Feasibility of a Morphing Rocket Nozzle for Thrust Vector Control based on Corrugated Composite Laminates
Source abstract
Abstract
Abstract The paper presents technological, experimental and numerical studies aimed at the development of a morphing nozzle in composite material with a deformable divergent section, which is designed to control the vector of thrust in rockets without using mechanisms or localized flexible joints. The nozzle design is characterized by corrugated composite walls and longitudinal elements that make possible a separation of load paths involved in bending response, bearing of internal pressures and related force resultants. Mechanical requirements and conditions of pressure, temperature and gas velocity in the morphing part of the nozzle are defined by selecting and investigating two potential application scenarios. Thereafter, both technological aspects and the assessment of mechanical performances are addressed by designing, manufacturing and testing a composite demonstrator with morphing capabilities. A lightweight and flexible thermal protection system is proposed, designed and numerically analyzed. Finally, a virtual demonstrator of the composite morphing nozzle is developed. Results point out the possibility of manufacturing composite elements with axial load bearing capability that may undergo significant bending deformation without failures. The integration of a flexible thermal protection systems leads to a promising concept for the development of innovative morphing nozzle for rocket engine applications.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Aeroelasticity and Vibration Control · Rocket and propulsion systems research · Composite Structure Analysis and Optimization
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (65)
Show source-provided references
1. Boyce, R., Tirtey, S., Brown, L., Creagh, M., Ogawa, H.: SCRAMSPACE: scramjet-based access-to-space systems. In 17th AIAA International Space Planes and Hypersonic Systems and Technologies Conference. p. 2297. San Francisco, California (2011). https://doi.org/10.2514/6.2011-22910.2514/6.2011-229 ↗
2. Smart, M.K., Tetlow, M.R.: Orbital delivery of small payloads using hypersonic airbreathing propulsion. J. Spacecr. Rocket. 46(1), 117–125 (2009). https://doi.org/10.2514/1.3878410.2514/1.38784 ↗
3. Dimotakis, P., Garwin, R., Katz, J., Vesecky, J.: 100 lbs to Low Earth Orbit (LEO): Small-Payload Launch Options. Mitre Corp Mclean Va Jason Program Office. (1999)
4. Cohen-Zur, A., Natan, B.: Experimental investigation of a supersonic combustion solid fuel ramjet. J. Propul. Power 14(6), 880–889 (1998). https://doi.org/10.2514/2.537910.2514/2.5379 ↗
5. Sutton, G.P., Biblarz, O.: Rocket propulsion elements. John Wiley & Sons (2016)
6. French, J.R., Griffin, M.D.: Space vehicle design, pp. 231–236. AIAA Education Series, Washington, DC (1991)
7. Orientation, S.S.M.E.: Space Transportation System Training Data. BC98–04, Rocketdyne Propulsion & Power, Boeing (1998)
8. Haidn, O.J.: Advanced rocket engines. Advances on propulsion technology for high-speed aircraft 1, 6–1 (2008)
9. Woodberry, R.F.H., Zeamer, R.J.: Solid rocket thrust vector control. NASA SP-8114, 4–17 (1974)
10. Wendel, G.M.: U.S. Patent No. 4649701. U.S. Patent and Trademark Office, Washington, DC (1987)
11. Berdoyes, M., Dauchier, M., Just, C.: A New Ablative Material Offering SRM Nozzle Design Breakthroughs. In 47th AIAA/ASME/SAE/ASEE Joint Propulsion Conference & Exhibit, p. 6052. San Diego, California (2011). https://doi.org/10.2514/6.2011-605210.2514/6.2011-6052 ↗
12. Ram Mohan, C.H., Ramanathan, J., Kumar, S., Gupta, A.V.S.S.K.S.: Characterisation of Materials Used in Flex Bearings of Large Solid Rocket Motors. Def. Sci. J. 61(3), (2011). https://doi.org/10.14429/dsj.61.5210.14429/dsj.61.52 ↗
13. Descamps, C., Gautronneau, E., Rousseau, G., Daurat, M.: P80 SRM low torque flex-seal development− thermal and chemical modeling of molding process. Progress in Propulsion Physics 1, 141–152 (2009). https://doi.org/10.1051/eucass/20090114110.1051/eucass/200901141 ↗
14. Ren, J., Zhang, X., Yang, J., Wang, C., Liu, Y., Yang, W.: Structural analysis and testing of a miniature flexible joint under pressure and vector loading. J. Mech. Sci. Technol. 28(9), 3637–3643 (2014). https://doi.org/10.1007/s12206-014-0825-810.1007/s12206-014-0825-8 ↗
