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Reported study of composite-propellant burning summarizes recent advances in understanding behavior of propellant formulations based on ammonium perchlorate (AOP), binder, and aluminum in various proportions and particle size distributions. Approach presented incorporates adapted version of earlier model for monopropellant AP. Objective is to predict burning-rate characteristics of composite propellants at high pressure.
Large aluminum particle behavior in composite propellant combustion
Metallized and nonmetallized composite solid propellant burning rates, analyzing effects of acceleration, noting agglomeration and nonnormal conditions
The thermal decomposition of ammonium perchlorate (AP) and ammonium-perchlorate-based composite propellants is studied using the simultaneous thermogravimetric modulated beam mass spectrometry (STMBMS) technique. The main objective of the present work is to evaluate whether the STMBMS can provide new data on these materials that will have sufficient detail on the reaction mechanisms and associated reaction kinetics to permit creation of a detailed model of the thermal decomposition process. Such a model is a necessary ingredient to engineering models of ignition and slow-cookoff for these AP-based composite propellants. Results show that the decomposition of pure AP is controlled by two processes. One occurs at lower temperatures (240 to 270 C), produces mainly H2O, O2, Cl2, N2O and HCl, and is shown to occur in the solid phase within the AP particles. 200(micro) diameter AP particles undergo 25% decomposition in the solid phase, whereas 20(micro) diameter AP particles undergo only 13% decomposition. The second process is dissociative sublimation of AP to NH3 + HClO4 followed by the decomposition of, and reaction between, these two products in the gas phase. The dissociative sublimation process occurs over the entire temperature range of AP decomposition, but only becomes dominant at temperatures above those for the solid-phase decomposition. AP-based composite propellants are used extensively in both small tactical rocket motors and large strategic rocket systems.
Burning solid ammonium perchlorate composite propellants surface structure observation to assess heterogeneous or subsurface reactions, using scanning electron microscope
The response functions of composite propellants are theoretically derived, including explicitly the pressure-dependent degradation term in the condensed phase, hypothesizing that the overall rate-limiting reactions are in the relatively low temperature condensed phase. The method of 'inner' and 'outer' expansions with the reduced activation energy as the singular perturbation parameter has been employed. The results cover subsurface reactions with and without surface reactions, adiabatic and uniform-combustion models for the quasi-steady gas phase processes. The response functions display several experimentally observed features like dependence on mean pressure and the instability behavior of some 'zero-n' propellants.
This work was conducted to define further the effects of propellant composition variables on the acceleration-induced burning rate augmentation of solid propellants. The rate augmentation at a given acceleration was found to be a nonlinear inverse function of the reference burning rate and not controlled by binder or catalyst type at a given reference rate. A nonaluminized propellant and a low rate double-base propellant exhibited strong transient rate augmentation due to surface pitting resulting from the retention of hot particles on the propellant surface.
Seven formulations of ammonium perchlorate composite propellant (APCP) are developed and their properties relevant for successful additive manufacture are characterized. Extrusion in a custom-built 3D printing system and spindle viscometry are used to collect viscosity measurements of curing primary and non-curing secondary versions of the formulations. The formulations that behave similarly to a Bingham plastic, with apparent viscosities between 4 and 8 thousand Pa*s at 30 minutes post-mix, are determined to be most suitable for printing applications. Measurements of one material show a yield stress of 1 kPa. Ambient pressure burn rates of 2.0–2.9 mm/s were measured for the compositions tested. All measured burn rates were comparable to the lower end of typical burn rates for APCP. In conclusion, the results of the characterization demonstrate a propellant suitable for use in a 3D printing system.
The Cohen & Strand model for AP composite propellants is applied as boundary conditions, one for AP and one for binder, in solving the heat conduction equation in each to compute linear and non-linear combustion response properties for each and for the aggregate propellant. Iterations couple AP and binder through the quasi-steady flame processes. Illustrative results for linear response functions (pressure-coupled and velocity-coupled) are presented for a monomodal AP propellant varying AP size, pressure and crossflow speed, and examples of non-linear responses to arbitrary waveforms are shown. A quantitative comparison with response function data is limited to one well-characterized research formulation. Mechanistic implications are discussed, including recommendations for future modeling work.
Rocket engine combustion mechanism of ammonium perchlorate composite propellants
A burner is designed to model on a large scale (millimeters) the complex vapor phase processes that take place on awkwardly small scales (about a hundred microns) in the combustion of practical AP/ composite propellants at conventional pressures. Binder vapor evolution is modeled with gaseous fuel (ethane in the experiments reported) flow through a porous plate and oxidizer vapor with the flow of a gaseous oxidizer (air and enriched air in the experiments reported) through discrete holes in the porous plate. Measured flame standoff distance and surface temperature variations are consistent with theoretical predictions at atmospheric pressure. Data obtained at several atmospheres are discussed in the light of the current theories of propellant burning that place varying emphasis on the roles of chemical kinetics and fluid dynamic diffusion/mixing in the vapor phase of a burning composite propellant. The potential and proposed future applications of the burner are indicated.
Mechanical characterization of solid fuel propellants - stress-strain behavior of inert composite propellant under multiaxial loading conditions
Ammonium perchlorate composite propellant with organic Cu/II/ chelate catalytic additive
Surface flame spreading characteristics of ICRPG reference composite propellant composed of ammonium perchlorate with polyurethane binder
A review is presented of theoretical and experimental studies of composite propellant combustion. The theoretical investigations include a model of the combustion of a nonmetallized ammonium perchlorate (AP) propellant (noting time scales for vapor-phase combustion and the condensed phase) and response functions in pressure-coupled oscillations. The experimental studies are discussed with reference to scale-modeling apparatus, flame standoff distance versus velocity as a function of pressure, and results from T-burner firings of a nonmetallized AP/polysulfide propellant. Research applications including problems with nitramine propellants, the feasibility of stop-restart rockets with salt quench, and combustion problems in large boosters are outlined.
Controlled sound field effects on burning rate of composite solid propellants in rocket motor
A study of life-cycle cost is conducted to determine acceptable options for composite propellant tanks at low cost and weight and for use at moderate pressures. The review examines all cost issues relevant to the production, mass, applications, and reliability of the tanks for pressure-fed rockets. Specific attention is given to the manufacturing and life-cycle issues relevant to the use of composite materials in this application since composites are effective materials for liquid propellant tanks. Specific costs and parametric considerations are given for several tank candidates with 62,303-lb capacities. The mass sensitivity of the fourth stage for the concept vehicle is shown to be high, and the use of a 325-psi fourth-stage tank is shown to yield the minimum cost/lb for the stage. Wound S-glass/epoxy composites can be employed as cost-effective replacements for steel in the design of liquid-propellant tanks.
Spectrographic measurements of composite solid propellant flame zone structure