Heat and Mass Transfer in Rocket Propulsion

A special issue of Aerospace (ISSN 2226-4310). This special issue belongs to the section "Astronautics & Space Science".

Deadline for manuscript submissions: 31 October 2026 | Viewed by 1424

Editors


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Guest Editor
College of Engineering, University of Hawaii, Honolulu, HI 96822, USA
Interests: rocket propulsion; combustion; cooling dynamics; fluid dynamics; heat transfer; acoustics; thermal engineering; aerospace science; mass transfer; propulsion; cooling; energetic systems

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Guest Editor
Faculty of Engineering, Division of Mechanical and Space Engineering, Hokkaido University, Hokkaido, Japan
Interests: hybrid rocket; combustion; space propulsion

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Guest Editor
1. Laboratory of Space Systems, Hokkaido University, Hokkaido, Japan
2. Letara Ltd., Hokkaido, Japan
Interests: nozzle erosion; space exploration; hybrid rockets

Special Issue Information

Dear Colleagues,

We invite you to contribute your latest advancements in rocket propulsion systems to the upcoming Special Issue, “Heat and Mass Transfer in Rocket Propulsion”. While the title may appear modest, it reflects a fundamental truth: rocket systems are, at their core, thermal devices. Heat and mass transfer are not peripheral—they are the beating heart of propulsion, and among the most critical sources of failure.

This is well understood in combustion-based systems—comprising liquid, solid, hybrid, and monopropellants—where thermal loads and material erosion dictate performance and reliability; however, even electric propulsion systems are not exempt from this. Their continuous operation and absence of liquid propellants complicate thermal management, demanding innovative strategies to dissipate heat and safeguard component integrity.

Heat and mass transfer phenomena permeate nearly every subsystem in rocket propulsion:

  1. Combustion Chambers and Nozzles

Flames transfer heat to chamber walls, injector plates, and nozzle throats. Radiative contributions must be quantified through high-fidelity numerical models alongside convection. The nozzle throat is especially vulnerable, particularly in solid rockets employing pintle mechanisms for thrust modulation.

  1. Cooling Channels and Cryogenic Handling

In cooling and feed systems, heat absorbed by the coolant induces phase change—from liquid to gas—under subcritical conditions or during cryogenic propellant management. Conversely, in high-performance turbopumps, pressure-induced mass transfer drives heat exchange and bubble formation, with implications for cavitation and system stability.

  1. Solid and Hybrid Propellants

Heat and mass transfer near the propellant surface operate in a tightly coupled feedback loop, generating hot gases for thrust from solid materials. In hybrid rockets, mass transfer involves relatively simple pyrolysis; in solid rockets, energetic regression leads to complex flame structures and dynamic heat–mass interactions.

  1. Monopropellants

Catalytic compartments decompose cold liquid propellants into hot gases via multiphase mass transfer. The exothermic reaction reheats the catalyst bed, sustaining decomposition. This delicate thermal loop is essential for efficiency and complete gas-phase exhaust.

  1. Electric Propulsion Systems

Discharge channels experience intense localized heating from ionization and acceleration, accelerating material erosion and reducing component lifetimes. The power processing unit (PPU) introduces additional thermal load, requiring careful isolation from sensitive spacecraft subsystems and efficient radiation-based heat rejection.

We welcome contributions that explore these phenomena across propulsion architectures—from experimental to modeling innovations and system-level integration. Your work in advancing rocket technology is deeply valued by the editorial team.

Dr. Giuseppe Gallo
Prof. Dr. Harunori Nagata
Dr. Landon Kamps
Guest Editors

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Keywords

  • combustion chambers and nozzles
  • cooling channels and cryogenic handling
  • solid and hybrid propellants
  • monopropellants
  • electric propulsion systems

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Published Papers (2 papers)

