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Cost estimates and feasibility of compression molded plastic motor cases and nozzles for solid rockets
Airbreathing/Rocket combined-cycle, and specifically rocket-based combined- cycle (RBCC), propulsion systems, typically employ an internal engine flow-path installed primary rocket subsystem. To achieve acceptably short mixing lengths in effecting the "air augmentation" process, a large rocket-exhaust/air interfacial mixing surface is needed. This leads, in some engine design concepts, to a "cluster" of small rocket units, suitably arrayed in the flowpath. To support an early (1964) subscale ground-test of a specific RBCC concept, such a 12-rocket cluster was developed by NASA's Marshall Space Flight Center (MSFC). The small primary rockets used in the cluster assembly were modified versions of an existing small kerosene/oxygen water-cooled rocket engine unit routinely tested at MSFC. Following individual thrust-chamber tests and overall subsystem qualification testing, the cluster assembly was installed at the U. S. Air Force's Arnold Engineering Development Center (AEDC) for RBCC systems testing. (The results of the special air-augmented rocket testing are not covered here.) While this project was eventually successfully completed, a number of hardware integration problems were met, leading to catastrophic thrust chamber failures. The principal "lessons learned" in conducting this early primary rocket subsystem experimental effort are documented here as a basic knowledge-base contribution for the benefit of today's RBCC research and development community.
This addendum report documents the results of two additional efforts for the Rocket Based Combined Cycle (RBCC) rocket-ejector mode research work carried out at the Penn State Propulsion Engineering Research Center in support of NASA s technology development efforts for enabling 3 d generation Reusable Launch Vehicles (RLV). The tasks reported here build on an earlier NASA MSFC funded research program on rocket ejector investigations. The first task investigated the improvements of a gaseous hydrogen/oxygen twin thruster RBCC rocket ejector system over a single rocket system. The second task investigated the performance of a hydrocarbon (liquid JP-7)/gaseous oxygen single thruster rocket-ejector system. To gain a systematic understanding of the rocket-ejector s internal fluid mechanic/combustion phenomena, experiments were conducted with both direct-connect and sea-level static diffusion and afterburning (DAB) configurations for a range of rocket operating conditions. For all experimental conditions, overall system performance was obtained through global measurements of wall static pressure profiles, heat flux profiles and engine thrust. Detailed mixing and combustion information was obtained through Raman spectroscopy measurements of major species (gaseous oxygen, hydrogen, nitrogen and water vapor) for the gaseous hydrogen/oxygen rocket ejector experiments.
Flight tests were conducted at the NACA Pilotless Aircraft Research Station, Wallops Island, to determine the characteristics of the Allegany Ballistics Laboratory's 6.2inch-diameter Deacon and lO-inch-scale model solid-propellant rocket motors. The tests were performed to assist in the development of these rockets which were designed for, and urgently needed to propel supersonic research models and pilotless aircraft. The tests showed that the rocket motors functioned properly under various flight- acceleration loads over a range of pre-ignition grain temperatures. A maximum velocity of 4180 feet per second was obtained at an elapsed time of 2.9 seconds with the 6.25-inch Deacon rocket motor at a gross weight of l9O pounds. Free-flight data of drag coefficient for the Deacon configuration for a Mach number range of 1.1 to 3.6 have been obtained from flight tests of several pounds. Camera studies of the take-off and flights of the Deacon rocket shared no evidence of breakup of propellant grains. An analysis of the forces to which the Deacon rocket grain is subjected was made. The analysis shows that the grain loading is most severe near the beginning and near the end of the rocket action time. The 10-inch-scale model rocket motor is a scaled model of the l6-inch- diameter multi-perforated, cast-grain rocket motor. A maximum velocity of 1625 feet per second at a time of 1.075 seconds was obtained at a gross weight of 309 pounds.
