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X-51A Scramjet Engine Completes Ground Tests
Nov 2, 2008
By Graham Warwick
A year from now, over the Pacific Ocean off California in airspace cleared of all civilian traffic, hypersonics could take a step closer to reality. In the same skies where five years earlier the X-43A Hyper-X flew for 10 sec. at Mach 9.6, powered by a supersonic-combustion ramjet, the X-51A WaveRider is planned to fly on scramjet power for 5 min., accelerating from Mach 4.7 to beyond Mach 6 and demonstrating that sustained hypersonic flight is practical.
Burning hydrogen in a heavy copper engine that simply soaked up the heat of supersonic combustion and began melting within seconds, the X-43A showed scramjet-powered flight was feasible. The X-51A will have a flightweight engine, cooled by its own hydrocarbon fuel and designed to run for as long as there is JP-7 in the tanks.
Boeing's X-51A and its Pratt & Whitney Rocketdyne (PWR) scramjet can trace their roots back 20 years to the X-30 National AeroSpace Plane, an overambitious and unsuccessful attempt to build a Mach 30 single-stage-to-orbit technology demonstrator. The X-51A's goals are far more modest, but it could lead directly to development of a hypersonic long-range strike missile. It would also be a step closer to an eventual air-breathing space access vehicle.
"The X-51A will demonstrate the technology is ready for application in a program," says Charles Brink, Air Force Research Laboratory program manager. AFRL is funding three-quarters of the $246-million contract, with the balance being provided by the U.S. Defense Advanced Research Projects Agency.
PWR has just completed ground runs of the flight clearance engine in the high-temperature tunnel at NASA Langley Research Center, making sure the scramjet will start when the X-51A separates from its modified missile booster, even if the Mach number and dynamic pressure (Q) are not quite as planned. Designated the SJX61-2 and known simply as "X-2," the engine completed eight runs at Mach 4.6 and 11 at Mach 5, for a total of 11.4 min., about twice the expected flight time.
The tests cleared the "start box" for the scramjet, showing margin to handle off-design conditions. "There was repeatable, fairly robust light-off throughout the envelope," says Brink. "We tested off-nominal - high-Q, low-Q, varied angles of attack, cold ethylene, hot ethylene - and saw very reliable light-off."
Easily ignited ethylene is used to start combustion and begin heating the hydrocarbon fuel so it will burn more readily when injected into the supersonic flow. X-2 was the first engine to be tested with the flight ethylene bottle and fuel pump planned for the X-51A.
"We found some 'ohs' about the software," says Brink. When testing at above-nominal dynamic pressure and engine airflow, the control system commanded a fuel/air ratio higher than allowed by the software and the engine shut down in mid-test. "I'm glad we tested off-condition. That might have bit us in flight," he says.
X-2's operability and performance met expectations. "It matched our predictions," says Curtis Berger, PWR's hypersonics programs director. "But our models are becoming pretty mature. This is our fourth flightweight fuel-cooled scramjet through freejet testing." The four engines between them logged 161 test runs since 2003, at speeds from Mach 4.5 to 6.5.
Last year, in the same NASA tunnel, the X-51A ground demonstrator engine, SJX61-1, completed 58 runs and 17.8 min. of combustion. "We had four risks left tied to X-2: mapping the start box, showing margin on the box, and the flight fuel pump and ethylene tank," says Berger. "They're burned down to green. We feel good about going to flight."
Vibration caused by the acoustic environment in the combustor was noticed in earlier scramjets and confirmed in X-1, says Berger, adding, "We designed for it in X-2." Where components mount to the engine and the engine attaches to the cruiser, isolators have been designed in. "The acoustic vibration levels are substantial, but nothing we couldn't design for. We understand it, have mitigated it and for the next system we have models to predict it."
Engines for all four X-51As will be delivered to Boeing by early November. The first of these, designated SJY61-4, will be mounted on the Boeing-built cruiser vehicle. This will then be attached to its modified Atacms missile booster and the complete stack, called the static test vehicle (STV), will go through ground vibration and structural modes testing. The STV will be refurbished to become the fourth flight vehicle.
For PWR, X-2 was the latest in a series of dual-mode ramjet/scramjets dating back to the performance test engine run in 2001 under the HySET program started by AFRL after cancellation of the X-30. The first flightweight ground demonstrator engine (GDE 1) ran in 2003 and had an open-loop fuel system. One stream of JP-7 cooled the engine structure; a second was heated and injected into the scramjet.
