Today’s rocket engines regeneratively cooled using high energy cryogenic propellants (e.g. LOX and LH2, LOX and LCH4) play a major role due to the high combustion enthalpy (10–13.4 kJ/kg) and the high specific impulse of these propellants. In the frame of the HYPROB/Bread project, whose main goal is to design build and test a 30 kN regeneratively cooled thrust chamber, a breadboard has been conceived in order to:
• investigate the behavior of the injector that will be employed in the full scale final demonstrator,
• to obtain a first estimate of the heat flux on the combustion chamber for models validation,
• to implement a “battleship” chamber for a first verification of the stability of the combustion
The breadboard is called HS (Heat Sink) and it is made of CuCrZr (Copper Chromium Zirconium alloy), Inconel 718 and TZM (Titanium Zirconium Molybdenum alloy). The aim of the present paper is to illustrate the thermostructural design conducted on the breadboard by means of a Finite Element Method code taking into account the viscoplastic behavior of the adopted materials. An optimization process has been carried out in order to keep the structural integrity of the breadboard maximizing the life cycles of the component. Heat fluxes generated by combustion gases have been evaluated by means of CFD quick analyses, while convection and radiation with the external environment have not been considered in order to be as conservative as possible from a thermostructural point of view. Transient thermal analyses and static structural analyses have been performed by means of ANSYS code adopting an axisymmetric model of the chamber. These analyses have demonstrated that the Breadboard can withstand the design goal of 3 thermo-mechanical cycles with a safety factor equal to 4 considering a firing time equal to 3 seconds.