Propellant Grain Research Articles

Position Normalization of Propellant Grain Point Clouds

Point cloud data obtained from scanning propellant grains with 3D scanning equipment exhibit positional uncertainty in space, posing significant challenges for calculating the relevant parameters of the propellant grains. Therefore, it is essential to normalize the position of each propellant grain’s point cloud. This paper proposes a normalization algorithm for propellant grain point clouds, consisting of two stages, coarse normalization and fine normalization, to achieve high-precision transformations of the point clouds. In the coarse normalization stage, a layer-by-layer feature points detection scheme based on k-dimensional trees (KD-tree) and k-means clustering (k-means) is designed to extract feature points from the propellant grain point cloud. In the fine normalization stage, a rotation angle compensation scheme is proposed to align the fitted symmetry axis of the propellant grain point cloud with the coordinate axes. Finally, comparative experiments with iterative closest point (ICP) and random sample consensus (RANSAC) validate the efficiency of the proposed normalization algorithm.

Long‐Term Creep Prediction of NEPE Propellant Based on SSM Method

AbstractThroughout the entire operational lifespan of a solid rocket motor, the propellant grain experiences creep due to gravitational forces, potentially influencing the motor′s reliability. To enhance the efficiency of creep tests for solid propellants, short‐term (3000 seconds) creep tests were conducted on nitrate ester plasticized polyether (NEPE) propellant at stress levels of 0.15 MPa, 0.20 MPa, 0.25 MPa, and 0.30 MPa using both the step stress method (SSM) and the conventional constant creep test (CCT). Furthermore, mid‐term (10000 seconds) and long‐term (7 days) creep tests were conducted. Based on the traditional generalized Kelvin model, the Saint‐Venant body was incorporated to derive a visco‐elastic‐plastic model with overstress considered, and constitutive model parameters were determined through data fitting. The findings demonstrate the efficacy of the constitutive model in well characterizing propellant creep behavior. According to the model, the yield stress of NEPE propellant was determined to be 0.2302 MPa, representing a significant 64.03% reduction compared to its design strength. This insight holds relevance for structural integrity analysis and the evaluation of solid motor storage life.

Investigation of Gas-Turbine Afterburner with Aluminized Fuel-Rich Propellant

This paper describes the design and development of a compact afterburner system for a mini gas turbine engine using aluminized fuel-rich propellant. The working principle of the system is analogous to a dual combustor ramjet engine in which the propellant is burnt in the primary chamber. Hot gases from the primary chamber combust further in the secondary chamber with incoming air from the inlet. In this work, fuel-rich gases were injected into the afterburner through radially mounted gas generators. The hot gases mix with the oxygen-rich turbine exhaust and burn further, resulting in high-enthalpy gases. These high-enthalpy gases were expanded in the convergent nozzle to generate higher exit velocity. This study investigated the thrust enhancement capability of the gas turbine afterburner system with fuel-rich propellant grains at different operating conditions. Furthermore, the effect of increasing afterburner length and decreasing nozzle exit diameter on the performance of the system was also examined. An overall static thrust of about 320 and 360 N was obtained for three and four grains, respectively, with maximum unburnt fuel residues of 11% in both the cases, out of which four grain configurations achieved a maximum thrust enhancement of around 180%.

Impact of Solid Rocket Propellant Grain Manufacturing Limitations on Launch Vehicle Capability

It is examined if any limitations in existing solid rocket propellant grain manufacturing methods adversely affected the payload capability of recent space launch vehicles. It is seen if the transition from heavy, segmented metal rocket motor casings to lightweight monolith composite casings is possible without loss of ability to design and realize high-performance grain configurations using simple and safe methods. Considering payload fraction as the comparative performance metric, recently flown solid rocket-propelled, small-lift launch vehicles were surveyed and ranked. Solid rocket boosters of underperforming launch vehicles were investigated for manufacturing factors influencing payload fraction by comparing them to boosters of better-performing launch vehicles in their weight class. Relationships between payload fraction and the solid boosters’ mass fractions, casing construction, shape of thrust profile, propellant grain configuration and method employed to manufacture the grain were analysed. It is shown that those launch vehicles that did not possess or use the technology necessary to manufacture high-performance grain configurations like undercut finocyl in monolith composite casings ended up having boosters delivering poor thrust profiles with high inert mass ultimately leading to low payload fractions.