As a follow-on to the X-43A, AFRL and NASA had planned to build the larger X-43C, powered by three scramjets burning storable hydrocarbon fuel. The first engine was 95% built when NASA canceled the program in 2004, but the scramjet was completed and ground-tested as the GDE-2. "This was the first Air Force scramjet tested at NASA, and the first time we closed the loop on the thermal system," says Brink.
Achieving thermal balance with a closed-loop fuel system is a key to making scramjets practical. Using the fuel to cool the structure allows the engine to be made of Inconel 625 nickel-based alloy rather than more-exotic high-temperature materials. At the same time, the heat absorbed by the fuel "cracks" the high-flashpoint JP-7 into lighter hydrocarbons that burn more readily when injected into the supersonic flow.
In the X-51A, fuel flows through channels inside the walls of the scramjet. As the fuel moves from front to back through the engine, heat combines with a catalytic coating on the heat-exchanger panels to break down the JP-7, which is then brought forward to hot-gas distribution valves that spray the vaporized fuel into the combustion chamber.
Thermal equilibrium must be maintained as the vehicle accelerates. "The system has to maintain enough flow through the structure to keep it cool, put enough heat into the fuel so it burns, and not recirculate or dump fuel," says Berger. "It's balancing the fuel flow so it keeps cool enough, gets hot enough and produces maximum thrust at various Mach numbers. How that is all done is what we know."
Where the fuel is injected is another critical aspect of making a scramjet practical. In the supersonic flow, air and fuel must mix and burn in milliseconds. Injecting fuel at the front of the engine gives more time, but risks "unstarting" the inlet as backpressure from combustion blows the shockwave system out of the duct. These shocks on the forebody and inlet compress the air entering the engine. "We want to burn the fuel as close to the inlet as we can, but we can unstart the engine and disgorge the shock," says NASA's Ken Rock.
Therefore, fuel is first injected toward the rear of the engine then staged forward as the vehicle accelerates and dynamic pressure increases, making it harder to unstart the inlet. "At lower Mach we release the heat further aft, and at higher Mach we inject fuel further forward to get increased performance as the vehicle accelerates," Rock says.
While the X2 engine tests were under way, Boeing was beginning assembly of the first X-51As. The 168-in.-long missile-representative cruiser vehicle is built from conventional materials such as aluminum and titanium. A tungsten nose, composite leading edges and lightweight ablator on the skin and in the nozzle provide thermal protection. With its modified Atacms booster and flow-through interstage, the complete stack as carried aloft by the B-52 mothership will be 301-in. long.
Flight operations will begin at NASA Dryden Flight Research Center on Edwards AFB, Calif., in February next year. The first X-51A is expected to arrive by July to begin ground compatibility tests with the B-52. The first captive flight is planned for August over the Edwards range to vet communications and telemetry links. A dress rehearsal over the Pacific using P-3s to record and relay telemetry is planned for September.
All four flights slated for early October 2009 through late February 2010 will share one goal, "to light off and accelerate through as many Mach numbers as we can," says Brink. "Realistically if we get two flights out of four we'll be happy. Look at the statistics. Things will go wrong." Flights 3 and 4 will carry specialized software for NASA Langley to measure vehicle aerodynamic parameters in flight.
After takeoff from Edwards, the B-52 will climb to almost 50,000 ft. and release the stack. The booster will burn for almost 30 sec. and accelerate to Mach 4.6-4.8. During the boost, air will flow through the cruiser's engine, exiting via the interstage, to start the inlet and begin warming the scramjet and its circulating fuel.
After booster burnout and separation, the vehicle will coast for a couple of seconds, then ethylene will be injected to light off the engine. Heated by the burning ethylene, fuel will be introduced and the two flows combusted simultaneously until thermal equilibrium is achieved and the vehicle can accelerate on JP-7 alone. Thermal balance occurs within seconds, says Berger. "Then it will only stop flying when it runs out of fuel."
For the X-51A that will mean about 300 sec. of powered flight followed by 500 sec. of unpowered descent to a watery end in the Pacific. "Boeing is exploring a recovery system if we go ahead with further vehicles," says Brink. "We can do away with some instrumentation and miniaturize components to make room."
Boeing, meanwhile, has schemed variants of the X-51 "from B through H," says program manager Joe Vogel. The proposed X-51B would be powered by an Alliant Techsystems thermally throated ramjet, a simplified subsonic-combustion engine designed to maintain a Mach 5 cruise.
Using "minimal funds" added by Congress, Boeing has completed a "fairly detailed" installation study on the X-51B, and ATK is about to begin ground tests of the engine, says Brink, but there is no Air Force funding for the vehicle. For now the focus is on the X-51A, and on being able to correlate ground and flight tests of a fuel-cooled scramjet. "We are on the path to practical hypersonics," says Berger.