Stress analysis & life prediction of a cryogenic rocket engine thrust chamber considering low cycle fatigue, creep and thermal ratchetting

The paper deals with stress analysis, cyclic and creep life prediction of a cryogenic rocket engine thrust chamber, being used in one of the satellite launch vehicles of ISRO. The thrust chamber is of double walled construction wherein high conductivity copper alloy is used for the inner wall and stainless steel for the outer. Regenerative cooling of the chamber is achieved by passing the fuel through rectangular coolant passages milled on outer surface of the inner wall. The inner and outer walls are bonded together by brazing at high temperature. Failure of a double walled chamber occurs due to thinning of the inner wall and bulging into the chamber due to three mechanisms viz. (i) low cycle fatigue (ii) thermal ratchetting and (iii) creep. To capture the structural behaviour of the chamber in a complete sequence of operation of the engine, axisymmetric modeling and cyclic stress analysis is carried out using the ANSYS finite element analysis software package. High temperature mechanical properties, low cycle fatigue and creep properties of copper are characterised. Results of creep tests conducted at various temperatures are utilized for evaluating creep constants of Norton secondary creep model available in ANSYS. Analysis is performed in a seven load step sequence simulating one complete hot test of the engine. Life prediction is done using the cumulative damage accumulation methodology, considering the above three damage mechanisms. Allowable number of hot runs permissible is then arrived at after assigning suitable factors of safety for each damage mode.