15. Lampani, L., Angelini, F., Bernabei, M., Marocco, R., Fabrizi, M., Gaundenzi, P.: Finite Element Analysis of a Solid Booster Flexible Bearing Joint for Thrust Vector Control. Aerotecnica & Spazio, The Journal of Aerospace Science, Technology and Systems 91(1), 2 (2012)
16. Douglass, H.W., Collins Jr, J.H., Ellis, R.A., Keller Jr, R.B.: Solid Rocket Motor Nozzles. NASA SP-8115 (1975)
17. Counter, D.N., Brinton, B.C.: Thrust vector control for the space shuttle solid rocket motor. In 11th AIAA Propulsion Conference (No. 75–1172). Anaheim, California (1975)10.2514/6.1975-1172 ↗
18. Caye, P., & Descamps, D.: Ariane 5 thrust vector control system development status. In 30th Joint Propulsion Conference and Exhibit. p. 3069. Indianapolis, Indiana (1994)10.2514/6.1994-3069 ↗
19. Barbarino, S., Bilgen, O., Ajaj, R.M., Friswell, M.I., Inman, D.J.: A review of morphing aircraft. J. Intell. Mater. Syst. Struct. 22(9), 823–877 (2011). https://doi.org/10.1177/1045389X1141408410.1177/1045389X11414084 ↗
20. Sofla, A.Y.N., Meguid, S.A., Tan, K.T., Yeo, W.K.: Shape morphing of aircraft wing: Status and challenges. Mater. Des. 31(3), 1284–1292 (2010). https://doi.org/10.1016/j.matdes.2009.09.01110.1016/j.matdes.2009.09.011 ↗
21. Yokozeki, T., Takeda, S.I., Ogasawara, T., Ishikawa, T.: Mechanical properties of corrugated composites for candidate materials of flexible wing structures. Compos. A Appl. Sci. Manuf. 37(10), 1578–1586 (2006). https://doi.org/10.1016/j.compositesa.2005.10.01510.1016/j.compositesa.2005.10.015 ↗
22. Thill, C.L., Etches, J., Bond, I., Potter, K., Weaver, P.: Morphing skins. The aeronautical journal 112(1129), 117–139 (2008). https://doi.org/10.1017/S000192400000206210.1017/S0001924000002062 ↗
23. Thill, C., Etches, J.A., Bond, I.P., Potter, K.D., Weaver, P.M.: Composite corrugated structures for morphing wing skin applications. Smart Mater. Struct. 19(12), 124009 (2010). https://doi.org/10.1088/0964-1726/19/12/12400910.1088/0964-1726/19/12/124009 ↗
24. Winkler, M., Kress, G.: Influence of corrugation geometry on the substitute stiffness matrix of corrugated laminates. Compos. Struct. 94(9), 2827–2833 (2012). https://doi.org/10.1016/j.compstruct.2012.03.00810.1016/j.compstruct.2012.03.008 ↗
25. Xia, Y., Friswell, M.I., Flores, E.S.: Equivalent models of corrugated panels. Int. J. Solids Struct. 49(13), 1453–1462 (2012). https://doi.org/10.1016/j.ijsolstr.2012.02.02310.1016/j.ijsolstr.2012.02.023 ↗
26. Previtali, F., Molinari, G., Arrieta, A.F., Guillaume, M., Ermanni, P.: Design and experimental characterisation of a morphing wing with enhanced corrugated skin. J. Intell. Mater. Syst. Struct. 27(2), 278–292 (2016). https://doi.org/10.1177/1045389X1559529610.1177/1045389X15595296 ↗
27. Airoldi, A., Fournier, S., Borlandelli, E., Bettini, P., Sala, G.: Design and manufacturing of skins based on composite corrugated laminates for morphing aerodynamic surfaces. Smart Mater. Struct. 26(4), 045024 (2017). https://doi.org/10.1088/1361-665X/aa606910.1088/1361-665X/aa6069 ↗
28. Airoldi, A., Sala, G., Di Landro, L. A., Bettini, P., Gilardelli, A.: Composite corrugated laminates for morphing applications. In Morphing Wing Technologies. p. 247–276. Butterworth-Heinemann (2018). https://doi.org/10.1016/B978-0-08-100964-2.00009-510.1016/B978-0-08-100964-2.00009-5 ↗
29. Schmitz, A., Horst, P.: Bending deformation limits of corrugated unidirectionally reinforced composites. Compos. Struct. 107, 103–111 (2014). https://doi.org/10.1016/j.compstruct.2013.07.04810.1016/j.compstruct.2013.07.048 ↗
30. Dawson, M., Brewster, G., Conrad, C., Kilwine, M., Chenevert, B., Morgan, O.: Monopropellant hydrazine 700 lbf throttling terminal descent engine for Mars science laboratory. In 43rd AIAA/ASME/SAE/ASEE Joint Propulsion Conference & Exhibit. p. 5481. Cincinnati, Ohio (2007). https://doi.org/10.2514/6.2007-548110.2514/6.2007-5481 ↗
31. Schmit, D.D., Anderson, J.W., Vote, F.C.: Long-life bipropellant system demonstration, viking orbiter propulsion system. J. Spacecr. Rocket. 18(4), 327–332 (1981). https://doi.org/10.2514/3.5782410.2514/3.57824 ↗
32. Northrop Grumman, Propulsion Product Catalogue.: https://www.northropgrumman.com/wp-content/uploads/NG-Propulsion-Products-Catalog.pdf. Accessed on 21 Aug 2022.
