Search Results (39)

Low regression rate is the most critical issue for the development and application of hybrid rocket motors (HRMs). Paraffin-based fuels are potential candidates for HRMs due to their high regression rates but adding polymers to improve strength results in insufficient regression rates for HRMs applications. In this work, Computational Fluid Dynamics (CFD) modeling and analysis were used to investigate the mixing and combustion of gaseous fuels and oxidizers in HRMs for various fuel grains and injector combinations. In addition, the regression rate characteristics and combustion efficiency were evaluated using a ground test. The results showed that the swirling flow with both high mixing intensity and high velocity could be formed by using the swirl injector. The highest mixing degree attained for the star-swirl grain and swirl injector was 86%. The reported combustion efficiency calculated by the CFD model attained a maximum of 93% at the nozzle throat. In addition, a spatially averaged regression rate of 1.40 mm·s⁻¹ was achieved for the star-swirl grain and swirl injector combination when the mass flux of N₂O was 89.94 kg·m⁻²·s⁻¹. This is around 191% higher than the case of non-swirling flow. However, there were obvious local regression rate differences between the root of the star and the slot. The regression rate increase was accompanied by a decrease in the combustion efficiency for the strong swirling flow condition due to the remarkable higher mass flow rate of gasified fuels. It was shown that the nano-sized aluminum was unfavorable for the combustion efficiency, especially under extreme fuel-rich conditions. Full article

Hybrid Propellant Rocket Motors (HPRMs) have been advancing rapidly in recent years. These improvements are finally increasing their competitiveness in the global launch-vehicle market. However, some topics, such as the pre-combustion chamber design, still require more in-depth studies. Few studies have examined this subject. This work proposes a low-computational-cost algorithm that calculates the minimum pre-combustion chamber length, with a vaporization and feed-system coupled instability model. This type of analysis is a key tool for minimizing a vehicle’s size, weight, losses, and costs. Additionally, coupling with internal ballistics codes can be implemented. Furthermore, the results were compared with real HPRMs to verify the algorithm’s reliability. The shortened pre-chamber architecture trimmed the inert mass and reduced the feed-system pressure requirement, boosting overall propulsive energy efficiency by $\approx 8\%$ relative to conventional L*-based designs. These gains can lower stored-gas enthalpy and reduce life-cycle CO and CO₂-equivalent emissions, strengthening the case for lighter and more sustainable access-to-space technologies. Full article

The process of spacecraft entry, deceleration, landing, and ascent requires high specific impulse, high reliability, and high-precision thrust adjustments for the power system. The new hybrid rocket motor adopts a complex-shaped grain and high-energy propellant, offering high-energy characteristics, continuously adjustable thrust, a relatively simple oxidant delivery system, and high reliability, making it an ideal power choice for the above systems. However, due to changes in the characteristic structure of the three-dimensional complex flame surface degradation process, it is difficult to accurately predict the motor performance. In this study, changes in the flow field structure and performance parameters during the operation of the cross-shaped grain hybrid rocket motor are presented using fuel surface reconstruction technology based on a dynamic mesh. The spatial distribution of the fuel surface is analyzed, and the accuracy of the model is verified via firing tests. The results show that the deviations of combustion chamber pressure and thrust are less than 0.6% and 1.7%, respectively. After the test, the deviation between the simulated port area and the CT-scanned port area is less than 3.5%. The accuracy of this model is verified in terms of the above two aspects, establishing a solid foundation for predicting the performance of future hybrid rocket motors with more complex-shaped grains. Full article

The conventional grey relational analysis (GRA) demonstrates limitations in dynamic simulation data evaluation due to its failure to simultaneously account for geometric similarity among dynamic indicators and the proximity of data curve distances. This deficiency manifests as a compromised robustness in noise resistance and interference suppression, consequently leading to discrepancies between model accuracy and practical scenarios. To address these shortcomings, this paper proposes a robust grey relational analysis-based accuracy evaluation method (RGRA-AEM). The methodology incorporates the expected penetration rate to facilitate interpolation computation and employs deviation acceptability as a distance threshold indicator. By integrating the grey relational degree, mean squared deviation distance, and accuracy modeling, this approach achieves enhanced stability in accuracy assessment. It effectively mitigates the inherent weakness of traditional GRA that overemphasizes sequential curve similarity while significantly improving the anti-noise performance and interference resistance of grey relational coefficients. Experimental validation through the internal ballistic test-simulation dynamic data of a hybrid rocket motor conclusively demonstrates the superior robustness of the proposed methodology. 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

