Numerical Investigation on the Service Life of a Liquid Rocket Engine Thrust Chamber

Rocket engine thrust chambers withstand very high temperatures and thermal gradients during service that induce multiple damaging phenomena such as plasticity, low-cycle-fatigue (LCF) and creep. Numerical models can be used during the design of these mechanical components in order to simulate the main mechanical damaging processes, accounting for complex material behavior as due to non-linear hardening phenomena and viscoplasticity. This work represents an improvement upon previous research by the authors, with particular reference to the addition of the Wang-Brown fatigue criterion, to consider the effects of multiaxiality and non-proportionality of loads, and the Voce model to account for non-linear isotropic hardening. A precipitation hardened copper alloy has been considered as the material of the thrust chamber internal structure. The most critical areas resulted to be on the internal surface of the chamber and in particular in correspondence of the throat region, consistently with experimental tests available in the literature conducted on similar geometries. Results demonstrated that low cycle fatigue and thermal ratcheting (plastic instability) are the dominant damaging phenomena for the considered test case.