ram-/scramjet combustion
Thermo-mechanical component testing
Air Dryer
Screw
Compressor
Heater 0
Auxiliary Air Supply
Combustion
Chamber
Heater 1
Heater 2
Supersonic combustion test facility, ITLR Stuttgart
H2K, DLR Köln
HEG, DLR Göttingen

Ground Based Testing
Hypersonic shock tunnel TH2, Shock Wave
Laboratory, RWTH Aachen
Low density facilities VXG, DLR Göttingen
Trisonic Test Section TMK, DLR Köln
Arc-heated wind tunnels L2K and L3K, DLR Köln

Numerical Methods
Aerodynamic design and multi-disciplinaryoptimization
tools
CFD including multidisciplinary coupling
(structure mechanics, flight mechanics,
combustion, chemsitry …)
CFD for continuum and free molecular regime
System analysis
Atmospheric re-entry including
aerothermal break-up
SCARAB (spacecraft atmospheric re-entry and
aerothermal break-up), HTG
TAU code, DLR

Flight Testing
SHEFEX I (flight: 2005), DLR
SHEFEX II (flight scheduled: 2011), DLR
SHEFEX III (project in preparation), DLR
EXPERT (flight scheduled: 2011), ESA with
German participation
HIFiRE flight program, cooperation AFRL / DLR
SCRAMSPACE I, The University of Queensland,
DLR member of international consortium
SHEFEX III aerothermodynamics
study, DLR
SHEFEX I launch, DLR
EXPERT (European eXPErimental
Re-entry Testbed), ESA

Measurement Techniques, Hardware Manufacturing
Measurement techniques
- Flow diagnostics in wind tunnels
- Flight instrumentation
Hardware manufacturing
- CMC materials for hot structures (nose
caps, body flaps, …)
EXPERT flap, MT Aerospace
IXV in H2K, DLR Köln
EXPERT payload 6, DLR Köln
EXPERT nose cap, DLR Stuttgart

Selected Applications, Research Activities, Projects
EC co-funded research projects
- LAPCAT II
- ATLLAS II
- FAST20XX
DFG funded Graduate School 1095/2
ESA flight experiment EXPERT
Hayabusa re-entry radiation measurements
BL Transition study on HIFiRE I configuration
DLR 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 Europe
Identification, development and acquisition of critical technologies, knowhow
and disciplines
Laying 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
3.5
3.5
4.5
4.5
6.0
6.0
8.0
8.0
8.0
8.0
5.0
5.0
8.0
8.0

LAPCAT II (Long-Term Advanced Propulsion Concepts and
Technologies II)
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 aerothermodynamics
Supersonic combustion experiments in connected tube and free-jet facilities
Air-turbo-rocket gas generator combustion experiments and CFD modeling
Penetration, mixing and supersonic combustion modeling
NOx reduction and environmental chemistry modeling
Mid-term review was successfully performed in March 2011
HyShot II in HEG, DLR Göttingen
Generic ram-/scramjet combustor,
ITLR Stuttgart
LAPCAT II small scale M8 configuration;
to be tested in H2K and TMK, DLR Köln
and HEG, DLR Göttingen

ATLLAS II (Aerodynamic and Thermal Load Interactions
with Lightweight Advanced Materials for High Speed
Flight II)
German Contributions (EADS-Innovation Work, DLR, Universität
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 materials
Combustor 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)
Kick-off scheduled for May 2011

FAST20XX (Future High-Altitude High-Speed Transport 20XX)
Suborbital flights (100km and higher); consideration of two vehicle concepts
Low Energy Concept:
Low Range
Space vehicle launched from an
airplane; low-energy ballistic flight
using hybrid propulsion (based on
EADS Astrium RLV demonstrator
Phoenix)
High Energy Concept:
Large Range
Space Liner, DLR Bremen
Vertically launched two-stage rocket
space vehicle; identification of the
conditions and constraints
experienced during high-energy
suborbital ultra-fast transport

FAST20XX (Future High-Altitude High-Speed Transport 20XX)
German Contributions (DLR, Aerospace Innovation GmbH, Astos
Solutions GmbH, TU Berlin, EADS Astrium):
System analysis for DLR Space Liner concept; trajectory optimization
Analysis of ground operation and launch facilities
Guidance, navigation & control technologies
Generation of experimental data base on dynamic stability derivatives and
lateral stability, aerodynamic data base consolidation
Control of laminar turbulent boundary layer transition
Aerodynamics in rarefied flow
Ascent and descent trajectory calculations
Transpiration cooling technology using porous CMC materials and
structures (sample manufacturing, ground verification)
Consideration of metallic / composite airframe technologies; subsystem
technologies and design
Definition and modeling of hybrid rocket motor; design, manufacturing and
ground test of scaled hybrid motor
Medical issues of human suborbital space flight