Structural Diagnosis of Solid Rocket Motors Using Neural Networks and Embedded Optical Strain Sensors

The main failures that could deteriorate the reliable operation of solid rocket motors (SRMs) and lead to catastrophic events are related to bore cracks and delamination. Current SRMs’ predictive assessment and damage identification practices include time-consuming and cost-demanding destructive inspection techniques. By considering state-of-the-art optical strain sensors based on fiber Bragg gratings, a theoretical study on the use of such sensors embedded in the circumference of the composite propellant grain for damage detection is presented. Deep neural networks were considered for the accurate prediction of the presence and extent of the defects, trained using synthetic datasets derived through finite element analysis method. The evaluation of this combined approach proved highly efficient in discriminating between the healthy and the damaged condition, with an accuracy higher than 98%, and in predicting the extent of the defect with an error of 2.3 mm for the bore crack depth and 1.6° for the delamination angle (for a typical ~406 mm diameter grain) in the worst case of coexistent defects. This work suggests the basis for complete diagnosis of solid rocket motors by overcoming certain integration and performance limitations of currently employed dual bond stress and temperature sensors via the more scalable, safe, sensitive, and robust solution of fiber optic strain sensors.

Structural integrity assessment of a solid propellant grain considering confining pressure effect

Confining pressure has a significant effect on the mechanical properties of solid propellant, and it is crucial to develop a refined structural integrity analysis and assessment method considering confining pressure effect and nonlinearity of propellant material for the design of propellant grain of a solid rocket motor (SRM), especially for the design of high charge modulus. In this work, an existing viscoelastic-viscodamage constitutive model considering confining pressure effect was implemented as a user-defined material subroutine and verified using a few experiments under various confining pressures. The mechanical responses and safety factor of a typical variable cross-section propellant charge SRM with various charge modulus under ignition pressurization load and room temperature were analyzed and evaluated. The results show that the user-defined material subroutine can well describe nonlinear mechanical responses of solid propellant under different experimental conditions. The Von Mises stress and minimum safety factor considering the confining pressure effect are higher than the value without considering the confining pressure effect, while the Von Mises strain is opposite. In addition, regardless of whether the confining pressure effect is considered or not, the maximum Von Mises stress and strain show a nonlinear increasing relationship with the charge modulus, and the minimum safety factor decreases with charge modulus. However, when analyzing the structural integrity of high charge modulus, using two evaluation methods will yield completely different evaluation results. It is believed that this research can support structural integrity analysis and design of high charge modulus SRM.

A stochastic constitutive model and its application to HTPB propellant

AbstractTo address the issue of randomness in the mechanical properties of the hydroxyl‐terminated polybutadiene (HTPB) propellant, a stochastic constitutive model (SCM) with a lognormally distributed random parameter Λ was proposed to describe their mechanical behaviors, and the structural integrity of a HTPB propellant grain was analyzed based on it. The results indicate that the stress‐strain curves predicted by the SCM have a good agreement with the experimental curves, and the experimental curves fall within a 95 % probability interval predicted by the SCM. The mechanical response of HTPB propellant grain under ignition pressurization is associated with the random parameters Λ. The maximum equivalent stress and safety factor increase approximately linearly with the increase of random parameters Λ, while the maximum equivalent strain and maximum damage coefficient decrease approximately linearly with the increase of random parameters Λ. The error in the mechanical response of the grain obtained based on the SCM and the experimental constitutive model is basically not more than 2 %, the SCM can effectively characterize the randomness in the mechanical response of propellant grain caused by the dispersion of HTPB propellant mechanical properties.

