Calculation of Turbine Axial Thrust by Coupled CFD Simulations of the Main Flow Path and Secondary Cavity Flow in an SLI LOX Turbine

Each single reusable Space Launch Initiative (SLI) booster rocket is an engine operating at a record vacuum thrust level of over 730,000 Ibf using LOX and LH2. This thrust is more than 10% greater than that of the Delta IV rocket, resulting in relatively large LOX and LH2 turbopumps. Since the SLI rocket employs a staged combustion cycle the level of pressure is very high (thousands of psia). This high pressure creates many engineering challenges, including the balancing of axial-forces on the turbopumps. One of the main parameters in the calculation of the axial force is the cavity pressure upstream of the turbine disk. The flow in this cavity is very complex. The lack of understanding of this flow environment hinders the accurate prediction of axial thrust. In order to narrow down the uncertainty band around the actual turbine axial force, a coupled, unsteady computational methodology has been developed to simulate the interaction between the turbine main flow path and the cavity flow. The CORSAIR solver, an unsteady three- dimensional Navier-Stokes code for turbomachinery applications, was used to solve for both the main and the secondary flow fields. Turbine axial thrust values are presented in conjunction with the CFD simulation, together with several considerations regarding the turbine instrumentation for axial thrust estimations during test.