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An ultra-lean-burn preburner has been developed by KARI. This paper describes the general structural design, the results of the finite element analyses (FEA) and the experimental results related to structural issues during the development. Before the fabrication, two burst experiments with the specimens simulating the brazing joints were performed and compared with the FEA results, which increases the reliability of the analyses and the design. Also, 2D FEA of the combustion chamber cooling channel were performed for the first combustion region upstream of the liquid oxygen (LOX) hole and the second region downstream of the hole, where the hottest spot locates downstream of the region between the adjacent LOX holes. Various structural modifications were analyzed by 3D FEA and a screen structure was introduced to reduce the stress over highly stressed regions. During the development, some proof and leakage tests were performed for the head, the chamber with and without flange, and the preburner assembly, of which the burst test was performed. Several firing tests of the assembly were performed to show the operation without any structural failure.

Survey on the hypergolic igniter and its rupture discs for liquid rocket engines was performed. The patents of the igniters for US MC-1 and Russia RD-170 engines and the discs for NASA`s space vehicle were analyzed. The types of discs and holders, characteristics related to rupture pressures and working fluids, and ASME standards of the discs were examined. Also, survey on structural analyses of the disc were performed. Typical design features and experimental results of the currently developing igniter by the authors were presented.

A series of computational analyses was performed to predict the cooling process by the cooling channel of preburners used for kerosene-liquid oxygen staged combustion cycle rocket engines. As an oxygen-rich combustion occurs in the kerosene fueled preburner, it is of great importance to control the wall temperature so that it does not exceed the critical temperature. However, since the heat transfer is proportional to the speed of fluid running inside the channel, the high heat transfer leads to a trade-off of pressure loss. For this reason, it is necessary to establish a certain criteria between the pressure loss and the heat transfer or the wall surface temperature. The design factors of the cooling channel were determined by the computational research, and a test model was manufactured. The test model was used for the hot fire tests to prove the function of the cooling mechanism, among other purposes.

Thermal and structural finite element analyses were performed for the turbopump turbine bladed disk model with shroud of a liquid rocket engine. The only 1/80 part model was analyzed which consists of 3D eight node isoparametric solid elements. The applied loading history consists of a startup condition with a thermal spike and a steady state. Heat transfer coefficient on the blade was predicted using the commercial Navier-Stokes solver, Fluent. Transient thermal responses during startup and steady states were calculated using a 3D finite element code developed. Maximum stress and shroud tip displacement under the influence of centrifugal and thermal loading were also determined.