Search Results (56)

Hybrid rocket engines (HREs) are increasingly considered for space transportation due to their inherent safety, cost-effectiveness, and operational flexibility. However, their diffusion flame structure promotes soot formation, leading to potentially significant emissions of black carbon (BC) directly into the stratosphere. This review provides a comprehensive analysis of soot formation and evolution in hybrid rocket combustion, covering fuel pyrolysis, polycyclic aromatic hydrocarbon (PAH) growth, particle nucleation, surface growth, and oxidation processes. The physico-chemical properties and nanostructural evolution of soot are discussed in relation to combustion conditions typical of HREs. Particular emphasis is placed on the environmental and climatic implications of BC emissions, including radiative forcing, atmospheric lifetime, and heterogeneous chemical interactions. Existing diagnostic techniques for soot measurement are critically assessed, highlighting their limitations under the extreme conditions of rocket exhaust plumes. A key outcome of this review is the identification of a major knowledge gap: although preliminary experimental emission-index measurements for HRE soot have recently become available, the database remains extremely limited, fuel- and configuration-specific, and not yet supported by standardised diagnostic protocols. Addressing this gap is essential for accurate environmental impact assessments and for the development of sustainable propulsion technologies. Full article

Hybrid rocket engines (HREs), which pair a fluid oxidizer with a solid fuel, offer safety and handling advantages, can reduce environmental impact relative to selected legacy systems, and are capable of deep throttling and restart, making them strong candidates for “green” in-space propulsion applications. However, until very recently, there has not been any flight heritage of an HRE used in a spaceflight mission. Over the past decade, the Propulsion Research Laboratory at Utah State University (PRL-USU) has matured a portfolio of HRE technologies—low-energy arc ignition, digital throttling, additively manufactured sustainable fuels, the Nytrox green oxidizer, and electroplated thruster assemblies—that together address the historical barriers to spaceflight adoption. This paper summarizes that progress, describes two flight systems built upon it, and presents a roadmap for future applications. Full article

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

Hybrid rocket engines offer a compromise between safety, controllability, and performance, making them attractive for small-scale propulsion systems. However, oxidizer selection remains a critical early-stage design decision that cannot be determined solely from ideal thermodynamic metrics. This study presents a comparative analysis of three oxidizers—nitrous oxide (N₂O), gaseous oxygen (GOX), and liquid oxygen (LOX)—for a 1 kN-class hybrid rocket engine using HDPE fuel under identical operating conditions. Equilibrium combustion performance was first evaluated using NASA Chemical Equilibrium with Applications (CEA) to determine optimal oxidizer-to-fuel ratios and theoretical specific impulse. These results were subsequently refined using Rocket Propulsion Analysis (RPA) to incorporate finite combustion chamber geometry and non-ideal nozzle expansion effects. The equilibrium analysis predicts maximum specific impulses of approximately 260 s for N₂O/HDPE and nearly 300 s for oxygen-based systems. However, finite-geometry modelling indicates that practical performance is reduced by approximately 5–8%, yielding delivered specific impulses of about 275 s for GOX and 272 s for LOX. The results demonstrate that although oxygen (GOX and LOX) provides higher thermodynamic performance, the practical advantage of LOX over GOX becomes marginal at the kilonewton scale. Consequently, oxidizer selection for small hybrid engines should be treated as a system-level trade-off involving performance, infrastructure complexity, and operational safety. Full article

In this paper, an integrated optimization is carried out to find the optimal hybrid rocket engine design for a modular multistage launch vehicle targeting a 500 km polar circular orbit. A single hybrid rocket engine unit is reused across the whole launch vehicle, with each stage constituted by a cluster of a specified number of units. Only the nozzle exit diameter of the units is allowed to change across each stage. This clustering approach is aimed at reducing the costs of the launch vehicle and at simplifying the optimization procedure. After a brief mission analysis based on Tsiolkovsky’s equation, a three-stage configuration is chosen for the launch vehicle, employing 16, 4, and 1 engine units for, respectively, the first, second, and third stage. A neural network-based surrogate model is employed to approximate the complex hybrid rocket internal ballistics, with the aim to reduce the computational cost of the optimization process. The surrogate model is trained to map a reduced number of design parameters to the performance and mass budget of a single engine unit using data from a 0-D hybrid rocket engine model. The accuracy of the trained network in predicting crucial features is then assessed. Finally, the trained network is integrated into a multidisciplinary optimization process. The aim is to identify the optimal rocket engine design and launch vehicle ascent trajectory that maximize the payload capacity to the target orbit. Full article

