Outer Shell (fuel grain housing) Inner Shell (NOS/rocket housing) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Model Geometry Outer Shell (fuel grain housing) Outer radius: 2.40” (~61mm) Inner radius: 2.36” (~60mm) Height: 21.46” (~545 m) Mat’l: Aluminum 7075 T6 Inner Shell (NOS/rocket housing) Outer radius: 1.75” + 0.5 mm (0.03225 m) Inner radius: 1.25” (0.03175 m) Height: 1.5” (0.0381 m) Mat’l: Al 7075 T6 with Composite over-wrap Composite: IM7 Carbon (fiber) / PEEK (matrix)

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Material Properties Al 7075-T6 (Modeled as Isotropic) Density: 2810 kg/m3 Longitudinal Mod., E1: 71.7e9 Pa Poisson’s Ratio, v12: 0.33 Carbon/PEEK Composite (Modeled as Isotropic) Density: 1600 kg/m3 Longitudinal Mod., E1: 71.7e9 Pa Transverse Mod., E2: 10.2e9 Pa Poisson’s Ratio, v12: 0.30 Shear Modulus, G12: 5.7e9 PEEK (matrix) Density: 1376 kg/m3 IM7 Carbon Fiber (12,000 filaments) (Modeled as Orthotropic) Density: 1780 kg/m3 Longitudinal Mod., E1: 278e9 Pa Poisson’s Ratio, v12: 0.20

Outer Shell (w/ composite) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Outer Shell (w/ composite) Figure 1: Outer Shell of Imbedded Fuel Grain Design (Meshed Elements – 8node93)

Outer Shell (w/ composite) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Outer Shell (w/ composite) Figure 2: Outer Shell of Imbedded Fuel Grain Design: Plot Results  Contour Plot  Element Solution  Stresses  von Mises stress

Outer Shell (w/ composite) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Outer Shell (w/ composite) Figure 3: Outer Shell of Imbedded Fuel Grain Design: Plot Results  Deformed Shape  Def + undeformed

Outer Shell (w/ composite) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Outer Shell (w/ composite) Figure 4: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints – Rotated view)

Outer Shell (w/ composite) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Outer Shell (w/ composite) Figure 5: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints - Front View)

Outer Shell (w/ composite) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Outer Shell (w/ composite) Figure 6: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints - Side View)

Inner Shell (All Aluminum) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Inner Shell (All Aluminum) Figure 7: Inner Shell of Imbedded Fuel Grain Design (Meshed Elements – 8node93)

Inner Shell (All Aluminum) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Inner Shell (All Aluminum) Figure 8: Inner Shell of Imbedded Fuel Grain Design: Plot Results  Contour Plot  Element Solution  Stresses  von Mises stress

Inner Shell (All Aluminum) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Inner Shell (All Aluminum) Figure 9: Inner Shell of Imbedded Fuel Grain Design: Plot Results  Deformed Shape  Def + undeformed

Inner Shell (All Aluminum) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Inner Shell (All Aluminum) Figure 10: Inner Shell of Imbedded Fuel Grain Design: (Pressure & Constraints – Rotated view)

Inner Shell (All Aluminum) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Inner Shell (All Aluminum) Figure 11: Inner Shell of Imbedded Fuel Grain Design: (Pressure & Constraints – Front view)

Inner Shell (All Aluminum) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Inner Shell (All Aluminum) Figure 12: Inner Shell of Imbedded Fuel Grain Design: (Pressure & Constraints – Side view)

Outer Shell (Aluminum only) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Outer Shell (Aluminum only) Figure 13: Outer Shell of Imbedded Fuel Grain Design (Meshed Elements – 8node93)

Outer Shell (Aluminum only) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Outer Shell (Aluminum only) Figure 14: Outer Shell of Imbedded Fuel Grain Design: Plot Results  Contour Plot  Element Solution  Stresses  von Mises stress

Outer Shell (Aluminum only) Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Outer Shell (Aluminum only) Figure 15: Outer Shell of Imbedded Fuel Grain Design: Plot Results  Deformed Shape  Def + undeformed

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Outer Shell (Aluminum only) Figure 16: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints – Rotated view)

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Outer Shell (Aluminum only) Figure 17: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints - Front View)

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Outer Shell (Aluminum only) Figure 18: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints - Side View)

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Figure 19: ELEMENT LAYERS

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Figure 20: LAYER ORIENTATION AND THICKNESS

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Figure 21: LAYER ORIENTATION AND THICKNESS continued…

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Figure 22: COMPOSITE PROPERTIES

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Figure 23: ALUMINUM PROPERTIES

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Figure 24: FAILURE CRITERIA FOR COMPOSITES

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Figure 25: INVERSE TSAI-WU STRENGTH RATIO INDEX

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Figure 26: X-COMP OF STRESS

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Figure 27: Y-COMP OF STRESS

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Figure 28: X-COMP OF STRESS

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Figure 29: SHEAR XY-DIR

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Figure 30: SHEAR YZ-DIR

Inner and Outer Shell ANSYS Stress Modeling (Embedded Fuel Grain Concept) Figure 31: SHEAR XZ-DIR