PROJECT METEOR HYBRID ROCKET MOTOR Marc Balaban Ken Court Chad Eberhart Patrick Haus Chris Natoli Nohl Schluntz DETAILED DESIGN REVIEW Friday November 9, 2007 5/14/2019

CONTENTS METEOR Overview Hybrid Background Team Organization Project Deliverables & Needs Constraints/Risks Specifications List Hybrid Rocket Concept Strategy Detail Design Overall Hybrid Rocket Motor Structure Injection Combustion/Exhaust Nozzles Ignition P08104 Deliverables SDII Project Plan Projected Costs - BOM Questions/Discussion *Please feel free to ask questions or make comments during the presentation* 5/14/2019

PROJECT METEOR OVERVIEW 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 5/14/2019

PROJECT METEOR OVERVIEW ~ 24 km 5/14/2019

Rocket Motor which combines: HYBRID BACKGROUND Rocket Motor which combines: Liquid Oxidizer: Nitrous Oxide (NOX) Solid Propellant: Hydroxyl Terminated Poly-Butadiene (HTPB) Previous Accomplishments Design of a Static Test Rocket Motor Extensive Horizontal Ground Testing 50 second Burn Time 5/14/2019

P08105 ORGANIZATION Patrick Haus – Project Leader Chris Natoli – Lead Engineer Marc Balaban – Fluids/Combustion Specialist Ken Court – Fuel Injection Specialist Chad Eberhart – Fluids/Combustion Specialist Nohl Schluntz – Fuel Injection Specialist 5/14/2019

Support a launchable test flight at 24 km (80,000 ft) 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) 5/14/2019

* IT’S ONLY ROCKET SCIENCE* CONSTRAINTS - RISKS Safety First Scope of Work METEOR is very challenging Budget = $5000 Time = 22 Weeks (12 Remaining) Integration to other METEOR Teams Internal Temperature and Pressure Titanium Shell (Process & Strength) Lead Time Machine Shop Availability External Resources * IT’S ONLY ROCKET SCIENCE* 5/14/2019

PROJECT SPECIFICATIONS Design Specification Importance Units of Measure Marginal Value Ideal Value   Specific Impulse 4 sec 220 250 Thrust 5 N 490 500 Burn Time 25 60 Oxidizer/Fuel Ratio (--) 6 8 Overall Mass Flow Rate kg/s 0.35 0.3677 Pressure Loss Pa 2.76E+06 2.06E+06 Oxidizer Mass Flow Rate 0.25 0.3152 Regression Rate m/s 0.0009 0.00074294 Chamber Pressure 6.89E+06 7129345.974 Exit Mach Number Mach # 5.548 Ratio of Spec Heats 3 -- 1.258 Nozzle Area Ratio 175 189 Scale: 1 Least Important - 5 Most Important 5/14/2019

HYBRID ROCKET DESIGN STRATEGY Test Flight Design Flying Rocket - Structure - Injector - Combustion - Ignition - Nozzle Test Steel Rocket Design Iteration 5/14/2019

OVERALL HYBRID ROCKET MOTOR DESIGN Supersonic Nozzle Post-Combustion HTPB Fuel Grain Pre-Combustion Titanium Shell (t = 1/8’’) Brackets Injector Plate 5/14/2019

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 Adaptability Ease of Integration 5/14/2019

STRUCTURE EXPLODED VIEW 5/14/2019

COMBUSTION CHAMBER – HAND CALCULATIONS Hoop Stress σh,max σh,max = 20,500 psi Radial Deflection δr,max δr,max = 0.0032 in Longitudinal Stress σl,max σl,max = 10,000 psi Longitudinal Deflection δr,max = 0.00987 in 5/14/2019

ANSYS RESULTS – HOOP STRESS & DEFLECTION Boundary Conditions Titanium Shell P0 = 1000 psi Thickness = 1/8 in E = 16,800 ksi Bisymmetric Results σh,max = 21,046 psi δr,max = 0.003158 in σallow = 25,000 psi Yield FOS = 5.12 5/14/2019

ANSYS RESULTS – LONGITUDINAL STRESS & DEFLECTION Boundary Conditions Titanium Shell F = 19,072 lbf Thickness = 1/8 in E = 16,800 ksi Results σL,max = 13,047 psi δr,max = 0.009731 in σallow = 15,000 psi Yield FOS = 8.53 5/14/2019

STRUCTURE – THEORETICAL VS. SIMULATED Parameter Hand Calculations ANSYS Results % Deviation Hoop Stress (psi) σh,max 20,500 21,046 2.66 Radial Deflection (in) δr,max 0.0032 in 0.003158 1.31 Longitudinal Stress (psi) σl,max 10,000 psi 13,047 30.47 Longitudinal Deflection (in) 0.00987 in 0.009731 1.41 5/14/2019

Use a Composite Sleeve for added strength CARBON FIBER SHELL Plan of Action Use a Composite Sleeve for added strength Reduce Combustion Chamber Deflection Lightweight Addition Additional Considerations High Temperature Epoxy Fiber Orientation Lay-up Process 5/14/2019

THERMAL CONSIDERATIONS Attempted to model heat transfer through: Combustion Chamber Nozzle Difficulties Transient Heat Flow Moving Boundary Condition Do not have dQ/dt (Heat Generation) Convection, h Specific Gas Constant, R Plan of Action Combustion Analysis Improve Convection Condition 3MTM NextelTM 440 Woven Fabric Ceramic Insulator for Nozzle High Temperature Epoxy FOS for Thermal Stresses 5/14/2019

