Effect of characteristic structure of nested composite hybrid rocket fuel grain on combustion properties

This work numerically and experimentally investigated the effect of the characteristic structure of nested composite fuel grains on their combustion properties. The characteristic structure comprised multiple helical grooves inside the fuel grain port, which formed during the combustion process. Three-dimensional steady-state simulations were employed to analyze the burning behavior of composite fuel grains with different scales of the characteristic structure (i.e., groove depth) of 0, 1, and 2 mm. An obvious swirl-gas flow field and large tangential velocity appeared for fuel grains with the characteristic structure, which was conductive to enhancing the propellant mixing. A larger flame region and more intense burning were correspondingly achieved, during which greater amounts of H2O and CO2 were generated than by fuel grain without the characteristic structure. Numerical results verified that the characteristic structure was theoretically beneficial to improving the combustion properties of the grains. Firing experiments were conducted using a laboratory-scale hybrid rocket engine with oxygen as the oxidizer. The flame structure and pulsation features were synchronously analyzed using a radiation imaging technique. Pure paraffin-based fuel grains with a circular port were tested for comparison. Both regression rates and combustion efficiencies of the composite fuel grains with characteristic structure scales of 1 mm and 2 mm showed significant improvement. The flame images exhibited an obvious helical shape and large area, which was consistent with the numerical analysis. Both the numerical and experimental results confirmed that the helical characteristic structure in the composite fuel grain played a key role in enhancing the combustion properties and demonstrate potential for further development.