Measurement of alumina film induced ablation of internal insulator in solid rocket environment

This study investigates the ablation of internal insulation induced by the deposition of an alumina film with different lateral film speeds.A sub-scale test solid rocket motor(SRM)was designed in an impinging jet configuration to form an alumina film on the sample and to encourage the lateral movement of the film by a high-speed wall jet.Fifteen static fire tests of the test SRM were conducted with six different jet velocities(V_(jet)=100 m/s,150 m/s,200 m/s,268 m/s,330 m/s,and 450 m/s)that indirectly affected the velocity of the wall jet and the deposition rate of alumina droplets.The ablation velocity was deduced from the difference in the sample thickness after a test using a coordinate measuring machine.The droplet deposition mass flux and wall jet velocity were obtained via two-phase flow simulation with the same jet velocity and effective pressure.As a result,the characteristics of alumina-induced ablation and the changes in ablation with jet velocities were obtained.The area within0.8×jet diameter was focused upon,where the ratio of ablation velocity to incoming alumina mass was constant for each jet velocity,and showed a similarity in jet structure.When the ablation velocity was increased from 2.05 to 9.98 mm/s with increasing jet velocity,the ratio of the ablation velocity and alumina mass flux decreased from 1.07×10^(-4)to 0.49×10^(-4)m^(3)/kg as Al_(2)O_(3)-C reactions became less efficient with a reduced residence time of the film.Because the decrease in residence time by the wall jet is more pronounced for slow reactions involved in Al_(2)O_(3)-C reactions,fast reactions in Al_(2)O_(3)-C reactions are less affected and result in a convergence of the volumetric rate of ablation per unit mass of alumina.

Numerical simulation of multi-phase combustion flow in solid rocket motors with metalized propellant

Multi-phase flowfield simulation has been performed on solid rocket motor and effect of multi-phases on the performance prediction of the solid rocket motor(SRM) is investigation.During the combustion of aluminized propellant,the aluminum particles in the propellant melt and formliquid aluminum at the burning propellant surface.So the flow within the rocket motor is multi phase or two phase because it contains droplets and smoke particles of Al2O3.Flowsi mulations have been performed on a large scale motor,to observe the effect of the flowfield onthe chamber and nozzle as well.Uniform particles diameters and Rosin-Rammler diameter distribution method that is based on the assumption that an exponential relationship exists betweenthe droplet diameter,dand mass fraction of droplets with diameter greater thandhave been used for the si mulation of different distribution of Al2O3 droplets present in SRM.Particles sizes in the range of 1-100μm are used,as being the most common droplets.In this approachthe complete range of particle sizes is dividedinto a set of discrete size ranges,eachto be defined by single streamthat is part of the group.Roe scheme-flux differencing splitting based on approxi mate Riemann problem has been used to si mulate the effects of the multi-phase flowfeild.This is second order upwind scheme in which flux differencing splitting method is employed.To cater for the turbulence effect,Spalart-All maras model has been used.The results obtained show the great sensitivity of this diameters distribution and particles concentrations to the SRMflowdynamics,primarily at the motor chamber and nozzle exit.The results are shown with various sizes of the particles concentrations and geometrical configurations including models for SRM and nozzle.The analysis also provides effect of multi-phase on performance prediction of solid rocket motor.

Numerical Research on The Nozzle Damping Effect by A Wave Attenuation Method

Nozzle damping is one of the most important factors in the suppression of combustion instability in solid rocket motors.For an engineering solid rocket motor that experiences combustion instability at the end of burning,a wave attenuation method is proposed to assess the nozzle damping characteristics numerically.In this method,a periodic pressure oscillation signal which frequency equals to the first acoustic mode is superimposed on a steady flow at the head end of the chamber.When the pressure oscillation is turned off,the decay rate of the pressure can be used to determine the nozzle attenuation constant.The damping characteristics of three other nozzle geometries are numerically studied with this method under the same operating condition.The results show that the convex nozzle provides more damping than the conical nozzle which in turn provides more damping than the concave nozzle.All the three nozzles have better damping effect than that of basic nozzle geometry.At last,the phase difference in the chamber is analyzed,and the numerical pressure distribution satisfies well with theoretical distribution.

