Understanding the Role of Carbon Fiber Skeletons in Silicone Rubber-Based Ablative Composites

At present, silicone rubber-based ablative composites are usually enhanced by carbon fibers (CFs) to protect the case of solid rocket motors (SRMs). However, the effect of the CFs’ length on the microstructure and ablation properties of the silicone rubber-based ablative composites has been ignored. In this work, different lengths of CFs were introduced into silicone rubber-based ablative composites to explore the effect of fiber length, and ceramic layers of various morphologies were constructed after ablation. It was found that a complete and continuous skeleton in ceramic layers was formed by CFs over 3 mm in length. In addition, the oxyacetylene ablation results showed that the linear ablation rate declined from 0.233 to 0.089 mm/s, and the maximum back-face temperature decreased from 117.7 to 107.9 °C as the length of the CFs increased from 0.5 to 3 mm. This can be attributed to the fact that successive skeletons concatenated and consolidated the ceramic fillers as well as residues to form an integrated, robust, and dense ceramic layer.

Catalytic Effects of Ruthenocene Bimetallic Compounds Derived from Fused Aromatic Ring Ligands on the Main Oxidizing Agent for Solid Rocket Motor

We report the catalytic effect of three ruthenocene bimetallic compounds derived from fused aromatic rings of general formula [{Cp*Ru}2L], with Cp*: pentamethylcyclopentadiene and L = pentalene (1), 2,6-diethyl-4,8-dimethyl-s-indacene (2), and 2,7-diethyl-as-indacene (3), on the thermal decomposition of ammonium perchlorate (AP). The new compound 3 was characterized by a combination of multinuclear magnetic resonance (NMR) spectroscopy and elemental analysis. The differential scanning calorimetry (DSC) analysis of compound 3 shows a decrease in the decomposition temperature of AP to 347 ºC, increases the energy release to 2048 J g-1 and, consequently, leads to the lowest activation energy (42.9 kJ mol−1). These results are comparable to the typically used metallocene (catocene: 347 ºC and 2472 J g-1), suggesting a suitable and competitive alternative to be used as a modifier for composite solid propellants.

Effect of Nano-Sized Energetic Materials (nEMs) on the Performance of Solid Propellants: A Review

As a hot research topic, nano-scale energetic materials have recently attracted much attention in the fields of propellants and explosives. The preparation of different types of nano-sized energetic materials were carried out, and the effects of nano-sized energetic materials (nEMs) on the properties of solid propellants and explosives were investigated and compared with those of micro-sized ones, placing emphasis on the investigation of the hazardous properties, which could be useable for solid rocket nozzle motor applications. It was found that the nano-sized energetic materials can decrease the impact sensitivity and friction sensitivity of solid propellants and explosives compared with the corresponding micro-sized ones, and the mechanical sensitivities are lower than that of micro-sized particles formulation. Seventy-nine references were enclosed.

Exploration of a new affordable thermal protection system utilizing 2.5D silica/polysiloxane composite

Ablative materials are used as thermal protection systems (TPS) for reentry vehicles and solid rocket motor (SRM) nozzle applications. Phenolic and cyanate ester are the state-of-the-art (SOTA) resin systems used in many of the ablative composites today, including MX-2600 (silica/phenolic) from Cytec Solvay Group. While these ablatives have worked well, more demanding requirements drive the need for affordable lightweight advanced composites capable of handling high heat fluxes with minimal mass loss. These advanced ablative composites result in lighter reentry heat shields and solid rocket motors, increasing payload capabilities of spacecraft and rockets. Molding compound made of aerospace grade 99% SiO2 fabric and polysiloxane resin showed considerable improvement over MX-2600 in ablation properties in recent studies. In order to meet increased mechanical strength demands, NASA recently developed an ablative composite using a 3D quartz woven/cyanate ester composite material designed for the Orion spacecraft. While 3D woven composites provide excellent out-of-plane mechanical and ablation properties, they are very expensive, which limits their application. This research explores needle-punched silica fabric, sometimes referred to as 2.5D, which provides similar out-of-plane mechanical benefits to 3D woven composites in a more flexible VARTM manufacturing process at a much lower cost. The needle-punched silica fabric was infiltrated with polysiloxane resin and mechanical tests were performed. The needle-punched composites showed an increase of 181% in flexural strength, 27% in interlaminar shear strength, 2% in tensile strength, and 13% in compressive strength. In aerothermal ablation tests, the 2.5D out-performed the 2D laminate in char yield, mass loss, and recession rate; and in char yield and mass loss (%), the 2.5D out-performed the industry standard MX-2600 molding compound. The increased out-of-plane strength and char yield make it a promising and affordable ablative candidate for ablation performance with enhanced mechanical properties.

Determining energetic characteristics and selecting environmentally friendly components for solid rocket propellants at the early stages of design

This paper has investigated the possibility to theoretically calculate a value of the specific impulse for highly energetic compositions using only two parameters – the heat of the reaction and the number of moles of gaseous decomposition reaction products. Specific impulse is one of the most important energetic characteristics of rocket propellant. It demonstrates the level of achieving the value of engine thrust and propellant utilization efficiency. Determining the specific impulse experimentally is a complex task that requires meeting special conditions. For the stage of synthesis of new promising components, the comparative analysis of energetic characteristics, forecasting the value of specific impulse, especially relevant are calculation methods. Most of these methods were first developed to determine the energetic characteristics of explosives. Since explosives and rocket propellants in many cases have similar energy content and similar chemical composition, some estimation methods can be used to assess the specific impulse of solid rocket propellant. The specific impulse has been calculated for 45 compositions based on environmentally friendly oxidizers (ammonium dinitramide, hydrazinium nitroformate, hexanitrohexaazaisowurtzitane) and polymer binders polybutadiene with terminal hydroxyl groups, glycidylazide polymer, poly-3-nitratomethyl-3-methyloxetane). It was established that the estimation data obtained correlate well with literary data. Deviation of the derived values of the specific impulse from those reported in the literature is from 0.4 % to 1.8 %. The calculation results could be used for preliminary forecasting of energetic characteristics for highly energetic compositions, selecting the most promising components, as well as their ratios.

Effect of Reinforcement Fiber Arrangement on Thermal and Mechanical Properties of High Silica/Phenolic Resin Insulation Layer

The failure of the high silica/phenolic resin insulation layer under extreme thermal conditions has become an important reason for the trouble of solid rocket motors. A great number of studies have shown that the arrangement of reinforcement fibers is a significant factor in the failure of fiber-reinforced plastic. In this paper, the thermal and mechanical properties of the high silica/phenolic resin insulation layer with different arrangements were analyzed, and the causal relationship between the failure of the insulation layer and the arrangement of reinforcement fibers was given. Two types of heat-insulating layers with strong arrangement and weak arrangement were designed. After the SRM firing test, it is concluded that the essential reason for the failure of the insulation layer is the strength anisotropy caused by the weak arrangement of reinforcement fibers. Besides, the reinforcement fibers of strong arrangement are distributed in all directions, which compensates for the axial strength defects of the weakly arranged insulation layer.