(1) Background: The scarcity and imbalance of real fault data significantly limit the development of data-driven fault diagnosis methods for liquid rocket engines (LREs), especially under few-shot conditions. (2) Methods: To address this issue, this study proposes a GAN-based fault data augmentation framework for multivariate LRE time-series signals and a hybrid diagnostic classifier combining convolutional neural networks (CNNs), bidirectional long short-term memory (BiLSTM), and multi-head attention (MHA). The GAN component is introduced to alleviate fault-data scarcity and class imbalance by generating additional fault-like samples, while the classifier is designed to capture local features, long-range temporal dependencies, and diagnostically informative temporal regions. (3) Results: A multidimensional evaluation based on temporal similarity, statistical consistency, and global distribution discrepancy indicates that the generated samples preserve important characteristics of the original signals under the current evaluation protocol. On the augmented LRE dataset, the proposed classifier achieved strong diagnostic performance. In addition, supplementary experiments on the public HIT aero-engine dataset further support the effectiveness of the classifier architecture, its component-wise contribution, and its behavior under imbalanced few-shot settings, while also demonstrating the value of uncertainty-aware prediction. (4) Conclusions: The results provide encouraging evidence that the proposed framework can improve LRE fault diagnosis under data-scarce conditions. However, the present findings should be interpreted within the scope of the available data and evaluation setting. More comprehensive generator-side ablation, broader external validation, and physics-oriented assessment of the generated signals are still needed before stronger conclusions can be made. Full article

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

The high-temperature engine nozzle is a critical component of a rocket motor, and its stability and performance are significantly influenced by internal high-temperature gas radiative heat transfer. Due to the non-gray nature of the nozzle medium and the complexity of the Radiative Transfer Equation (RTE), rapid and accurate simulation of radiative heat transfer is crucial for engineering applications. This paper presents a high-efficiency solution coupling the Full-Spectrum Correlated k-Distribution (FSCK) model with the Null-Collision Monte Carlo Method (NCMCM). To address the inherent computational bottleneck of linear traversal in unstructured grids, a hybrid ray-localization model integrating KD-tree and Bounding Volume Hierarchy (BVH) is proposed. This model shifts the search mechanism from element-wise iteration to spatial topological indexing, achieving logarithmic search complexity and significantly mitigating the sensitivity of computational cost to grid scale. Furthermore, a collaborative MPI–OpenMP parallel framework is established to maximize hardware utilization, where an optimized guided scheduling strategy effectively counteracts the stochastic load imbalances encountered in traditional static schemes. Results indicate that the proposed method reduces the total execution time to approximately 1/4 compared to traditional models. Simulations identify the convergent section as the primary radiation zone, where CO₂ contributes less to the radiative source term than H₂O under high-temperature conditions. Full article

The integrity analysis of a combustion chamber that uses Ablative Thermal Protection Systems (ATPSs) is a process that requires the analysis of the thermal and mechanical behavior of the materials involved and their interaction. A 1D thermal model for multilayered combustion chambers of hybrid rocket engines and solid rocket motors is developed, taking into consideration the thermal behavior of charring ATPSs during phase change and the capability of implementing an ablation process. A stress model is also implemented to assess the structural integrity of the combustion chamber that undergoes pressure and thermal loads. A numerical finite-difference model is used to implement analytical models and simulate the behavior of the materials. Bibliographic data and finite element analysis tools are used to evaluate and verify the models developed. Lastly, six different materials are used as a case study, and a parametric optimization is applied to obtain the minimum-mass designs using the materials selected. Full article

Liquid rocket engines occasionally experience abnormal phenomena with unclear mechanisms, causing difficulty in design improvements. To address the above issue, a data mining method that combines ante hoc explainability, post hoc explainability, and prediction accuracy is proposed. For ante hoc explainability, a feature selection method driven by data, models, and domain knowledge is established. Global sensitivity analysis of a physical model combined with expert knowledge and data correlation is utilized to establish the correlations between different types of parameters. Then a two-stage optimization approach is proposed to obtain the best feature subset and train the prediction model. For the post hoc explainability, the partial dependence plot (PDP) and SHapley Additive exPlanations (SHAP) analysis are used to discover complex patterns between input features and the dependent variable. The effectiveness of the hybrid feature selection method and its applicability under different noise combinations are validated using synthesized data from a high-fidelity simulation model of a pressurization system. Then the analysis of the causes of a large vibration phenomenon in an active engine shows that the prediction model has good accuracy, and the feature selection results have a clear mechanism and align with domain knowledge, providing both accuracy and interpretability. The proposed method shows significant potential for data mining in complex aerospace products. Full article

