For propulsion systems using gel fuels, reducing the gel fuel viscosity is essential for achieving better atomization and combustion. In this paper, we investigate the flow and heat transfer in a water-gel with a temperature and shear dependent viscosity. We consider several different channels, mimicking the transport of gelled fuels in propulsion systems, and we also look at corrugation, which is a way of enhancing fluid mixing and thus improving the heat transfer characteristics. The rheological parameters in the constitutive model of the gel are fitted with experimental data. The influence of different corrugation profiles, corrugation configuration parameters and the Reynolds number on the mean apparent viscosity and the pressure drop are investigated. It was found that the flow recirculation formed in the valley of the corrugations enhances the heat transfer and thus the temperature of the main flow. We also noticed an increase in the pressure drop due to the stronger viscous dissipation. Furthermore, it was observed that the sinusoidal corrugation can achieve lower viscosity with a lower pressure drop compared with triangular and trapezoidal corrugations. A shorter wavelength and a deeper wave amplitude of the corrugation seemed to be better for reducing the gel fuel viscosity, while we must consider the adverse consequence of increased pressure drop. A larger Reynolds number was helpful for both lowering the pressure drop and for reducing the viscosity. In addition, compared with a smooth straight pipe, a Y-shape corrugated channel with a constant inlet velocity reduced the mean apparent viscosity by 70.8%, and this value increased to 72.6% by further applying a pulsed inlet velocity, which can greatly enhance the gel fuel atomization and thus improve the combustion efficiency.

The rheological behavior of gel propellants is crucial for their practical applications, especially in the rocket engine and ramjet fields. The thixotropic characteristics of gel propellants are an important component of their rheological properties and have a notable impact on their flow and injection process. However, most gel propellants contain rich, dynamic cross-linked network structures, which impart complex non-Newtonian fluid properties, and it is difficult to establish a unified mathematical model. In view of this, this study addresses the thixotropy of a prepared RP-3 kerosene gel and determines the mathematical model and model parameters describing its thixotropy. Experiments show that the kerosene gel exhibits shear-thinning properties as well as thixotropy. To describe the microstructural changes in the gel, three thixotropic constitutive models are introduced to analyze the rheological data, and the constitutive equation parameters are optimized. The three models are all structural dynamic models, which can be used to describe microstructural changes within the material. In addition, the fitting of the constitutive equation is a multiparameter optimization problem, and an appropriate optimization method must be used for parameter fitting. Therefore, the Bayesian optimization method combined with Gaussian process regression and the upper confidence bound (UCB) acquisition function is used in the multiparameter fitting of the constitutive models. Both experiments and numerical results show that the thixotropic model, which introduces a pre-factor with shear strain and assumes that the breakdown of the gel structure is related to energy dissipation rather than the shear rate, has a better fitting effect and prediction ability with regard to the gel. Combined with transient experiments at different shear rates, the model parameters of the constitutive law can be determined quickly by applying the Bayesian optimization method.