{"id":4925,"date":"2026-07-20T13:10:43","date_gmt":"2026-07-20T11:10:43","guid":{"rendered":"https:\/\/simuneer.de\/uncategorized\/masten-space-systems-reactive-flow-and-heat-transfer-optimisation-for-reusable-spacecraft\/"},"modified":"2026-07-20T13:20:26","modified_gmt":"2026-07-20T11:20:26","slug":"masten-space-systems-reactive-flow-and-heat-transfer-optimisation-for-reusable-spacecraft","status":"publish","type":"post","link":"https:\/\/simuneer.de\/en\/case-studies\/masten-space-systems-reactive-flow-and-heat-transfer-optimisation-for-reusable-spacecraft\/","title":{"rendered":"Masten Space Systems: Reactive flow and heat transfer optimisation for reusable spacecraft"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\">Masten Space Systems is a private company founded in 2004 and headquartered in Mojave, California, USA, by David Masten. Masten\u2019s focus on reusable rocket technology is driven by the goal of enabling space transportation and reliable planetary landers for the Earth, Moon, Mars, and beyond. <\/p>\n\n<p class=\"wp-block-paragraph\">One of Masten\u2019s recent pioneering space flight vehicle projects was to design a reusable aircraft designed to fly to the edge of space, the XS-1. The XS-1 aircraft will be capable of launching a 3,000-pound spacecraft to the earth\u2019s orbit at a cost of $5M, which is ten times less than today\u2019s launch systems. A key objective of the program is to fly the XS-1 10 times in 10 days in order to demonstrate its \u201caircraft-like\u201d operability, cost efficiency and reliability. Key anticipated characteristics of the aircraft include a physical size and dry weight typical of today\u2019s business jets.  <\/p>\n\n<p class=\"wp-block-paragraph\">One of the new innovations in this effort is a full-scale additively manufactured aluminum thrust chamber assembly for the 25,000 lbf LOX\/LCH4 dual expander propulsion system. The dual expander cycle offers an ideal cycle in this size range, enabling reusability, optimal closed-loop performance, and cost effective design and production price points. <\/p>\n\n<h2 class=\"wp-block-heading\">CFD for the simulation, analysis and optimisation of critical spacecraft components<\/h2>\n\n<p class=\"wp-block-paragraph\">Masten Space Systems is using<strong> Fidelity Flow Solver with OpenLabs<\/strong>, Cadence\u2019s unstructured multi-purpose CFD solver package, for the design and analysis of various elements of reusable spacecraft and lunar vehicles for the testing of thrust chambers. In this article we talk about the numerical studies of three of their aeronautical configurations. <\/p>\n\n<h2 class=\"wp-block-heading\">Simulation of plume impingement and thermal load<\/h2>\n\n<p class=\"wp-block-paragraph\">For the testing of thrust chambers, Masten Space Systems had to determine the temperature on the impingement plate in order to avoid reaching critically high temperatures. To do this, they simulated the impact of a hot plume at multiple times the speed of sound and a temperature hotter than the melting temperature of steel on a plate by using an inert multi-species approach. The results are shown in Figure 1, comparing the live fire test of the plume impingement in the photograph with the predicted temperature simulated by CFD. There is a clear qualitative agreement between the two.   <\/p>\n\n<figure class=\"wp-block-image size-full\"><img fetchpriority=\"high\" decoding=\"async\" width=\"926\" height=\"459\" src=\"https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-1-Plume_impingement_test_Comparison_of_a_photograph_and_the_simulated_static_temperature-Kopie.webp\" alt=\"Plume impingement test. Comparison of a photograph and the simulated static temperature \" class=\"wp-image-4912\" srcset=\"https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-1-Plume_impingement_test_Comparison_of_a_photograph_and_the_simulated_static_temperature-Kopie.webp 926w, https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-1-Plume_impingement_test_Comparison_of_a_photograph_and_the_simulated_static_temperature-Kopie-300x149.webp 300w, https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-1-Plume_impingement_test_Comparison_of_a_photograph_and_the_simulated_static_temperature-Kopie-768x381.webp 768w\" sizes=\"(max-width: 926px) 100vw, 926px\" \/><figcaption class=\"wp-element-caption\">Figure 1: Plume impingement test. Comparison of a photograph and the simulated static temperature <\/figcaption><\/figure>\n\n<h2 class=\"wp-block-heading\">Injector study<\/h2>\n\n<p class=\"wp-block-paragraph\">For the optimisation of spacecraft it is important to clearly understand the conditions of the injectors, combustion chamber and nozzle of the rocket engine. One of the critical points for example is that the walls cannot be subject to excessive thermal stress. <\/p>\n\n<p class=\"wp-block-paragraph\">To analyse the combustion process and heat transfer in a generic injector configuration, a CFD study was carried out using a reactive multi-species simulation approach with a reduced chemical mechanism.<\/p>\n\n<p class=\"wp-block-paragraph\">Figure 2 beside shows the injector geometry, consisting of two concentric pipes connected to a rectangular chamber. Via the inner tube Gaseous Oxygen (<strong>GOX<\/strong>) is injected, whereas Gaseous Methane (<strong>GCH4<\/strong>) is injected around it via the outer pipe. The purpose of the chamber is to create a recirculation zone, preventing the flame from blowing out. The recirculation of hot combustion products ensures a stable continuous combustion process after the engine is fired.   <\/p>\n\n<figure class=\"wp-block-image size-full\"><img decoding=\"async\" width=\"978\" height=\"603\" src=\"https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-2-Kopie-1.webp\" alt=\"Injector geometry\" class=\"wp-image-4913\" srcset=\"https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-2-Kopie-1.webp 978w, https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-2-Kopie-1-300x185.webp 300w, https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-2-Kopie-1-768x474.webp 768w\" sizes=\"(max-width: 978px) 100vw, 978px\" \/><figcaption class=\"wp-element-caption\">Figure 2: Injector geometry<\/figcaption><\/figure>\n\n<p class=\"wp-block-paragraph\">Two grids were generated: one coarse mesh at 1.8 million cells and one refined mesh containing 2.4 million cells with cylindrical viscous layers as shown in Figure 3.