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NASA NTRS1977

Composite propellant combustion modeling studies

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.

Ramohalli, K.↗

NASA NTRS1979

High performance ammonium nitrate propellant

A high performance propellant having greatly reduced hydrogen chloride emission is presented. It is comprised of: (1) a minor amount of hydrocarbon binder (10-15%), (2) at least 85% solids including ammonium nitrate as the primary oxidizer (about 40% to 70%), (3) a significant amount (5-25%) powdered metal fuel, such as aluminum, (4) a small amount (5-25%) of ammonium perchlorate as a supplementary oxidizer, and (5) optionally a small amount (0-20%) of a nitramine.

Anderson, F. A.↗

NASA NTRS1980

Process for the leaching of AP from propellant

A method for the recovery of ammonium perchlorate from waste solid rocket propellant is described wherein shredded particles of the propellant are leached with an aqueous leach solution containing a low concentration of surface active agent while stirring the suspension.

Shaw, G. C.↗

NASA NTRS1980

Combustion in an acceleration field: A survey of Soviet literature

The effect of an acceleration field on the burning rate of a solid propellant was measured from -900g's to +1000g's using both double base and ammonium perchlorate based propellants. The acceleration fields were simulated using a centrifuge device and the burning rate was recorded. Both metalized and non-metalized variations of each propellant were tested and it was found that acceleration fields affect the burning rate. For the most part the theoretical predictions and the experimental results agreed.

Radloff, S. J.↗

NASA NTRS1980

Predicted and measured effects of pressure and crossflow velocity on composite propellant burning rate

A theoretical model for prediction of burning rates of composite (ammonium perchlorate oxidizer) solid propellants as a function of pressure and crossflow velocity was developed. Included in this model is the capability for treatment of multimodal oxidizer particle sizes and metalized formulations. In addition, an experimental device for measuring the effects of crossflow velocity on propellant burning rate was developed and used to characterize a series of AP/HTPB propellants with systematically varied formulation parameters. Model predictions of zero-crossflow burning rate versus pressure characteristics were found to be in agreement with data, while the agreement between erosive burning predictions and data is, in general, good. The experimental data indicate that the dominant factor influencing the sensitivity of composite propellant burning rate to crossflow is the base (no-crossflow) burning rate versus pressure characteristics of the propellant (lower base burning rate leading to increased crossflow sensitivity). Finally, the model was used to examine the effects of motor scaling on erosive burning: erosive burning is predicted to diminish with increasing motor size, in agreement with experience.

King, M. K.↗

NASA NTRS1980

An empirical propellant response function for combustion stability predictions

An empirical response function model was developed for ammonium perchlorate propellants to supplant T-burner testing at the preliminary design stage. The model was developed by fitting a limited T-burner data base, in terms of oxidizer size and concentration, to an analytical two parameter response function expression. Multiple peaks are predicted, but the primary effect is of a single peak for most formulations, with notable bulges for the various AP size fractions. The model was extended to velocity coupling with the assumption that dynamic response was controlled primarily by the solid phase described by the two parameter model. The magnitude of velocity coupling was then scaled using an erosive burning law. Routine use of the model for stability predictions on a number of propulsion units indicates that the model tends to overpredict propellant response. It is concluded that the model represents a generally conservative prediction tool, suited especially for the preliminary design stage when T-burner data may not be readily available. The model work included development of a rigorous summation technique for pseudopropellant properties and of a concept for modeling ordered packing of particulates.

Hessler, R. O.↗

NASA NTRS1981

Heat sterilizable solid-propellant development

The binders tested were polyurethanes made from two hydroxy-terminated polybutadienes, R-45 and Butarez HT, one hydroxy-terminated butadiene-acrylonitrile copolymer, Hycar 1300X 17, and a hydroxy-terminated prepolymer, Esterdiol 560, made from the dimerized fatty acid Empol 1010. The isocyanates used most extensively were isophorone diisocyanate (IPDI) and a polymeric diisocyanate, DDI. Stress relaxation was used to examine the chemical changes that took place in the binder when subjected to the sterilization temperatures. The thermal stability of the oxidizer, ammonium perchlorate (AP), was tested by thermogravimetry in the isothermal and nonisothermal modes. The effect of particle size, recrystallization, moisture content, and doping on the heat stability of AP could be evaluated by this method. The volatile degradation products, obtained when AP samples were aged at 135 C for prolonged periods, were analyzed by mass spectroscopy.