长时间工作固体火箭发动机长尾喷管外绝热装置设计

固体火箭发动机长尾喷管周围一般安装有电子仪器,故而对喷管壳体表面温度有严格的限制。对于某长时间工作的发动机,为满足喷管壳体表面温度要求,同时降低消极质量,设计了一种新型双腔外绝热装置,以实现在较小的消极质量下具有较好的绝热性能。对该绝热装置进行了内流场及传热计算分析,而后进行了绝热结构优化及试验验证。结果表明:该双腔外绝热装置可以将长时间工作固体火箭发动机长尾喷管外壁温度从483℃降低至103℃,降低约78.7%;而采用同等材料同等质量的常规外防护装置只能从483℃降低至227℃,降低约53.0%;而要达到相同的防护效果,同等材料常规外防护装置的质量将增加约160%。双腔外绝热装置中段及尾端处温度随时间变化趋势与实测结果吻合较好,有望应用于其他长时间工作发动机。

壁面开孔方式对可渗透喷管推力性能影响数值研究

为降低传统大扩张比喷管在低空飞行时喷管内燃气过膨胀带来的推力损失,提出一种具有自适应高度补偿功能的可渗透壁喷管。对采用不同壁面开孔方式的可渗透喷管进行数值模拟,对比并分析喷管的全弹道推力性能。计算结果显示,可渗透喷管在低空下的推力补偿效果明显,比冲增益最高达10%,在高空下的推力损失低至1%,高度平均比冲增益最高达1.5%。在孔隙率、壁面开孔形状相同的情况下,壁面开孔尺度越小可渗透喷管的推力性能越好,但总体上不同壁面开孔尺度的可渗透喷管的全弹道性能差异为0.6%。产生性能差异的主要原因是相同孔隙率的情况下,低空通过小尺度孔进入喷管的气流更均匀,对可渗透段内壁面压强的提升以及分离激波的削弱效果更好,因此带来的低空推力补偿效果更好。在孔隙率、壁面开孔尺度相同的情况下,采用圆柱孔的可渗透喷管的推力性能要优于圆锥孔的可渗透喷管。综合性能最好的圆柱孔可渗透喷管与综合性能较差的渐缩型圆锥孔可渗透喷管的全弹道性能相差约3.3%。

后摆心潜入式喷管柔性接头力学特性数值仿真

针对后摆心潜入式喷管柔性接头在燃气压力与摆动联合载荷下,弹性件与增强件的力学特性计算问题,建立了对称刚体-柔性体结合的几何模型;采用了有限元方法,获取了柔性接头在燃气压力、摆动载荷及联合载荷下应力、弹性比力矩分布规律。研究表明:随着燃气压力增大,弹性比力矩降低;随摆角增大,弹性比力矩增大。文中的数值仿真方法,可以应用于柔性接头力学特性的计算,为柔性接头强度的安全性评估提供指导。

固体发动机喷管热结构耦合数值仿真研究

针对在热载荷与内压联合作用下,固体火箭发动机潜入式喷管的热结构耦合数值仿真问题,采用流体仿真软件与结构计算软件,展开了数值模拟。在流体仿真软件中,计算了潜入式喷管工作过程的内部稳态流场,提取了高温燃气流动参数与固体壁面对流换热系数。在有限元结构计算平台内,编写了非均布壁面压力载荷与非均布对流换热系数子程序,耦合求解了喷管热结构耦合问题,获取了热防护材料内部温度场与应力场分布。研究表明,热载荷是引起喉衬应力的主要原因。喉衬环向压应力与拉应力随时间呈现先增大后减小的过程。经地面喷管结构完整性热试车试验验证,该热结构耦合数值仿真方法可用于喷管结构完整性与安全性分析,为喷管结构设计提供合理指导。

