Propõe-se aqui uma metodologia de projeto aero-termo-estrutural de motores foguete a propelente sólido. O projeto de um motor foguete deve ser realizado com o objetivo de cumprir requisitos de uma missão. Para cada veículo espacial, com uma nova missão, um novo motor pode ser projetado, necessitando para isso de uma série de ferramentas robustas, capazes de compreender todas as combinações de esforços existentes no funcionamento de um motor, sob condições de altas pressões e temperaturas. A metodologia aqui proposta é testada e validada em bancada de ensaios desenvolvida para este fim. Os resultados obtidos mostram que a metodologia utilizada se aproxima bastante dos resultados teóricos e pode ser ajustada por coeficientes de eficiência com grande facilidade. / It is proposed here an aero-thermo-structural design methodology for solid propellant rocket motors. The design of a rocket motor must be carried out in order to fulfill requirements of a mission. For each new space vehicle, with a new mission, a new motor can be designed, requiring for it a variety of robust tools, able to comprise all combinations of load existing in the operation of a motor under high pressures and temperatures. The methodology proposed here is tested and validated in bank of tests developed for this purpose. The results show that the methodology is very close to the theoretical results and can be adjusted by coefficients of efficiency with great ease.

Este trabalho aborda o projeto de hélices navais auxiliado por computador, particularizando-os para a aplicação no sistema de propulsão de veículos autônomos de superfície (ASVs). São apresentadas as principais aplicações e características do casco demais sistemas que compõem os ASVs. Em seguida, trata-se da análise dos parâmetros principais que definem a geometria de um hélice naval. É proposta uma ferramenta numérica voltada à geração da superfície do hélice e do seu modelo sólido, a partir dos perfis transversais da pá, cuja distribuição radial é originada em dados de tabelas de séries sistemáticas. O trabalho é complementado por uma apresentação e análise dos métodos principais considerados para a manufatura auxiliada por computador de hélices que podem ser empregados tanto em ASVs como em outros veículos aquáticos não tripulados. / This work deals with the computer aided design of marine propellers applied to the propulsion system of autonomous surface crafts (ASVs). The main applications and component systems of ASVs are introduced. An analysis of the propeller main geometric parameters is performed, and a numerical tool is proposed for the surface and solid model generation using data provided by the propeller systematic series for the sectional profile radial description. Finally, it is presented the introduction and analysis of the computer aided manufacturing processes considered for the propulsion of ASVs and other unmanned aquatic vehicles.

The use of electric propulsion for spacecraft primary propulsion, attitude control and station-keeping is ever-increasing as the technology matures and is qualified for flight. In addition, alternative propellants are under investigation, which have the potential to offer systems-level benefits that can enable particular classes of missions. Condensable propellants, particularly iodine, have the potential to significantly reduce the propellant storage system volume and mass. Some of the most widely used electric thrusters are electrostatic thrusters, which require a thermionic hollow cathode electron source to ionize the propellant for the main discharge and for beam neutralization. Failure of the hollow cathode, which often needs to operate for thousands of hours, is one of the main life-limiting factors of an electrostatic propulsion system. Common failure modes for hollow cathodes include poisoning or evaporation of the thermionic emitter material and erosion of electrodes due to sputtering. The mechanism responsible for the high energy ion production resulting in sputtering is not well understood, nor is the compatibility of traditional thermionic hollow cathodes with alternative propellants such as iodine. This work uses both an emissive probe and Langmuir probe to characterize the near-plume of several hollow cathodes operating on both xenon and iodine by measuring the plasma potential, plasma density, electron temperature and electron energy distribution function (EEDF). Using the EEDF the reaction rate coefficients for relevant collisional processes are calculated. A low current (< 5 A discharge current) hollow cathode with two different hexaboride emitters, lanthanum hexaboride (LaB6) and cerium hexaboride (CeB6), was operated on xenon propellant. The plasma potential, plasma density, electron temperature, EEDF and reaction rate coefficients were measured for both hexaboride emitter materials at a single cathode orifice diameter. The time-resolved plasma potential measurements showed low frequency oscillations (<100 kHz) of the plasma potential at low cathode flow rates (<4 SCCM) and spot mode operation between approximately 5 SCCM and 7 SCCM. The CeB6 and LaB6 emitters behave similarly in terms of discharge power (keeper and anode voltage) and plasma potential, based on results from a cathode with a 0.020�-diameter. Both emitters show almost identical operating conditions corresponding to the spot mode regime, reaction rates, as well as mean and RMS plasma potentials for the 0.020� orifice diameter at a flow rate of 6 SCCM and the same discharge current. The near-keeper region plasma was also characterized for several cathode orifice diameters using the CeB6 emitter over a range of propellant flow rates. The spot-plume mode transition appears to occur at lower flow rates as orifice size is increased, but has a minimum flow rate for stable operation. For two orifice diameters, the EEDF was measured in the near-plume region and reaction rate coefficients calculated for several electron- driven collisional processes. For the cathode with the larger orifice diameter (0.040�), the EEDFs show higher electron temperatures and drift velocities. The data for these cathodes also show lower reaction rate coefficients for specific electron transitions and ionization. To investigate the compatibility of a traditional thermionic emitter with iodine propellant, a low-power barium oxide (BaO) cathode was operated on xenon and iodine propellants. This required the construction and demonstration of a low flow rate iodine feed system. The cathode operating conditions are reported for both propellants. The emitter surface was inspected using a scanning electron microscope after various exposures to xenon and iodine propellants. The results of the inspection of the emitter surface are presented. Another low current (< 5 A), BaO hollow cathode was operated on xenon and iodine propellants. Its discharge current and voltage, and plume properties are reported for xenon and iodine with the cathode at similar operating conditions for each. The overall performance of the BaO cathode on iodine was comparable to xenon. The cathode operating on iodine required slightly higher power for ignition and discharge maintenance compared to xenon, as evident by the higher keeper and anode potentials. Plasma properties in the near- plume region were measured using an emissive probe and single Langmuir probe. For both propellants, the plasma density, electron energy distribution function (EEDF), electron temperature, select reaction rate coefficients and time-resolved plasma potentials are reported. For both propellants the cathode operated the same keeper (0.25 A) and discharge current (3.1 A), but the keeper and anode potentials were higher with iodine; 27 V and 51 V for xenon, and 30 V and 65 V for iodine, respectively. For xenon, the mean electron energy and electron temperature were 7.5 eV and 0.7 eV, with bulk drift energy of 6.6 eV. For iodine, the mean electron energy and electron temperature were 6.3 eV and 1.3 eV, with a bulk drift energy of 4.2 eV. A literature review of relevant collisional processes and associated cross sections for an iodine plasma is also presented.

