Thermo-structural analysis of regenerative cooling thrust chamber cylinder segment based on experimental data

To evaluate the structural failure risk of the regenerative cooling thrust chamber cylinder segment, a Finite Element Method (FEM) based on experimental data was developed. The methodology was validated and utilized to reveal the thermal response and the nonlinear deformation behavior of the cylinder segment phase by phase. The conclusions of the research are as follows: The 2D heat flux distribution caused by the injector determines the uneven temperature distribution on the gas-side wall and leads to the temperature disparity between various cooling channels; The reason for the accumulation of residual strain is that the tensile strain generated in the post-cooling phase is greater than the compressive strain produced in the hot run phase; Through the single-cycle simulation, two potential failure locations with conspicuous deformations were found, but it is difficult to determine which point is more dangerous. However, the multi-cycle thermo-structural analysis gives the evolution of the stress-strain curve and gradually discloses that the low-temperature corner of a particular channel is the most likely location to fail, rather than the maximum residual strain point of the gas-side wall. The damage analysis for dangerous point indicates that the quasi-static damage accounts for the majority of the total damage and is the main factor limiting the service life.