Influence studyof flow separation on the nozzle vibration response

In the present paper,the vibration response difference of the upper stage nozzlewith higher expansion ratio between ground and altitude simulation hot-firing test is analyzed.lt indicates that the acceleration response of the nozzle under ground hot-firing test is muchhigher than that of the altitude condition.In order to find the essential reason,the experimentaland numerical simulation studies of the flow separation are developed by using the test enginenozzle.The experimental data show that the nozzle intemal flow occurred flow separation andthe divergence cone intemal wall pressure pulsation increased significantly downstream fromthe separation location.The numerical simulation and experimental results indicate that theincrease of internal wall pressure and turbulence pulsating pressure are the substantial reason ofvibration response increasing aggravatingly during the ground firing test.

Multi-phase flow effect on SRM nozzle flow field and thermal protection materials

Multi-phase flow effect generated from the combustion of aluminum based composite propellant was performed on the thermal protection material of solid rocket motor(SRM) nozzle.Injection of alumina(Al2O3) particles from 5% to 10% was tried on SRM nozzle flow field to see the influence of multiphase flow on heat transfer computations.A coupled,time resolved CFD(computational fluid dynamics) approach was adopted to solve the conjugate problem of multi-phase fluid flow and heat transfer in the solid rocket motor nozzle.The governing equations are discretized by using the finite volume method.Spalart-Allmaras(S-A) turbulence model was employed.The computation was executed on the different models selected for the analysis to validate the temperature variation in the throat inserts and baking material of SRM nozzle.Comparison for temperatures variations were also carried out at different expansion ratios of nozzle.This paper also characterized the advanced SRM nozzle composites material for their high thermo stability and their high thermo mechanical capabilities to make it more reliable simpler and lighter.

可渗透壁自适应高度补偿喷管工作机理数值研究

提出了一种带有可渗透壁面的自适应高度补偿概念喷管(可渗透喷管),对该喷管的典型工作状态进行了数值模拟并对其高度补偿机理进行了解释。数值模拟结果显示,在低落压比条件下,外界大气透过喷管可渗透段进入喷管内部,抑制了喷管壁面处的回流产生,削弱了壁面处分离斜激波的强度,从而提高了喷管的低空推力性能。而在高落压比条件下,喷管内部燃气透过可渗透段壁面泄出,削弱了燃气的膨胀能力,使得喷管的高空推力性能有所损失。当可渗透喷管的低空推力性能提升幅度大于其高空推力性能损失时,喷管即具备了高度补偿能力。对喷管的推力构成分析表明,低落压比时,喷管可渗透段处外界大气流入所导致的喷管内压升高是其具有高度补偿能力的主要原因。基础扩张比的大小对可渗透喷管高度补偿性能影响显著,可渗透喷管比传统喷管的推力提升幅度最高可达34%,不同基础扩张比的可渗透喷管低空推力补偿能力相差最大25%。将不同基础扩张比喷管的高度平均比冲进行对比可发现,存在最优的喷管基础扩张比,该可渗透喷管高度平均比冲比传统喷管高度平均比冲高3%。

