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  • XCOR's piston-pump rocket engine

    I just love the throw it on the wall and see if it'll stick mentality of the NewSpace guys

    Usually rocket engines pump their fuel using turbopumps which are capable of pumping huge volumes, but are complex to design, expensive and notoriously finicky.

    For the first stage of a large rocket there is no other choice, but XCOR and United Launch Alliance (Atlas V and Delta IV boosters) wondered about an alternative for smaller rockets like in XCOR's Lynx spaceplane or an upper stage: a piston pump.

    Piston pumps are very well understood, highly reliable and cheap to build, largely being based on the basic tech used for terrestrial reciprocating pumps and auto engines. The real question was would it work with cryogenic fuels?

    It appears to have worked.



    Aviation Week link....

    Xcor Aerospace has demonstrated that its piston pump technology can be used with liquid hydrogen, opening up potential applications for upper-stage engines, on-orbit propellant transfer and other uses.

    According to Xcor, piston pumps cost less than traditional turbopumps, last longer and can operate over a wide range of speeds, pumping more fuel the faster they go. They can also start and stop quickly, says the company, which has built and flown a three-cylinder crankshaft pump on a 1,500-lb.-thrust rocket motor. Xcor did the demonstration under contract to United Launch Alliance (ULA).

    Turbopumps are the heart of most high-performance rocket engines. They take the propellants and deliver them to the combustion chamber at the extreme speeds and pressures needed to generate the massive thrust required. But turbopumps are complex, expensive, and wear out quickly.

    Now Xcor is developing bigger piston-pump-fed rocket engines for its Lynx suborbital vehicle. These burn liquid oxygen and kerosene, while Xcor uses liquid nitrogen for testing because it is safer. Then ULA asked if the technology could be expanded to liquid hydrogen, which led to a series of bench tests that indicated piston pumps could be used in cryogenic engines.

    ULA says Xcor “has demonstrated the beginnings of an important technology development path” that could improve the competitiveness of future launch vehicles. Now Xcor is hoping its technology will find a place in ULA’s long-range product road map.

    Credit: Xcor
    Last edited by Dr Mordrid; 30 June 2010, 19:37.
    Dr. Mordrid
    ----------------------------
    An elephant is a mouse built to government specifications.

    I carry a gun because I can't throw a rock 1,250 fps

  • #2
    Another advance in the piston rocket pump

    http://www.xcor.com/press/2013/13-09...milestone.html

    XCOR hydrogen rocket piston pump

    XCOR Aerospace and United Launch Alliance announced significant progress today in the XCOR/ULA liquid hydrogen (LH2) engine development program.

    “We are happy to announce that we have successfully operated our liquid hydrogen pump at full design flow rate and pressure conditions,” said XCOR Chief Executive Officer Jeff Greason. “This milestone builds on our earlier success with liquid oxygen and kerosene pumps, which have powered many of our hotfires. Achieving this goal allows us to proceed with integrated testing of our liquid hydrogen demonstrator engine, fed by our liquid hydrogen and liquid oxygen piston pumps. The ultimate goal is a far more cost-effective upper-stage engine for ULA and their customers.”

    Conceived as a lower-cost, risk-managed program, the XCOR LH2 engine program is intended to produce a flight-ready cryogenic upper-stage engine in the 25,000 lbf thrust class with growth potential up to 50,000 lbf thrust or more. When complete, it should cost significantly less to produce and be easier to operate than competing rocket engine technologies.

    However, it isn’t just about thrust class. "Factors such as the extreme low temperature and small molecule size of liquid hydrogen present new technical challenges compared to liquid oxygen or kerosene,” said Greason. "Demonstrating our ability to safely pump this fluid at high flow rates and pressures, with relatively low mass is a significant engineering milestone that will deliver yet another line of innovation and business to XCOR."

    “XCOR’s and ULA’s investment in this program should result in much lower cost and more capable commercial and government launch capabilities,” said XCOR Chief Operating Officer Andrew Nelson. “By drawing from several hundred years of human experience in the development of piston machinery, XCOR seeks to dramatically increase reliability, reusability and long term manufacturability of rocket propellant pumps. The decrease in manufacturing and maintenance costs of XCOR’s rocket propellant pumps is at least an order of magnitude in volume production when compared to traditional rocket turbo machinery.”

