Identifying the optimal design of a new launch vehicle is most important because design decisions made in the early development phase limit the later performance of the vehicles and determine the a...

Accurate calculations of the heat transfer and the resulting maximum wall temperature are essential for the optimal design of reliable and efficient regenerative cooling systems. However, predicting the heat transfer of supercritical methane flowing in cooling channels of a regeneratively cooled rocket combustor presents a significant challenge. High-fidelity CFD calculations provide sufficient accuracy but are computationally too expensive to be used within elaborate design optimization routines. In a previous work it has been shown that a surrogate model based on neural networks is able to predict the maximum wall temperature along straight cooling channels with convincing precision when trained with data from CFD simulations for simple cooling channel segments. In this paper, the methodology is extended to cooling channels with curvature. The predictions of the extended model are tested against CFD simulations with different boundary conditions for the representative LUMEN combustor contour with varying geometries and heat flux densities. The high accuracy of the extended model’s predictions, suggests that it will be a valuable tool for designing and analyzing regenerative cooling systems with greater efficiency and effectiveness.

Traditional experimental design methods often face challenges in handling complex aerospace systems due to the high dimensionality and nonlinear behavior of such systems, resulting in nonoptimal experimental designs. To address these challenges, machine learning techniques can be used to further increase the application areas of modern Bayesian Optimal Experimental Design (BOED) approaches, enhancing their efficiency and accuracy. The proposed method leverages neural networks as surrogate models to approximate the underlying physical processes, thereby reducing computational costs and allowing for full differentiability. Additionally, the use of reinforcement learning enables the optimization of sequential designs and essential real-time capability. Our framework is validated by optimizing experimental designs that are used for the efficient characterization of turbopumps for liquid propellant rocket engines. The reinforcement learning approach yields superior results in terms of the expected information gain related to a sequence of 15 experiments, exhibiting mean performance increases of 9.07% compared to random designs and 6.47% compared to state-of-the-art approaches. Therefore, the results demonstrate significant improvements in experimental efficiency and accuracy compared to conventional methods. This work provides a robust framework for the application of advanced BOED methods in aerospace testing, with implications for broader engineering applications.