Numerical and experimental study of the thermochemical erosion of a graphite nozzle in a hybrid rocket motor with a star grain

Abstract

Hybrid rocket motors is a promising propulsion system because of its intrinsic advantages over a conventional solid rocket motor and liquid rocket engine. However, serious nozzle erosion is a key problem that prevents hybrid rocket motors from being widely used, especially for propulsion systems with long operating times. In this paper, the erosion of a graphite-based nozzle coupled with a combustion flow field is studied in a hybrid rocket motor with a star grain. As the oxidizer and fuel, 90% hydrogen peroxide and hydroxide-terminated polybutadiene are adopted, respectively. The nozzle erosion was simulated coupled with the flow field in a typical hybrid rocket motor through three-dimensional numerical simulations. The simulations are based on a pure-gas steady numerical model considering turbulence, fuel pyrolysis, oxidizer/fuel reactions, thermal conduction and solid-gas boundary interactions on the fuel and nozzle surfaces. The results indicate that the nozzle erosion is greatly influenced by the inner flow field. The flame near the grain trough is thicker than that near the grain peak. Therefore, the maximum erosion rate (0.042 mm/s) occurs near the nozzle throat corresponding to the grain trough. The OH and H2O contribute 49.8% and 45.5% to the erosion rate, respectively, in this area. Furthermore, 56.6% and 31.9% contributions are made by OH and H2O, respectively, in the area corresponding to the grain peak. The O, CO2 and O2 make much lower contributions to the total erosion. In addition, a firing test is carried out to characterize the graphite nozzle erosion on a full-scale hybrid rocket motor with star grain. The nozzle inner profiles before and after test show that the erosion behavior of the graphite material is strictly related to the fuel shape.