Additively manufactured aluminium nested composite hybrid rocket fuel grains with breathable blades

Qu, Dandan; Lin, Xin; Zhang, Kun; Li, Zhiyong; Wang, Zezhong; Liu, Guoliang; Meng, Yang; Luo, Gengxing; Wang, Ruoyan; Yu, Xilong

doi:10.1080/17452759.2023.2235680

Cited by 4 publications

(3 citation statements)

References 56 publications

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“…Because of the development of 3D printing technology, preparing a complex grain structure at one time by using 3D printing technology is convenient, and the prepared fuel grain has the advantages of homogeneous components, structural integrity, and fewer defects . Researchers began to prepare hybrid fuels through material extrusion (ME), , vat polymerization (VP), − power bed fusion (PBF), , and direct ink writing (DIW) . The vat polymerization technology has a high molding accuracy and high technical maturity, which makes it suitable for fabricating solid fuels with a complicated geometry.…”

Section: Introductionmentioning

confidence: 99%

Combustion Characteristics of Vat-Photopolymerized Fuels with a Spiral Star Port for Hybrid Propulsion

Chen,

Fu,

Yang

et al. 2024

Langmuir

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Despite hybrid rocket motors offering distinct advantages over solid or liquid rocket motors, their low regression rate and insufficient combustion efficiency remain significantly unimproved. This study focuses on the effects of the helix lead on the regression rate distribution and combustion efficiency of vat-polymerized fuel grains with a spiral star port for a hybrid rocket. Both experimental and numerical investigations were conducted to study the combustion characteristics and regression rate distribution of three-dimensional (3D) print grains. Spiral star grains with varying helix leads of 60, 90, and 120 mm were fabricated using light-curing 3D printing technology. A 3D simulation model was developed to obtain the temperature distribution, species mass distribution, and combustion efficiency. Furthermore, firing tests were performed on a two-dimensional radial hybrid combustion test stand to measure the regression rate. Digital image processing of computed tomography images was used to determine the regression rate. Simulation results indicated that the spiral star grain port helps to improve the combustion efficiency compared with those seen with round tube and straight star port grains. With an increase in the axial distance, the flame zone gradually shrinks, and the smaller the helix lead, the faster the shrinkage. At a mass flow rate of 1.50 g/s for oxygen, the regression rate of the spiral star grains is significantly higher than that of the straight star grain and the conventional round tubular grains, and the regression rate gradually increases with a decrease in the helix lead. This finding is expected to solve the problem of the low regression rate of solid fuels with spiral star pore-shaped grains prepared by the light-curing 3D printing method.

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Section: Introductionmentioning

confidence: 99%

Combustion Characteristics of Vat-Photopolymerized Fuels with a Spiral Star Port for Hybrid Propulsion

Chen,

Fu,

Yang

et al. 2024

Langmuir

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show abstract

“…In recent years, three-dimensional (3D) printing technology has become sufficiently developed and successfully applied to the manufacturing of hybrid rocket fuel grains [25][26][27][28][29][30][31][32]. This technique allows for direct integral molding of polymeric fuel grains with a complex single port, which is difficult to accomplish using traditional manufacturing methods [25].…”

Section: Introductionmentioning

confidence: 99%

“…Varying regression rates of fuels generate groove structures that facilitate oxidant vortex flow to improve turbulence and combustion efficiency. Lin et al [31,32] subsequently modified the helical structure framework by perforation and used metallic materials to strengthen the mechanical properties and combustion characteristics of the fuel grains. These studies validated the potential of embedded skeletal reinforcement.…”

Section: Introductionmentioning

confidence: 99%

Regression Rate and Combustion Efficiency of Composite Hybrid Rocket Grains Based on Modular Fuel Units

Pan,

Lin,

Wang

et al. 2024

Aerospace

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This study investigated combustion characteristics of composite fuel grains designed based on a modular fuel unit strategy. The modular fuel unit comprised a periodical helical structure with nine acrylonitrile–butadiene–styrene helical blades. A paraffin-based fuel was embedded between adjacent blades. Two modifications of the helical structure framework were researched. One mirrored the helical blades, and the other periodically extended the helical blades by perforation. A laboratory-scale hybrid rocket engine was used to investigate combustion characteristics of the fuel grains at an oxygen mass flux of 2.1–6.0 g/(s·cm2). Compared with the composite fuel grain with periodically extended helical blades, the modified composite fuel grains exhibited higher regression rates and a faster rise of regression rates as the oxygen mass flux increased. At an oxygen mass flux of 6.0 g/(s·cm2), the regression rate of the composite fuel grains with perforation and mirrored helical blades increased by 8.0% and 14.1%, respectively. The oxygen-to-fuel distribution of the composite fuel grain with mirrored helical blades was more concentrated, and its combustion efficiency was stable. Flame structure characteristics in the combustion chamber were visualized using a radiation imaging technique. A rapid increase in flame thickness of the composite fuel grains based on the modular unit was observed, which was consistent with their high regression rates. A simplified numerical simulation was carried out to elucidate the mechanism of the modified modular units on performance enhancement of the composite hybrid rocket grains.

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Effect of characteristic structure of nested composite hybrid rocket fuel grain on combustion properties

Wang,

Lin,

Wang

et al. 2024

Acta Astronautica

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Additively manufactured aluminium nested composite hybrid rocket fuel grains with breathable blades

Cited by 4 publications

References 56 publications

Combustion Characteristics of Vat-Photopolymerized Fuels with a Spiral Star Port for Hybrid Propulsion

Combustion Characteristics of Vat-Photopolymerized Fuels with a Spiral Star Port for Hybrid Propulsion

Regression Rate and Combustion Efficiency of Composite Hybrid Rocket Grains Based on Modular Fuel Units

Effect of characteristic structure of nested composite hybrid rocket fuel grain on combustion properties

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