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The effects of different types of nano-sized metal particles, such as aluminum (nAl), zirconium (nZr), titanium (nTi), and nickel (nNi), on the properties of a variety of solid rocket propellants (composite, fuel-rich, and composite modified double base (CMDB)) were analyzed and compared with those of propellants loaded with micro-sized Al (mAl) powder. Emphasis was placed on the investigation of burning rate, pressure exponent (n), and hazardous properties, which control whether a propellant can be adopted in solid rocket motors. It was found that nano-sized additives can affect the combustion behavior and increase the burning rate of propellants. Compared with the corresponding micro-sized ones, the nano-sized particles promote higher impact sensitivity and friction sensitivity. In this paper, 101 references are enclosed.

This research paper presents the design and development of a solid rocket motor composed of sugar-based propellant for Rocket Assist Take Off (RATO) systems. RATO systems can be integrated with different platforms that require an initial boost to be launched such as the C130 aircraft. Sugar-based propellants offer a cost-effective and environmentally friendly alternative to conventional solid rocket propellants with effective launch performances. The research purpose is to design and develop prototype rockets, verify rocket performance, and optimize the design for upscaling to larger calibers. Additionally, to establish a standard method for manufacturing sugar-based propellant grains to ensure consistency and repeatability in every batch production. During the development, non-destructive testing was performed to check the grains’ quality and a series of static firings were conducted to measure the rocket performance. Three design concepts were developed for the 40 mm rocket to achieve sufficient thrust, enhance the overall performance, and achieve a boost-sustain profile. However, upscaling the motor to 75 mm posed new challenges in the design process, requiring modification to achieve the required thrust, ensure structural integrity, and improve grain quality. Further research is required to excel in large calibre rocket performance and characterize the propellant through BEM testing.

The aim of the new investigation is the evaluation of solid rocket Propellant. In which performing numerical analysis of solid rocket propellant and calculating the constraints involved as derived from thrust i.e. velocity involved in the solid rocket propulsion motor usage. This paper aims to show the viability of solid rocket propellant for modern and future applications. Solid rocket motors are simple in design and fabricating. The need for a propellant that produces the same specific impulse as another chemical rocket engine. So it is needed to have a solid rocket motor with an enhanced combustion characteristic at a reasonable O/F ratio. For a healthy ecology, an economically reliable, highly effective, and environmentally concerned propellant is constantly suitable. As a superior alternative among the already used propellants in the sector, the paper suggested fuel PolyMethyl MethAcrylate (PMMA), PolyButadiene AcryloNitrile (PBAN) CoPolymer, and Aluminum hydride (AlH 3 ), and oxidizers such as Nitrocellulose and Difluoramine. The desired O/F ratio for the technical criteria was found to result in a high combustion characteristic. With the features discovered through numerical and analytical research, we have suggested a design for the SRM that includes post-combustion, which enhances the reaction and creates the innovative elements of the existing SRM.

In this study, the feasibility of electrospraying as an alternative processing technique for the preparation of composite solid rocket propellants (SRPs) was investigated. The main objective was to improve microstructural homogeneity and interfacial contact between the oxidizer, energetic additive, and metallic fuel without altering the chemical composition of the formulation. Additionally, porous electrosprayed SRP formulations were prepared to examine the influence of controlled porosity on thermal decomposition behavior. The prepared materials were characterized using scanning electron microscopy combined with energy-dispersive X-ray spectroscopy (SEM/EDS) to assess microstructural features and component distribution. Thermal decomposition behavior and kinetic parameters were evaluated using simultaneous DSC/TG analysis conducted at multiple heating rates. Safety-related properties were assessed through friction sensitivity testing, while post-decomposition solid residues were analyzed using SEM/EDS and X-ray diffraction. The results show that electrospraying improves structural homogeneity, reduces solid residue formation after thermal decomposition, and decreases apparent activation energy, while maintaining unchanged friction sensitivity. These findings demonstrate the potential of electrospraying as a physical processing route for tailoring the microstructure and thermal behavior of composite solid rocket propellants.

The aging of any propellant is defined as the change in the physical, chemical, and performance parameters of solid rocket propellants. The propellant’s service life and aging properties are important parameters of the study, especially for missiles and other defense applications. Hydroxyl-terminated polybutadiene (HTPB) based composite solid propellants with ammonium perchlorate (AP) are the most prominently used propellants in the operations of solid rocket motors in the defense and space sectors. Thus, studying this composite solid propellant is of essential when determining ambient service life. Performance parameters studied in this research are burn rate under high-pressure conditions in Crawford bomb setup, Thermogravimetric Analysis, and Fourier Transform Infrared Spectroscopy (FTIR). SEM and X-ray diffraction (XRD) analysis of the aged sample were also conducted to ascertain the chemical composition and morphological changes in the samples. Naturally aged propellant strands manufactured in different years have been compared with freshly prepared ones to establish a trend for deriving conclusions. The results from different analysis techniques, FTIR, XRD, and FESEM, depicted that oxidation of metals happens while aging of propellant due to atmospheric moisture, and the metal oxides prominently affect the propellant chemical composition and decomposition process of the propellant samples. The ballistic properties of the aluminium added samples showed an increment in burn rate. In contrast, the bimetal addition of aluminium and magnesium combined as an additive decreased the ballistic burn rate.