Multi-Objective Reverse Design and Pattern Analysis of Solid Propellant Grains

Solid propellant grain reverse design aims to discover optimal grain geometries by shape optimization methods to match the desired solid motor performance curves. To maximize the performance matching degree and the propellant loading fraction simultaneously, this study develops a multi-objective evolutionary neural network for the grain reverse design, where the burning surface regression calculation is efficiently employed using the fast-sweeping method. Then, grain shape feature extraction and pattern analysis are achieved through image singular value decomposition and self-organizing mapping, respectively. Finally, the design case of a dual-thrust motor and a Mars ascent vehicle show that the method can well balance the performance-matching degree and propellant loading fraction. Moreover, without any training data set, it can generate dozens of grain shape patterns, highlighting their diversity and providing new ideas for solid rocket motor designers. Our method can offer a new pathway for the research field of solid rocket motor design.

Stable aluminum-lithium alloy fuels for solid propellants by facile surface modifying

As a highly reactive metal fuel, aluminum–lithium (Al-Li) alloy is an ideal candidate for replacing Al powders in solid propellants. However, the Li solid solution and AlLi compounds on the surface of Al-Li alloy powders display high reactivity, which can react with a large number of organic and inorganic reagents. Thus, the incompatibility of Al-Li alloy with other components of propellants makes it difficult to be further applied in propellants. In this study, surface-modified Al-Li alloy powders (Li content of 5 wt%) with 1H,1H,2H,2H-perfluorodecyltrimethoxysilane (FAS17) were prepared by a facile self-assembly method, which made the alloy powders super-hydrophobic. The results of SEM, XPS and FIB-TEM show that the surface of Al-Li alloy powder is well-coated by an evenly distributed FAS17 layer. Due to the fluoroalkyl on the surface of the powders, the water contact angle increased by 91°and the intensity of the reaction between alloy powders and water is significantly reduced, which results in improved compatibility with other components of propellants.Meanwhile, the propellant grain of surface-modified powders had fewer defects than the sample before coating, and showed original excellent combustion performance. The average combustion pressure and pressurization rate increased by ∼114 kPa and ∼8613 kPa/s, and the steady burning rate increased by 0.24 mm/s. Therefore, the surface-modified Al-Li alloy powders with FAS17 are expected to be an attractive candidate as a highly active and stable fuel in solid propellants.

Research on the low-frequency fatigue behavior of NEPE solid composite propellant based on fractional derivative constitutive model

The long-term fatigue loading history from offshore vibration environment will cause microdamage and affect the mechanical properties of NEPE solid propellant grains. The paper investigates the evolution law of microdamage through constant-strain-amplitude fatigue tests, and proposes an improved fractional derivative constitutive model for effectively predicting the low-frequency fatigue behavior of NEPE solid propellant based on the experimental phenomena. The evolution law of microdamage is negative power functional with the loading time and exponential with the maximum loading strain during the fatigue loading process. The stress-softening behavior, the Mullins effect, and the accumulation of residual strain are observed, as characteristics of low-frequency fatigue behavior. The theoretical modeling of the stress-softening behavior and the Mullins effect is proven to be significant for effectively predicting the low-frequency fatigue behavior by the improved fractional derivative constitutive model, while strain-modfication is also necessary for eliminating the influence of residual strain. The fatigue damage in solid propellant grains cannot be neglected when assessing the structural integrity of a solid propellant grain which has experienced long-term transportation or offshore storage.

Synthesis of propellant grade HHTPB by hydrogenation of HTPB using Pd-activated charcoal as catalyst