INJECTION BACKGROUND Assumptions Fully Developed, Turbulent, Steady, Viscous Flow Liquid Phase Current test setup Nine Hole Straight Injector (1-Piece) Bolts to Steel Test Chamber Improvements Interchangeable Injector Inserts Geometry of Inserts (Flow Characteristics) Working with DELPHI (Bill Humphrey) Atomization Relocation of Pressure Transducer Weight Reduction 5/14/2019

TEST INJECTOR DESIGN Base Injector Pressure Gasket Insert Test Piece Snap Ring Insert Test Piece Base Injector Pressure Gasket 5/14/2019

INJECTION – EXPECTED RESULTS Improve Atomization Increase Combustion Stability Reduce Pressure Loss From George P. Sutton’s Rocket Propulsion Elements ∆P ≈ 30% Po 5/14/2019

INJECTOR – PRESSURE LOSS ø Z L2 L1 L3 1 2 D1 D2 1 2 5/14/2019

INJECTION TESTING In House Testing Delphi Testing (Possibility) Volumetric Flow Rate Visualization of Flow Geometry Delphi Testing (Possibility) High Speed Video High Speed Photography Electro sensing plate Test Stand Clear Acrylic Tubing Injector 5/14/2019

COMBUSTION / EXHAUST DETAILS Assumptions Locally Isentropic Compressible Flow Ratio of Specific Heats (γ) = 1.258 Complete Combustion Current test setup HTPB (Hydroxyl-Terminated Polybutadiene) as the solid fuel grain Nitrous Oxide (NOX) as the oxidizer Cylindrical fuel grain geometry Linear (Laval) Convergent-Divergent Supersonic Nozzle Improvements Fuel Grain Type (Paraffin Wax, HTPB) Geometry 5/14/2019

THRUST – NOZZLE CALCULATIONS Equation Projected Thrust: R ~ 200 lbf Area Ratio: Mach Number: Ae/At ~ 16 - 155 Me ~ 3 - 5.5 Isentropic: Po/Pe ~ 177 PROGRAMS USED MATLAB MICROSOFT EXCEL 5/14/2019

Demonstration Isentropic_Nozzle.m MATLAB DEMO Demonstration Isentropic_Nozzle.m MATLAB Program used to determine isentropic flow properties 5/14/2019

SUPERSONIC NOZZLE DESIGN Annular - Mach 4 Annular - Mach 3 8° Conical - Mach 4 12° Conical - Mach 4 5/14/2019

Nozzle cost-performance analysis Resolution of data acquisition system DELIVERABLES FOR P08104 Nozzle cost-performance analysis Resolution of data acquisition system 5/14/2019

FUEL GRAIN Geometry Fuel Composition Regression Rate Currently cylindrical design Investigate use of star-pattern Fuel Composition Currently HTPB Investigate Paraffin wax Regression Rate Optimize fuel consumption through experimentation Cylindrical (Current) 6-Point Star 5/14/2019

VELCRO© PLUG Purpose Provide back pressure during ignition Equipment Velcro will be used to hold the plug in place. The pull strength for which the plug should be released will determine which Velcro will be selected Velcro can be purchased based on pull strength criteria Procedures Tensile test to determine yield Simulate Temperature conditions 5/14/2019

IGNITION - IGNITERS Pyromix Igniter Ultra-Low Current Igniter Materials 1.2 V, 20mA light bulb Black powder Advantages requires only 25mA to fire highly shock proof Disadvantages very rapid burn rate Pyromix Igniter Materials Nichrome bridgewire-30 AWG Pyromix potassium perchlorate sulfur high grade epoxy Advantages requires very low voltage to fire epoxy offers hotter and more sustained burn rates 5/14/2019

IGNITION – IGNITERS (Cont) Thermex Igniter Materials 1.2V, 20mA light bulb Thermex powder 65% potassium perchlorate 20% charcoal 10% aluminum powder 5% red Ferric Oxide Advantages Requires very low voltage to fire Thermex offers much hotter and more sustained burn rates 5/14/2019

IGNITION – TESTING PROCEDURES Determine most efficient battery under various amperage voltage temperature Heat gun will be used to record temperature of fuel. Test “Blow Out” condition 5/14/2019

> 50% Reduction in Weight Operational at 80,000 ft SUMMARY ~ 100% Increase in Thrust > 50% Reduction in Weight Operational at 80,000 ft 5/14/2019

SENIOR DESIGN II PROJECT PLAN Week 11 Order Materials Paper / Binder Edge Update Revisions / Suggestions Senior Design II Week 1 Inventory Fabrication Injector Plate Test Fixture Fabrication Injector Insert Fabrication Fuel Grain Fabrication Week 2 & 3 Combustion Chamber & Nozzles Testing Fuel Grain Regression Ignition Week 4 Horizontal Test Fire Combustion Chamber Materials Week 5 Data Analysis Design Modifications Week 6 Horizontal Test Fire 2 Week 7 Horizontal Test Fire 3 Week 8 Fabrication Modification …. Vertical Test 1 Week 9 Vertical Test Stand (2) Week 10 Project Paper Week 11 Delivery 5/14/2019

EXPECTED COSTS - BOM 5/14/2019

SPECIAL THANKS TO: Dr. Jeffrey Kozak Dr. Dorin Patru Dr. Steve Weinstein Dr. Amitabah Ghosh Dr. Lawrence Agbezuge Bill Humphrey (Delphi) Thomas Fountain (RIT) Harris Corporation 5/14/2019

QUESTIONS / COMMENTS Please feel free give suggestions and critiques 5/14/2019