As a continuation of an investigation of the release characteristics of an MB-1 rocket carried internally by the Convair F-106A airplane, six missile-bay baffle configurations and a rocket end plate have been investigated in the 27- by 27-inch preflight jet of the NASA Wallops Station. The MB-1 rocket used had retractable fins and was ejected from a missile bay modified by the addition of six different baffle configurations. For some tests a rocket end plate was added to the model. Dynamically scaled models (0.04956 scale) were tested at a simulated altitude of 22,450 feet and Mach numbers of 0.86, 1.59, and 1.98, and at a simulated altitude of 29,450 feet and a Mach number of 1.98. The results of this investigation indicate that the missile-bay baffle configurations and the rocket end plate may be used to reduce the positive pitch amplitude of the MB-1 rocket after release. The initial negative pitching velocity applied to the MB-1 rocket might then be reduced in order to maintain a near-level-flight attitude after release. As the fuselage angle of attack is increased, the negative pitch amplitude of the rocket is decreased.
The objectives are: 1) To support the Cornell wave instruments in a study of dayside ion outflow. 2) In conjunction with the U. of Alaska ground optical data, a prime objective was to measure the topside Cusp ion spectra responsible for dayside proton aurora. If such a correlative measurement could be made, then monitoring of this cusp precipitation from the ground could be routinely achieved. The nature of Cusp ions has and will continue to provide information about dayside magnetic reconnection. 3) A third objective was to study the dayside microburst electron precipitation from the BPS/CPS population. The Scifer rocket flight showed a bursty electron population at 1000 km altitude correlated closely with pulsation ground aurora on closed field lines. The frequency of this pulsating aurora is about 1 Hz. Ground pulsation measurements have recorded dayside bursts of Pc1 waves which could very well be the source of the electrons responsible for the pulsating aurora. In support of the Caper flight, UNH provided ground induction antennas to measure the equatorial Pc1 waves that might be dumping trapped electrons from the Central Plasma Sheet population. The Caper flight was launched on the last day of the window and all the Cornell and UNH instrumentation worked perfectly. Unfortunately the rocket trajectory flew very far to the west of the ground site at Longyearbyen missing conjugacy by several hundred kilometers. This meant the intended aurora was not crossed and all the ground experiments were far from being near the foot print of the rocket ruling out correlative science. The "miss" was primarily due to a decision during the countdown by the Andoya Rocket Range to move the azimuth of the rocket to the west to avoid Norwegian fishing boats at the splash point of the first two stages, and to make matters worse, the dispersion of the fourth stage of the rocket added entirely in this direction. Although no publications have resulted from the UNH data up to this point, a joint publication with the U. of Alaska group using both the Scifer and Caper data is in preparation. The data will continue to be worked on. There is interest in the Caper data as evidence by two recent papers presented at the "Low Latitude Boundary Layer Chapman Conference" held in New Orleans, Louisiana in April 2001.
The Dendrite Remelting Rocket Experiment was performed aboard a Black Brant VC Sounding Rocket during a period which gravity levels of approximately 0.00001 g prevailed. The experiment consisted of cooling an aqueous ammonium chloride solution in a manner such that crystallization of ammonium chloride crystals proceeded throughout a three minute period of zero-g. The crystallization process during flight was recorded on 35 mm panatomic-x film. A number of ground crystallizations were similarly recorded for comparison purposes. The convective and thermal conditions in aqueous and metallic liquid systems were assessed under conditions of the flight experiment to help establish the relevance of the rocket experiment to metals casting phenomena. The results indicate that aqueous or metallic convective velocities in the Dendrite Remelting Rocket Experiment cell are of insignificant magnitudes at the 0.0001 to 0.00001 g levels of the experiment. The crystallization phenomena observed in the Rocket Experiment, therefore, may be indicative of how metals will solidify in low-g.
