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.