Advantages of Using Additive Manufacturing to Build "Green" Fuels for Hybrid Propulsion

A, Whitmore Stephen

doi:10.35840/2631-5009/7502

Cited by 3 publications

(5 citation statements)

References 12 publications

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“…3 Previously, the authors of this report have experienced considerable success with small spacecraft systems using gaseous oxygen (GOX) and 3-D printed thermoplastics like ABS (acrylonitrile-butadienestyrene) as the propellants. 4,5 However, GOX was rejected for this upper-stage application due to its low density, required storage pressures, and significant potential for fire hazards when stored in significant quantities at high pressures. Due to its high density, hydrogen peroxide (H 2 O 2 ) was considered to be very promising oxidizer for this application.…”

Section: Hybrid Rockets As a Green Propulsion Alternativementioning

confidence: 99%

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Catalyst development for an arc-ignited hydrogen peroxide/ABS hybrid rocket system

Whitmore¹,

Martinez²,

Merkley³

2018

AAOAJ

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The authors have collaborated with an industry partner to develop a prototype upper stage for a dedicated nano-launch vehicle. In addition to providing sufficient impulse for orbit insertion, the unique motor system also provides capability for multiple restarts; allowing operation as an orbital maneuvering thruster. The hybrid motor design uses 85%-90% hydrogen peroxide solution and 3-D printed ABS (acrylonitrilebutadiene-styrene) as propellants. In the original system design the peroxide catalyst bed was completely removed and a patented arc-ignition system thermally ignited the propellants. The thermal ignition system was effective but resulted in a combustion latency of approximately 1-second, reducing overall performance and allowing for significant variability in the delivered total impulse. This work investigates whether adding a small catalyst pack for ignition augmentation can eliminate or significantly reduce the observed ignition latency and improve overall system performance. The effectiveness of multiple catalytic minerals including potassium permanganate, manganese dioxide, manganese (III) oxide, and potassium nitrate were examined and compared to traditional noble-metal catalyst materials like silver or platinum. These alternative materials are significantly less expensive than noble metals. Catalytic activity test results, designs for an augmentation catbed integrated with the thermal ignition system, and preliminary unaugmented and augmented hot-fire test results are presented. Aeronautics and Aerospace Open Access Journal Research Article Open AccessCatalyst development for an arc-ignited hydrogen peroxide/ABS hybrid rocket system 357

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Section: Hybrid Rockets As a Green Propulsion Alternativementioning

confidence: 99%

“…Both of these activation methods are quite time consuming, and while nitric acid solutions are relatively benign; working with samarium nitrate poses major health concerns and must be handled with extreme caution. 5 These recurring hands-on activities add to the cost of the catbed development.…”

Section: Traditional Noble Metal Catalyst Materialsmentioning

confidence: 99%

Catalyst development for an arc-ignited hydrogen peroxide/ABS hybrid rocket system

Whitmore¹,

Martinez²,

Merkley³

2018

AAOAJ

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“…16 Previously, the authors of this report have experienced considerable success with small spacecraft systems using gaseous oxygen (GOX) and 3-D printed thermoplastics as the propellants. 17,18 However, GOX was rejected for this upper-stage application due to its low density, required storage pressures, and significant potential for fire hazards when stored in significant quantities at high pressures. Due to its high density, hydrogen peroxide (H 2 O 2 ) was considered to be very promising oxidizer for this application.…”

Section: Hybrid Rockets As a Green Propulsion Alternativementioning

confidence: 99%

High-performing hydrogen peroxide hybrid rocket with 3-D printed and extruded ABS fuel

