6/13/20161 P ROJECT METEOR H YBRID R OCKET M OTOR Ken Court Chad Eberhart Patrick Haus Chris Natoli Nohl Schluntz S ENIOR D ESIGN P ROJECT R EVIEW Friday May 16, 2007

6/13/20162  Multidisciplinary Senior Design  Purpose: Deliver Pico satellites into low-earth orbit at low cost MICROSYSTEMS ENGINEERING, SCIENCE, AND TECHNOLOGIES FOR THE EXPLORATION AND UTILIZATION OF OUTER SPACE REGIONS PROJECT METEOR OVERVIEW

6/13/20163 P08105 DELIVERABLES / NEEDS  Support a launchable test flight at 24 km (80,000 ft) ◊ Specific Impulse: 220 sec ◊ Burn time: 20 sec ◊ Thrust to Weight Ratio: ~ 3:1  Ensure Safety to all participants  Integration with P08106 (Flying Rocket Body)

6/13/20164 Supersonic Nozzle Post-Combustion HTPB Fuel Grain Pre-Combustion Titanium Shell (t = 1/8’’) Brackets Injector Plate OVERALL HYBRID ROCKET MOTOR DESIGN

6/13/20165 STRUCTURE DETAILS  Titanium Chamber & Welded Flanges ◊ High Structural Strength → E = 16,800 ksi ◊ Melting Point → 1604ºC  Bolt Hole Pattern Provides FOS = 2.7 (Plus FOS from Rods)  Dual O-Rings for sealing  Vibration Dampener Advantages  Durability  Lightweight ◊ lbs  Adaptability  Ease of Integration

6/13/20166 STRUCTURE – THEORETICAL VS. SIMULATED ParameterHand CalculationsANSYS Results% Deviation Hoop Stress (psi) σ h,max 20,50021, Radial Deflection (in) δ r,max in Longitudinal Stress (psi) σ l,max 10,000 psi13, Longitudinal Deflection (in) δ r,max in

6/13/20167 TEST INJECTOR DESIGN Injector Hub Gasket Orifice Insert Snap Ring

6/13/20168 INJECTOR – PRESSURE LOSS ø Z L2L2 L1L1 L3L3 1 2 D1D1 D2D2

INJECTION TESTING 6/13/20169  Increased holes decreased pressure and velocity  Fluid breakup 16 inches downstream  Need to maintain higher velocity  Devise method of building back pressure

6/13/ THRUST – NOZZLE CALCULATIONS EquationProjected Thrust: R ~ 200 lbf Area Ratio: Mach Number: Ae/At ~ Me ~ Isentropic: Po/Pe ~ 177 PROGRAMS USED  MATLAB  MICROSOFT EXCEL

6/13/ Annular - Mach 4 Annular - Mach 3 8° Conical - Mach 4 12° Conical - Mach 4 SUPERSONIC NOZZLE DESIGN

6/13/ IGNITION DEVICES  Mini bulb  Most miss fires Filament burned up after a few seconds  Epoxy  Acted as high insulator Nichrome wire was unable to reach high temp.  Nitrocellose / Pyrodex  Most effective Nichrome wire was able to heat up and ignite Pyrodex  Pyrodex is the most effective ignition component  Robust  Reliable  Sustainable burn times based on volume  Nichrome wire  Best delivery source Does not burn up Works under low amperage and long lead wires

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6/13/ Results  ~ 100% Theoretical Increase in Thrust  58.8% Theoretical Reduction in Weight  Designed and constructed 1:1 scale model  Successfully tested new injector plate and orifice inserts  Validated P07105’s current igniter configuration  Designed under budget

6/13/ Future Suggestions  Component research at graduate level  Undergraduate implementation  Improve manufacturing techniques  Improve testing procedures  Construct Titanium motor

6/13/ SPECIAL THANKS TO:  Dr. Jeffrey Kozak  Dr. Dorin Patru  Dr. Steve Weinstein  Dr. Amitabah Ghosh  Dr. Lawrence Agbezuge  Paul Gaylo  Mr. Natoli  Harris Corporation  Global Machining

6/13/  Please feel free give suggestions and critiques QUESTIONS / COMMENTS