双脉冲固体火箭发动机Ⅰ脉冲燃烧室壁面烧蚀特性研究

针对双脉冲固体火箭发动机Ⅰ脉冲燃烧室壁面烧蚀热防护问题,基于热解动力学和热化学烧蚀理论,建立了芳纶/三元乙丙橡胶(EPDM)变热物性传热烧蚀模型,结合Ⅰ脉冲燃烧室绝热层工作过程的热载荷环境分布特征,开展了Ⅰ脉冲绝热材料与钢壳体一体化传热烧蚀研究,分析了不同脉冲间隔时间、不同脉冲工作时间对绝热层烧蚀特性的影响。研究结果表明:热流作用初期绝热材料表面升温迅速,但温度上升速率和炭化层厚度增长速率随能量扩散不断降低;Ⅱ脉冲工作时,Ⅰ脉冲绝热层烧蚀严重区域与气流剪切力极大值区域对应;不考虑炭化层整体剥落的前提下,脉冲间隔时间越长,Ⅰ脉冲绝热层烧蚀厚度越小,但Ⅰ脉冲燃烧室壳体温度越高,越容易影响发动机结构完整性;脉冲工作时间越长,烧蚀厚度增加速率越小;双脉冲发动机工作时间一定时,Ⅱ脉冲工作时间占比越大,烧蚀厚度越大。炭化层厚度在24 s左右达到最大值。

基于RBF代理优化的固体火箭发动机喷管型面设计

针对固定扩张比与扩张段长度的二维轴对称固体火箭发动机喷管进行扩张段型面优化,优化目标为喷管推力最大化,优化参数为贝塞尔曲线控制点的径向位置,优化方法采用径向基函数(Radial Basis Function, RBF)代理优化算法。采用纯气相与两相流两种模型分别进行优化设计,纯气相的结果表明,对于10个控制点表达的贝塞尔曲线,优化后的推力提高了1.64%。以此优化型面为初始型面,增加控制点个数至16个,二次优化后的推力又提高了0.095%。增大优化参数范围,同时引入判断拐点的约束,对于10个控制点表达的贝塞尔曲线进行单轮优化,结果同上述经过两轮优化之后的结果相近,优化后的喷管推力提高了1.78%,说明算法具有较强的稳定性。通过对不同控制参数个数的贝塞尔曲线优化过程的对比,给出了合理选择控制点个数的方法与建议。两相流的优化结果表明,由于颗粒的滞后影响造成了两相流损失,两相流喷管的推力小于纯气相喷管,但两相流喷管优化后的推力较优化前初始型面的推力提高了1.87%,略高于纯气相喷管。RBF代理优化算法适用于由任意数量控制点组成的贝塞尔曲线表达的喷管扩张段型面优化,并有较高的效率与较强的稳定性。

基于流固耦合的固体发动机复合喷管烧蚀型面演变

由于材料烧蚀性能不同,固体火箭发动机复合喷管普遍存在烧蚀台阶,严重影响喷管结构完整性,降低喷管性能。为了预示固体火箭发动机复合结构喷管内不同热防护材料交接处的烧蚀台阶型面演变过程,建立了一种能反映喷管两相流环境下防热材料烧蚀过程的流固耦合计算方法。依据热化学烧蚀与粒子侵蚀机理,考虑瞬态计算中烧蚀型面的退移,模拟了石墨-高硅氧/酚醛复合喷管烧蚀型面演化过程,验证了计算方法的有效性。模拟得到的收敛段烧蚀台阶型面与实验结果吻合较好,扩张段台阶计算深度略低于实验值。仿真结果表明:收敛段受热化学烧蚀与粒子侵蚀共同作用,两种材料粒子侵蚀速率的差异可达0.36 mm/s,是收敛段烧蚀台阶形成的主要原因,扩张段烧蚀台阶的产生仅受热化学烧蚀的影响,交接处退移速率最大差值为0.044 mm/s;烧蚀台阶形成后,拐角处暴露的石墨材料会受到较强的粒子冲刷效应;喷管喉部前端的石墨材料因烧蚀型面变化,喷管实际喉部向出口移动1.96 mm。

