RLV thrust cell liner coating analysis and design considerations

This study addresses the relative impact of cooling channel wall and protective thermal coating thickness on the deformation fields of reusable launch vehicle (RLV) thrust cell liners under in-service loading conditions. The ultimate objective is to identify an optimum liner and coating design that produces stress and deformation fields leading to improved life/durability. A reference case based on the work of previous studies is introduced and subsequent changes in geometry and materials are investigated. Analyses are accomplished through the application of the cylindrical version of the higher-order theory for functionally graded materials/structural components. This theory provides a unique analytical tool for the design of advanced aircraft engine structural components with active cooling channels based on the concept of functionally graded material architectures through which improved deformation and life can be attained. The sensitivity of the cooling channel wall deformation to changes in the wall thickness is demonstrated which is commensurate with the observed failure mode. Most importantly, the presence of a NiCrAlY thermal barrier coating is shown to substantially reduce the cooling channel wall distortion.