Investigation of FDM-printed open-framework-reinforced helical PEWAX grains as a robust, high regression hybrid rocket fuel

Zdybal, Dominik; Pabarcius, Lucas; Laczewski, Andrzej; Wyciszkiewicz, Bartosz; Zwolak, Agata; Slawecki, Piotr; Wyzlinski, Maciej

doi:10.2514/6.2021-1247

Cited by 8 publications

(4 citation statements)

References 8 publications

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“…The primary intent of this study was to determine the effects of pitch length on fuel performance. A decrease in pitch length caused regression rates to increase by up to 26.7% and the corresponding combustion efficiency to decrease by 34% compared to an identical straight port grain [24]. The significant decrease in combustion efficiency is believed to be aGributed to an insufficient length of the post-combustion chamber.…”

Section: Helical Portsmentioning

confidence: 98%

“…It should be noted that the ABS used in this study had a lower ballistic performance than traditional ABS due to the addition of flame retardants. Zdybal et al [24] combined the concept of an armored grain with complex port geometries by investigating the performance of an FDM-printed polyamide-12 skeleton grain (10% infill) impregnated with polyethylene wax containing 5% EVA with a helical port geometry. Figure 11 illustrates the printed skeleton structure and the fuel grain after testing.…”

Section: Helical Portsmentioning

confidence: 99%

“…A decrease in thread pitch, increase in groove depth, and increase in groove width resulted in increased average regression rates by 40%, 15-20%, and 10%, respectively, for the dimensions tested [25]. Zdybal et al [24] combined the concept of an armored grain with complex port geometries by investigating the performance of an FDM-printed polyamide-12 skeleton grain (10% infill) impregnated with polyethylene wax containing 5% EVA with a helical port geometry. Figure 11 illustrates the printed skeleton structure and the fuel grain after testing.…”

Section: Helical Portsmentioning

confidence: 99%

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Performance of Additively Manufactured Fuels for Hybrid Rockets

Nguyen

Thomas

2023

Aerospace

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Hybrid rocket engine (HRE) performance is dependent on fuel/oxidizer selection and fuel grain geometry. A literature review was performed to identify key trends and findings related to the application of the additive manufacturing (AM) of fuel systems for HREs. The effects of complex combustion port geometries, embedded structures, and end-burning systems, along with the use of metallic additives, turbulators, diaphragms, gel-like fuels, powdered fuels, liquid fuels, and liquifying fuels and their impact on regression rates, combustion efficiencies, and/or mechanical strength are thoroughly documented here. In general, the application of AM to HRE fuels can be implemented to increase regression rates and combustion efficiency, and tailor HRE designs. Chemical equilibrium analysis computations were completed to characterize the theoretical performance of HTPB and common AM fuels (ABS, PLA, PC, PMMA, Nylon 6, and a UV-based fuel) with common oxidizers (LOX and N2O). AM fuels exhibit a similar theoretical performance as the commonly used HTPB fuel, and proper selection of the fuel can yield improved performance and design metrics. Development of AM approaches for HRE fuel design have significantly expanded their design trade space and should enable the competitive application of HREs for future propulsion missions.

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Section: Helical Portsmentioning

confidence: 98%

Section: Helical Portsmentioning

confidence: 99%

Section: Helical Portsmentioning

confidence: 99%

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Performance of Additively Manufactured Fuels for Hybrid Rockets

Nguyen

Thomas

2023

Aerospace

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“…The regression rate in an HRE can be improved by distorting the boundary layer to increase shear forces in addition to improving the mixing of oxidizer and fuel while promoting heat transfer to the solid fuel [19]. This distortion is typically achieved by optimizing the oxidizer injection process and the fuel grain structure, based on the use of swirling-oxidizer injection techniques and complex port morphologies [20][21][22][23][24][25].…”

Section: Introductionmentioning

confidence: 99%

Combustion Characteristics of a Swirl-Radial-Injection Composite Fuel Grain with Applications in Hybrid Rockets

Wang,

Lin,

Wang

et al. 2023

Aerospace

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The combustion characteristics of a swirl-radial-injection composite fuel grain were experimentally and numerically investigated. This composite grain permits swirl-radial oxidizer injection based on three hollow helical blades, each having a constant hollow space allowing uniform oxidizer injection into the main chamber along the axial direction. The oxidizer enters from channel inlets located along a hollow outer wall. This wall, together with the three blades, is fabricated as one piece from acrylonitrile-butadiene-styrene using three-dimensional printing. Paraffin-based fuel is embedded in the spaces between adjacent blades. Firing tests were conducted with gaseous oxygen as the oxidizer, using oxidizer mass flow rates ranging from 7.45 to 30.68 g/s. Paraffin-based fuel grains using conventional fore-end injection were used for comparison. Regression rate boundaries were determined taking into account the erosion of the oxidizer channels. The data show that the regression rate was significantly increased even at the lower limit. Images of the combustion chamber flame and of the exhaust plume were also acquired. The flame was found to be concentrated in the main chamber and a smoky plume was observed, consistent with the high regression rate. A three-dimensional simulation was employed. The present design was found to improve fuel/oxidizer mixing and combustion efficiency compared with a fuel grain using fore-end injection. Both the experimental results and numerical simulations confirmed the potential of this swirl-radial-injection fuel grain.

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A new strategy for the reinforcement of paraffin-based fuels based on cellular structures: The armored grain — Ballistic characterization

Bisin

Paravan

2023

Acta Astronautica

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Investigation of FDM-printed open-framework-reinforced helical PEWAX grains as a robust, high regression hybrid rocket fuel

Cited by 8 publications

References 8 publications

Performance of Additively Manufactured Fuels for Hybrid Rockets

Performance of Additively Manufactured Fuels for Hybrid Rockets

Combustion Characteristics of a Swirl-Radial-Injection Composite Fuel Grain with Applications in Hybrid Rockets

A new strategy for the reinforcement of paraffin-based fuels based on cellular structures: The armored grain — Ballistic characterization

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