LE-7

The LE-7 and its succeeding upgrade model the LE-7A are staged combustion cycle

Staged combustion cycle (rocket)

The staged combustion cycle, also called topping cycle or pre-burner cycle, is a thermodynamic cycle of bipropellant rocket engines. Some of the propellant is burned in a pre-burner and the resulting hot gas is used to power the engine's turbines and pumps...

LH2/LOX

Lox

Lox is salmon fillet that has been cured. In its most popular form, it is thinly sliced—less than in thickness—and, typically, served on a bagel, often with cream cheese, onion, tomato, cucumber and capers...

liquid rocket engines

Liquid rocket

A liquid-propellant rocket or a liquid rocket is a rocket engine that uses propellants in liquid form. Liquids are desirable because their reasonably high density allows the volume of the propellant tanks to be relatively low, and it is possible to use lightweight pumps to pump the propellant from...

produced in Japan

Japan

Japan is an island nation in East Asia. Located in the Pacific Ocean, it lies to the east of the Sea of Japan, China, North Korea, South Korea and Russia, stretching from the Sea of Okhotsk in the north to the East China Sea and Taiwan in the south...

for the H-II

H-II

The H-II rocket was a Japanese satellite launch system, which flew seven times between 1994 and 1999, with five successes. It was developed by NASDA in order to give Japan a capability to launch larger satellites in the 1990s. It was the first two-stage liquid-fuelled rocket Japan made using only...

series of launch vehicles. Design and production work was all done domestically in Japan, the first major (main/first-stage

Multistage rocket

A multistage rocket is a rocket that usestwo or more stages, each of which contains its own engines and propellant. A tandem or serial stage is mounted on top of another stage; a parallel stage is attached alongside another stage. The result is effectively two or more rockets stacked on top of or...

) liquid rocket engine with that claim, in a collaborative effort from the National Space Development Agency (NASDA), Aerospace Engineering Laboratory (NAL), Mitsubishi Heavy Industries

Mitsubishi Heavy Industries

, or MHI, is a Japanese company. It is one of the core companies of Mitsubishi Group.-History:In 1870 Yataro Iwasaki, the founder of Mitsubishi took a lease of Government-owned Nagasaki Shipyard. He named it Nagasaki Shipyard & Machinery Works, and started the shipbuilding business on a full scale...

, and Ishikawajima-Harima. NASDA and NAL have since been integrated into JAXA. However, a large part of the work was contracted to Mitsubishi, with Ishikawajima-Harima providing turbomachinery

Turbomachinery

Turbomachinery, in mechanical engineering, describes machines that transfer energy between a rotor and a fluid, including both turbines and compressors. While a turbine transfers energy from a fluid to a rotor, a compressor transfers energy from a rotor to a fluid...

, and the engine is often referred to as the Mitsubishi LE-7(A).

The original LE-7 was designed to be a high efficiency, medium-sized motor with sufficient thrust for use on the H-II, and classified as expendable

Expendable launch system

An expendable launch system is a launch system that uses an expendable launch vehicle to carry a payload into space. The vehicles used in expendable launch systems are designed to be used only once , and their components are not recovered for re-use after launch...

since the engine was non-recoverable after launch.

H-II Flight 8, only operational LE-7 failure

The fuel turbopump

Turbopump

A turbopump is a gas turbine that comprises basically two main components: a rotodynamic pump and a driving turbine, usually both mounted on the same shaft, or sometimes geared together...

had an issue using the originally designed inducer (a propeller-like axial pump

Axial flow pump

An axial flow pump, or AFP, is a common type of pump that essentially consists of a propeller in a pipe. The propeller can be driven directly by a sealed motor in the pipe or mounted to the pipe from the outside or by a right-angle drive shaft that pierces the pipe.The main advantage of an AFP is...

used to raise the inlet pressure of the propellant

Propellant

A propellant is a material that produces pressurized gas that:* can be directed through a nozzle, thereby producing thrust ;...

ahead of the main turbopumps to prevent cavitation

Cavitation

Cavitation is the formation and then immediate implosion of cavities in a liquidi.e. small liquid-free zones that are the consequence of forces acting upon the liquid...