The potential for throttle control of hybrid rocket systems has long been known as a potential advantage for a variety of applications. Because only a single flow path is controlled, theoretically, hybrids should be significantly easier to throttle than bipropellant systems. Unfortunately, the slow response times and nonlinearity of traditional position-control valves have limited practical applications of hybrid throttling. This paper presents an alternative throttling system where the oxidizer flow path is broken into multiple streams, with each flow path controlled by a solenoid-operated on/off valve. The parallel paths allow significantly faster and more precise control than can be achieved using a single position-control valve. The achievable thrust levels are limited only by the size and number of components in the valve cascade. The 8-bit digital throttle system, developed by Utah State University’s Propulsion Research Lab, uses commercial, off-the-shelf components. The throttle system was tested using a 200-N hybrid rocket motor, burning gaseous oxygen, and ABS plastic as propellants. The testing campaign of more than 50 hot fires has demonstrated multiple profiles, including deep throttle ramps, multistep boxcars, and sine waves at frequencies varying from 0.25 to 1-Hz. Comparisons to analytical models are also presented, showing good agreement. Fourier-transform spectra demonstrating the total-system, frequency response are also presented. Full article

Hybrid rockets have very interesting characteristics like simplicity, reliability, safety, thrust modulation, environmental friendliness and lower costs, which make them very attractive for several applications like sounding rockets, small launch vehicles, upper stages, hypersonic test-beds and planetary landers. In recent years, advancements have been made to increase hybrid motor performance, and two of the most promising solutions are vortex injection and paraffin-based fuels. Moreover, both technologies can be also used to tailor the fuel regression rate, in the first case varying the swirl intensity, and in the second case with the amount and type of additives. In this way, it is possible not only to design high-performing hybrid motors, but also to adjust their grain and chamber geometries to different mission requirements, particularly regarding thrust and burning time. In this paper, the knowledge about these two technical solutions and their coupling is extended. Three sets of experimental campaigns were performed in the frame of the Italian Space Agency-sponsored PHAEDRA program. The first one investigated a reference paraffin fuel with axial and standard vortex injection. The second campaign tested vortex injection with low values of swirl numbers down to 0.5 with a conventional plastic fuel, namely polyethylene. Finally, the last campaign tested another, lower regressing, paraffin-based fuel with the same low swirl numbers as the second campaign. Full article

High-speed submerged marine vehicles, such as torpedoes, traveling at velocities of an order of 100 m/s and above, require powerful propulsion to overcome the tremendous hydrodynamic drag. This paper aims to investigate a marine hybrid-propellant water-breathing ram rocket (marine ramjet or ducted rocket) under various underwater cruise conditions. At high underwater cruise speeds, the ram rocket outperforms regular rocket motors, substantially increasing its specific impulse and thrust. This investigation utilized a unique test facility capable of dynamically testing the marine ramjet. Over 20 dynamic experiments have been conducted, revealing the submerged motor characteristics at different cruise speeds, water-to-propellant mass ratios, and oxidizer-to-fuel mass ratios, thereby creating a performance map of the marine ramjet. The results were compared with static firing data and theoretical calculations, showing a good agreement with standard specific impulse improvement of about 55% compared to a regular hybrid rocket, reaching a maximum value of 380 s. The significant increase in performance demonstrates the potential of the water-breathing ramjet for propelling high-speed underwater vehicles. Full article

Increased performance with reduced overall cost, and precise design and optimization of launch systems are critical to affordability. In this respect, the use of hybrid motors has increased to ease handling based on motor selection. In the current study, the launch vehicle’s performance is enhanced by incorporating a hybrid rocket motor into the last stage and optimized using particle swarm optimization to develop a six-degrees-of-freedom tool. This modification aims to increase payload placement flexibility, facilitate handling, and reduce costs. Thanks to the interactive subsystems within this research, this innovative study more comprehensively considers the launch vehicle trajectory design problem, allowing the simultaneous consideration of the effect of launch vehicle geometry along with other parameters in the system. In this context, the proposed method is applied to the Minotaur-I launch vehicle, and contributions of the detailed design and optimization are presented. Optimization results show that the percentage differences between these models for the original vehicle were observed to be 11.55% in velocity and 8.02% in altitude. However, there were differences of 10.06% and 48.8%, 15.8% and 23.2%, and 19.5% and 78.9% in altitudes and velocities when the center of gravity and moment of inertia changes were neglected, and constant aerodynamic coefficients were assumed, respectively. In all these cases, it was observed that the flight path angle was not close to zero. Moreover, the same mission was achieved by the launch vehicle with the optimized hybrid last stage and the propulsion performance was increased by about 7.64% based on the specific impulse and total impulse-over-weight ratio. Full article

