Comprehensive ignition characterization of a non-toxic hypergolic hybrid rocket propellant

Abstract

This paper describes a comprehensive characterization of ignition properties of a metal-hydride based non-toxic hypergolic hybrid rocket propellant. The propellant consists of Rocket Grade Hydrogen Peroxide (RGHP) as oxidizer, high-density Polyethylene (HDPE) as fuel and sodium borohydride (NaBH4) as the additive, embedded in the HDPE matrix. Ignition quality was characterized as ignition delay, ignition probability and flame spread. In a drop-test setup, ignition characteristics were determined as a function of seven parameters: RGHP concentration, additive loading, oxidizer droplet impact velocity, oxidizer droplet volume, pressure, diluent gas, and environmental exposure. The parameters encompass thermo-chemical, fluid/droplet dynamics and environmental factors affecting ignition. Ignition delays as low as 3 ms were observed, one of the lowest using non-toxic hypergolic hybrid propellants in open-air. An overwhelming majority of conditions tested yielded <10 ms ignition delays and 100% ignition success. All conditions tested affected ignition to varying degrees with RGHP concentration, NaBH4 loading and drop impact velocity significantly affecting ignition. Further, contrary to expectations, exposing sanded fuel samples to humidity for a few h enhanced ignition instead of hampering it and exposure for 24 h did not lead to ignition degradation. Tests with diluent gases other than air (at atmospheric and elevated pressures) revealed that atmospheric oxygen played a negligible role in the reaction process. This proved that oxygen for the initial ignition event was obtained from RGHP decomposition, with atmospheric oxygen playing no role in ignition performance. Aside from demonstrating excellent ignition characteristics, our results further show a need to go beyond thermo-chemical properties and to consider aspects of ignition other than ignition delay in hypergolic propellant research to enable a complete understanding of the ignition processes. The comprehensive ignition characterization demonstrates the chosen propellant's ability to overcome ignition challenges in hybrid rockets and serves as a proof of concept for its further development.