    With the completion of the flow rate and pressure tests, Nelson added, “We are proud to say that our collaboration with ULA has borne significant results. This is a new application of time-tested principles that tangibly demonstrates we can produce an upper-stage cryogenic engine with similar or better performance than today’s state of the art, with long life, reusability and reliability at significantly less cost. And it is only taking place at XCOR.”

    “Today’s milestone is further validation of the effort that we began with XCOR several years ago, leveraging more than a century of automotive industry insights to develop a truly new concept in engine design,” noted George Sowers, ULA's Vice President of Human Launch Services. “These technology demonstrations have paved the way for ULA’s support of the liquid hydrogen engine program. We are beginning to see substantial results from ULA’s continued investment of time and resources in the ULA/XCOR hydrogen engine program and look forward to the next phase of development in this groundbreaking endeavor.”
    Dr. Mordrid
    ----------------------------
    An elephant is a mouse built to government specifications.

    I carry a gun because I can't throw a rock 1,250 fps

    Comment


    • #3
      Another advance in the piston rocket pump

      http://www.xcor.com/press/2013/13-09...milestone.html

      XCOR hydrogen rocket piston pump

      XCOR Aerospace and United Launch Alliance announced significant progress today in the XCOR/ULA liquid hydrogen (LH2) engine development program.

      “We are happy to announce that we have successfully operated our liquid hydrogen pump at full design flow rate and pressure conditions,” said XCOR Chief Executive Officer Jeff Greason. “This milestone builds on our earlier success with liquid oxygen and kerosene pumps, which have powered many of our hotfires. Achieving this goal allows us to proceed with integrated testing of our liquid hydrogen demonstrator engine, fed by our liquid hydrogen and liquid oxygen piston pumps. The ultimate goal is a far more cost-effective upper-stage engine for ULA and their customers.”

      Conceived as a lower-cost, risk-managed program, the XCOR LH2 engine program is intended to produce a flight-ready cryogenic upper-stage engine in the 25,000 lbf thrust class with growth potential up to 50,000 lbf thrust or more. When complete, it should cost significantly less to produce and be easier to operate than competing rocket engine technologies.

      However, it isn’t just about thrust class. "Factors such as the extreme low temperature and small molecule size of liquid hydrogen present new technical challenges compared to liquid oxygen or kerosene,” said Greason. "Demonstrating our ability to safely pump this fluid at high flow rates and pressures, with relatively low mass is a significant engineering milestone that will deliver yet another line of innovation and business to XCOR."

      “XCOR’s and ULA’s investment in this program should result in much lower cost and more capable commercial and government launch capabilities,” said XCOR Chief Operating Officer Andrew Nelson. “By drawing from several hundred years of human experience in the development of piston machinery, XCOR seeks to dramatically increase reliability, reusability and long term manufacturability of rocket propellant pumps. The decrease in manufacturing and maintenance costs of XCOR’s rocket propellant pumps is at least an order of magnitude in volume production when compared to traditional rocket turbo machinery.”

      With the completion of the flow rate and pressure tests, Nelson added, “We are proud to say that our collaboration with ULA has borne significant results. This is a new application of time-tested principles that tangibly demonstrates we can produce an upper-stage cryogenic engine with similar or better performance than today’s state of the art, with long life, reusability and reliability at significantly less cost. And it is only taking place at XCOR.”

      “Today’s milestone is further validation of the effort that we began with XCOR several years ago, leveraging more than a century of automotive industry insights to develop a truly new concept in engine design,” noted George Sowers, ULA's Vice President of Human Launch Services. “These technology demonstrations have paved the way for ULA’s support of the liquid hydrogen engine program. We are beginning to see substantial results from ULA’s continued investment of time and resources in the ULA/XCOR hydrogen engine program and look forward to the next phase of development in this groundbreaking endeavor.”
      Dr. Mordrid
      ----------------------------
      An elephant is a mouse built to government specifications.

      I carry a gun because I can't throw a rock 1,250 fps

      Comment

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