To derive more performance from the conventional composite propellant based on hydroxyl-terminated polybutadiene (HTPB) and ammonium perchlorate (AP), it is envisaged to hydrogenate HTPB, which increases the H/C (hydrogen to carbon ratio) of the base polymer. This paper attempts to describe the partial hydrogenation of HTPB using a catalytic method that uses palladium supported by activated charcoal as a catalyst and HTPB polymer as a precursor. HTPB has a hydroxyl value of 41.0 mg KOH/g with a number-average molecular weight (Mn) of 6150, polydispersity (PD) of 2.25 was used as a precursor. Iso-propyl alcohol (IPA) and toluene were used as a solvent media to disperse the HTPB polymer during hydrogenation. The estimate revealed an increase in specific impulse (ISP) up to 1.2 s with ∼37 % hydrogenated HTPB (HHTPB) as binder in composite solid propellants. Partial hydrogenation is only attempted to retain other process capabilities essential for realizing a defect-free solid propellant grain with good structural integrity. In contrast, others attempted to reach near saturation. A reactor capacity of 100 ml, operating at 60 bar pressure, was used to synthesize HHTPB, and the extent of hydrogenation was controlled based on the numerous experiments varying the reactor parameters like operating temperature, operating pressure, and solvent-to-polymer ratio for a given catalyst concentration. Detailed characterization of the end product by FTIR, 1H NMR and 13C NMR to reveal the degree of hydrogenation along with generic polymer characteristics. The measured hydroxyl value of HHTPB is comparable with HTPB; however, a marginal increase in molecular weight and polydispersity was noticed at 37 % conversion, wherein other researchers found a loss in -OH value. Thermogravimetry analysis revealed that no significant change in the gasification rate. A slight increase in the H/C ratio and calorific value was observed for HHTPB compared to HTPB. Despite the increase in viscosity of HHTPB, the increase in the vinyl-type functional distribution of HHTPB aids for better process-ability during propellant processing. However, the propellant formulation should be optimized with the help of plasticizers, solid loading, etc., to achieve the required properties.

Investigation on A Viscoelastic Creep Damage Constitutive Model for HTPB Propellant and Its Application in Finite Element Analysis

Solid rocket motor (SRM) is typically kept in storage for a significant portion of its lifespan. During storage, the propellant grain creeps under the action of gravity. To investigate the creep properties of hydroyl-terminated polybutadiene (HTPB) propellant under long-term loading, a creep damage constitutive model is developed based on the generalized Kelvin model and continuum damage mechanics theory. Parameters for this model are determined through creep tests conducted on HTPB propellant under various stress levels. Furthermore, to enable the application of the developed propellant constitutive model in the finite element analysis of SRM, the derived constitutive equation is transformed into an incremental form and integrated into the user subroutine UMAT of the finite element analysis platform ABAQUS. Subsequent to this, a three-dimensional SRM model containing the case, the insulator, and the propellant grain is established. The mechanical response of the grain under thermal and gravitational loads is calculated and analyzed. The results indicate that the stress concentration region in the grain is located at the stress release boot in the forward dome of the motor, where damage occurs. The methods employed in this paper and the conclusions drawn can serve as a reference for evaluating the structural integrity and storage lifespan of the SRM.

Evaluation of Mixing Effect on Coupled Heat Release and Transfer Performance of a Novel Segregated Solid Rocket Motor

The effect of mixing on coupled heat release and transfer performance of a novel segregated solid motor is numerically evaluated with a transient two-dimensional combustion model. The results show that vortex structures are formed and evolved in the combustion chamber. Quantitative calculation of the mixing effect shows the inhomogeneous distribution of oxidant and fuel species. The well-mixing area is located in a narrow belt-like coupled combustion region near the burning surface of the propellant. Heat transfer coefficient decreases greatly due to lower combustion reaction rate and enlarged flow channel area. Heat transfer coefficients near the two ends of the propellant grain are higher than other parts due to the influence of vortex mixing. Raising the inlet mass flow rate leads to enhanced mixing and heat transfer, which results in a lower temperature and regression rate of the propellant with combustion time. Temperature and oxidation rates of H2 and CO are unevenly distributed in the boundary layer of coupled combustion. Increasing the mass flux of inlet oxidizer gas leads to a higher combustion heat release rate. Therefore, the gas-phase temperature increases significantly. The heat release rate reaches the maximum near the ends of the propellant grain, where vortex mixing strengthens the coupled combustion process in the motor.

Friction-induced ignition study of HTPB propellant based on a coupled chemo-mechano-thermodynamic model under ultrahigh acceleration overload conditions

A method is proposed to assess the friction-induced thermal safety of free-cast solid rocket motors subjected to ultrahigh acceleration overload conditions. By measuring the ignition possibility of propellant specimens during the extrusion friction process and determining the reaction kinetics and constitutive parameters, a coupling model considering the thermal, mechanical and chemical effects is proposed. The kinetic parameters of the thermal decomposition reaction and the parameters of the constitutive model are then calibrated accordingly by compression tests covering a large range of strain rates and differential scanning calorimetry (DSC) tests. Experiments on friction ignition are then conducted to validate the developed model at different extrusion pressures and sliding velocity conditions. The results show that the model developed in this work can accurately predict the ignition possibility and temperature distribution of the propellant. Based on this model, dynamic process simulations of a solid rocket motor subjected to an ultrahigh overload of 10000g were performed. Friction primarily occurs at the bottom and side surfaces of the propellant grain, and ignition is more likely to occur at the outer apex of the bottom surface. The temperature rise in the early stages of overload is primarily driven by the frictional conversion of the bottom surface.

