Advancing rocket science at DLR Lampoldshausen

At the German Aerospace center’s institute of space propulsion, PhDs do hands-on work and computer modelling on rocket engines.

Clara Morris has always been fascinated by science. While studying physics and aerospace engineering in Sydney, she joined the rocketry team. In 2019, her team won its category in the Spaceport America Cup, an intercollegiate rocket engineering competition. "That was a pretty big deal," Clara Morris says, "because it was the first time a team from Australia had ever participated in the competition."

Winning was just part of the journey that brought her to the German Aerospace Center's (DLR) Institute of Space Propulsion in the small town of Lampoldshausen, Baden-Württemberg. "I always thought the space part of aerospace was cool," she recalls. But rather than space travel for tourist or commercial reasons, she is drawn to research.

Working on real-world challenges in space science

Clara Morris, who is originally from New Zealand and studied in Sydney, Australia, did her honors thesis with DLR Lampoldshausen, a highly regarded and unique site for aerospace research. But because of Covid, she was unable to travel to Germany. Nevertheless, her work on combustion chamber simulations seemed to have impressed the scientists at the DLR institute in Southern Germany. They offered her a Ph.D. position. "That was when I saw the real Lampoldshausen," she says.

The institute is tucked away in the forest, far from the nearest town. For good reason: The DLR Institute of Space Propulsion has some of the largest rocket test benches in the world, and every major European rocket engine of the past few decades has been tested here at some point, including the Ariane 6 engines. Doing so in a sparsely populated area makes sense. Rocket testing is not a quiet business.

One of the major research projects in Lampoldshausen is the  Liquid Upper Stage Demonstrator Engine (LUMEN), which aims to realize a 25 kilonewton thrust engine from the component to the system level. The engine successfully passed its first hot fire test recently, which represents a major achievement in the field of space research.

For her Ph.D., Clara Morris is focusing on heat transfer simulations for the combustion chamber and the cooling channels of the LUMEN engine, which uses liquid oxygen and methane. While this may sound dry, heat transfer and cooling are real challenges for rocket engines in general. "It's very difficult to get accurate simulations of heat transfer," she says. "It's a tough nut to crack, and that's another factor that draws me to the project."

She's working on what's called a "breadboard engine" in space exploration parlance. Breadboard engines are modular, so each component can be tested with, say, a different turbo pump or cooling channels with different parameters. "It's very exciting because there are only a few breadboard engines in the world."

International researchers and network of experts and suppliers

Clara Morris is one of many international PhD students at DLR Lampoldshausen. Prof. Jan Deeken, Head of the Rocket Engine System Department at DLR Institute of Space Propulsion in Lampoldshausen, explains the appeal of the institute: "What's really fascinating about our work here at DLR is that it's real hands-on work on rocket engines. You don't find that in many places in the world. And for us, rocket engines are basically the coolest machines on earth.“

Prof. Jan Deeken also explains that DLR Lampoldshausen has managed to maintain a start-up culture over the years. "We are able to follow ideas from the very beginning to the point where we can apply them to a real flight engine. And that's unique in Europe.“

For Tobias Traudt, project leader of LUMEN, the knowledge and background of the international team is invaluable. Researchers from Australia, Japan, Korea, France, Bulgaria, and many other places around the world are working here. "There is so much expertise in so many different fields at the institute that you can get expert advice on almost any challenge." In addition to experienced scientists, there are interns and students working on their bachelor's or master's theses from the nearby University of Stuttgart, Ph.D. students from all over the world, and postdoctoral fellows deepening their research.

In addition, technicians from nearby towns who speak the German Swabian dialect work at the site and provide a glimpse of the local culture. The institute is part of a dense network of excellent infrastructure, a broad knowledge base, suppliers, universities, and research institutes. "This kind of network is crucial for the development of cutting-edge technology," says Prof. Jan Deeken.

Clara Morris clearly appreciates the unique environment in which she works. When asked what she would recommend to other internationals coming to work at DLR Lampoldshausen, she replies: "Take advantage of the many networking opportunities". She has found a group of people at DLR Lampoldshausen that she meets for lunch and social activities. She has also met Ph.D. students from other DLR sites. "It's so interesting to see what other people are working on, from implementing hydrogen cells in aircraft to wind turbines and transportation solutions for the future," she says. "It's always interesting and you can always learn something new."

Tip for international researchers: Are you looking for an excellent research position in the German Southwest? Check out our academic job engine.

Author: Siri Schubert