Understanding the combustion behavior of gel fuel droplets is pivotal for enhancing burn rates, lowering ignition delay and improving the operational performance of next-generation propulsion systems. Vapor jetting in burning gel fuel droplets is a crucial process that enables an effective transport (convectively) of unreacted fuel from the droplet domain to the flame zone and accelerates the gas-phase mixing process. Here, first we show that the combusting ethanol gel droplets (organic gellant laden) exhibit a new oscillatory jetting mode due to aperiodic bursting of the droplet shell. Second, we show how the initial gellant loading rate (GLR) leads to a distinct shell formation which self-tunes temporally to burst the droplet at different frequencies. Particularly, a weak-flexible shell is formed at low GLR that undergoes successive rupture cascades occurring in same region of the droplet. This region weakens due to repeated ruptures and causes droplet bursting at progressively higher frequencies. Contrarily, high GLRs facilitate a strong-rigid shell formation where consecutive cascades occur at scattered locations across the droplet surface. This leads to droplet bursting at random frequencies. This method of modulating jetting frequency would enable an effective control of droplet trajectory and local fuel-oxidizer ratio in any gel-spray based energy formulation.

Jetting in burning gel fuel droplets is an important process which, in addition to pure vaporization, enables the convective transport of unreacted fuel vapors from the droplet interior to the flame envelope. This aids in accelerating the fuel efflux and enhancing the mixing of the gas phase, which improves the droplet burn rates. In this study, Schlieren imaging was used to characterize different jetting dynamics that govern the combustion behavior of organic-gellant-laden ethanol gel fuel droplets. To initiate jetting, the gellant shell of the burning gel fuel droplet was subjected to either oscillatory bursting or isolated bursting, or both. However, irrespective of the jetting mode, the jets interacted with the flame envelope in one of three possible ways. Based on the velocity and the degree to which a jet disrupts the flame envelope, it is classified as either a flame distortion, a fire ball outside the flame or a pin hole jet (localized flame extinction), where the pin hole jets have the highest velocity (1000–1550 mm/s), while the flame distortion events have the lowest velocity (500–870 mm/s). Subsequently, the relative number of the three types of jetting events during the droplet lifetime was analyzed as a function of the type of organic gellant. It was demonstrated that the combustion behavior of gel fuels (hydroxypropyl methylcellulose: HPMC at 3 wt.%) that tend to form thin-weak-flexible shells is dominated by low-velocity flame distortion events, while the gel fuels (methylcellulose: MC at 9 wt.%) that facilitate the formation of thick-strong-rigid shells are governed by high-velocity fire ball and pin hole jets. Overall, this study provides critical insights into the jetting behavior and its characterization, which can help us to tune the droplet gasification and the gas phase mixing to achieve an effective combustion control strategy for gel fuels.