In accordance with the flow characteristics of vortex valve variable-thrust solid rocket motors, a cold flow experimental system based on Particle Image Velocimetry was established. A flow velocity vector diagram of vortex chamber was generated, and the vortex structure was analyzed. The results provided an experimental foundation for numerical simulation. The flow characteristics in vortex chamber and in the throat and divergent sections of the nozzle were modeled and simulated. The flow in the vortex chamber conformed to the complex Rankine vortex, and the flow field was divided into three different zones. The vortex core was the primary influence factor for thrust modulation. The resultant velocity reached Mach number 1 before gas arrived at nozzle throat, and the axial velocity still reached Mach number 1 at nozzle throat. Hence, the axial velocity can be used to judge the occurrence of choking at the nozzle throat. The intensity of swirl flow in divergent section of the nozzle was evidently lower than that in vortex chamber and throat. As a result, a low-pressure zone emerged around the central axis, thereby causing thrust losses.

Solid rocket motors (SRMs) play a pivotal role in space exploration owing to their reliability and high thrust-to-weight ratios. SRM propellant health monitoring is in critical demand owing to the complex operational scenarios throughout the entire life cycle of SRMs. To achieve in situ detection of three-dimensional stress, this study introduces a novel flexible three-dimensional stress sensor (FSS). First, a liquid metal pressure-sensing element with a variable cross-section was designed and numerically modeled. The performance of the FSS under different loading conditions was analyzed using finite element modeling. The sensing element prototype was fabricated using mold casting and liquid metal injection methods. The fabricated sensing-element prototype with an area ratio of 1:5 exhibited a sensitivity coefficient of 1.5%/kPa at a pressure of 300 kPa, a maximum hysteresis error of 3.98%, and a stability error of 0.17%. Finally, the FSS was developed by integrating multiple pressure-sensing elements and encapsulating the force-concentrating layers. The fabricated FSS prototype was characterized using simulated propellant experiments. Via comparison with the simulation results, the FSS was found to detect multiaxial stress differences when embedded within a propellant.

This study investigates the influence of selected combustion rate catalysts on the ballistic, physicochemical, and mechanical properties of non-isocyanate heterogeneous solid rocket propellants. Methods for curing prepolymers and modifying hydroxyl-terminated polybutadiene (HTPB) to obtain carboxyl-terminated polybutadiene (CTPB) and its epoxidized derivative (EHTPB) are discussed. The initial stage involved the synthesis of CTPB and EHTPB. The obtained compounds were analyzed for viscosity, comparing their properties to those of the base polymer HTPB. FTIR spectra of the synthesized compounds were recorded. Crosslinking systems were formulated based on the synthesized substances and tested for tensile strength. The final stage consisted of preparing solid heterogeneous rocket propellants containing selected catalysts—catocene and iron nanopowder—and evaluating their burning rate, hardness, and density. The results of the rocket propellant tests indicate that both catalysts perform effectively in the proposed system. Significantly higher burning rates were achieved compared to the catalyst-free formulation. The addition of 1% catocene resulted in a 2.5-fold increase in burning rate. Even better performance was observed with iron nanopowder—1% addition led to an almost threefold increase in burning rate. Neither catalyst significantly affected the hardness of the propellant; all samples exhibited hardness values in the range of 71–76 Shore A. Increasing the catocene content led to a decrease in the final propellant density, whereas the addition of iron nanopowder increased the density relative to the base formulation.

Nowadays, space exploration and sending satellites for different causes are more in demand. Current work is on Solid Rocket Propellant (SRP) which is used for boosters at the time of launch, correcting the satellite orbit with the help of thrusters and in missiles. Current work is to develop an easily available propellant, low cost, eco-friendly and simple to mold without compromising performance. An analytical study of the SRP parameters such as characteristic velocity, specific impulse, thrust at fixed O/F ratio is carried out. This paper proposed fuel as paraffin (C50H102) with sugar (C12H22O11) and oxidizer as potassium perchlorate (KCLO4). Thermal insulation is not used in the middle of the propellant and the outer casing because the heat does not sustain for long period for a small-scale rocket model. The specific impulse achieved with this SRP is 201.7 for an O/F ratio of 4.

In this study, a simplified stochastic temperature model is proposed for estimating the storage reliability of solid rocket propellants by temperature-induced damage. The cumulative damage to solid rocket propellants depends on the storage temperature history, and the storage reliability is related to the temperature variation and uncertainty. Therefore, a stochastic approach is required for the temperature model to estimate storage reliability. Several studies for the temperature specifications of weapons systems and materiel have focused on determining the limits of the operational environment. This paper presents a simple annual temperature model for storage reliability estimation by simulating domestic temperature statistics using temperature data provided by the Korea Meteorological Administration and Monte Carlo simulation. The simplified stochastic temperature model consists of six temperature distributions and three normalized diurnal temperature profiles. The simplified stochastic temperature model divides a year into three temperature categories grouped by month. Each temperature category has two temperature distributions, diurnal minimum and maximum temperatures, and one normalized diurnal temperature profile. It was confirmed that the logarithmic cumulative damage index induced by temperature variation and uncertainty for one year in solid rocket propellants has a normal distribution, and the proposed simplified stochastic temperature model can adequately simulate the cumulative damage distribution of the solid rocket propellants.