33. McBride, B. J.: Computer program for calculating and fitting thermodynamic functions. National Aeronautics and Space Administration, Office of Management, Scientific and Technical Information Program. vol. 1271. (1992)
34. Adler, D., Dubrov, E., Manheimer-Timnat, Y.: The performance of a hydrazine engine with an improved catalyst. Acta Astronaut. 2(7–8), 613–625 (1975). https://doi.org/10.1016/0094-5765(75)90005-310.1016/0094-5765(75)90005-3 ↗
35. ASTM Standard D3039/D3039M-14.: Standard Test Method for Tensile Properties of Polymer Matrix Composite Materials. ASTM International, West Conshohocken, PA, (2014)
36. ASTM Standard D3518/D3518M − 13.: Standard Test Method for In-Plane Shear Response of Polymer Matrix Composite Materials by Tensile Test of a ±45°. ASTM International, West Conshohocken, PA, (2013)
37. Hexply M49 Product Datasheet.: https://www.hexcel.com/user_area/content_media/raw/HexPly_M49_eu_DataSheet.pdf. Accessed on 14 Sept 2021
38. EOS Gmbh, PA2200 Product Datasheet.: https://eos.materialdatacenter.com/eo/en. Accessed on 14 Sept 2021
39. Dassult Systemes Simulia Corporation.: Abaqus Analysis User Maual Version 6.12. (2012)
40. Department of Defense Handbook.: Composite materials handbook. Volume 3: polymer matrix composites materials usage, design, and analysis, MIL-HDBK-17–3F. Document Automation and Production Service (DAPS). (2002)
41. Tauzia, J. M.: Thermal insulations, liners and inhibitors. In Solid rocket propulsion technology. pp. 553–583. (1993). Pergamon Press. https://doi.org/10.1016/B978-0-08-040999-3.50018-710.1016/B978-0-08-040999-3.50018-7 ↗
42. Silva, J., Gamboa, P., Nunes, C., Paulo, L., Franco, N.: Cork: Is it a good material for aerospace structures? In 52nd AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics and Materials Conference 19th AIAA/ASME/AHS Adaptive Structures Conference 13th, p. 2159. Denver, Colorado (2011). https://doi.org/10.2514/6.2011-215910.2514/6.2011-2159 ↗
43. Smith, E., Laub, B., Beck, R., Fretter, E.: Thermal/ablation model of low density cork phenolic for the Titan IV Stage I engine thermal protection system. In 27th Thermophysics Conference, p. 2905. Nashville, Tennessee (1992). https://doi.org/10.2514/6.1992-290510.2514/6.1992-2905 ↗
44. Boehrk, H., Stokes, J.L.: Kinetic parameters and thermal properties of a cork-based material. In 20th AIAA International Space Planes and Hypersonic Systems and Technologies Conference, p. 3532. Glasgow, Scotland (2015). https://doi.org/10.2514/6.2015-353210.2514/6.2015-3532 ↗
45. Gul, J., Saleemi, A.R., Mirza, S., Feroze, N., Mansha, M.: Thermal and mechanical characteristics of cork filled insulation for aerospace applications. Plast., Rubber Compos. 39(1), 28–32 (2010). https://doi.org/10.1179/174328910X1260885183201010.1179/174328910X12608851832010 ↗
46. Bhuvaneswari, C.M., Kakade, S.D., Deuskar, V.D., Dange, A.B., Gupta, M.: Filled Ethylene-propylene Diene Terpolymer Elastomer as ThermalInsulator for Case-bonded Solid Rocket Motors. Def. Sci. J. 58(1), 94 (2008)10.14429/dsj.58.1628 ↗
47. Natali, M., Rallini, M., Puglia, D., Kenny, J., Torre, L.: EPDM based heat shielding materials for Solid Rocket Motors: A comparative study of different fibrous reinforcements. Polym. Degrad. Stab. 98(11), 2131–2139 (2013). https://doi.org/10.1016/j.polymdegradstab.2013.09.00610.1016/j.polymdegradstab.2013.09.006 ↗
48. Chen, R., Lu, S., Li, C., Ding, Y., Zhang, B., Lo, S.: Correlation analysis of heat flux and cone calorimeter test data of commercial flame-retardant ethylene-propylene-diene monomer (EPDM) rubber. J. Therm. Anal. Calorim. 123(1), 545–556 (2016). https://doi.org/10.1007/s10973-015-4900-x10.1007/s10973-015-4900-x ↗