Accurate quantification of metallic contaminants in rocket exhaust plumes serves as a critical diagnostic indicator for engine wear monitoring. This paper develops a hybrid method combining atomic emission spectroscopy (AES) theory with a genetic algorithm (GA) optimized backpropagation (BP) network to quantify the metallic element concentrations in liquid-propellant rocket exhaust plumes. The proposed method establishes linearized intensity–concentration mapping through the introduction of a photon transmission factor, which is derived from radiative transfer theory and experimentally calibrated via AES measurement. This critical innovation decouples the inherent nonlinearities arising from self-absorption artifacts. Through the use of the transmission factor, the training dataset for the BP network is systematically constructed by performing spectral simulations of atomic emissions. Finally, the trained network is employed to predict the concentration of metallic elements from the measured atomic emission spectra. These spectra are generated by introducing a solution containing metallic elements into a CH₄-air premixed jet flame. The predictive accuracy of the method is rigorously evaluated through 32 independent experimental trials. Results show that the quantification error of metallic elements remains within 6%, and the method exhibits robust performance under conditions of spectral self-absorption, demonstrating its reliability for rocket engine health monitoring applications. Full article

Nitrous oxide is a highly suitable oxidizer for hybrid rockets due to its self-pressurizing properties, moderate cost, and high accessibility. However, its vapor pressure and density are highly dependent on ambient temperature, requiring careful consideration of temperature variations in real applications. To mitigate this issue, an oxidizer called Nytrox was produced by adding a small fraction of oxygen to bulk nitrous oxide. This modification enables the hybrid rocket propulsion system to maintain a nearly constant average thrust and total impulse across a wide range of ambient temperatures. A series of 7 s hot-fire tests of a small Nytrox/polypropylene hybrid rocket engine operating at ~60 barA of running tank pressure demonstrated a consistent average thrust of 45.3 ± 0.7 kgf and a total impulse of 307.6 ± 3.9 kgf·s within a N₂O temperature range of 5.9–22.6 °C, compared to highly varying values of the N₂O/polypropylene one within a N₂O temperature range of 10.8–29.8 °C. Furthermore, the specific impulse of the Nytrox hybrid rocket engine increases mildly with decreasing temperature because of the increasing amount of added oxygen that benefits the combustion for generating the thrust. Full article

Hybrid Rocket Engines (HREs) combine the advantages of solid and liquid propellants, offering thrust control, simplicity, safety, and cost efficiency. Part of the research on this rocket architecture focuses on optimising combustion chamber design to enhance performance, a process traditionally reliant on time-consuming experimental adjustments to chamber lengths. In this study, two configurations of HREs were designed and tested. The tests aimed to study the impact of post-chamber lengths on rocket engine performance by experimental firings on a laid-back test engine. This study focused on designing, manufacturing, and testing a laid-back hybrid engine with two chamber configurations. The engine features a small combustion chamber, an L-shaped mount, a spark ignition, and nitrogen purging. Data acquisition includes thermocouples, pressure transducers, and a load cell for thrust measurement. Our experimental findings provide insights into thrust, temperature gradients, pressure, and plume characteristics. A non-linear regression model derived from the experimental data established an empirical relationship between performance and chamber lengths, offering a foundation for further combustion flow studies. The post-chamber length positively impacted the engine thrust performance by 2.7%. Conversely, the pre-chamber length negatively impacted the performance by 1.3%. Further data collection could assist in refining the empirical relation and identifying key threshold values. Full article

This paper presents the design and experimental evaluation of a throttleable pintle-centrifugal injector system tailored for hybrid rocket engines, aimed at improving combustion efficiency and enabling precise throttling control. The novel injector system combines the principles of swirl injection and pintle-based throttling, offering fine adjustment of oxidizer flow rates to optimize combustion dynamics. Cold-flow experiments using deionized water were conducted to assess the injector’s performance across a range of flow rates and pintle strokes. Results demonstrate that the pintle stroke effectively regulates injection pressure drop and atomization characteristics, with significant improvements observed in spray cone angle and droplet size distribution. The injector system achieved a pressure drop variation ratio of 4.162 at a flow rate adjustment ratio of 6.841, indicating a strong capacity for deep throttling. These findings highlight the potential of the pintle-centrifugal injector to enhance the performance and adaptability of hybrid rocket motors, offering promising applications in modern aerospace propulsion systems. Full article

Equivalent ratio (ER) is an important factor affecting detonation characteristics and propulsion performance of rotating detonation rocket engine (RDRE). In this paper, the effects of different equivalent ratios detonation characteristics and thrust performance of methane-oxygen RDRE were studied by 2D numerical simulation. The premixed reactants were injected through the injection holes to simulate the discrete injection of reactants on the injection panel in actual RDRE, the number of injection holes was 60 and 120. The results show that there is hybrid detonation mode (HDM), co-direction multi-wave detonation mode (CMM) and unstable detonation mode (UDM) in detonation combustion due to the influence of equivalent ratio and the number of injection holes, and the co-directional multi-wave detonation mode is beneficial to the thrust stability of RDRE. At the last, the number of detonation waves in RDRE decreases with the increase in the equivalent ratio, and the specific impulse (I_sp) increases with the increase of the equivalent ratio. Full article