Table of Contents - Aerocon Systems

Table of ContentsWilliam Colburn 1956 First Telemetered Rocket...........................................................3A Front Note on Safety......................................................................................................11Forward..............................................................................................................................13Chapter 1 - Introduction.....................................................................................................15Definition:......................................................................................................................15History: ..........................................................................................................................15Principles: ......................................................................................................................16Tank and Feed System:..................................................................................................16Motor Casing and Solid Component: ............................................................................17Injector and Valve:.........................................................................................................17Nozzle:...........................................................................................................................17Igniter:............................................................................................................................17Chapter 2 - Physical Configuration of a Hybrid Motor .....................................................18The Valve/Injector .........................................................................................................18Fig 1: An Injector with valve in the closed position..........................................................18Fig 2: The Hybrid Injector/Valve in the Open Position.....................................................19The U/C Valve as Injector .............................................................................................19The Forward Closure or Bulkhead.................................................................................19Fig 3: A typical physical arrangement for a hybrid motor.................................................20The Case Insulation .......................................................................................................21The Solid Grain..............................................................................................................21The Motor Case .............................................................................................................22The Nozzle.....................................................................................................................22Chapter 3 - Numerical Calculations for Hybrid Design ....................................................23Common Equations........................................................................................................23Density Values...............................................................................................................26Chapter 4 - A Practical Example in Design.......................................................................28Fig 4: Inverted gear grain Shape......................................................................................31Chapter 5 - Hybrid Grain Design.......................................................................................32Fig 5: Phantom view of an inverted gear grain core..........................................................32Fig 6: Dimensional Drawing to define the inverted gear grain in Fig 5............................33Fig 7: Representation of the Multi-Perf and the AMROC Style Hybrid Fuel grains.........34Fig 8: Multi-Perf Grains Before and After Firing..............................................................35Fig 9: Double D Grain .......................................................................................................35Fig 10: Bundled Tube Simulation of AMROC Type Core................................................36Chapter 6 - Hybrid Motor Injector Design ........................................................................38Fig 11: Injector Test Setup.................................................................................................40Some speculation on injection .......................................................................................40Vortex Injection .............................................................................................................41Combustion instability and remedies.............................................................................41Chapter 7 - The Choice of Fuel..........................................................................................43Historical Fuels..............................................................................................................43Current Fuel technology ................................................................................................44

Chapter 8- The Ignition System.........................................................................................44Fig 12: Hybrid Motor Ignition Schemes............................................................................45Fig 13: Laser Initiation of a Hybrid Motor ........................................................................46Fig 14: Direct Laser Initiation of a Hybrid Motor .............................................................47Fig 15: Simple Safe/Arm for Motor Ignition.....................................................................48Fig 16: Hypertek Ignition Scheme.....................................................................................49Fig 17: Oxidizer Pyro Valve..............................................................................................49Hybrid System Sequencing................................................................................................51Chapter 9 - The Motor Case...............................................................................................53Fig 18: Diagram for Derivation of Strength Equations .....................................................54Fig 19: Tank and Motor Case Construction Methods........................................................57Fig 20: Typical Pinned Closure .........................................................................................58Fig 21: Ring Closure Retention Methods ..........................................................................58Fig 22: Depiction of the “Y” Joint Concept.......................................................................59Chapter 10 - The Nozzle....................................................................................................61Fig 23: Gas Velocity Profile in a DeLaval Nozzle ............................................................61Fig 24: Nozzle Ratios.........................................................................................................62Fig 25: Eductor Scheme for Simulating High Altitude Firing Conditions ........................63Fig 26: “Standard” Nozzle Profile ....................................................................................63Chapter 11 - System Assembly and Integration ................................................................67Fig 27: Man Rated Hybrid Propulsion System..................................................................68Chapter 12 - Testing...........................................................................................................70Fig 28: Basic Hybrid System Test Stand ...........................................................................71Chapter 13 - Random Thoughts on Hybrid Propulsion Systems.......................................73Chapter 14 - The SORAC Project......................................................................................77Fig 29: The SORAC Sounding Rocket on the 58 foot Baxter Launch Rail ......................77Fig 30: SORAC Sounding Rocket Liftoff .........................................................................80Appendix A........................................................................................................................83Glossary of Common Rocketry Terms ..........................................................................83Appendix B - Oxidizer Characteristics.............................................................................89Appendix C Fuel Characteristics .......................................................................................93Fig 31: Oxidizer/Fuel Ratios..............................................................................................93Fig 33: Additive Properties................................................................................................94Appendix D - Materials .....................................................................................................95Fig 34: Material Properties, Case and Tank.......................................................................95Appendix E- The U/C Valve..............................................................................................97Fig. 35: Small Hybrid System Using the U/C Valve.........................................................98Appendix F- Tooling..........................................................................................................99Fig 36: Nozzle Alignment Tool .........................................................................................99Fig 37: Simplified Strong-back for Assembly...................................................................99Fig 38: Drill Press Adaptation to Inert Mixing System ...................................................100Fig 39: SORAC Casting Cup Method for Pouring Hybrid Grains ..................................101

Fig 40: SORAC Filament Winder....................................................................................102Fig 41: Drilling/Tapping Station......................................................................................102Appendix G-Tank General preparation ...........................................................................103Appendix H – The History of Hybrid Research ..............................................................105Fig 42: Hybrid Research Time Line ................................................................................105Appendix I- Resources.....................................................................................................107Afterthoughts- Revision A Additions ..............................................................................109Hybrid Motor using Gelled Oxidizer...........................................................................109Friends of Amateur Rocketry...........................................................................................109Fig 44: This Blockhouse is being constructed at the Mojave Site of FAR......................110Manned Spaceplane Hybrid Motor Design......................................................................110Fig 45: Soars manned Spaceplane Motor Head End .......................................................111Steve Zwaska’s 4.0 Inch Hybrid Vehicle ........................................................................111Fig 46: 4 inch Overall Arrangement ................................................................................112Fig 47: 4 inch Grain Configuration..................................................................................112Fig 48: 4 inch Motor General Arrangement ....................................................................113HAH-203-2 ......................................................................................................................115Fig 49: September 2003 Flight to 27,000 feet .................................................................115MicroHybrids...................................................................................................................117Rattworks Experimental Injectors....................................................................................119SpaceShip One Analysis..................................................................................................129INDEX .............................................................................................................................131