The strange story of the Demon UAV and fluidic thrust vectoring.
Or: How to fly a plane with no control surfaces at all...
Many years ago in the University of Manchester I came across a project called FLAVIIR. I wasn't personally involved, but I was interested: It's primary focus was fluidic flight control: Flight control with no flaps and no mechanical thrust vectoring.
Simple. Stealthy. Elegant.
The FLAVIIR project was a 6 year project between BAE Systems, Cranfield University and my alma mater, Manchester University. It featured a grab bag of blue sky technologies that would be developed into a flight ready UAV.
The most notable were fluidic flapless flight controls.
The fluidic controls were twofold: Coanda effect blown flaps to replace mechanically actuated flaps and ailerons in roll, and fluidic thrust vectoring to replace elevators/ mechanical thrust vectoring in pitch, and rudders in yaw.
So why fluidic thrust vectoring? Why not a conventional mechanical system?
Mechanical thrust vector systems are complex, heavy (to 20%-30% of engine weight), have expensive high temp components and a short life. They can also be quite inefficient, with up to 10% thrust loss.
What is fluidic thrust vectoring?
By injecting mixing flow adjacent to a jet exhaust plume, the direction of the exhaust can be induced to change without mechanical intervention. There are many ways to do this: Co-flow injection, shock impingement and counter flow injection.
Efficiency of operation is high: Co flow injection can produce sizeable control inputs with as little as 1% of injected flow.
There has even been a study on passive fluidic thrust vectoring, entraining aircraft boundary layer air without active injection: More efficient still.
But FLAVIIR used Co flow injection.
New technologies were trialled and matured into increasingly integrated and sophisticated platforms, starting with small electric motor craft & wind tunnel testing, and building to turbojet scale prototypes.
The goal: An integrated demonstrator UAV bringing together all the advanced concepts under development.
The Demon.
Demon flew in 2009 & 2010, and was the first aircraft to fly without the use of flaps or geometry shape changes.
BAE Systems is a massive defence contractor, so you'd expect something to come of this, but there was radio silence until 2019, when the Magma UAV flew: A development of the technologies pioneered in the Demon, with efficient supersonic nozzle fluidic vectoring.
Here's a Magma video: Flaps are only used for takeoff and landing.
What's to follow this? Who knows. The technology is promising, particularly for high reliability stealthy drones or high altitude applications. Keep your eyes open.
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It's the greatest story never told: It's the story of how a frugal county in the North of England invented the modern world.
Put on a flat cap and call up the whippet, because this is a thread about my home county, and the inventions that came out of Yorkshire!
Steel!
Benjamin Huntsman invented high homogeneity crucible steel in Sheffield in the 1740s, firing with coke to fully melt the steel and homogenise the carbon content.
This became used… everywhere, and supercharged the ongoing industrial revolution.
Steam trains.
Steam locomotion had been in development for some decades by 1812, but arguably the world's first commercially successful steam locomotive was Matthew Murray's Salamanca. To him, we owe speed.
A liquid rocket boost stage needs to pump fuel and cryogenic oxidiser to the combustion chamber at a rate that beggars belief: The 33 engines on the boost stage of SpaceX's monstrous ‘Superheavy’ booster each chew through about 700 kg of propellant every second. Put all those engines together and the flow rate of liquid fuel & oxygen would be sufficient to empty an Olympic swimming pool in under 2 minutes, if you could find an Olympic swimming pool for cryogenic propellant.
Can you think of any conventional lightweight pump that can do this? Me neither. You need something special…
The turbopump comprises a typically-axial turbine powered by hot, pressurised gas flow that powers centrifugal compressor pumps that pump the colossal quantities of propellant required and pressurize it to, potentially, hundreds of standard atmospheres.
It's a handy, lightweight way to provide pumping power, but it does require that you have a source of hot, high-pressure gas to work with.
Now, where would you find that in a rocket engine?
Indeed. In order to burn fuel, we must pump it. In order to pump it, we may have to burn some of it.
Um…
The Gas Generator Cycle.
A small quantity of the pressurised fuel & oxidiser flows are tapped, brought to a small combustor, vaporised, ignited then expanded through a turbine that powers the fuel and oxygen compressor cycles.
