Acrylonitrilebutadiene-styrene thermoplastic, widely mass-produced for noncombustion applications including household plumbing and structural materials, is evaluated and compared with hydroxyl-terminated polybutadiene as a potential fuel for hybrid rocket motors. Acrylonitrilebutadiene-styrene has several mechanical properties, including its ability to be fabricated into a wide variety of shapes using fused deposition modeling, which are very attractive as a potential hybrid rocket fuel. The acrylonitrilebutadiene-styrene grains were fabricated using fused deposition modeling from existing rapid-prototyping stock materials composed of 50∶43∶7 butadiene, acrylonitrile, and styrene mole fractions. The acrylonitrilebutadiene-styrene grains were burned with nitrous oxide as the matching oxidizer and compared for performance and consistency against fuel grains of equal size cast from hydroxyl-terminated polybutadiene and burned with nitrous oxide. Test results demonstrate a higher burn-to-burn consistency for ...

Comparing Hydroxyl Terminated Polybutadiene and Acrylonitrile Butadiene Styrene as Hybrid Rocket Fuels

Results from a development campaign, where modern additive manufacturing methods are used to fabricate hybrid rocket fuel grains with embedded helical ports, are presented. The fuel grains were constructed from acrlyonitrile butadiene styrene using commercially available three-dimensional printer feedstock material. Gaseous oxygen is used as the oxidizer for this test campaign. When compared to cylindrical fuel ports, significant increases in fuel regression rates were observed, and these increases in regression rate diminished with time as the helical fuel port burns to become progressively more cylindrical. Comparisons to the helical pipe flow skin friction correlation developed by Mishra and Gupta indicate that increased skin friction only partially accounts for the increased regression rate. The Mishra–Gupta correlation underpredicts the regression rate amplification early in the fuel burn and overpredicts that value late in the burn. The authors conclude that radial wall-blowing due to fuel pyrolysis...

/pdf/high-regression-rate-hybrid-rocket-fuel-grains-with-helical-3y80u4jkg3.pdf

High Regression Rate Hybrid Rocket Fuel Grains with Helical Port Structures

This paper details the development of a new ignition system concept that circumvents many of the difficulties associated with the current state of the art for hybrid rocket ignition systems. The technology is based on the unique electrical breakdown properties of additively manufactured acrylonitrile butadiene styrene. Strategic application of an electric field across the top of an additively manufactured acrylonitrile butadiene styrene fuel grain induces an electrostatic arc along the horizontally stacked manufactured surface features, and results in a small amount of pyrolyzed fuel vapor. When this event occurs simultaneous with the introduction of an oxidizing flow, the ablated hydrocarbon vapor together with residual energy from the electrical arc rapidly seeds combustion. Multiple incremental prototype systems were designed, built, and tested. Best conditions for successful operation were discovered, including minimum ignition pressure, optimal geometry, and electrical power requirements. An embedded...

Development of a Power-Efficient, Restart-Capable Arc Ignitor for Hybrid Rockets

Results of a testing campaign to assess multiple commercially available three-dimensional printer materials for effectiveness in an arc-ignition system for hybrid rockets are presented. Previously, a form of additive manufacturing known as fused deposition modeling was used to fabricate high-density acrylonitrile butadiene styrene (ABS) fuel grains so that, when properly layered, they possess unique electrical breakdown properties. When subjected to an inductive charge, an electrical arc flows along the layered material surface and seeds combustion when the arc occurs simultaneously with the introduction of an oxidizing flow. This study investigates commercially available three-dimensional printable materials to search for equivalent or possibly superior fuel alternatives to ABS. Test specimens include photopolymers processed using polyjet (stereolithography) and fused-deposition printing. Comparison metrics include general arc ability, pyrolysis rate, dissipated power, characteristic velocity, and abilit...

Survey of Selected Additively Manufactured Propellants for Arc Ignition of Hybrid Rockets

This paper details the advantages of employing modern additive manufacturing methods to fabricate hybrid rocket fuels for intrinsically safe and green small spacecraft propulsion systems. Using add...

/pdf/three-dimensional-printing-of-green-fuels-for-low-cost-small-1dtwjc6zts.pdf

Three-Dimensional Printing of “Green” Fuels for Low-Cost Small Spacecraft Propulsion Systems

Development of a Power Efficient, Restart-Capable Arc Ignitor for Hybrid Rockets

Devices, methods, and systems for providing a restartable ignition system for a hybrid rocket system. In one embodiment, an ignition device includes a housing and at least two electrodes. The housing includes a first side and a second side and defines a bore with an axis extending therethrough between the first and second sides, the bore defining an internal surface of the housing. The at least two electrodes extend through the housing to the internal surface. The at least two electrodes are configured to be spaced apart so as to provide an electrical potential field along the internal surface between the at least two electrodes. Such housing is formed with and includes multiple flat layers such that the multiple flat layers provide ridges along the internal surface. With this arrangement, the internal surface with the ridges are configured to concentrate an electrical charge upon being subjected to the electrical potential field.

Restartable Ignition Devices, Systems, and Methods Thereof

Because hybrid rocket propellant materials are individually chemically stable prior to mixing within the combustion chamber, these systems possess well-known safety advantages. Unfortunately, the relative stability of traditional hybrid propellants also makes hybrid systems difficult to ignite. Hybrid ignition has historically involved one of three means, 1) pyrotechnic charges, 2) plasma torch, and 3) electric spark plugs with bi-propellant injectors. All of these methods possess distinct disadvantages. This paper details the development of new concept for hybrid rocket ignition that circumvents many of the difficulties associated with conventional ignition systems. During a testing campaign investigating Acrylonitrile Butadiene Styrene (ABS) as a fuel for hybrid rocket systems, it was discovered that ABS possesses unique electrical breakdown characteristics that facilitate ignition. Strategic application of an electric field induces an electrostatic arc along the surface of an additively-manufactured ABS fuel section resulting producing hydrocarbon vapor that seeds combustion. This behavior forms the basis of a novel arc ignition system. Multiple incremental prototype systems were designed, built, and tested. Minimum conditions for successful operation were discovered, including minimum ignition pressure, optimal geometry, and electrical power requirements. Hands-off restart capability was demonstrated repeatedly on a lab-scale system. Paths of inquiry for future research are outlined. INTRODUCTION AND RESEARCH

/pdf/power-efficient-restart-capable-acrylonitrile-butadiene-4zu9q7sl1n.pdf

Power Efficient, Restart-Capable Acrylonitrile-Butadiene-Styrene Arc Ignitor for Hybrid Rockets

Embodiments of the present invention are directed to various devices, systems and methods of providing a restartable, hybrid-rocket system that uses Acrylonitrile Butadiene Styrene (ABS) and compressed air containing oxygen levels up to 40% as a propellant. Alternatively, embodiments of the present invention includes restartable hybrid rocket system that uses a heterogeneous matrix of ABS and a solid oxidizing agent in addition to compressed air as a propellant. When the ABS is exposed to an electrical potential field, the electrical field's effect on the ABS produces localized arcing between multiple layers of the ABS resulting in joule heating and pyrolysis of the ABS. The pyrolysis produces spontaneous combustion of the ABS once the oxidizer flow provides a local oxygen partial pressure greater than two atmospheres at the surface of the ABS.

Methods and systems for restartable, hybrid-rockets

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