Structural Integrity Assessment of an NEPE Propellant Grain Considering the Tension-Compression Asymmetry in Its Mechanical Property.

In order to investigate the effect of tension-compression asymmetry of propellant mechanical properties on the structural integrity of a Nitrate Ester Plasticized Polyether (NEPE) propellant grain, the unified constitutive equations under tension and compression were established, a new method for grain structural integrity assessment was proposed and the structural integrity of the NEPE propellant grain under the combined axial and transverse overloads was evaluated. The results indicate that the mechanical state of the NEPE propellant grain is in the coexistence of tension and compression under the combined axial and transverse overloads, and the tension and compression regions in the propellant grain is independent of the propellant constitutive behavior. The tension-compression asymmetry of the propellant mechanical properties has a certain impact on its mechanical response. The maximum equivalent stress and strain considering the tension-compression asymmetry falls between that obtained through the tension and compression constitutive model, and is the same as damage coefficient. The safety factor of the NEPE propellant grain considering the tension-compression asymmetry of its mechanical properties is larger than that non-considering, and the traditional method of structural integrity assessment is conservative.

Experimental Investigation on Aluminum-Based Water Ramjet for Propelling High-Speed Underwater Vehicles

Major challenges in developing and realizing a novel aluminum–water reaction-based water ramjet propulsion system for high-speed underwater vehicles and demonstration of a water-breathing jet propulsion test facility are investigated. Two stages of combustion, propellant grain combustion and subsequent water combustion, with primary combustion products are adopted. High-pressure-molded propellant grains up to 45% of micro–nano () aluminum were prepared and combusted in the primary chamber, which exhibits mild ignition delay, and a residue of 4–6% was retained. Once water is injected into the secondary chamber, the net thrust generation is increased more than twice from the exhaust jet and improves the specific impulse by 40%. The lean fuel conditions in the secondary chamber lead to reduction in combustion propensity, which causes drop in efficiency. The ultrafine iron-oxide-catalyzed micro–nano blended propellants marginally improved the propulsive performance than the uncatalyzed compositions. The efficiency of the catalyzed propellants was enhanced up to 38.6%. Aluminum agglomeration in primary combustion considerably occurred; apparently, only a fraction of aluminum particles or agglomerates are completely burnt within the secondary chamber, and the remaining aluminum particles are either partially burnt or go unreacted.

Flow Field Simulation Tool of Solid Propulsion Control Systems for Missile Applications

In order to achieve hit-to-kill miss distances against manoeuvrable ballistic missile targets, future generation missiles calls for fast response non-conventional propulsion control systems during terminal homing period in high-endo to exo-atmosphere regions augmenting aero control. Based on advances in thrust modulation controlling throat area in solid propulsion pintle motor, control systems are developed for missile Divert and Attitude Control Systems (DACS) applications using multiple nozzles in pitch/yaw directions connected to common gas generator. Control thrust vector for lateral and attitude corrections is generated with proportional distribution of total thrust in pitch/yaw directions through real time thrust modulation of pintle nozzles
 Towards development of propulsion control systems based on solid propulsion, prototype systems: Thrust Controlled Motor (TCM) and Divert Thruster Flight Propulsion Control System (DTFPCS) are developed to demonstrate thrust modulation/ control thrust vector generation in solid propulsion and finalize unified controller for various missile control applications. Design & development process of prototype systems calls for flow field simulation tool for parametric design analysis/optimization and generate performance maps/control parameters based on detailed flow distributions. Present paper presents flow field simulation tools with Steady Flow Field (SFF) model and Dynamic Flow Field (DFF) model integrating dynamics of pintle movement with steady flow solver. Parametric analysis of geometrical profiles of pintle/throat regions and effect of pintle speed on system response are presented for system design optimization. Performance maps and controller maps of prototype systems are generated based on flow field distributions for nozzle thrust modulation. Simulated results are compared with open loop hot tests and unified controller parameters are updated for control thrust vector generation. Finally flow field distributions of DTFPCS operating modes: neutral-thrust and lateral-thrust are presented demonstrating the utility of simulation tool in design analysis and system development. Present simulation tool is critical in system design optimization and unified controller development for various flight control applications with minimum number of developmental tests. Further work of integrating propellant grain geometry variation during motor hot tests, with flow field model is in progress to predict control system performance for various missile control applications.