EXPERT (European eXPErimental Re-entry Testbed), ESA
German Contributions (DLR, Universität Stuttgart, HTG, MT Aerospace):
Scientific Payloads
DLR Stuttgart,
HTG,
IRS Stuttgart
IRS Stuttgart
DLR Köln
IRS Stuttgart
HTG
P/L #01 FADS Flush Air Data System
P/L #02 PYREX Nose Heating
P/L #03 PHLUX Catalysis
P/L #04 Natural transition
P/L #05 Roughness induced
transition
P/L #06 SWBLI onto Flaps
P/L #07 SWBLI ahead of Flaps
P/L #08 Flap Heating
P/L #10 RESPECT Shock-layer
chemistry through spectrometry
P/L #11 Nose-TPS Step Junction
P/L #12 Base Flow
P/L #13 SFS - Skin Friction Sensors
P/L #15 Flying Winglet - Sharp Hot Structure “SHS”
P/L #18 Inter-metallic TPS Flight Experiment

EXPERT (European eXPErimental Re-entry Testbed), ESA
Scientific Payloads 6, 7 and 8
Hardware of payload 6
payload 6, DLR Köln,
flap and cavity instrumentation
payload 7,
CIRA (Italy),
SWBLI
ahead of flap
payload 8, RUAG/ETH (Switzerland),
infrared camera to measure the flap rear
surface temperature

Study of BL Transition on the HIFiRE I Configuration in HEG
DLR Project IMENS-3C and DLR-JAXA cooperative Task: High Enthalpy Aerothermodynamics
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
JAXA cone model
- 7° half-angle cone
- nose radii 2.25 mm and 5 mm
- length 1100 mm
- equipped with thermocouples and
pressure transducers

DLR Flight Experiment SHEFEX II
Suborbital flight
Rocket system VS 40 (brasilian)
Controlled hypersonic flight
Mass approx. 400 kg
Velocity app. M = 11
Re-entry duration 50 s
Passenger experiments (EADS ASTRIUM,
MT-Aerospace, IRS (Universität Stuttgart),
AFRL)

DLR Flight Experiment SHEFEX II
Involved DLR sites and institutes:
Bremen:
Mission analysis, navigation technology,
avionics
Braunschweig:
Aerodynamic vehicle layout, fairing structure,
parachute control system, aerodynamic flight
control
Göttingen:
Hypersonic wind tunnel tests
Köln:
Flight instrumentation and hypersonic wind
tunnel tests, MHD-System, oxide based TPS
Stuttgart:
Program coordination, vehicle design, TPS and
hot structures
Oberpfaffenhofen:
Rocket design, subsystems, RCS-control,
operation
Institute of Space Systems
Bremen �
Braunschweig � Institute of Flight Systems
Institute of Aerodynamics and Flow Technology
� Göttingen
� Köln-Porz
Institute of Materials Research
� Stuttgart
Institute of Structures and Design
� Oberpfaffenhofen
Mobile Rocket Base

DLR Flight Experiment SHEFEX II
Hybrid navigation system
Instrumentation: TC,
heatflux, pressure,
pyrometer (app. 150
gauges), 2 cameras,
COMPARE (IRS)
New ablative fin
Aerodynamic control
Hybrid CMC/metallic
canards
9 TPS systems
1 actively cooled segment
4 „Hot“ antennas

DLR Flight Experiment SHEFEX II
Instrumentation Section A - B
Tile
A0
A1
A3
A5
A7
B1
B3
B5
B7
TS
3
1
1
1
1
3
3
5
3
PRS
8
1
1
1
1
PYR
1
Remark
Massive C/C-SiC nose
(FADS)
SiC-Tex (Astrium)
C/SiC (Astrium)
2 TS in PRS sensor
C/SiC (MT-Aerospace)
TS : Sheath thermocouple type S
PRS : Pressure port for pressure measurement
PYR : Pyrometer measurement

DLR Flight Experiment SHEFEX II
Instrumentation Section C - E
Tile
C1
C3
C5
C7
D1
D2
D3
D5
D6
D7
E1
E3
E5
E7
TS
2
TK
3
11
3
9
3
3
3
3
3
3
6
3
3
3
PRS
1
2
1
1
1
1
1
1
1
1
1
HF
1
1
1
1
1
1
1
Remark
ACTIVE Experiment
2 TS in PRS sensor
ACTIVE reference
SPFI (Astrium)
WHIPOX (DLR)
Metal-TPS (Astrium)
Panel
Panel
Panel
TS : Sheath thermocouple type S TK : Sheath thermocouple type K
PRS : Pressure port for pressure measurement HF :Heat flux sensor (VATELL HFM)

DLR Flight Experiment SHEFEX II
Instrumentation of fin section
Canards
Fins
Cameras will be embedded in a separate small fin
High temperature insulation and a quartz window will
be used to thermally isolate the camera
Two 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
Camera location
Possible camera system

DLR Flight Experiment SHEFEX II current Status
All hardware and experiments available
Final acceptance tests in July 2011
Pre-campaign at Andoya rocket range in June 2011
Start of campaign and system assembly at Andoya Rocket range in
August 2011
Opening of launch window September 12th , 2011
ANDOYA rocket range Proposed trajectory and impact region

Thank You!