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

Abstract

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.

Nytrox as “Drop-in” Replacement for Gaseous Oxygen in SmallSat Hybrid Propulsion Systems

“…Experience based on the results of References [32,33] have lead the authors to conclude that 90% peroxide is an unsuitable oxidizer for in-space applications, where cold-soak commonly occurs. It is likely that significantly higher oxidizer solutions with concentrations at 98% or greater could have avoided these pooling issues, however, at these concentrations peroxide becomes a class 4 oxidizer, and is no longer really a "green" propellant.…”

“…Recent work by Whitmore et al [32,33] and other organizations [34,35] have adapted hybrid rockets for use with medium-to-high grade (90%) H 2 O 2 . Hydrogen peroxide is a very efficient and dense propellant, and is an extremely strong oxidizer.…”