Mech eng fans will be interested in this great article on high altitude
engines, which have potential for application to the heavy, high altitude
lift needed for SRM.

Please view online to access rich media.

http://www.bbc.co.uk/news/science-environment-17864782

A

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Key tests for Skylonspaceplane project

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The pre-cooler demonstration is a major step in proving the Skylon concept

UK engineers have begun critical tests on a new engine technology designed
to lift a spaceplane into orbit.

The proposed Skylon vehicle would operate like an airliner, taking off and
landing at a conventional runway.

Its major innovation is the Sabre engine, which can breathe air like a jet
at lower speeds but switch to a rocket mode in the high atmosphere.

Reaction Engines Limited (REL) believes the test campaign will prove the
readiness of Sabre's key elements.

This being so, the firm would then approach investors to raise the £250m
needed to take the project into the final design phase.

"We intend to go to the Farnborough International Air Show in July with a
clear message," explained REL managing director Alan Bond.

"The message is that Britain has the next step beyond the jet engine; that
we can reduce the world to four hours - the maximum time it would take to
go anywhere. And that it also gives us aircraft that can go into space,
replacing all the expendable rockets we use today."

To have a chance of delivering this message, REL's engineers will need a
flawless performance in the experiments now being run on a rig at their
headquarters in Culham, Oxfordshire.

The test stand will not validate the full Sabre propulsion system, but
simply its enabling technology - a special type of pre-cooler heat
exchanger.

Sabre is part jet engine, part rocket engine. It burns hydrogen and oxygen
to provide thrust - but in the lower atmosphere this oxygen is taken from
the atmosphere.

The approach should save weight and allow Skylon to go straight to orbit
without the need for the multiple propellant stages seen in today's
throw-away rockets.

But it is a challenging prospect. At high speeds, the Sabre engines must
cope with 1,000-degree gases entering their intakes. These need to be
cooled prior to being compressed and burnt with the hydrogen.

Reaction Engines' breakthrough is a module containing arrays of extremely
fine piping that can extract the heat and plunge the intake gases to minus
140C in just 1/100th of a second.

Ordinarily, the moisture in the air would be expected to freeze out
rapidly, covering the pre-cooler's pipes in a blanket of frost and
compromising their operation.

But the REL team has also devised a means to stop this happening,
permitting Sabre to run in jet mode for as long as is needed before making
the transition to a booster rocket.

Sabre engine: How the test will work

Groundbreaking pre-cooler

1. Pre-cooler During flight air enters the pre-cooler. In 1/100th of a
second a network of fine piping inside the pre-cooler drops the air's
temperature by well over 100C. Very cold helium in the piping makes this
possible.

On the test rig, a pre-cooler module of the size that would eventually go
into a Sabre has been placed in front of a Viper jet engine.

The purpose of the 1960s-vintage power unit is simply to suck air through
the module and demonstrate the function of the heat exchanger and its
anti-frost mechanism.

Helium is pumped at high pressure through the module's nickel-alloy piping.

The helium enters the system at about minus 170C. The ambient air drawn
over the pipes by the action of the jet should as a consequence dip rapidly
to around minus 140C.

Sensors will determine that this is indeed the case.

The helium, which by then will have risen to about minus 15C, is pushed
through a liquid nitrogen "boiler" to bring it back down to its run
temperature, before looping back into the pre-cooler.

"It is important to state that the geometry of the pre-cooler is not a
model. That is a piece of real Sabre engine," said Mr Bond.

"We don't have to go away and develop the real thing when we've done these
tests; this is the real article."

The manufacturing process for the pre-cooler technology is already proven,
but investors will be looking to see that the module has a stable operation
and can meet the promised performance.

The BBC was given exclusive access to film the rig in action.

Because REL is working on a busy science park, it has to meet certain
environmental standards.

This means the Viper's exhaust goes into a silencer where the noise is
damped by means of water spray.

The exhaust gases are at several hundred degrees, and so the water is
instantly vaporised, producing huge clouds of steam.

Anyone standing outside during a run gets very wet because the vapour rains
straight back down to the ground.

Future direction

The REL project has generated a lot of excitement. One reason for that is
the independent technical audit completed last year.

The UK Space Agency engaged propulsion experts at the European Space Agency
(Esa) to run the rule over the company's engine design.

Esa's team, which spent several months at Culham, found no obvious
showstoppers.

"Engineering is never simple. There are always things in the future that
need to be resolved - problems crop up and you have to solve them," said Dr
Mark Ford, Esa's head of propulsion engineering.

"The issue is, 'do we see anything fundamental from stopping this engine
from being developed?', and the answer is 'no' at this stage.

"The main recommendation we made is that we would like next to see a
sub-scale engine - so, a smaller version than the final engine - being
tested.

"So far we've looked at critical component technologies. The next step is
to put those technologies together, build an engine and see it working.

"We want a demonstration of the thermodynamic cycle. We'd also like to see
the engine operating in air-breathing and rocket mode, and the transition
between the two."

This sub-scale engine is one of the activities proposed for the next phase
of the project.

Also included is a series of flight test vehicles that would demonstrate
the configuration of the engine nacelles - the air intakes.

Additionally, updated design drawings would be produced for the Sabre
engine and the Skylon vehicle.

So far, 85% of the funding for Reaction Engines' endeavours has come from
private investors, but the company may need some specific government
support if it is to raise all of the £250m needed to initiate every
next-phase activity.

"What we have learned is that a little bit of government money goes a long
way," said Mr Bond.

"It gives people confidence that what we're doing is meaningful and real -
that it's not science fiction. So, government money is a very powerful tool
to lever private investment."

This public seed fund approach to space has certainly found favour recently
within government.

Ministers put more than £40m into developing the communications payload for
the first satellite operated by the Avanti broadband company, and they are
giving more than £20m to SSTL to make a prototype radar satellite.

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