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Prospects of Aluminum Modifications as Energetic Fuels in Chemical Rocket Propulsion

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Chemical Rocket Propulsion

Part of the book series: Springer Aerospace Technology ((SAT))

Abstract

The use of metals as high-energy fuels has been for long time a common approach to increase performance of chemical rocket propulsion in general. This effort was initially triggered by theoretical thermochemical considerations, but under real operating conditions, a series of collateral and unforeseen effects occurred, with both positive and negative consequences. After six decades, the use of micron-sized Al is the most common practice at industrial level for solid rocket propulsion in particular. Yet attempts are under way to mitigate some of the most deleterious effects: notably, the two-phase flow losses and slag accumulation taking place in gasdynamic nozzles. In this paper, a range of modified Al powders is discussed, going from nano-sized uncoated to coated Al particles and from chemically to mechanically activated micron-sized Al. These variants are duly characterized and comparatively tested under laboratory burning conditions. Due to page limitations, mainly the class of aluminized composite propellants (ammonium perchlorate/inert binder) and operating conditions often used in space applications are investigated. The reader is cautioned to avoid making generalizations to other formulations and conditions based on this limited dataset. Each of the tested Al variants has its own properties, and implementation in full-scale propulsive systems needs to be carefully evaluated for an overall assessment. The recommended strategy for best results is a dual mode Al mixture, synergistically exploiting each component. Other metal fuels, especially hydrides and boron compounds, are examined as well. New trends, capable of drastically changing the current situation but still in their infancy as of this writing, are briefly discussed at the end of the paper.

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Abbreviations

a:

Multiplicative factor in the Vieille steady burning rate law, (mm/s)/barn

actAl:

Activated Al

ADN:

Ammonium dinitramide

AFM:

Atomic force microscopy

ALEX™:

ALuminum EXploded (a trademark by APT, Tomsk, Russia)

AP:

Ammonium perchlorate

APT:

Advanced Powder Technologies

as :

Mean surface particle diameter, nm

BET:

Brunauer–Emmett–Teller

BPR:

Ball-to-powder mass ratio

c:

Specific heat, J/g K

CA:

Chemical activation

CAl :

Active metal content, mass %

CCP:

Condensed combustion products

D:

particle diameter, cm

EDX:

Energy dispersive X-ray analysis

EEW:

Electrical explosion of wires

EM:

Energetic materials

F-ALEXA :

ALuminum EXploded, coated by trihydroperfluoro-undecyl alcohol

F-ALEXE :

ALuminum EXploded, coated by ester from esterification of trihydroperfluoro-undecyl alcohol with maleic anhydride

GAP:

Glycidyl azide polymer

HEDM:

High-energy-density material

HMX:

Cyclotetramethylenetetranitramine

HTPB:

Hydroxyl-terminated polybutadiene

IARC:

International Agency for Research on Cancer

ICP:

Inductively coupled plasma analysis

Is :

Gravimetric specific impulse, s

Iv :

Volumetric (or density) specific impulse, s·g/cm3

k:

Thermal conductivity, J/cm s K

L-ALEX™:

ALuminum EXploded, coated by stearic acid

LH2 :

Liquid hydrogen

LOx:

Liquid oxygen

ℳ:

Molecular mass, g/gmole

MgxBy :

composite metal made, in mass, by x % Mg and y % B

MM:

Mechanical milling

n:

Pressure exponent in the Vieille steady burning rate law

nAl:

Nano-sized aluminum

NAp.:

not applicable

NAv.:

not available

O/F:

Oxidizer-to-fuel ratio

p:

Pressure, bar

P-ALEX™:

ALuminum EXploded, coated by palmitic acid process control agent

PDL:

Pressure deflagration limit

PTFE:

Polytetrafluoroethylene

rb :

Steady burning rate, mm/s

RDX:

Cyclotrimethylenetrinitramine

SEM:

Scanning electron microscopy

SPLab:

Space propulsion laboratory

SRB:

Solid rocket booster

SRM:

Solid rocket motor

S sp :

Specific surface area, m2/g

TEM:

Transmission electron microscopy

TG:

Thermogravimetry

Tmelt :

melting temperature, K

Tvap :

vaporization/decomposition temperature, K

VF-ALEX:

ALuminum EXploded, coated by Fluorel™ FC-2175 (copolymer of vinylidene fluoride and hexafluoropropylene made by 3M) and ester

XRD:

X-ray diffraction analysis

Δh 0 f :

Standard heat of formation, kJ/mole (see Table 1)

Δh melt :

melting enthalpy, kJ/mole (see Table 1)

Δh r :

reaction enthalpy, kJ/g or kJ/cm3 (see Table 1)

Δh vap :

vaporization/decomposition enthalpy, kJ/mole (see Table 1)

ΔV:

Vehicle velocity increment, m/s

μAl:

Micron-sized aluminum

ρ:

Density, g/cm3

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  1. Space Propulsion Laboratory (SPLab), Department of Aerospace Science and Technology, Politecnico di Milano, 20156, Milan, Italy

    Luigi T. DeLuca, Filippo Maggi, Stefano Dossi, Marco Fassina, Christian Paravan & Andrea Sossi

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  1. Luigi T. DeLuca
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  1. Space Propulsion Laboratory (SPLab) Department of Aerospace Science and Technology, Politecnico di Milano, Milan, Italy

    Luigi T. De Luca

  2. Institute of Space and Astronautical Science (ISAS), Japan Aerospace Exploration Agency (JAXA), Sagamihara, Japan

    Toru Shimada

  3. Department of Chemical Engineering, Mendeleev University of Chemical Technology, Moscow, Russia

    Valery P. Sinditskii

  4. The Inner Arch, Poissy, France

    Max Calabro

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DeLuca, L.T., Maggi, F., Dossi, S., Fassina, M., Paravan, C., Sossi, A. (2017). Prospects of Aluminum Modifications as Energetic Fuels in Chemical Rocket Propulsion. In: De Luca, L., Shimada, T., Sinditskii, V., Calabro, M. (eds) Chemical Rocket Propulsion. Springer Aerospace Technology. Springer, Cham. https://doi.org/10.1007/978-3-319-27748-6_8

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  • DOI: https://doi.org/10.1007/978-3-319-27748-6_8

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