This document discusses strategies for 3D printing advanced hybrid rocket fuel grains and developing hybrid-like liquid rocket motors. It begins with an overview of traditional rocket propulsion systems and the characteristics of hybrid rockets. It then outlines several ways additive manufacturing can be used to print complex fuel grain port designs that increase combustion efficiency and regression rate compared to traditional casting methods. These include printing the entire fuel grain, printing ports and shells to be filled, and combining printed and cast propellants. The document also proposes developing hybrid-like liquid rocket motors that remove turbopumps to reduce costs by using simpler, more accessible liquid fuels than traditional highly refined rocket fuels. In summary, additive manufacturing opens up new design possibilities for hybrid rocket fuel grains and moves toward
Proton Exchange Membrane Fuel Cells (PEMFC) are promising contender as the next generation energy source because of their striking features including high energy density, low operating temperature, easy scale up and zero environmental pollution.
My presentation on resin transfer molding. Not much description included. For reference i would recommend
" Composite manufacturing by Sanjay Mazumdar".
Proton Exchange Membrane Fuel Cells (PEMFC) are promising contender as the next generation energy source because of their striking features including high energy density, low operating temperature, easy scale up and zero environmental pollution.
My presentation on resin transfer molding. Not much description included. For reference i would recommend
" Composite manufacturing by Sanjay Mazumdar".
Metal matrix composites (MMCs) possess significantly improved properties including highspecific strength; specific modulus, damping capacity and good wear resistance compared to unreinforced alloys. There has been an increasing interest in composites containing low density and low cost reinforcements. Among various discontinuous dispersoids used, fly ash is one of the most inexpensive and low density reinforcement available in large quantities as solid waste by-product during combustion of coal in thermal power plants. Hence, composites with fly ash as reinforcement are likely to overcome the cost barrier for wide spread applications in automotive and small engine applications.
Using the scholar data and researcher point of view on composite materials. We illustrate the application of composite material in aerospace industry. Composites are highly efficient to make the parts and structure of aircrafts. We found the characteristics of the composite material make it very suitable material for aerospace industry. Composites like carbon fiber, carbon epoxy, and glass epoxy are very light and high strength which is mostly used in aircraft industries. In addition, our study takes the first step to highlight the uses of composite material to manufacture the different parts of aircraft's.
Composites have been part of new advances and their importance is remarkable over the years.
Apart from their limited research in aeronautical and laboratories, they have to be included in general applications extensively so as to get more effectiveness , strength,performance.
this seminar gives general idea on Metal Matrix Composites their production processes and types and their applications.
Autoclave is a closed vessel (Round or Cylindrical) in which processes occur under simultaneous application of high temperature and pressure. Autoclave molding technique is similar to vacuum bag and pressure bag molding method with some modifications. This method employs an autoclave to provide heat and pressure to the composite product during curing.
HEAT TRANSFER : STEADY STATE HEAT CONDUCTION NUMERICALS part2PRAMOD MAURYA
NUMERICAL SOLUTION FROM MUMBAI UNIVERSITY QUESTION PAPERS
7. A steam pipe of 5 cm inside diameter and 6.5 cm outside diameter is covered with a 2.75 cm radial thickness of high temperature insulation (k = 1.1 W/m.K). The surface heat transfer coefficient for inside and outside surfaces are 4650 W/m2.K and 11.5 W/m2.K, respectively. The thermal conductivity of the pipe material is 45 W/m.K. If the steam temperature is 200°C and ambient air temperature is 25°C, determine : (i) Heat loss per metre length of pipe (ii) Temperature at the interface. (iii) Overall heat transfer coefficient.
An electric cable of 20 mm diameter is insulated with rubber, which is exposed to atmosphere at 30°C. Calculate the most economical thickness of rubber insulation (k = 0.175 W/m.K). When cable surface temperature with and without insulation is at 70°C. Also calculate the percentage increase in heat dissipation and current carrying capacity when most economical thickness is provided. Take heat transfer coefficient, h = 9.3 W/m2.K.
plastic testing ASTM,ISO,IEC
mechanical,chemical,electrical optical testing.
Polymer Testing provides a forum for developments in the testing of polymers and polymeric products and is hence of interest to those concerned with testing rubbers and plastics in research, in production and in connection with the specification and purchase of products.
In materials science, Functionally Graded Material (FGM) may be characterized by the variation in composition and structure gradually over volume, resulting in corresponding changes in the properties of the material. The materials can be designed for specific function and applications.
This presentation contains the basics of the composites, types of the composites and the processing of the composites or we can say that manufacturing of the composites. This presentation can also help who are working on the de-lamination of the laminates.