基于蒙特卡洛法的喷管中强非均匀性介质辐射换热问题求解加速策略

固体火箭发动机喷管内的辐射换热不可忽视,使用传统蒙特卡洛法模拟效率低下,而现有蒙特卡洛法加速策略研究多局限于辐射物性跨越1个数量级的情况,这与实际喷管中的强非均匀性特点不符。因此,辐射物性跨越2~3个数量级时,以零碰撞蒙特卡洛法为基准,对加权零碰撞蒙特卡洛法和分解蒙特卡洛法两种加速策略进行比较探究,分别考察了灰介质立方体、非灰介质圆柱体算例。结果表明:加权零碰撞蒙特卡洛法在零碰撞衰减系数取全局最大值的60%以上、分解蒙特卡洛法在控制介质辐射物性取全局最大值的3%以内时,二者均可在保证计算精度的前提下缩减计算用时;相较分解蒙特卡洛法,加权零碰撞蒙特卡洛法的加速性能更好,其在非灰算例中的效率提升最高可达14%。此外,还提出了一种改进的轴对称网格定位方法,在几种典型路径中计算用时可缩减43%以上。

喷管两相湍流数值模拟及湍流模型性能评估

研究固体火箭发动机喷管中颗粒质量流率对两相流的影响规律以及不同RANS模型对该问题的预测性能,可为喷管设计等工程应用提供重要参考。在欧拉-拉格朗日(Euler-Lagrange)框架下,通过3D大涡模拟(3D LES)研究了颗粒质量流率对喷管两相流场的影响规律,以3D LES结果作为参考依据,分析了不同RANS模型针对喷管两相流在2D轴对称和3D模拟中的性能。结果表明:由于扩张段内颗粒集中在中轴线附近区域,颗粒质量流率越大,该区域马赫数越低,温度越高;壁面附近存在无颗粒区,故边界层内流动几乎不受颗粒影响。另外,采用不同湍流模型计算得到的颗粒分布与LES基本相同。在2D轴对称RANS模拟中,发现RNG k-ε模型所预测的气相质量流率和喷管比冲与LES结果吻合最好;在高颗粒质量分数下(约30%),不同湍流模型预测的相对比冲损失差别可超过3%。在3D RANS模拟中,发现Realizable k-ε模型表现出最佳的综合性能,所预测的物理量沿中轴线分布的准确性均优于其他模型。当颗粒质量分数约为31.2%时,Realizable k-ε模型所预测的比冲为与LES结果相比误差仅1.56%。

长尾喷管气凝胶隔热层结构设计

固体火箭发动机长尾喷管外围通常放置舵机等控制系统,为了满足控制系统的工作温度要求,设计了一种用于长尾喷管段的新型热防护复合结构。长尾段隔热层采用具有低热导率、低密度特点的二氧化硅气凝胶材料。首先建立了气凝胶材料热导率计算模型,并对高温环境气凝胶材料导热性能进行测试。随后结合气凝胶材料热导率计算,建立了长尾喷管的热防护复合结构模型,并对喷管热防护结构模型进行了瞬态传热分析和力学性能分析。结果表明,喷管热防护结构设计满足材料力学性能。在发动机工作20 s后气凝胶材料可以将喷管的长尾段外壳壁面温度控制在320 K以下。相较于传统的高硅氧酚醛隔热材料,气凝胶材料隔热效果表现更优,且可以有效减少喷管热防护结构的消极质量。

入口流场不均匀性对固体火箭发动机大膨胀比喷管内流场的影响

在高机动飞行过程中,固体火箭发动机承受长时间的小过载会导致喷管入口处燃气方向改变,而药柱空间非均匀燃烧又会导致燃气密度分布不均匀,从而影响喷管入口处质量通量分布。二者均会造成入口燃气流动非均匀性,这是引起喷管流场不均匀性的主要原因之一,直接影响发动机性能。以膨胀比为100的固体火箭发动机喷管为研究对象,改变入口处质量通量分布规律与入射方向,结合计算流体力学软件研究入口流场不均匀性对喷管内流场的影响规律。结果表明:当喷管入口质量通量呈抛物面分布时,入口的不均匀性对喷管内流场影响较小,在喷管喉部位置不均匀效应基本消除;由俯仰过载导致燃气非垂直入射时,喷管入口位置流场周向不均匀性高达23%;随着燃气充分膨胀,不均匀效应减弱,在喷管扩张比达到92.8时,流场基本均匀,但是在有限扩张比条件下由入射角度导致的流场不均匀效应无法完全消除。