Hybrid rocket motors have great development potential due to their outstanding thrust adjustment flexibility and long-term operation ability. However, nozzle erosion during the motor operation can cause an increase in the throat area of the nozzle, which leads to a decrease in combustion chamber pressure and nozzle efficiency. Therefore, a performance prediction model for hybrid rocket motors considering nozzle erosion has become a key technology that must be addressed when developing hybrid rocket motors. This study uses dynamic grid technology to simulate the regression of the combustion surface and nozzle erosion, which fits well with experimental values. The behavior of high-energy particles in the combustion chamber is simulated through a discrete phase model. Notably, distinctive behavior is observed in Al and Mg droplets, with Al droplets exhibiting incomplete vaporization in the combustion chamber while Mg droplets completely vaporize. A ground firing test using the Φ336 mm hybrid rocket motor lasting 200 s is conducted. The results show that the dynamic numerical simulation, accounting for nozzle erosion, substantially enhances performance prediction accuracy. The average deviation in motor thrust remains below 1.8%, and the combustion chamber pressure deviation stays under 2.6%, confirming the precision of the model. Ultimately, both simulation and experimental outcomes indicate a gradual decrease in specific impulse and characteristic velocity over the long-term operation, attributed to the gradual deviation of the oxygen-fuel ratio. This research provides valuable insights for guiding hybrid rocket motor design and optimizing design parameters to improve overall performance. This model can achieve long-duration and high-precision performance predictions for hybrid rocket motors. Full article

This study focuses on an innovative green propellant based on paraffin, stearic acid, and coal, used in hybrid rocket engines. Additionally, lab-scale firing tests were conducted using a hybrid rocket motor with gaseous oxygen as the oxidizer, utilizing paraffin-based fuels containing stearic acid and coal. The mechanical performance results revealed that the addition of stearic acid and coal improved the mechanical properties of paraffin-based fuel, including tensile, compression, and flexural strength, under both ambient and sub-zero temperatures (−21 °C). Macrostructural and microstructural examinations, conducted through optical and scanning electron microscopy (SEM), highlighted its resilience, despite minimal imperfections such as impurities and micro-voids. These characteristics could be attributed to factors such as raw material composition and the manufacturing process. Following the mechanical tests, the second stage involved conducting a firing test on a hybrid rocket motor using the new propellant and gaseous oxygen. A numerical simulation was carried out using ProPEP software to identify the optimal oxidant-to-fuel ratio for the maximum specific impulse. Following simulations, it was observed that the specific impulse for the paraffin and for the new propellant differs very little at each oxidant-to-fuel (O/F) ratio. It is noticeable that the maximum specific impulse is achieved for both propellants around the O/F value of 2.2. It was observed that no hazardous substances were present, unlike in traditional solid propellants based on ammonium perchlorate or aluminum. Consequently, there are no traces of chlorine, ammonia, or aluminum-based compounds after combustion. The resulting components for the simulated motor include H₂, H₂O, O₂, CO₂, CO, and other combinations in insignificant percentages. It is worth noting that the CO concentration decreases with an increase in the O/F ratio for both propellants, and the differences between concentrations are negligible. Additionally, the CO₂ concentration peaks at an O/F ratio of around 4.7. The test proceeded under normal conditions, without compromising the integrity of the test stand and the motor. These findings position the developed propellant as a promising candidate for applications in low-temperature hybrid rocket technology and pave the way for future advancements. Full article