Kalfayan, S. H.↗

NASA NTRS1981

A pocket model for aluminum agglomeration in composite propellants

This paper presents a model for the purpose of estimating the fraction of aluminum powder that will form agglomerates at the surface of deflagrating composite propellants. The basic idea is that the fraction agglomerated depends upon the amount of aluminum that melts within effective binder pocket volumes framed by oxidizer particles. The effective pocket depends upon the ability of ammonium perchlorate modals to encapsulate the aluminum and provide a local temperature sufficient to ignite the aluminum. Model results are discussed in the light of data showing effects of propellant formulation variables and pressure.

Cohen, N. S.↗

NASA NTRS1982

Sterilizable Binder Is Stable at 135 degrees C

Polyurethane binder for solid propellants endures heat sterilization without decomposition based on an ester diol. Binder resists oxidation under prolonged exposure to 135 degrees C temperature, low enough in viscosity to be handled easily during processing, and readily mixed with oxidizers, such as ammonium perchlorate. Polyurethane is also suitable material for encapsulants, potting compounds, and coatings that must be sterilized.

Kalfayan, S. H.↗

NASA NTRS1983

Equations for Composite-Propellant Burning

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.

Strand, L. D.↗

NASA NTRS1983

Combustion response to compositional fluctuations

A mechanism involving compositional fluctuations at certain frequencies is examined by which the heterogeneity of a composite solid propellant may contribute directly to the combustion response function of combustion instability theory. A combustion model appropriate to ammonium perchlorate (AP) is used to derive the combustion response to compositional fluctuations, and the properties of the combustion response are discussed in terms of the theoretical results obtained. The concentration exponent, i.e., the dependence of the burn rate on AP concentration, is found to be a signficant combustion parameter and to have a tremendous range of variability. It is suggested that the combustion response to compositional fluctuations may be a dominating factor in driving combustion instability.

Cohen, N. S.↗

NASA NTRS1981

Processing modifications for improved propellants - Coated oxidizers

The present investigation is concerned with a technique which makes it possible to improve greatly the performance of composite propellants by alleviating the combustion instability problem. The technique involves the coating of the oxidizer crystals (typically ammonium perchlorate) with a suitably selected chemical. For each application the chemical for the coating is chosen on the basis of a screening procedure including the employment of differential scanning calorimetry and the use of a thermogravimetric analyzer. It is particularly important that the coat chemicals have good thermochemical stability at temperatures up to the normal surface temperature of the propellant during time-independent combustion (typically 800 to 900 K). At higher temperatures, sudden degradation should occur over a vary narrow temperature range (10-20 C).

Helmy, A. K.↗

NASA NTRS1985

Coated oxidizers for combustion stability in solid-propellant rockets

Experiments are conducted in a laboratory-scale (6.25-cm diameter) end-burning rocket motor with state-of-the-art, ammonium perchlorate hydroxy-terminated polybutadiene (HTPB), nonmetallized propellants. The concept of tailoring the stability characteristics with a small amount (less than 1 percent by weight) of COATING on the oxidizer is explored. The thermal degradation characteristics of the coat chemical are deduced through theoretical arguments on thermal diffusivity of the composite material (propellant). Several candidate coats are selected and propellants are cast. These propellants (with coated oxidizers) are fired in a laboratory-scale end-burning rocket motor, and real-time pressure histories are recorded. The control propellant (with no coating) is also tested for comparison. The uniformity of the coating, confirmed by SEM pictures and BET adsorption measurements, is thought to be an advance in technology. The frequency of bulk mode instability (BMI), the pressure fluctuation amplitudes, and stability boundaries are correlated with parameters related to the characteristic length (L-asterisk) of the rocket motor. The coated oxidizer propellants, in general, display greater combustion stability than the control (state-of-the-art). The correlations of the various parameters are thought to be new to a field filled with much uncertainty.

Helmy, A. M.↗

NASA NTRS1980

Solid-propellant rocket motor internal ballistics performance variation analysis, phase 5