The all rocket mode of operation is shown to be a critical factor in the overall performance of a rocket based combined cycle (RBCC) vehicle. An axisymmetric RBCC engine was used to determine specific impulse efficiency values based upon both full flow and gas generator configurations. Design of experiments methodology was used to construct a test matrix and multiple linear regression analysis was used to build parametric models. The main parameters investigated in this study were: rocket chamber pressure, rocket exit area ratio, injected secondary flow, mixer-ejector inlet area, mixer-ejector area ratio, and mixer-ejector length-to-inlet diameter ratio. A perfect gas computational fluid dynamics analysis, using both the Spalart-Allmaras and k-omega turbulence models, was performed with the NPARC code to obtain values of vacuum specific impulse. Results from the multiple linear regression analysis showed that for both the full flow and gas generator configurations increasing mixer-ejector area ratio and rocket area ratio increase performance, while increasing mixer-ejector inlet area ratio and mixer-ejector length-to-diameter ratio decrease performance. Increasing injected secondary flow increased performance for the gas generator analysis, but was not statistically significant for the full flow analysis. Chamber pressure was found to be not statistically significant.
The all rocket mode of operation is a critical factor in the overall performance of a rocket based combined cycle (RBCC) vehicle. However, outside of performing experiments or a full three dimensional analysis, there are no first order parametric models to estimate performance. As a result, an axisymmetric RBCC engine was used to analytically determine specific impulse efficiency values based upon both full flow and gas generator configurations. Design of experiments methodology was used to construct a test matrix and statistical regression analysis was used to build parametric models. The main parameters investigated in this study were: rocket chamber pressure, rocket exit area ratio, percent of injected secondary flow, mixer-ejector inlet area, mixer-ejector area ratio, and mixer-ejector length-to-inject diameter ratio. A perfect gas computational fluid dynamics analysis was performed to obtain values of vacuum specific impulse. Statistical regression analysis was performed based on both full flow and gas generator engine cycles. Results were also found to be dependent upon the entire cycle assumptions. The statistical regression analysis determined that there were five significant linear effects, six interactions, and one second-order effect. Two parametric models were created to provide performance assessments of an RBCC engine in the all rocket mode of operation.
The purpose of this experimental research was to compare Marshall Space Flight Center's electrets with Thiokol's fixed flow air samplers during the Space Shuttle Solid Rocket Booster Demonstration Model-3 static test firing on October 19, 1978. The measurement of rocket exhaust effluents by Thiokol's samplers and MSFC's electrets indicated that the firing of the Solid Rocket Booster had no significant effect on the quality of the air sampled. The highest measurement by Thiokol's samplers was obtained at Plant 3 (site 11) approximately 8 km at a 113 degree heading from the static test stand. At sites 11, 12, and 5, Thiokol's fixed flow air samplers measured 0.0048, 0.00016, and 0.00012 mg/m3 of CI. Alongside the fixed flow measurements, the electret counts from X-ray spectroscopy were 685, 894, and 719 counts. After background corrections, the counts were 334, 543, and 368, or an average of 415 counts. An additional electred, E20, which was the only measurement device at a site approximately 20 km northeast from the test site where no power was available, obtained 901 counts. After background correction, the count was 550. Again this data indicate there was no measurement of significant rocket exhaust effluents at the test site.
This grant was originally awarded for the flight of the AMICIST sounding rocket. However, upon launch failure of the PHAZE rocket, additional resources were placed in this grant to cover the launch of the PHAZE II rocket. AMICIST was successfully launched from the Poker Flat Range on February 24, 1995, and the PHAZE II was successfully launched also from the Poker Flat Range on February 10, 1997. The major objective of the AMICIST flight was to investigate the bursts of transverse ion acceleration occurring during aurora, commonly known as Lower Hybrid Solitary Structures, with the flight of two scientific payloads to unravel space from time effects. The data clearly showed that the structures of ion acceleration were a spatial phenomena having a scale size transverse to the local magnetic field of about 100 m. On the other hand, structures in the auroral electrons were generally observed on this flight to be temporal features that occurred at the same time at the two payloads separated by a few kilometers. The primary objective of the PHAZE rocket flight was to further study the temporal features of auroral electron precipitation having many electron detectors, some fixed in energy, that could study the distribution function of the auroral electrons on time scales of a fraction of a millisecond. A important paper on this topic has just been submitted for publication which uses the PHAZE data to show that the potential structure (electric field parallel to the magnetic field) that accelerates the auroral electrons within one Earth radius of the ground, is not static, but rather fluctuates with frequencies close to the local proton and hydrogen gyrofrequencies. The fluctuation appears to be an actual turning on and off of the electric field at these frequencies. When the potential is turned off, ambient electrons can enter the region and be accelerated along B when the potential is on creating field- aligned bursts which manifest themselves as flickering aurora seen from the ground. The on/off model can explain many of the dynamic features of the aurora which have been unexplained since man first looked up at the visual display. Much needs to be done yet to understand how ions couple into this process.