Whitmore¹,

Armstrong²,

Heiner³

et al. 2018

AAOAJ

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Development of a high-performing hybrid rocket system that employs 90% hydrogen peroxide and 3-D printable thermoplastic materials is reported. Traditionally, highgrade peroxide has been employed as a monopropellant using noble-metal catalysts to initiate thermal decomposition. Catbeds beds are expensive, heavy, and contribute no propulsive mass to the system. Catbeds exhibit limited operational lifetimes, and are often rendered inactive due to the high temperatures of thermal decomposition. The presented alternative thermally-decomposes the injected peroxide stream using an electrostatic ignition system, where as a moderate electric field is introduced to the additively layered ABS fuel grain. Electrostatic arcs are induced within the 3-D printed surface features, and produce sufficient pyrolyzed fuel vapor to induce spontaneous combustion when a flow of gaseous oxygen is introduced. Heat released is sufficient to thermally decompose the injected peroxide stream. The liberated heat and oxygen from decomposition drive full combustion along the length of the fuel grain. Gaseous oxygen pre-leads as small as 250ms reliably initiate combustion. Multiple on-demand relights are provided with this system. Achieved laboratory specific impulse values exceed 215s under ambient conditions, with a projected vacuum value exceeding 300s. Density specific impulse values exceeding 4000N-s/liter are achievable with this system.

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“…The introduction of FDM into the manufacturing process of HRM fuel grains has also allowed for the creation of far more complex combustion port geometries. The traditional method of 'cast and cure,' which is used for materials such as HTPB and paraffin, requires a mold and internal tooling that can be quite complex depending on the desired geometry of the fuel grain [12]. Although recent work has been done on the use of disposable tooling structures, it is generally accepted that once the fuel mixture has cured, the internal tooling must be removed before the motor is ready for use.…”

Section: Introductionmentioning

confidence: 99%

“…Several recent studies have explored the use of rapid prototyping in the design and fabrication of HRM fuel grains. The bulk of research in this field has been carried out at the Utah State University and has centered around the exploration of the effects of a helical fuel grain on the performance of the HRM regression rate [12,[14][15][16][17]. It has been shown that the helical combustion port significantly increased the regression rate when compared to straight cylindrical ports.…”

Section: Introductionmentioning

confidence: 99%

Small-Scale Static Fire Tests of 3D Printing Hybrid Rocket Fuel Grains Produced from Different Materials

McFarland

Antunes

2019

Aerospace

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The last decade has seen an almost exponential increase in the number of rocket launches for sounding missions or for delivering payloads into low Earth orbits. The emergence of new technologies like rapid prototyping, including 3D printing, is changing the approach to rocket motor design. This project conducted a series of small-scale static fire tests of fused deposition manufacturing hybrid rocket motors that were designed to explore the performance of a variety of commonly available fused deposition manufacturing materials. These materials included acrylonitrile butadiene styrene, acrylonitrile styrene acrylate, polylactic acid (PLA), polypropylene, polyethylene terephthalate glycol, Nylon, and AL (PLA with aluminum particles). To test the performance of small-scale fuel grains, a modular apparatus with a range of sensors fitted to it was designed and manufactured. The small-scale testing performed static burns on two fuel grains of each material with initial dimensions of 100 mm long and 20 mm in diameter with a 6 mm straight circular combustion port. The focus of this study was mainly on the regression rates of each material of fuel grains. Acrylonitrile styrene acrylate and Nylon showed the highest regression rates, while the polyethylene terephthalate glycol regression rates were relatively poor. Also, the acrylonitrile butadiene styrene and acrylonitrile styrene acrylate demonstrating relatively high regression rates when compared to existing hybrid fuels like hydroxyl-terminated polybutadiene.

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Advantages of Using Additive Manufacturing to Build "Green" Fuels for Hybrid Propulsion

Cited by 3 publications

References 12 publications

Catalyst development for an arc-ignited hydrogen peroxide/ABS hybrid rocket system

Catalyst development for an arc-ignited hydrogen peroxide/ABS hybrid rocket system

High-performing hydrogen peroxide hybrid rocket with 3-D printed and extruded ABS fuel

Small-Scale Static Fire Tests of 3D Printing Hybrid Rocket Fuel Grains Produced from Different Materials

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