Este trabalho aborda o projeto de hélices navais auxiliado por computador, particularizando-os para a aplicação no sistema de propulsão de veículos autônomos de superfície (ASVs). São apresentadas as principais aplicações e características do casco demais sistemas que compõem os ASVs. Em seguida, trata-se da análise dos parâmetros principais que definem a geometria de um hélice naval. É proposta uma ferramenta numérica voltada à geração da superfície do hélice e do seu modelo sólido, a partir dos perfis transversais da pá, cuja distribuição radial é originada em dados de tabelas de séries sistemáticas. O trabalho é complementado por uma apresentação e análise dos métodos principais considerados para a manufatura auxiliada por computador de hélices que podem ser empregados tanto em ASVs como em outros veículos aquáticos não tripulados. / This work deals with the computer aided design of marine propellers applied to the propulsion system of autonomous surface crafts (ASVs). The main applications and component systems of ASVs are introduced. An analysis of the propeller main geometric parameters is performed, and a numerical tool is proposed for the surface and solid model generation using data provided by the propeller systematic series for the sectional profile radial description. Finally, it is presented the introduction and analysis of the computer aided manufacturing processes considered for the propulsion of ASVs and other unmanned aquatic vehicles.

A one-dimensional, steady-state numerical model of the combustion of homogeneous solid propellant has been developed. The combustion processes is modeled in three regions: solid, two-phase (liquid and gas) and gas. Conservation of energy and mass equations are solved in the two-phase and gas regions and the eigenvalue of the system (the mass burning rate) is converged by matching the heat flux at the interface of these two regions. The chemical reactions of the system are modeled using a global kinetic mechanism in the two-phase region and an elementary kinetic mechanism in the gas region. The model has been applied to RDX, HMX and GAP. There is very reasonable agreement between experimental data and model predictions for burning rate, temperature sensitivity, surface temperature, adiabatic flame temperature, species concentration profiles and melt-layer thickness. Many of the similarities and differences in the combustion of RDX and HMX are explained from sensitivity analysis results. The combustion characteristics of RDX and HMX are similar because of their similar chemistry. Differences in combustion characteristics arise due to differences in melting temperature, vapor pressure and initial decomposition steps. A reduced mechanism consisting of 18 species and 39 reactions was developed from the Melius-Yetter RDX mechanism (45 species, 232 reactions). This reduced mechanism reproduces most of the predictions of the full mechanism but is 7.5 times faster. Because of lack of concrete thermophysical property data for GAP, the modeling results are preliminary but indicate what type of experimental data is necessary before GAP can be modeled with more certainty.

In this study, a detailed service life assessment procedure for solid propellant rockets under random environmental temperature and transportation loads is introduced. During storage and deployment of rocket motors, uncontrolled thermal environments and random vibratory loads due to transportation induce random stresses and strains in the propellant which provoke mechanical damage. In addition, structural capability degrades due to environmental conditions and induced stresses and strains as well as material capability parameters have inherent uncertainties. In this proposed probabilistic service life prediction, uncertainties along with degradation mechanisms are taken into consideration. Vibration loads are accounted by utilizing acceleration spectral density values which are induced during various deployment scenarios of ground, air and sea transportation. Furthermore, thermal loads are represented with a mathematical model being a harmonic function of time. Throughout the finite element analyses, a linear viscoelastic material model is to be used for the propellant. Change in the structural capability of the propellant with time is calculated using Laheru&#039 / s cumulative damage model. Moreover, to include aging effect of the propellant, Layton model is used. To determine the effects of induced stress and strains under variations and uncertainties in the random loads and material constants, mathematical surrogate models are constructed using response surface method. Limit state functions are utilized to predict failure modes of the solid rocket motor. First order reliability method is used to calculate reliability and probability of failure of the propellant grain. With the proposed methodology, instantaneous reliability of the propellant grain is determined within a confidence interval.