The results of research aimed at improving the predictability of internal ballistics performance of solid-propellant rocket motors (SRM's) including thrust imbalance between two SRM's firing in parallel are presented. Static test data from the first six Space Shuttle SRM's is analyzed using a computer program previously developed for this purpose. The program permits intentional minor design biases affecting the imbalance between any two SMR's to be removed. Results for the last four of the six SRM's, with only the propellant bulk temperature as a non-random variable, are generally within limits predicted by theory. Extended studies of internal ballistic performance of single SRM's are presented based on an earlier developed mathematical model which includes an assessment of grain deformation. The erosive burning rate law used in the model is upgraded and made more general. Excellent results are obtained in predictions of the performances of five different SRM's of quite different sizes and configurations. These SRM's all employ PBAN type propellants with ammonium perchlorate oxidizer and 16 to 20% aluminum except one which uses carboxyl terminated butadiene binder. The only non-calculated parameters in the burning rate equations that are changed for the different SRM's are the zero crossflow velocity burning rate coefficients and exponents. The results, in general, confirm the importance of grain deformation. The improved internal ballistic model makes practical development of an effective computer program for application of an optimization technique to SRM design which is also demonstrated. The program uses a pattern search technique to minimize the difference between a desired thrust-time trace and one calculated based on the internal ballistic model.

Sforzini, R. H.↗

NASA NTRS1987

Pressure-coupled combustion response model for solid propellants based on Zeldovich-Novozhilov approach

An exact analytical solution is given to the problem of long-time propellant thermal response to a specified pressure oscillation. Coupling to the gas phase is made using the quasisteady Zeldovich-Novozhilov approximation. Explicit linear and lowest order (quadratic) nonlinear expressions for propellant response are obtained from the implicit nonlinear solutions. Using these expressions, response curves are presented for an ammonium perchlorate composite propellant and HMX monopropellant.

Harstad, K. G.↗

NASA NTRS1990

RSRM-9 (360L009): Ballistics mass properties

The propulsion performance and reconstructed mass properties data from Thiokol's RSRM-9 motors which were assigned to the STS-36 launch are presented. The SRM propellant, TP-H1148, is a composite type solid propellant, formulated of polybutadiene acrylic acid acryonitrile terpolymer binder (PBAN), epoxy curing agent, ammonium perchlorate oxidizer and aluminum powder fuel. A small amount of burning rate catalyst (iron oxide) was added to achieve the desired propellant burn rate. The propellant evaluation and raw material information for the RSRM-9 are included. The propellant grain design consists of four segments. There is a forward segment with an eleven point star with a transition into a tapered circular perforated (CP) configuration. There are two center segments that result in a double tapered CP configuration and an aft segment with a triple taper CP configuration and a cutout for the partially submerged nozzle. The ballistic performance presented is based on the Operational Flight Instrumentation (OFI) 12.5 sample per second pressure data for the steady state and tail off portion of the pressure trace. No high sample rate pressure gauges, Development Flight Instrumentation (DFI), were used on this flight and therefore no ignition data is presented.

Drendel, Albert S.↗

NASA NTRS1990

Space Shuttle Flight Support Motor no. 1 (FSM-1)

Space Shuttle Flight Support Motor No. 1 (FSM-1) was static test fired on 15 Aug. 1990 at the Thiokol Corporation Static Test Bay T-24. FSM-1 was a full-scale, full-duration static test fire of a redesigned solid rocket motor. FSM-1 was the first of seven flight support motors which will be static test fired. The Flight Support Motor program validates components, materials, and manufacturing processes. In addition, FSM-1 was the full-scale motor for qualification of Western Electrochemical Corporation ammonium perchlorate. This motor was subjected to all controls and documentation requirements CTP-0171, Revision A. Inspection and instrumentation data indicate that the FSM-1 static test firing was successful. The ambient temperature during the test was 87 F and the propellant mean bulk temperature was 82 F. Ballistics performance values were within the specified requirements. The overall performance of the FSM-1 components and test equipment was nominal.

Hughes, Phil D.↗

NASA NTRS1989

The University of Arizona program in solid propellants

The University of Arizona program is aimed at introducing scientific rigor to the predictability and quality assurance of composite solid propellants. Two separate approaches are followed: to use the modern analytical techniques to experimentally study carefully controlled propellant batches to discern trends in mixing, casting, and cure; and to examine a vast bank of data, that has fairly detailed information on the ingredients, processing, and rocket firing results. The experimental and analytical work is described briefly. The principle findings were that: (1) pre- (dry) blending of the coarse and fine ammonium perchlorate can significantly improve the uniformity of mixing; (2) the Fourier transformed IR spectra of the uncured and cured polymer have valuable data on the state of the fuel; (3) there are considerable non-uniformities in the propellant slurry composition near the solid surfaces (blades, walls) compared to the bulk slurry; and (4) in situ measurements of slurry viscosity continuously during mixing can give a good indication of the state of the slurry. Several important observations in the study of the data bank are discussed.

Ramohalli, Kumar↗