49. Ahmed, A.F., Hoa, S.V.: Thermal insulation by heat resistant polymers for solid rocket motor insulation. J. Compos. Mater. 46(13), 1549–1559 (2012). https://doi.org/10.1177/002199831141885010.1177/0021998311418850 ↗
50. Deuri, A.S., Bhowmick, A.K., Ghosh, R., John, B., Sriram, T., De, S.K.: Thermal and ablative properties of rocket insulator compound based on EPDM. Polym. Degrad. Stab. 21(1), 21–28 (1988). https://doi.org/10.1016/0141-3910(88)90062-610.1016/0141-3910(88)90062-6 ↗
51. Hu, X., Gao, H., Zhou, X., Cui, Y., Ge, H.: A new approach to rubber reinforcement. RSC Adv. 4(26), 13662–13668 (2014). https://doi.org/10.1039/C3RA47537A10.1039/C3RA47537A ↗
52. Amorim cork composites, Ablative Thermal Protection, Since the beginning of space exploration, Brochure.: http://www.amorimcorkcomposites.com/en-us/materials-applications/aerospace/. Accessed 24 Oct 2017
53. Díaz-Parralejo, A., Cuerda-Correa, E.M., Macías-García, A., Sánchez-González, J., Díaz-Díez, M.: The excellent mechanical properties of cork: a novel approach through the analysis of contact stress. International Scholarly Research Notices (2014). https://doi.org/10.1155/2014/89843910.1155/2014/898439 ↗
54. Natali, M., Kenny, J.M., Torre, L.: Science and technology of polymeric ablative materials for thermal protection systems and propulsion devices: a review. Progress in Material Science 84, 192–275 (2016). https://doi.org/10.1016/j.pmatsci.2016.08.00310.1016/j.pmatsci.2016.08.003 ↗
55. Bergman, T.L., Incropera, F.P., Dewitt, D.P., Lavine, A.S.: Fundamentals of heat and mass transfer. John Wiley & Sons (2011)
56. Hexcel, Hexweb CR III product datasheet.: https://www.hexcel.com/user_area/content_media/raw/HexWeb_CRIII_DataSheet.pdf. Accessed on 19 Aug 2022
57. DeSain, J.D., Brady, B.B.: Thermal conductivity of liquid hydrazine (N2H4) at 293.2 Kelvin and 0.101 to 2.068 Megapascals. J. Thermophys. Heat Trans. 23(4), 828–835. (2009). https://doi.org/10.2514/1.3877510.2514/1.38775 ↗
58. Zhang, J., Zhi, S., Sun, B.: Estimation of thermophysical properties of solid propellants based on particle packing model. Science China Technol. Sci. 56(12), 3055–3069 (2013). https://doi.org/10.1007/s11431-013-5368-110.1007/s11431-013-5368-1 ↗
59. Turchi, A., Bianchi, D., Thakre, P., Nasuti, F., Yang, V.: Radiation and roughness effects on nozzle thermochemical erosion in solid rocket motors. J. Propul. Power 30(2), 314–324 (2014). https://doi.org/10.2514/1.B3499710.2514/1.B34997 ↗
60. Natali, M., Rallini, M., Puglia, D., Kenny, J., Torre, L.: An Armadillo Like Flexible Thermal Protection System for Inflatable Decelerators: A Novel Paradigm. Macromol. Mater. Eng. 299(3), 379–390 (2014). https://doi.org/10.1002/mame.20130026710.1002/mame.201300267 ↗
61. Canfield, A.: Braided carbon/carbon nozzle development. In 21st Joint Propulsion Conference, p. 1096. Monterey, California (1985). https://doi.org/10.2514/6.1985-109610.2514/6.1985-1096 ↗
62. Rao, G.V.R.: Exhaust nozzle contour for optimum thrust. Journal of Jet Propulsion 28(6), 377–382 (1958). https://doi.org/10.2514/8.732410.2514/8.7324 ↗
63. Rao, G.V.R.: Recent developments in rocket nozzle configurations. ARS journal 31(11), 1488–1494 (1961). https://doi.org/10.2514/8.583710.2514/8.5837 ↗
64. Bruno, C., Czysz, P.A.: Future spacecraft propulsion systems: enabling technologies for space exploration. Springer Science & Business Media (2009)10.1007/978-3-540-88814-7 ↗
65. Herbert, J.T., Kovitch, F.J, McCorkle, M.: U.S. Patent No. 3390899. Washington, DC: U.S. Patent and Trademark Office (1968)