This work describes the development of a hybrid rocket propulsion system for a reusable sounding rocket, as part of the first phase of the UKZN Phoenix Hybrid Sounding Rocket Programme. The programme objective is to produce a series of low-to-medium altitude sounding rockets to cater for the needs of the African scientific community and local universities, starting with the 10 km apogee Phoenix-1A vehicle. In particular, this dissertation details the development of the Hybrid Rocket Performance Code (HRPC) together with the design, manufacture and testing of Phoenix-1A’s propulsion system. The Phoenix-1A hybrid propulsion system, generally referred to as the hybrid rocket motor (HRM), utilises SASOL 0907 paraffin wax and nitrous oxide as the solid fuel and liquid oxidiser, respectively. The HRPC software tool is based upon a one-dimensional, unsteady flow mathematical model, and is capable of analysing the combustion of a number of propellant combinations to predict overall hybrid rocket motor performance. The code is based on a two-phase (liquid oxidiser and solid fuel) numerical solution and was programmed in MATLAB. HRPC links with the NASA-CEA equilibrium chemistry programme to determine the thermodynamic properties of the combustion products necessary for solving the governing ordinary differential equations, which are derived from first principle gas dynamics. The combustion modelling is coupled to a nitrous oxide tank pressurization and blowdown model obtained from literature to provide a realistic decay in motor performance with burn time. HRPC has been validated against experimental data obtained during hot-fire testing of a laboratory-scale hybrid rocket motor, in addition to predictions made by reported performance modelling data. Development of the Phoenix-1A propulsion system consisted of the manufacture of the solid fuel grain and incorporated finite element and computational fluid dynamics analyses of various components of the system. A novel casting method for the fabrication of the system’s cylindrical single-port paraffin fuel grain is described. Detailed finite element analyses were performed on the combustion chamber casing, injector bulkhead and nozzle retainer to verify structural integrity under worst case loading conditions. In addition, thermal and pressure loading distributions on the motor’s nozzle and its subsequent response were estimated by conducting fluid-structure interaction analyses. A targeted total impulse of 75 kNs for the Phoenix-1A motor was obtained through iterative implementation of the HRPC application. This yielded an optimised propulsion system configuration and motor thrust curve. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2013.

Solid propellant rocket motors are the most widely used propulsion systems for military applications that require high thrust to weight ratio for relatively short time intervals. Very wide range of magnitude and duration of the thrust can be obtained from solid propellant rocket motors by making some small changes at the design of the rocket motor. The most effective of these design criteria is the geometry of the solid propellant grain. So the most important step in designing the solid propellant rocket motor is determination of the geometry of the solid propellant grain. The performance prediction of the solid rocket motor can be achieved easily if the burnback steps of the rocket motor are known. In this study, grain burnback analysis for some 3-D grain geometries is investigated. The method used is solid modeling of the propellant grain for some predefined intervals of burnback. In this method, the initial grain geometry is modeled parametrically using commercial software. For every burn step, the parameters are adapted. So the new grain geometry for every burnback step is modeled. By analyzing these geometries, burn area change of the grain geometry is obtained. Using this data and internal ballistics parameters, the performance of the solid propellant rocket motor is achieved. To verify the outputs obtained from this study, rocket motor tests are performed. The results obtained from this study shows that, the procedure that was developed, can be successfully used for the preliminary design of a solid propellant rocket motor where a lot of different geometries are examined.

In this study, experimental investigation of solid propellant combustion instability using an end burning T-Burner setup is performed. For this purpose, a T-Burner setup is designed, analyzed, constructed and tested with all its sub components. T-Burner setup constructed is mainly composed of a base part, a control panel and the T-Burner itself. Combustion chamber, pressure stabilization mechanism, pressurization system, measurement instruments and data acquisition systems form the T-Burner. Pressure stabilization mechanism is utilized in two different alternatives, first of which is by the use of nitrogen gas and a small surge tank with a cavitating venturi. This is a brand new approach for this kind of system. The second alternative is the use of a choked nozzle for pressure stabilization. Resonance frequencies of the system with the two different pressure stabilization mechanisms are experimentally evaluated. Helmholtz frequency of the T-burner constructed is calculated and no Helmholtz instability is observed in the system. Constructed T-Burner setup is operated for a specific solid propellant. System worked successfully and pressure data are obtained. Pressure data revealed oscillatory behaviour. Decay and growth rates of pressure oscillations are used for the calculation of pressure response of the propellant tested. By the use of this T-Burner comparison of the behavior of different propellants can be performed. It can be used as a test device for measuring quantitatively the response of a burning propellant to unsteady motions.

Thesis (M.App.Sc.) - Carleton University, 2007. / Includes bibliographical references (p. 194-202). Also available in electronic format on the Internet.