Test facilities for VINCI super( registered )

With the replacement of the current upper-stage ESC-A of the Ariane 5 launcher by an enhanced cryogenic upper-stage, ESA's Ariane 5 Midterm Evolution (A5-ME) program aims to raise the launcher's payload capacity in geostationary transfer orbit from 10 to 12 tons, an increase of 20 %. Increasing the in-orbit delivery capability of the A5-ME launcher requires a versatile, high-performance, evolved cryogenic upper-stage engine suitable for delivering multiple payloads to all kinds of orbits, ranging from low earth orbit to geostationary transfer orbit with increased perigee. In order to meet these requirements the re-ignitable liquid oxygen/liquid hydrogen expander cycle engine VINCI super( registered ) currently under development is designated to power the future upper stage, featuring a design performance of 180 kN of thrust and 464 s of specific impulse. Since 2010 development tests for the VINCI super( registered ) engine have been conducted at the test benches P3.2 and P4.1 at DLR test site in Lampoldshausen under the ESA A5-ME program. For the VINCI super( registered ) combustion chamber development the P3.2 test facility is used, which is the only European thrust chamber test facility. Originally erected for the development of the thrust chamber of the Vulcain engine, in 2003 the test facility was modified that today it is able to simulate vacuum conditions for the ignition and startup of the VINCI super( registered ) combustion chamber. To maintain the test operations under vacuum conditions over an entire mission life of the VINCI super( registered ) engine, including re-ignition following long and short coasting phases, between 2000 and 2005 the test facility P4.1 was completely rebuilt into a new high-altitude simulation facility. During the past two P4.1 test campaigns in 2010 and 2011 a series of important milestones were reached in the development of the VINCI super( registered ) engine. In preparation for future activities within the frame of ESA's A5-ME program DLR has already started the engineering of a stage test facility for the prospective upper stage. The new test facility P5.2 is to perform the qualification of the anticipated upper stage with the VINCI super( registered ) engine. In the past year DLR has started the design phase for these modifications. The main design drivers are the test configuration and operation domain described in the test request.