A series of Reynolds-averaged Navier-Stokes calculations were employed to study the performance of rocket-based combined-cycle systems operating in an all-rocket mode. This parametric series of calculations were executed within a statistical framework, commonly known as design of experiments. The parametric design space included four geometric and two flowfield variables set at three levels each, for a total of 729 possible combinations. A D-optimal design strategy was selected. It required that only 36 separate computational fluid dynamics (CFD) solutions be performed to develop a full response surface model, which quantified the linear, bilinear, and curvilinear effects of the six experimental variables. The axisymmetric, Reynolds-averaged Navier-Stokes simulations were executed with the NPARC v3.0 code. The response used in the statistical analysis was created from Isp efficiency data integrated from the 36 CFD simulations. The influence of turbulence modeling was analyzed by using both one- and two-equation models. Careful attention was also given to quantify the influence of mesh dependence, iterative convergence, and artificial viscosity upon the resulting statistical model. Thirteen statistically significant effects were observed to have an influence on rocket-based combined-cycle nozzle performance. It was apparent that the free-expansion process, directly downstream of the rocket nozzle, can influence the Isp efficiency. Numerical schlieren images and particle traces have been used to further understand the physical phenomena behind several of the statistically significant results.
A flight investigation was conducted to determine the effects of an inlet modification and rocket-rack extension on the longitudinal trim and low-lift drag of the Douglas F5D-1 airplane. The investigation was conducted with a 0.125-scale rocket-boosted model which was flight tested at the Langley Pilotless Aircraft Research Station at Wallops Island, Va. Results indicate that the combined effects of the modified inlet and fully extended rocket racks on the trim lift coefficient and trim angle of attack were small between Mach numbers of 0.94 and 1.57. Between Mach numbers of 1.10 and 1.57 there was an average increase in drag coefficient of about o,005 for the model with modified inlet and extended rocket racks. The change in drag coefficient due to the inlet modification alone is small between Mach numbers of 1.59 and 1.64
Youth space science model rocket projects in rocket motor design, static tests, propellant mixing, and rocket launch
A cumulative listing of all scientifically successful rockets that have been identified from various sources is presented. The listing starts with the V-2 rocket launched on 7 March 1947 and contains all rockets identified up to 31 December 1971.
The present paper deals with the problem of determining various solar eclipse variables as observed from a sounding rocket for various rocket trajectories. By applying the methods described to a set of trajectories, a set of boundary conditions, launch azimuth, quadrant elevation, and launch time may be selected to optimize any aspect of eclipse observation within the constraints imposed by rocket performance.
A rocket sled test was performed as part of the development test program of the Space Shuttle Solid Rocket Booster (SRB) Decelerator Subsystem. The test objectives were to evaluate the nose cap/pilot chute deployment behavior and performance. The tests were performed by accelerating the sled and test article to the desired deployment conditions and then ejecting the SRB nose cap by firing three 30,000-lb thrusters. The nose cap then deployed the pilot chute (11.5-ft diam) which, in turn, initiated drogue chute pack deployment. Text conditions simulated the design deployment environment of dynamic pressure of 200 and 270 psf (corresponding sled velocities of 445 and 530 ft/s) and were conducted in configurations representative of SRB (solid rocket booster) angles of attack of 80 and 140 deg, respectively. A test description and summary of results are presented.
A discussion of the H-225K hybrid rocket motor, produced by the American Rocket Company, is given. The H-225K motor is presented in terms of the following topics: (1) hybrid rocket fundamentals; (2) hybrid characteristics; and (3) hybrid advantages.