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Record-Setting Composite Heat Exchanger Panel Successfully Tested

WEST PALM BEACH, Fla. (Aug. 17, 2004)--- As part of completing activities under NASA’s Next Generation Launch Technology (NGLT) Program, Pratt & Whitney (P&W) Space Propulsion recently tested a composite hydrocarbon fuel-cooled heat-exchanger panel at Mach 6.5. This was the largest lightweight panel to ever be successfully tested in a scramjet environment in the United States.

The NASA Glenn Research Center-led team exposed the 6”x 30” heat exchanger to Mach 6.5 flight conditions during rig testing at United Technologies Research Center located at Hartford, Conn. The exchanger, comprised of a carbon-carbon (C/C) composite “hot face” sheet (supported by a metallic back structure), performed better than predicted and incurred no structural degradation during testing.

“Developing light-weight and durable heat exchangers is a key step in enabling access to space using scramjet propulsion systems,” P&W Space Propulsion Manager of Hypersonics Joaquin Castro said. “This test helped us validate our analytical predictions and design tools.”

Mounted in the scramjet rig’s combustor, the heat exchanger was exposed to hot gases soaring to 4000F, while at the same time being cooled by (conventional JP-7 aviation fuel) propellant flowing through its metallic coolant containment system.

“This novel heat exchanger concept has a provision to easily disassemble and reassemble the hot sheet for possible repair or replacement,” stated Castro. “This unique feature makes the concept robust and especially suited for reusable propulsion systems.”

Additionally, this lightweight heat exchanger system supported by lightweight backstructure, under development at P&W, has the potential of reducing the scramjet engine flowpath weight by more than 35 percent.

“This technology was accelerated from conceptual design through component level demonstration by the close and effective partnership between NASA Glenn and Pratt & Whitney,” said Harry Cikanek, NASA Glenn Research Center Associate Director for Exploration Systems. “Integration of advanced materials with novel heat exchanger designs paves the way for insertion of this technology in future aerospace propulsion systems.”

Last year, P&W in partnership with the U.S. Air Force successfully ground tested the world’s first flight-weight, hydrocarbon-fueled scramjet engine at speeds of Mach 4.5 and Mach 6.5. P&W also is the propulsion provider for the Air Force Scramjet Engine Demonstrator-WaveRider (SED-WR) program that aims to flight-test a hydrocarbon-fueled scramjet powered vehicle in 2008 in partnership with Boeing.

P&W Space Propulsion is a leader in liquid, electric and hypersonic propulsion. P&W's Web site address is www.pw.utc.com.

Pratt & Whitney, a United Technologies (NYSE: UTX) company, is a world leader in the design, manufacture and service of aircraft engines, space propulsion systems and industrial gas turbines.

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