STE thrust chamber technology: Main injector technology program and nozzle Advanced Development Program (ADP)
The purpose of the STME Main Injector Program was to enhance the technology base for the large-scale main injector-combustor system of oxygen-hydrogen booster engines in the areas of combustion efficiency, chamber heating rates, and combustion stability. The initial task of the Main Injector Program, focused on analysis and theoretical predictions using existing models, was complemented by the design, fabrication, and test at MSFC of a subscale calorimetric, 40,000-pound thrust class, axisymmetric thrust chamber operating at approximately 2,250 psi and a 7:1 expansion ratio. Test results were used to further define combustion stability bounds, combustion efficiency, and heating rates using a large injector scale similar to the Pratt & Whitney (P&W) STME main injector design configuration including the tangential entry swirl coaxial injection elements. The subscale combustion data was used to verify and refine analytical modeling simulation and extend the database range to guide the design of the large-scale system main injector. The subscale injector design incorporated fuel and oxidizer flow area control features which could be varied; this allowed testing of several design points so that the STME conditions could be bracketed. The subscale injector design also incorporated high-reliability and low-cost fabrication techniques such as a one-piece electrical discharged machined (EDMed) interpropellant plate. Both subscale and large-scale injectors incorporated outer row injector elements with scarfed tip features to allow evaluation of reduced heating rates to the combustion chamber.