BURNING RATES OF SOLID PROPELLANTS SECTION REPORT NO. 4-3
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Classes of instability behavior are reviewed and related to theory and to aspects of the combustion process. Experimental methods for small-scale testing of stability characteristics of propellants are described and typical results are presented.
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The techniques of propellant selection and characterization and the compromises that may be forced on the designer by the change of a propellant parameter are discussed. Rules for the selection of a general propellant type are presented. The characterization of various propellant properties is then approached parameter by parameter. Tailoring pitfalls and compromises are identified whenever possible, and appropriate cross references are used. Related design criteria monographs frequently are cited for a more detailed treatment of the topic under discussion. A list of source references is provided. These references, coupled with established texts in the field, should give the depth of knowledge necessary to the designer to aid in the selection of the most nearly optimum propellant for the design application.
Thermal vacuum design supporting thruster tests indicate no problems under the worst case conditions of sink temperature and spin rate. The reliability of the system was calculated to be 0.92 for a five-year mission. Minus the main energy storage capacitor it is 0.98.
Instantaneous burning rate data for a polybutadiene acrylic acid propellant, containing 16 weight percent aluminum, were calculated from the pressure histories of a test motor with 96.77 sq cm of burning area and a 5.08-cm-thick propellant web. Additional acceleration tests were conducted with reduced propellant web thicknesses of 3.81, 2.54, and 1.27 cm. The metallic residue collected from the various web thickness tests was characterized by weight and shape and correlated with the instantaneous burning rate measurements. Rapid depressurization extinction tests were conducted in order that surface pitting characteristics due to localized increased burning rate could be correlated with the residue analysis and the instantaneous burning rate data. The acceleration-induced burning rate augmentation was strongly dependent on propellant distance burned, or burning time, and thus was transient in nature. The results from the extinction tests and the residue analyses indicate that the transient rate augmentation was highly dependent on local enhancement of the combustion zone heat feedback to the surface by the growth of molten residue particles on or just above the burning surface. The size, shape, and number density of molten residue particles, rather than the total residue weight, determined the acceleration-induced burning rate augmentation.
The ways are described by which propellant processing is affected by choices made in designing rocket engines. Tradeoff studies, design proof or scaleup studies, and special design features are presented that are required to obtain high product quality, and optimum processing costs. Processing is considered to include the operational steps involved with the lining and preparation of the motor case for the grain; the procurement of propellant raw materials; and propellant mixing, casting or extrusion, curing, machining, and finishing. The design criteria, recommended practices, and propellant formulations are included.
The results of curing vinyl alcohol terpolymers of ethylene, propylene and vinyl acetate are reported for an average functionality of 1.24 when reacted with an equivalent amount of diisocynate, and saturated polyisoprene derivative is described having terminal methyl ester functionality. The development is reported of two hydroxy-telechelic polyisoprenes prepared by DEAB initiated free radical polymerization followed by LiAlH4 reduction of the end groups.
Various experimental factors were examined to determine the source of difficulty in an isoprene polymerization in the 5-gallon reactor which gave a non-uniform product of low functionality. It was concluded that process improvements relating to initiator and monomer purity were desirable, but that the main difficulty was in the initiator feed system. A new pumping system was installed and an analog simulation of the reactor, feed system and initiator decomposition kinetics was devised which permits the selection of initial initiator concentrations and feed rates to use to give a nearly uniform initiator concentration throughout a polymerization run. An isoprene polymerization was run in which the process improvements were implemented.
Experimental results concerning the transient burning-rate augmentation of a 16% aluminum polybutadiene acrylic acid (PBAA) propellant burned in a 2-in. web motor at pressure levels from 300 to 1200 psia with centrifugal accelerations from 0 to 140 g. The orientation of the acceleration vector was varied to determine its effect on the transient burning rate. The burning-rate augmentation was strongly dependent on (1) acceleration level, (2) propellant distance burned (or burn time), and (3) orientation of the acceleration vector with respect to the burning surface. This transient rate augmentation resulted from the retention of molten metallic residue on the burning surface by the normal acceleration loading. The presence of the residue altered the combustion zone heat transfer and caused increased localized burning rates, as evidenced by the pitted propellant surfaces that were observed from extinction tests conducted at various acceleration levels.