Essentially there are 3 types of Li-ion battery cell (Cylindrical, Prismatic and Prismatic Pouch).
The documents aims to provide a simple comparative between the 3 types.
Metal matrix composites (MMCs) possess significantly improved properties including highspecific strength; specific modulus, damping capacity and good wear resistance compared to unreinforced alloys. There has been an increasing interest in composites containing low density and low cost reinforcements. Among various discontinuous dispersoids used, fly ash is one of the most inexpensive and low density reinforcement available in large quantities as solid waste by-product during combustion of coal in thermal power plants. Hence, composites with fly ash as reinforcement are likely to overcome the cost barrier for wide spread applications in automotive and small engine applications.
Using the scholar data and researcher point of view on composite materials. We illustrate the application of composite material in aerospace industry. Composites are highly efficient to make the parts and structure of aircrafts. We found the characteristics of the composite material make it very suitable material for aerospace industry. Composites like carbon fiber, carbon epoxy, and glass epoxy are very light and high strength which is mostly used in aircraft industries. In addition, our study takes the first step to highlight the uses of composite material to manufacture the different parts of aircraft's.
Composites have been part of new advances and their importance is remarkable over the years.
Apart from their limited research in aeronautical and laboratories, they have to be included in general applications extensively so as to get more effectiveness , strength,performance.
this seminar gives general idea on Metal Matrix Composites their production processes and types and their applications.
Autoclave is a closed vessel (Round or Cylindrical) in which processes occur under simultaneous application of high temperature and pressure. Autoclave molding technique is similar to vacuum bag and pressure bag molding method with some modifications. This method employs an autoclave to provide heat and pressure to the composite product during curing.
HEAT TRANSFER : STEADY STATE HEAT CONDUCTION NUMERICALS part2PRAMOD MAURYA
NUMERICAL SOLUTION FROM MUMBAI UNIVERSITY QUESTION PAPERS
7. A steam pipe of 5 cm inside diameter and 6.5 cm outside diameter is covered with a 2.75 cm radial thickness of high temperature insulation (k = 1.1 W/m.K). The surface heat transfer coefficient for inside and outside surfaces are 4650 W/m2.K and 11.5 W/m2.K, respectively. The thermal conductivity of the pipe material is 45 W/m.K. If the steam temperature is 200°C and ambient air temperature is 25°C, determine : (i) Heat loss per metre length of pipe (ii) Temperature at the interface. (iii) Overall heat transfer coefficient.
An electric cable of 20 mm diameter is insulated with rubber, which is exposed to atmosphere at 30°C. Calculate the most economical thickness of rubber insulation (k = 0.175 W/m.K). When cable surface temperature with and without insulation is at 70°C. Also calculate the percentage increase in heat dissipation and current carrying capacity when most economical thickness is provided. Take heat transfer coefficient, h = 9.3 W/m2.K.
plastic testing ASTM,ISO,IEC
mechanical,chemical,electrical optical testing.
Polymer Testing provides a forum for developments in the testing of polymers and polymeric products and is hence of interest to those concerned with testing rubbers and plastics in research, in production and in connection with the specification and purchase of products.
In materials science, Functionally Graded Material (FGM) may be characterized by the variation in composition and structure gradually over volume, resulting in corresponding changes in the properties of the material. The materials can be designed for specific function and applications.
This presentation contains the basics of the composites, types of the composites and the processing of the composites or we can say that manufacturing of the composites. This presentation can also help who are working on the de-lamination of the laminates.
Essentially there are 3 types of Li-ion battery cell (Cylindrical, Prismatic and Prismatic Pouch).
The documents aims to provide a simple comparative between the 3 types.
DEVELOPMENT OF PARAFFIN BASED FUEL FOR HYBRID ROCKET MOTORJHUMKI NANDY
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High Performance Computing for Instabilities in Aerospace Propulsion Systemsinside-BigData.com
In this deck from PASC 2019, Thierry Poinsot from Toulouse Fluid Mechanics Institute presents: High Performance Computing for Instabilities in Aerospace Propulsion Systems.
"Combustion produces more than 80 percent of the world's energy. This will continue for a long time as the global energy growth remains much larger than what new renewable energies can provide. Our civilization must allow the growth of combustion sources but, at the same time, keep global warming as well as pollution under control. Science has a key role in this scenario: it must optimize combustion systems far beyond the present state of the art. To do this, one promising path is to use High Performance Computation to compute and optimize combustors before they are built. This talk focuses on aerospace propulsion where optimization often leads to the occurrence of instabilities where combustion couples with acoustics, leading to unacceptable oscillations (the most famous example is the Apollo engine which required 1330 full scale tests to reach acceptable oscillation levels). The talk will show how simulation is used to control these problems, in real gas turbine engines and in rocket engines."