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Research

39 pages, 2285 KB  
Article
Nozzle Erosion Reconstruction Model for Data Analysis in Rocket Engines and Correlation with Chamber Pressure
by Ryan J. Thibaudeau and Stephen A. Whitmore
Aerospace 2026, 13(7), 575; https://doi.org/10.3390/aerospace13070575 (registering DOI) - 25 Jun 2026
Abstract
Graphite nozzles remain the dominant choice for small hybrid and solid rocket motors operating on laboratory and university budgets, owing to their low cost, ease of machining, and rapid turnaround during iterative design campaigns. These same programs, however, must contend with the fact [...] Read more.
Graphite nozzles remain the dominant choice for small hybrid and solid rocket motors operating on laboratory and university budgets, owing to their low cost, ease of machining, and rapid turnaround during iterative design campaigns. These same programs, however, must contend with the fact that graphite erodes through coupled thermochemical and mechanical mechanisms when exposed to the oxidizing species generated by high-energy propellant combustion, and the resulting throat-area growth fundamentally alters the time histories of chamber pressure, thrust, and delivered specific impulse. This paper presents a nozzle-erosion reconstruction model that extracts the time-resolved throat area from coupled thrust and chamber-pressure measurements using the thrust coefficient relationship, scales the reconstructed area history against pre- and post-test throat measurements, identifies the onset and rate of erosion, and accounts for variable sensor lag between the thrust-stand and pressure-transducer signal chains. The model is exercised on two complementary sets of laboratory-scale GOX/ABS hybrid hot-fire data that together span roughly two orders of magnitude in total throat-area change and peak chamber pressures from 0.5 to 3.4 MPa: a controlled three-operating-point campaign conducted in support of the NASA Plume-Surface Interaction (PSI) program, and a set of higher-pressure firings from the laboratory development series in which the technique was matured. Reconstructed erosion-onset times, erosion rates, and total throat-diameter change are reported for each firing, the reconstruction accuracy is characterized as a function of erosion magnitude. A correlation of graphite erosion with chamber pressure is examined across the combined envelope. The results demonstrate the robustness of the reconstruction technique and provide a reusable framework for post-test reconstruction of transient nozzle geometry in rocket-engine ground testing. Full article
(This article belongs to the Special Issue Heat and Mass Transfer in Rocket Propulsion)
20 pages, 14893 KB  
Article
Performance Degradation and Regeneration of Palladium Catalysts for Hybrid Rockets
by Sergio Cassese, Luca Mastroianni, Riccardo Guida, Stefano Mungiguerra, Vincenzo Russo, Tapio Salmi and Raffaele Savino
Aerospace 2026, 13(3), 238; https://doi.org/10.3390/aerospace13030238 - 3 Mar 2026
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Abstract
The renewed interest in hydrogen peroxide-based space propulsion systems has highlighted the persistent issue of catalyst degradation during long-term operation. Although several studies have investigated the underlying causes of this phenomenon, effective regeneration techniques capable of restoring catalytic activity have not yet been [...] Read more.
The renewed interest in hydrogen peroxide-based space propulsion systems has highlighted the persistent issue of catalyst degradation during long-term operation. Although several studies have investigated the underlying causes of this phenomenon, effective regeneration techniques capable of restoring catalytic activity have not yet been clearly demonstrated. This study investigates the mechanisms responsible for performance degradation and proposes a viable regeneration strategy for palladium-based catalysts. Experimental analyses were conducted on a batch of commercial Al2O3/Pd pellets subjected to multiple firing cycles in a 10 N-class hybrid mini-thruster. Monitoring of the propulsive performance revealed a progressive decline in catalytic activity, ultimately preventing ignition of the hybrid rocket engine. To characterize the degradation mechanisms, the pellets were examined through visual inspection, static hydrogen peroxide decomposition tests, and Temperature Programmed Reduction (TPR) analysis. The results indicated significant surface oxidation of palladium, leading to reduced decomposition efficiency. A chemical regeneration procedure based on sodium borohydride (NaBH4) treatment was subsequently developed to restore catalytic performance. The regenerated pellets were tested under the same experimental conditions that had previously led to ignition failure. Their propulsive performance was then compared with both the degraded pellets and a new batch of equivalent catalysts. The results demonstrate that the regeneration process successfully restored the catalytic activity to levels comparable with the original state, enabling stable and efficient hybrid combustion. These findings confirm the role of surface oxidation in catalyst degradation and demonstrate that targeted chemical treatment can significantly extend catalyst lifetime. The proposed regeneration strategy offers a practical method to reduce costs of ground-based experimental campaigns and support the future deployment of hydrogen peroxide-based propulsion systems in space applications by providing insights into the mechanisms that can degrade the performance of palladium catalysts. Full article
(This article belongs to the Special Issue Heat and Mass Transfer in Rocket Propulsion)
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