Cooling Methods for Liquid Rocket Engine Nozzles

Abstract

This study presents a review and comparative analysis of design approaches, material selection, and manufacturing technologies for regeneratively cooled liquid rocket engine nozzles. The thermophysical and mechanical properties of AISI 316 stainless steel, Inconel alloy, and CuCrZr copper alloy were analyzed to assess their applicability for different nozzle components. In addition, the strength characteristics of welded joints between similar and dissimilar materials produced by TIG and MIG welding were experimentally evaluated. The results demonstrate that Inconel exhibits the highest suitability for the load-bearing section of the nozzle due to its superior high-temperature strength and structural stability, whereas CuCrZr provides the most effective solution for the inner cooled wall because of its high thermal conductivity and heat removal capability. The study also shows that the use of hybrid material configurations combined with optimization of welding and joining technologies contributes to improved cooling efficiency, enhanced mechanical integrity, and increased operational reliability of liquid rocket engine nozzles. The obtained results may serve as a basis for the development and manufacturing of advanced regeneratively cooled propulsion systems.