Watch the video: https://wp.me/p3RLHQ-kq4
Learn more: https://pasc19.pasc-conference.org/
Sign up for our insideHPC Newsletter: http://insidehpc.com/newsletter
2. 2
Basics: Major Rocket Propulsion Systems
(A) Liquid - most capable, expensive – Saturn 5, Shuttle Main Engine
(B) Solid - cheap and simple, most common – Tactical missiles,
Shuttle SRM Boosters
(C) Hybrid - safe, moderate expense, low performance (thrust,
efficiency), rarely used (Virgin Galactic - SpaceShip 1, 2)
Rockets are categorized by the phase states of their propellants.
These states have a great deal to do with how a rocket is used.
Oxidizer/
Fuel
Mixture
(Solid)
Oxidizer
(Liquid)
Fuel
(Solid)
Valve
Oxidizer
Fuel
Turbo-
pumps
(A) (B) (C)
3. 3
Hybrid Rocket Characteristics
Typical Selling Points for Hybrid Rockets
Advocates Like to say Hybrids:
Have Medium Performance (ideally near liquids)
Are Easily Shipped - “Responsive”
Can be throttled, re-lit like liquids
Simple, safe and inexpensive
The truth is…
We can’t burn them fast enough (low thrust)
They are not as efficient as they should be
Oxidizer
Valve
Fuel
4. 4
Fuel Grain Production – The Fundamental Problem
A Simplified Explanation of Casting
• Real castings often involve multiple ports, and stiffening webs
• Mandrels must be simple shapes
– No undercuts
– Little surface area
Mold or
Liner
Mandrel
Propellant
Grain
Port
5. 5
How We Generally Think of Hybrid Rocket Combustion
Similar illustrations appear throughout hybrid rocket literature
• Generally we assume gas flow parallel to the fuel surface
• We accept that convection will be weak
• Burn rate is limited by how fast gases can diffuse across the Flame
Pyrolysis by Radiation and Weak Convection
Fuel Grain (often HTPB Rubber)
FlameSheet
Head
End
Radiation (weak)
“Blowing” Conduction (weak)
Oxidizer Nozzle
End
6. 6
Traditional Techniques to Improve Performance
The techniques used to improve performance have problems too
Wagon Wheel
Low mass fraction
Challenging Fabrication
Chunks and splinters
Swirl Injection
Effect dies out
Slicing and Stacking
Complex
Chunks
Paraffin (wax) as High Regression Rate fuel
Mechanically weak
Ejects unburned fuel (lowering Isp)
Patent US5339625 A
Patent US6601380 B2
7. 7
Printed Hybrid (and other) Rockets
Major Advances Enabled by Additive Manufacturing
8. 8
Traditional versus Additive Manufactured Grain
Printing allows port shapes that dramatically increase performance
MJM Acrylic Fuel Grains
• Same
– Mass
– Dimensions
– Cross Section
• Helical shape forces
convection
• Creates 25% more
surface area
• More efficient
• Burns > Twice as Fast
AM fuel grains move from Radiation to Forced Convection
9. 9
Printing Strategies
Several Ways to Take Advantage of AM
• Print the whole fuel grain
– Seamless, monolithic, strong
– ABS is as good as traditional HTPB, but…
• Friendlier Chemistry
– Stronger, Stiffer, Greener
– Recyclable scrap
• Print just the port, or port and shell
– Cast paraffin, HTPB or other fuels
– Use printed structures to manipulate oxidizer flow
• Turbulence – inducing features
• Swirl - inducing features
Printed ABS
Printed Paraffin
Printed
Turbulator/
Cast Paraffin
10. 10
Printing Strategies (cont’d)
Several Ways to Take Advantage of AM
• Print multiple fuels at once
– MJM Acrylic/Paraffin
– FFF Multi-Head extruders and Mixing Extruders
• Print empty cells and fill with a solid or liquid fuel
– Extremely high regression rates are possible
– Very powerful fuels can be used
• Print empty containers and fill with cast composite
solid propellant
– Propellants like APCP can be cast as traditional
– May offer new grain shape opportunities to combine thrust
and efficiency
MJM Co-Printed
Acrylic/Paraffin
Printed Cell Structure
for Liquids
11. 11
Printing Strategies (cont’d)
