This paper aims to validate the design contours and result parameters of the newly developed Dual Expansion Nozzle (DEN) using the Fastran software when it enters the non-adaptation regime with the increase in altitude and variation of the Nozzle Pressure Ratio (NPR). DEN design and Computational Fluid Dynamic (CFD) application utilize the High Temperature (HT) model defined by a calorically imperfect and thermally perfect gas, providing good accuracy compared to PG model. The computational domain is decomposed into subdivisions of structured grids using the algebraic grid generator software CFD-GEOM. The mesh convergence was analyzed using three mesh resolutions: coarse, medium, and fine. A comparison was made between the two conventional nozzles, MLN and the newly developed BPN, as both are currently used in aerospace propulsion to enhance aerodynamic performance. If a rocket engine operates under strongly over-expanded conditions with ambient pressure considerably higher than the nozzle exit pressure, and by increasing NPR value, the flow separates from the wall and can lead to high side loads. These loads are reduced in DEN. The flow separation point is observed close to the exit section for the DEN in comparison with Minimum Length Nozzle (MLN) and Best Performance Nozzle (BPN) for the same NPR, resulting in low flow separation and low side load effects for DEN. This result demonstrates a small loss in the exit Mach number, leading to less loss in the thrust coefficient and a small effect of boundary layer friction for DEN. Enhanced over-expanded aerodynamics is observed in DEN compared to MLN and BPN. The application is made for air with an exit Mach number equal to 3.00.
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