Inevitably the gas generator can't run with a completely nominal fuel:oxy mix, as it would get so hot that it would melt the turbine blades, so typically a gas generator will trade off some efficiency and run fuel rich to power the turbopumps.
-Why not oxy rich? Because fuel has a higher specific heat at constant pressure (Cp) and so you need less mass flow through the gas generator if it's fuel rich than oxy rich, meaning more useful propellant goes to the main combustor & nozzle that moves the rocket.
So the upside of a gas generator cycle is relative simplicity and robustness, which is why it's used on the most reliable rocket motors around, the SpaceX Merlin. The downside is that you trade away efficiency by throwing away some of your propellant, meaning that the tyranny of the Tsiolkowsky rocket equation will kick you where the sun don't shine.
Staged combustion attempts to address this, by taking either a fuel rich or oxy rich preburner, operating at a much higher flow volume than a standard gas generator, and routing the hot gases that leave the turbine straight to the combustion chamber so that they're not lost. This not only increases the average propellant exhaust velocity (since none of it is lost) and therefore efficiency, but also allows a lower average temperature in the preburner and turbine, since there's a higher volume throughput instead.
On the flipside you must deal with hugely increased engineering complexity, an increased potential for feedback control problems between the different parts of the engine, and also a much higher pressure preburner, since it will still need to deliver high working pressures to the combustion chamber after the losses of the turbine and injectors.
The Soviets got there first, and some of their genius manifested in the Russian RD180 oxy-rich staged combustion engine, which was bought by the Americans and used in Atlas rockets for many years. Its unique oxy-rich staged combustion cycle was efficient but not without drawbacks, as high temperature gaseous oxygen is brutal to exposed metal surfaces, demanding an enamel coating on many parts of the engine.
Last month Rolls-Royce won the UK's small modular reactor competition to develop and build SMRs in the UK. It could be a new dawn for nuclear power.
But who else was in the competition, what was special about each design, and which is your favourite?
An SMR thread…
What's an SMR?
A small modular reactor is a way of beating the brutally high capital costs of building nuclear power: By simplifying assembly (modularity) and minimising subsystem size so almost all of it is factory built you harvest industrial learner effects and low costs.
Boiling water vs pressurised water reactors.
All designs in this list are either PWRs or BWRs, the most common reactor styles today. I've a thread on the basics if you need it, but otherwise on with the show!
In April on a mountain in Chile the Vera Rubin observatory gathered first light, and this telescope will be world-changing! -Not because it can see the furthest… but because it can see the fastest!
The Vera Rubin telescope thread! The value of speed, and unique technology…
Who was Vera Rubin?
She first hypothesized the existence of dark matter, by observing that the rotation speed of the edge of the galaxy did not drop off with radius from the centre as much as it should. The search for dark matter, and other things, will drive this telescope…
Does it see a long way?
Yes, but it’s not optimized for that: The battle of the big mirrors is won by the Extremely Large Telescope which, yes, is meant to see a long way. Vera Rubin is not that big, but that doesn’t matter because it has a different and maybe better mission.
Rotating detonation engines: Riding the shockwave!
A technology that could revolutionise aviation, powering engines with endlessly rotating supersonic shockwaves. It could bring us hypersonic flight, super high efficiency and more.
The detonation engine thread…
Almost all jet engines use deflagration based combustion, not detonation, but while fuel efficiency has been improving for decades, we're well into the phase of decreasing returns and need some game-changing technologies.
One is the rotating detonation engine (RDE).
To understand the appeal of RDEs, you need to know that there are two forms of combustion cycle: Constant pressure, where volume expands with temperature, and constant volume, where pressure goes up instead.
Most jet engines use constant pressure. RDEs use constant volume.
As a new graduate I once had to sit down and draft an engine test program for a subsystem of a new model of Rolls-Royce aero engine. It was illuminating.
So here's a thread on some of the weirder things that this can involve: The jet engine testing thread!
Fan Blade Off!
Easily the most impressive test: A jet engine needs to be able to contain a loose fan blade. In the FBO test, either a full engine or a fan & casing rig in low vacuum is run to full speed, then a blade is pyrotechnically released.
Frozen.
The Manitoba GLACIER site in Northern Canada is home to Rolls-Royce's extreme temperature engine test beds. Not only must these machines be able to start in temperatures where oil turns to syrup, but in-flight ice management is crucial to safe flying.