<\/p>\n\n<figure class=\"wp-block-image size-full\"><img decoding=\"async\" width=\"981\" height=\"518\" src=\"https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-3-Kopie-1.webp\" alt=\"Injector computational grid &#x2013; quarter domain, 2.4 million cells\" class=\"wp-image-4914\" srcset=\"https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-3-Kopie-1.webp 981w, https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-3-Kopie-1-300x158.webp 300w, https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-3-Kopie-1-768x406.webp 768w\" sizes=\"(max-width: 981px) 100vw, 981px\" \/><figcaption class=\"wp-element-caption\">Figure 3: Injector computational grid \u2013 quarter domain, 2.4 million cells<\/figcaption><\/figure>\n\n<p class=\"wp-block-paragraph\">The simulation results were in good agreement with the measurement data. Figure 4 shows the simulated temperature field and a comparison between the simulated and experimental values of the static pressure and heat flux. <\/p>\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"996\" height=\"772\" src=\"https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-4-Kopie-1.webp\" alt=\"Predicted Injector flame temperatures, comparison of predicted static pressure and heat flux with experiment\" class=\"wp-image-4915\" srcset=\"https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-4-Kopie-1.webp 996w, https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-4-Kopie-1-300x233.webp 300w, https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-4-Kopie-1-768x595.webp 768w\" sizes=\"(max-width: 996px) 100vw, 996px\" \/><figcaption class=\"wp-element-caption\">Figure 4: Predicted Injector flame temperatures, comparison of predicted static pressure and heat flux with experiment<\/figcaption><\/figure>\n\n<h2 class=\"wp-block-heading\">Optimisation of the cooling channel of the combustion chamber and nozzle of a rocket engine<\/h2>\n\n<p class=\"wp-block-paragraph\">To evaluate the potential of optimising the cooling channel, a generic test model was constructed with 180 cooling channels. In the baseline design, the cooling channel has an Aspect Ratio (AT) of 4. <\/p>\n\n<p class=\"wp-block-paragraph\">Figure 5 displays their total pressure, heat flux and <strong>Thermal Barrier Coating (TBC)<\/strong> ,temperature predictions.<\/p>\n\n<figure class=\"wp-block-image size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"998\" height=\"890\" src=\"https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-5-Kopie-1.webp\" alt=\"Three sample channel geometries displaying higher cooling performance with lower pressure drop, ID 0 represents database baseline, and reference represents a reference design that would arise from conventional design practice \" class=\"wp-image-4916\" srcset=\"https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-5-Kopie-1.webp 998w, https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-5-Kopie-1-300x268.webp 300w, https:\/\/simuneer.de\/wp-content\/uploads\/2026\/07\/Figure-5-Kopie-1-768x685.webp 768w\" sizes=\"(max-width: 998px) 100vw, 998px\" \/><figcaption class=\"wp-element-caption\">Figure 5: Three sample channel geometries displaying higher cooling performance with lower pressure drop, ID 0 represents database baseline, and reference represents a reference design that would arise from conventional design practice <\/figcaption><\/figure>\n\n<p class=\"wp-block-paragraph\">These three designs all included contractions of the CH4 channel in the vicinity of the nozzle throat and then an opening up of the passage down stream. On one hand this structure appeared to accelerate the channel flow in the throat region, resulting in higher heat flux, and therefore greater cooling in that area, and maintain attached flow downstream. On the other hand, the opening up of the channel downstream appeared to reduce total pressure losses compared to the reference design.  <\/p>\n\n<p class=\"wp-block-paragraph\">The uniform aspect ratio baseline (ID 0) produced the lowest total pressure loss by not accelerating the channel flow anywhere, but it subsequently demonstrated the lowest cooling performance. In the search for an optimised design, <strong>Self Organising Maps (SOM)<\/strong> were used to cluster the different samples in a space, such that highdimension space data can be visualised in 2D maps and identify the design that leads to the best compromise between cooling efficiency and pressure drop in the cooling channels.   <\/p>\n\n<p class=\"wp-block-paragraph\">By using SOMs the design IDs 184, 227, and 258 were singled out as the ones having the most promising characteristics.<\/p>\n\n<h2 class=\"wp-block-heading\">Authors<\/h2>\n\n<p class=\"wp-block-paragraph\">Allan Grosvenor, Aerodynamics Lead, Masten Space Systems, USA<br\/>Jean-Charles Bonaccorsi, Technical Director, Cadence Design Systems<br\/>Jan Anker, Head of Combustion Modeling Group, Cadence Design Systems<\/p>\n\n<p class=\"wp-block-paragraph\"><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Masten Space Systems is using Fidelity Flow Solver, Cadence\u2019s unstructured multi-purpose CFD solver package \u2013 for the design and analysis of various elements of reusable spacecraft and lunar vehicles.<\/p>\n","protected":false},"author":9,"featured_media":4924,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[68,67],"tags":[],"class_list":["post-4925","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-aerospace","category-case-studies"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.0 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Masten Space Systems: Reactive flow and heat transfer optimisation for reusable spacecraft | Simuneer<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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