Ablation characteristics of insulator under high-temperature gas dual-pulse erosion

This study numerically simulated and investigated the flow field characteristics of a typical dual-pulse solid rocket motor with a soft pulse separation device through thermal insulation ablation under high-temperature dual-pulse erosion.The ablation rate of ethylene-propylene-diene monomer(EPDM)insulator was measured after the experiment.Experimental results were analyzed through scanning electron microscopy and microcomputed tomography.The ablation mechanism of the EPDM insulator under the operation conditions of a dual-pulse solid rocket motor was evaluated by analyzing the results.The results reveal that the internal flow field of the motor with a soft pulse separation device is uniform.The original charred layer existing on the EPDM insulator surface in the first pulse combustor is the decisive factor affecting the final ablation rate of the dual-pulse motor during the second pulse operation,and the ablation characteristic region is easily formed with the exfoliation of the charred layer.The ablation rate difference of the insulator increases with gas velocity.

长尾管固体火箭发动机内部流动特性仿真分析

为分析长尾管固体火箭发动机的内部流动特性,编制微分内弹道程序进行发动机内弹道解算;同时采用自定义函数建立质量进口条件、动网格技术模拟燃面推移、欧拉-拉格朗日模型结合粒子随机游走模型,对无长尾与有长尾结构固体火箭发动机三维两相瞬态内流场展开对比研究,对比了发动机的性能,分析了长尾结构对气相流动特性与不同直径颗粒的运动分布的影响。分析结果表明:内弹道与流场仿真的发动机平衡压力基本一致。有长尾结构带来了沿程阻力损失,内部平衡压强要高于无长尾结构发动机压力,导致了装药燃烧加快,输出推力反而减小;燃气流经长尾区域流速增加明显,但粒子作用会导致轴线附近流速与温度的震荡,温度整体变化小,故此区域热防护应该重点考虑;由于惯性,粒子在长尾区域先汇集后发散,随粒径增加,粒子汇集区越靠前,散布程度越大,气流对粒子运动作用越小。

小推力长工作时间固体火箭发动机喷管温度仿真分析

利用FLUENT发展了一种瞬态流-固-热一体化一步耦合三维有限元分析方法,并用该方法分析了一种采用无铝PET推进剂的小推力长工作时间(130 s)固体火箭发动机喷管温度场分布情况。分析结果表明,从喷管中心到喷管表面温度逐渐降低,喷管喉部中心温度达到2200℃以上,喉衬温度为1481~2000℃,隔热层温度为134~1864℃,壳体温度为134~234℃;喷管中心轴线上各点的温度开始时急剧增加,20 s后基本保持不变,从喷管出口到喷管入口,沿喷管中心轴线温度逐渐增加;喷管壳体表面温度随工作时间增加而增加,随离喷管出口的距离增加先增加而后逐渐降低;喷管喉部壳体表面温度最高,达220℃左右;推进剂燃温增加,喷管金属壳体表面温度呈线性增加;换热系数增加,金属壳体表面温度近似线性降低;燃烧室压强变化对金属壳体表面温度影响不大;隔热材料EPDM、5-Ⅲ和GFM降低金属壳体表面温度的效果突出。选用合适的隔热材料,做好喷管喉部位置的热防护是降低喷管壳体表面温度的有效方法。发动机试车结果与仿真结果吻合,验证了仿真分析方法的正确性。该瞬态流-固-热耦合一体化一步分析法,克服了过去流-固-热耦合方法步骤多、绝热假设不符合实际情况的局限性,可为合理设计固体发动机喷管、控制喷管温度提供依据。