Effect of Mechanical Heterogeneity on the Structural Integrity of HTPB Propellant Grain.

To investigate the structural effects of the mechanical heterogeneity of Hydroxyl-terminated polybutadiene (HTPB) propellant grain under ignition pressurization, a gradient finite element method was proposed to evaluate its structural integrity. The heterogeneous mechanical properties of the propellant grain were constructed and assessed. The results demonstrate that the mechanical properties of the propellant grain are spatially variable when taking into account the effect of the load. The range of variation in the mechanical properties is related to the size of the load and its effect on the mechanical properties of the propellant. Two key parameters that affect the mechanical response of the grain are the non-uniform distribution of the modulus and the damage strain threshold. An increase in the propellant modulus leads to an increase in the stress response and a decrease in the strain response of the propellant grain under ignition pressurization. Meanwhile, an increase in the damage strain threshold improves the propellant's modulus in the linear elastic stage in a disguised form. This also leads to an increase in the stress response and a decrease in the strain response when the strain response exceeds the damage strain threshold. The safety factor, based on the equivalent strain failure criterion of the grain, directly depends on both the strain response of the propellant grain and the maximum elongation of the propellant. Furthermore, the change in the safety factor of two propellant grains is primarily affected by the maximum elongation of the propellant.

Investigation of the Effect of Axial Gap on the Mechanical Response of a Cartridge-Loaded CMDB Propellant Grain under Vibration Loads

In this study, the effect of the axial gap on the mechanical response of a cartridge-loaded propellant grain under vibration loads is investigated. The wide strain rate range of uniaxial compression tests ( 1.7 × 10 − 3 ~ 4 × 10 3 s − 1 ) on the composite modified double base (CMDB) propellant was carried out by using a universal testing machine, a hydraulic testing machine, and a split Hopkinson pressure bar system, respectively. A linear viscoelastic constitutive model of the CMDB propellant was developed by using the experimental measurements. The results show the studied CMDB propellant has a strong strain rate dependence, exhibiting an initial linear elasticity followed by a strain hardening region. The dynamic process of collision between the propellant grain and the motor case in the axial direction induced by vibration loads was simulated with the developed constitutive model by using the finite element method. The effects of the gap size between the propellant grain and the case and the vibration frequency on the mechanical response of the grain were studied. This shows that with a constant vibration frequency, the stress of the grain increases first and then decreases with increasing gap size. Moreover, the stress increases with increasing vibration loads.

Computational Technique for Crack Propagation Simulation in Viscoelastic Solid Propellant

To further investigate the fracture response in propellant grain, numerical methodology is proposed to cope with crack propagation simulation especially for the mixed mode condition. The numerical discrete scheme of the propellant linear viscoelastic constitutive model is proposed, which provides a key means for the simulation of crack propagation. In order to simulate the cohesive traction distribution on the new crack surface, the extrinsic Park-Paulino-Roesler (PPR) cohesive zone model (CZM) is introduced. To let the crack propagate along any direction determined, element splitting technique and its corresponding topological operations are proposed step by step. Then, computational simulation implementation process is explained in greater detail. Typical fracture problem, single edge-notched tension test (SENT) is solved to demonstrate the efficiency and accuracy of the proposed method. In addition, double edge-notched tension test (DENT) as well as plate tension test with a slant crack is conducted to show the special fracture characters in viscoelastic solid propellant, like time dependence. Computational results reveal that the method proposed can be utilized in further fracture investigation in solid propellant combined with the experimental findings.