Zefiro 40 SRM Nozzle. Development and Innovations. Renato Marocco

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1 Zefiro 40 SRM Nozzle Development and Innovations Renato Marocco

2 SUMMARY Zefiro 40 Program objectives VEGA perspective configurations Zefiro 40 nozzle Self protected FJ design and technologies LRI divergent design and technologies Zefiro 40 Program Macro-planning

3 Zefiro 40 program objectives Zefiro 40 SRM is coinceived as the future second stage of VEGA E launcher. The Z40 development is performed introducing innovative technological aspects useful for the new generation of SRM. In particular the aim is to develop and qualify on a full scale prototype new technologies and materials for the development of a SRM with improved performance and reduced inert masses and recurring costs The technologies, materials and processes developed in the frame of the Zefiro 40 Program have the following potential returns: Ø Development of a new first stage (P120) for the Vega Consolidated Launcher (VEGA C) Ø New filament wounded cases for Large sizing SRM/SRB for applications on future Ariane 6

4 VEGA perspective configurations VEGA Consolidated (VEGA C) launcher vs actual VEGA: o P120 SRM as first stage instead of P80 SRM The VEGA Evolution (VEGA E) Launcher vs VEGA C: o Zefiro 40 as second stage alternative to Zefiro 23; o cryogenic upperstage (MYRA) instead of Z9 + AVUM Z40 In analogy to P80 SRM Development, the Zefiro 40 Program originally born as Technology Demonstrator for innovative materials (propellant, ultra-light thermal protections), technologies and process (carbon fibers pre-preg, etc.) could evolve in the development of innovative SRM/SRB.

5 Z40 SRM Development of new manufacturing technologies and processes are aimed to: cost reduction performance improvements materials supplier policy problems solution The figure shows a sketch of Z40 SRM in which the new technologies/materials are evidenced High performance internal thermal Male mould protection Self protected flexible joint Automatic Tape Laying New prepreg material Undercut casting Carbon phenolic divergent by Liquid Resin Infusion

6 Z40 SRM Nozzle Self protectd FJ Hybrid composite shims and synthetic rubber LRI Divergent 2D Braided fibre structure Infusion of suitable resin Throat diameter ~ 300 mm Expansion ratio ~ 37 MEOP ~ 110 bar Combustion time ~ 100 sec Biggest nozzle manufactured by AVIO Few components design Low stiffness self protected FJ LRI on braided divergent

7 Z40 SRM Nozzle Flexible Joint The self protected FJ is produced with synthetic rubber layers and spherical composite shims needed to act as structural reinforcements and thermal protection. Stringent FJ stiffness requirements led to adopt pad thickening and cone angle Instability at high pressure --> stiff shims manufactured by hybrid carbon-glass epoxy composite Technological challenges of : Hybrid composite shims (allow to strongly reduce FJ mass: composite vs metal, no further thermal protections) Synthetic rubber (more stable properties than natural, low stiffness) Self protected FJ manufacturing: transfer molding process is baseline, hot/cold components bonding is backup solution Mobile Ring Thermal Protection Mobile Ring Composite Shims Metallic Shims Rubber Pad Rubber Pads Fixed Ring Fixed Ring CLASSICAL PROTECTED FLEXIBLE JOINT SELF-PROTECTED FLEXIBLE JOINT

8 Z40 SRM Nozzle FJ Technological Development Plan SELF PROTECTED FJ MAIN ACTIVITIES FLOWCHART Feasibility Designing and building of Z40 scale shims tooling (prototype) Designing and building of Z23 scale shims tooling (prototype) Z23 scale shims Set up of Z40 scale shims looking by more suitable technology Set up of Z23 scale shims - Technologies trade off Analysis and comparison of two possible solutions (using preimpregnated tow and pre-impregnated fabric) Trade-off and shims manufacturing technology selection Manufacturing of Z23 scale Flexible Joint (by present technology) for test: - Z23 scale shim (prototype) - Selected rubber and adhesive behaviour - Preliminary process parameters Z23 scale FJ Z40 scale shims Qualification Backup technology if Flexible Joint manufacturing by present technology fails Qualification of composite shims manufacturing Design and manufacturing of FJ Z40 scale mould Qualification of Flexible Joint manufacturing Z40 scale FJ In scale test bomb hosting a FJ mockup simulator is in design phase Design phase for FJ Z40 mold (LLI)

9 Z40 SRM Nozzle - LRI Divergent AVIO present technology for the carbon phenolic divergent manufacturing consist in - winding tapes of composite pre-preg material (carbon phenolic) on a suitable mandrel - application of vacuum bag - hydroclave cycle - final machining to obtain the final piece In order to minimize defects occurring divergent manufacturing (especially wrinkles), the technology of Liquid Resin Infusion will be applied for the production of this components. This technology will be implemented in the following three main steps: 1. lay-up of pre-formed fibers structure on conical mandrel (braiding process) 2. impregnation of the preform with a suitable resin under a vacuum bag set-up (infusion process); 3. curing of impregnated preform. At the moment this process is in development phase in collaboration with external aeronautical company and University of Naples

10 Z40 SRM Nozzle LRI Divergent Technological Development Plan LRI DIVERGENT MAIN ACTIVITIES Braiding set up with carbon fibers (AS4 and IM7) Small scale conical mandrel for braiding set up At the moment infusion tests are ongoing. Process simulation has been setup. Cover factor vs braing angle on conical geometries is under study Sample mass % T ( C) Phenolic, Epoxy, Hybrid epoxyphenolic and BMI resins subjected to trade off tests

11 Zefiro 40 Program macro-planning Zefiro 40 Program start: 2009 Preliminary design up to LLI definition: Dicember 2011 (mandrel, forgings,etc.) Materials trade-off completion (selection of propellant, carbon fibers and nozzles materials): June 2012 PDR: September à DM1 FTB KP LLI PDR KP IMC DM00 KP IMC DM0 Hydro-proof DM00 KP IMC DM1 burst DM0 KP IMC QM1 CDR QM FTB QR

12 THANKS