The recent growth in maturity of paraffin-based hybrid propulsion systems reassesses the possibility to design an alternative Mars Ascent Vehicle (MAV) propelled by a European hybrid motor. As part of the Mars Sample Return (MSR) campaign, a Hybrid MAV would present potential advantages over the existent solid concept funded by NASA through offering increased performance, higher thermal resilience, and lower Gross Lift-Off Mass (GLOM). This study looks at the preliminary design of a two-stage European MAV equipped with HyImpulse’s hybrid engine called the Hyplox10. This Hybrid MAV utilizes the advantages inherent to this type of propulsion to propose an alternative MAV concept. After a careful analysis of previous MAV architectures from the literature, the vehicle is sized with all its components such as the propellant tanks and nozzle, and the configuration of the rocket is established. A detailed design of the primary structure is addressed. This is followed by a Finite Element Analysis (FEA), evaluating the structural integrity under the challenging conditions of Entry, Descent, and Landing (EDL) on Mars, considering both static and dynamic analyses. The outcome is a Hybrid MAV design that demonstrates feasibility and resilience in the harsh Martian environment, boasting a GLOM of less than 300 kg. Full article

This study deals with the mathematical modeling and numerical simulation of chemical propulsion systems (CPSs). For this, we investigate and summarize a comprehensive collection of the simulation modeling developments of CPSs in academic works, applications, and industrial fields. Then, we organize and analyze the simulation modeling approaches in several ways. After that, we organize differential-algebraic Equations (DAEs) for fundamental mathematical modeling consisting of the governing Equations (ordinary differential equations, ODEs) for the components and other equations derived from several physical rules or characteristics (algebraic equations or phenomenological equations, AEs) and then synthesize and summarize the fundamental structures of analytic mathematical modeling by types (liquid-propellant rocket engines, solid-propellant rocket motors, and hybrid-propellant rocket motors) of CPSs. Full article

This study investigated reconstruction techniques for building the instantaneous fuel regression rate of the hybrid rocket motor (HRM). Specifically, an experiment in a laboratory 500 N-class hybrid rocket motor with single-port wagon wheel fuel grain, operated with hydrogen peroxide (HP) and hydroxyl-terminated polybutadiene (HTPB) based fuel (including Al), was carried out. A piece of post-processing software was developed to reconstruct the instantaneous regression rate and other performance parameters of the HRM during the firing test. The results produced by the reconstruction techniques are in good agreement with experimental data obtained by traditional methods, with a maximum error of less than 5.75%. Moreover, compared with the traditional endpoint method, the reconstruction method had a significant advantage, which could ascertain the sensitivity of the regression rate to changes in the oxidizer mass flux and fit the formula of regression rate in a single firing test. Additionally, digital image processing techniques were employed to determine the axial distribution of the fuel regression rate after the test using computed tomography (CT) scanning. This served to verify the accuracy of the instantaneous reconstruction calculation. The error in the average regression rate between CT scanning and the reconstruction calculation was 1.91%, proving that the CT scanning and pixel statistic method of the calculating regression rate was practical for characterizing the axial distribution of the average regression rate during the firing test. In summary, the main objective of this study was to reconstruct the transient parameters of hybrid rocket motor with single-port wagon wheel fuel grain using reconstruction techniques, and to fit the formula of the regression rate through a single-firing test. Furthermore, this paper proposes a modified reconstruction method that is essential for investigating fuel regression rate during the firing test of HRMs. Full article

Space exploration greatly facilitates the development of advanced propulsion systems. Extensive research has shown that hybrid rocket motors have bright prospects for use in variable-thrust propulsion systems. However, the variable-thrust precision control of a hybrid rocket motor with a high-mass fraction of aluminum has not been adequately explored. In this paper, we propose a closed-loop control system for a high-performance laboratory-scale hybrid rocket motor, and verify its performance through tests on a hybrid rocket motor containing 98% hydrogen peroxide and hydroxyl-terminated polybutadiene with 58% of an aluminum additive. The results show that, first, the average value of thrust in the stable sections in the three stages were 400.7 N, 599.1 N, and 400.1 N when the target values were 400 N, 600 N, and 400 N, respectively. Second, the average thrust was stable, and the control error of the average value was better than 0.5%. Third, the real-time error in thrust was controlled to within ± 20 N with a steady-state error smaller than 5%. These results indicate that the proposed closed-loop control strategy for hybrid rocket motors with a high-mass fraction of aluminum can maintain a constant thrust and smooth transitions in case of variable thrust. Full article