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We have constructed a cryogenic wind tunnel facility at our laboratories at Culham, Oxfordshire. This facility has been used to develop a frost control system for the 'air precooler' heat exchanger of the Sabre engine. The Precooler is designed to cool the engine airflow (about 400kg/s) from intake recovered conditions (up to 1000°C at Mach 5) down to about -140°C prior to compression. At low altitudes atmospheric moisture will clog the matrix with frost within a few seconds unless preventive measures are taken.
Heat Exchangers: Frost Control
Wind Tunnel

The wind tunnel has a 150mm2 test section into which heat exchanger modules can be inserted. The wind tunnel draws in 0.3kg/s of air whose temperature and humidity is controlled to simulate actual conditions in flight. The heat exchanger matrix is cooled by cold gaseous nitogen whose thermal capacity matches the helium flow employed in the real engine. Although the test matrix is much smaller than the real precooler, it is built with the correct tube diameter, wall thickness and material. Therefore no 'scaling' problems can arise since it is tested at identical flow mass fluxes and Reynolds numbers to the real engine.

This facility has been in operation from 2001 to develop the frost control system over the full temperature, humidity and pressure range of the engine. This program is now drawing to a close since it has been successfully completed.

Heat Exchangers: Manufacturing

Wind Tunnel Closeup
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