) where the inducer would itself begin to cavitate and cause an imbalance resulting in excessive vibration

Vibration

Vibration refers to mechanical oscillations about an equilibrium point. The oscillations may be periodic such as the motion of a pendulum or random such as the movement of a tire on a gravel road.Vibration is occasionally "desirable"...

. A comprehensive post-flight analysis of the unsuccessful 8th H-II launch, including a deep ocean retrieval of the wreckage, determined that fatigue

Fatigue (material)

'In materials science, fatigue is the progressive and localized structural damage that occurs when a material is subjected to cyclic loading. The nominal maximum stress values are less than the ultimate tensile stress limit, and may be below the yield stress limit of the material.Fatigue occurs...

due to this vibration was the cause of premature engine failure.

LE-7A

The LE-7A is an upgraded model from the LE-7 rocket engine. Basic design is unchanged from the original model. The 7A had additional engineering effort placed on cost cutting, reliability, and performance developments. The renovation was undertaken to mate it with the likewise improved H-IIA

H-IIA

H-IIA is an active expendable launch system operated by Mitsubishi Heavy Industries for the Japan Aerospace Exploration Agency . The liquid-fueled H-IIA rockets have been used to launch satellites into geostationary orbit, to launch a lunar orbiting spacecraft, and to launch an interplanetary...

launch vehicle, with the common goal being a more reliable, more powerful and flexible, and more cost effective launch system.

Changes / improvements

Specific emphasis was placed on reducing or the amount of required welding

Welding

Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding a filler material to form a pool of molten material that cools to become a strong joint, with pressure sometimes...

by allowing for more machined or cast

Casting

In metalworking, casting involves pouring liquid metal into a mold, which contains a hollow cavity of the desired shape, and then allowing it to cool and solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process...

components, and to simplify as many of the remaining welds as possible. This resulted in a substantial rework of the pipe routing (which makes the outward appearance of the two models considerably different). To combat the fuel inducer complications described above, the fuel inducer was redesigned for the 7A. The oxidizer inducer was also redesigned, but this was primarily to poor performance at low inlet pressures as opposed to reliability concerns. The fuel turbopump itself was also the subject of various durability enhancements. Additionally the combustion chamber/injector assembly underwent a number of small changes, like decreasing the number of injector elements, to reduce machining complexity (and thus cost) and improve reliability. While these changes overall resulted in a drop in maximum specific impulse to 440 seconds (basically making the engine less fuel efficient), the trade off for lower cost and enhanced reliability was considered acceptable.

New nozzle design (side-loading problem)

For the new engine model, a nozzle

Nozzle

A nozzle is a device designed to control the direction or characteristics of a fluid flow as it exits an enclosed chamber or pipe via an orifice....

extension was designed that could be added to the base of the new standard “short” nozzle when extra performance was required. But when the engine was fitted with the nozzle extension, the 7A encountered a new problem with unprecedented side-loads and irregular heating on the nozzle strong enough to damage the gimbal

Gimbal

A gimbal is a pivoted support that allows the rotation of an object about a single axis. A set of two gimbals, one mounted on the other with pivot axes orthogonal, may be used to allow an object mounted on the innermost gimbal to remain immobile regardless of the motion of its support...

actuators and regenerative cooling tubes during startup. Meticulous computational fluid dynamics (CFD)

Computational fluid dynamics

Computational fluid dynamics, usually abbreviated as CFD, is a branch of fluid mechanics that uses numerical methods and algorithms to solve and analyze problems that involve fluid flows. Computers are used to perform the calculations required to simulate the interaction of liquids and gases with...

work was able to sufficiently replicate and trace the dangerous transient loading and a new one-piece “long” nozzle with full regenerative cooling (as opposed to the original short nozzle with a separate film-cooled extension) was designed to mitigate the problem. Before this new nozzle was ready, some H-IIA’s were launched using only the short nozzle. The 7A no longer uses a separate nozzle extension in any configuration.

LE-7A specifications