Several Ways to Take Advantage of AM
• Print hollow fuel grain
• Use cast propellants
– Less expensive (currently)
– Print flow management features
• Swirl, turbulence…
– Include oxidizers to make new APCP motors
• ABS extrusion temperature too hot for Ammonium
Perchlorate
• May be able to have higher thrust, longer burn
Printed ABS/
Cast Paraffin
12. 12
Performance Characterization of Hybrid Rocket Fuel Grains with Complex Port Geometries Fabricated Using Rapid Prototyping Technology
D. Armold, E. Boyer, B. McKnight, J. D. DeSain, J. K. Fuller, K. K. Kuo, and T. Curtiss
International Journal of Energetic Materials and Chemical Propulsion, Vol.13, 2014
0.1
1.0
40 50 60 70 80 90 100
Acrylic Correlation
Straight-Port
ST-SW 1/8 tpi
ST-SW 1/4 tpi
ST-SW 1/2 tpi
RegressionRate(mm/s)
Oxidizer Mass Flux (kg/m
2
-s)
150
Hot-Fire Test Results – Acrylic MJM
Increased regression rate through printed features
13. 13
Performance Characterization of Hybrid Rocket Fuel Grains with Complex Port Geometries Fabricated Using Rapid Prototyping Technology
D. Armold, E. Boyer, B. McKnight, J. D. DeSain, J. K. Fuller, K. K. Kuo, and T. Curtiss
International Journal of Energetic Materials and Chemical Propulsion, Vol.13, 2014
0.9
1.0
2.0
3.0
50 60 70 80 90 100
Paraffin Correlation
SP
TRB 1/2 tpi
ST-SW 1/8tpi
ST-SW 1/4 tpi
ST-SW 1/2 tpi
Swept HC 1/4 tpi
Lg Swept HC 1/4 tpi
RegressionRate(mm/s)
Oxidizer Mass Flux (kg/m
2
-s)
150
Hot-Fire Test Results – Paraffin MJM
Increased regression rate through printed features
14. 14
Performance Characterization of Hybrid Rocket Fuel Grains with Complex Port Geometries Fabricated Using Rapid Prototyping Technology
D. Armold, E. Boyer, B. McKnight, J. D. DeSain, J. K. Fuller, K. K. Kuo, and T. Curtiss
International Journal of Energetic Materials and Chemical Propulsion, Vol.13, 2014
2.0
3.0
4.0
40 50 60 70 80 90 100
Paraffin Correlation
SP Paraffin
SP Par80%/Al20%
1-V TRB Paraffin (1/4 tpi)
3-V TRB Paraffin (1/4 tpi)
1-V TRB Par80%/Al20% (1/4 tpi)
RegressionRate(mm/s)
Oxidizer Mass Flux (kg/m
2
-s)
1.4
150
Hot-Fire Test Results (cont’d)
Increased regression rate through printed features
15. 15
Test Results- Effects of Pre-Heating
Testing of Hybird Rocket Fuel Grains at Elevated Temperatures with Swirl Patterns Fabricated Using Rapid Prototyping Technology
Brendan R. McKnight, Derrick Armold2, J. Eric Boyer3, and Kenneth K. Kuo4
John D. DeSain5, Jerome K. Fuller6, Brian B. Brady7, and Thomas J. Curtiss8
50th AIAA Joint Propulsion Conference
Significant Increase in Regression Rate without Drop in Isp
1.2
1.4
1.6
1.8
2
2.2
2.4
2.6
2.8
3
40 50 60 70 80 90 100 200
Paraffin Correlation
Cast Paraffin SP 22C
Lg Swept HC 22C (1/4 tpi)
Lg Swept HC 50C (1/4 tpi)
Cast Paraffin SP 35C
Cast Paraffin SP 55C
RegressionRate,mm/s
Oxidizer Mass Flux, kg/(m^2-s)
AM enables faster burning, more efficient paraffin grains
16. 16
Combing Printed and Cast Propellants
Significant Increase in Regression Rate without Drop in Isp
Hollow AM grains with flow management features
AM hollow grains
• Provide Containment,
Structure
• Allow heating (energy
efficient, faster burn)
• Provide Flow Management
Features (Turbulators, etc.)
• Leave the port-positive in
place or melt it away
Pour (cast)
Almost Any
Propellant
Print
Almost
Any Port
Shape
17. 17
Combing Printed and Cast Propellants (cont’d)
Significant Increase in Regression Rate without Drop in Isp
Hollow AM grains with flow management features
AM hollow grains accept propellants that
are hard to “print” like APCP (ammonium
perchlorate composite propellant):
• Ammonium Perchlorate and some
energetic additives degrade at FDM/FFF
temperatures
• Crosslinked, Thermoset, HTPB (if you
must)
• Mechanically weak propellants (paraffin,
etc.)
