Numerical analysis of hybrid rocket internal ballistics is carried out with a Reynolds-averaged Navier–Stokes solver integrated with a customized gas–surface interaction wall boundary condition and coupled with a radiation code based on the discrete transfer method. The fuel grain wall boundary condition is based on species, mass, and energy conservation equations coupled with thermal radiation exchange and finite-rate kinetics for fuel pyrolysis modeling. Fuel pyrolysis is governed by the convective and radiative heat flux reaching the surface and by the energy required for the propellant grain to heat up and pyrolyze. Attention is focused here on a set of static firings performed with a lab-scale GOX/HDPE motor working at relatively low oxidizer mass fluxes. A sensitivity analysis was carried out on the literature pyrolysis models for HDPE, to evaluate the possible role of the uncertainty of such models on the actual prediction of the regression rate. A reasonable agreement between the measured and computed averaged regression rate and chamber pressure was obtained, with a noticeable improvement with respect to solutions without including radiative energy exchange.

The computational fluid dynamics of hybrid rocket internal ballistics is becoming a key tool for reducing the engine operation uncertainties and development cost as well as for improving experimental data analysis. Nevertheless, its application still presents numerous challenges for the complexity of modeling the phenomena involved in the fuel consumption mechanism and its coupling with the chemically reacting flowfield. This paper presents a review of the computational thermo-fluid-dynamic models developed for the internal ballistics of hybrid rockets burning gaseous oxygen with classical polymeric or paraffin-based fuels, with a special focus on the interaction between the fluid and the solid fuel surface. With the purpose of predicting the local fuel regression rate, which is the main parameter needed for the hybrid rocket design, the model is coupled with an improved gas/surface interface treatment based on local mass, energy and mean mixture-fraction balances, combined to either a pyrolysis-rate equation in the case of classical polymers, or to an additional equation for the liquid paraffin entrainment fraction of the total fuel consumption rate. A number of experimental test cases obtained from the static firing of two different laboratory-scale rockets are simulated to determine the models’ capabilities, showing very good agreement between the calculated and measured fuel regression rates with both standard pyrolyzing and liquefying fuels. The prediction of the chamber pressure measured with paraffin fuel resulted in it being more cumbersome for the single-phase flow assumption. The advantages and limitations of the models are discussed.

Hybrid rockets are chemical propulsion systems that, in the most common configuration, employ a liquid oxidizer (or gaseous in much rarer cases) and a solid fuel; the oxidizer, stored in tanks, is properly injected in the combustion chamber where the solid fuel grain is bonded

Over the past 40 years, the loss rate for commercial passenger aircrafts has decreased down to about one in ten million, whereas the loss rate for spaceflight has remained high, in the 1% range