• Novel grain shapes realized through AM
could allow almost any thrust profile
Some Traditional Port Cast
Propellant Shapes and their
Thrust Profiles
18. 18
Combing Printed and Cast Propellants (cont’d)
Significant Increase in Regression Rate without Drop in Isp
Hollow AM grains with flow management features
0
50
100
150
200
250
300
350
400
450
0 2 4 6 8 10 12 14
ABS / Paraffin with Integrated
3-Fin Turbulator and GOX
Pre Tank Post Tank Chamber Temp
19. 19
Combing Printed and Cast Propellants (cont’d)
Significant Increase in Regression Rate without Drop in Isp
Hollow AM grains with flow management features
20. 20
Large Printers are Now Capable of Launch Vehicle Size
SEEMECNC’S “PARTDADDY”
PHOTO COURTESY OF SEEMECNC
• New, large format printers (industrial robots) eliminate
size constraints for some fuels (CF/ABS) - VERY large
prints are possible
• Large enclosed printers can print 154Kg (340lb) ABS
• Delta printers have stationary build platforms, enabling
very large prints
A LARGE FFF PRINTER BASED ON INDUSTRIAL ROBOTS
PHOTO COURTESY LOCKHEED MARTIN CORPORATION.
AN ENCLOSED CARTESIAN FFF PRINTER WITH A HEATED
BUILD VOLUME
PHOTO COURTESY OF COSINE ADDITIVE, INC.
Print size – no longer a limitation
21. 21
Large Printers are Now Capable of Launch Vehicle Size
2-SEAT CAR BEING PRINTED ON BAAM
PHOTO COURTESY OF CINCINNATI INC.
• Cincinnati Inc’s BAAM, billed as Largest AM
• Print envelope 20 x 7.75 x 6 feet
• Carbon Fiber filled ABS material
(probably capable of CF/Nylon)
Print size – no longer a limitation
BAAM PRINTER, PHOTO COURTESY OF CINCINNATI INC.
23. 23
Liquid-Enhanced Hybrid and Hybrid-Like Liquid Motors
• Adding small amounts of liquid fuel
– Increases combustion temperature, further increasing regression rate for
the solid fuels
– Increases solid fuel surface area as liquids are consumed
• Adding large amounts of liquid fuel
– Moves us toward a simpler liquid motor
– Allows less expensive, more easily obtained fuels to be used
– Will need significant research
24. 24
Hybrid-Like Liquid Motors
Removing Turbopumps = Removing a Major Cost
• Can Liquid Motors be made like
Hybrids?
• Expensive, highly refined
“Rocket fuels” like RP1 are
unnecessary
– RP-1 used to lubricate pumps
(typically no pumps on hybrids)
– Jet A (commonly available
kerosene)
– “Bunker Fuel” (Alkane lengths of
C= 12 – 70)
– Biofuels
Oxidizer
Fuel
Turbo-
pumps
Fuel
Management
Structures
Fuel
25. 25
Fuel Metering Strategies
• Tapered Port Wall
• Stacked Cones
• Spiral
• Enhanced Hybrid (small amounts of liquid)
C) Liquid-Enhanced
Hybrid
B) SpiralA) Stacked Cone
26. 26
Post Combustion Chamber Pressure
Analogous to thrust, increases with added kerosene
Adding kerosene significantly increases burn rate over solid ABS
(blowout)
27. 27
Liquid Fuel Passive Metering Example:
Triple Canted Helix + Tapered Port Wall
Liquid Fuel Pours
Into Port as Port
Wall Regresses
Thin Port Wall (top)
Burns-Through First
28. 28
Liquid Fuel Passive Metering Example (cont’d):
Triple Canted Helix, Tapered Port Wall
Burned and Unburned Specimen
(50mm diameter)
Cut-away showing Canted Spiral
and Tapered Port Wall
31. 31
Conclusion (and Caveats)
• Novel port shapes and design features are possible though AM
• Regression rate (Thrust) can be Doubled
• Specific Impulse (Efficiency) can also be increased
• Launch-vehicle–size fuel grains are within reach
• Inexpensive liquid motors may be possible
• A small amount of liquid fuel can enhance Hybrids
• Entirely new concepts like heated paraffin motors are enabled
• These things are true for SMALL motors
• Nobody knows how to passively control the flow of liquid fuel yet
• More work is needed, especially at larger scales
32. 32
Acknowledgements:
• The Aerospace Corporation
– John DeSain, Brian Brady, Andrea Hsu, Tom Curtis, Cody Shaw, Kevin Dorman
– The Aerospace Corporation’s Independent Research and Development
program.
• Pennsylvania State University
