Vortex cooled thermoplastic chamber thruster for potential application to polymer based 3D printed space propulsion...

Area of Science:

• * Aerospace Engineering
• * Materials Science
• * Chemical Engineering

Background:

• * Abundant carbon dioxide (CO2) on Mars presents an opportunity for in-situ resource utilization (ISRU).
• * Conversion of CO2 into plastics can support space manufacturing and 3D-printed propulsion systems.
• * Thermoplastic materials offer potential for additive manufacturing of spacecraft components, but require thermal management solutions.

Purpose of the Study:

• * To investigate the feasibility of a vortex-cooled thermoplastic combustion chamber thruster.
• * To assess the viability of using Martian CO2-derived plastics for 3D-printed propulsion systems.
• * To evaluate the thermal protection and propulsion performance of a thermoplastic thruster with swirl-cooled injection.

Main Methods:

• * A 10 N class bipropellant thruster using propane and gaseous oxygen was modified with a thermoplastic combustion chamber.
• * Swirl-type oxidizer injection was implemented to create a cooling layer along the inner chamber surface.
• * Extensive firing tests were conducted to analyze the effects of injection configuration and mass flow rate on cooling performance.

Main Results:

• * Stable cooling layers were successfully formed, providing adequate thermal protection for the plastic chamber.
• * Combustion flame was maintained centrally, with temperatures exceeding the chamber material's ignition point.
• * Characteristic velocity efficiency exceeded approximately 80% across various injection configurations.

Conclusions:

• * Vortex cooling is a viable method for thermally protecting thermoplastic combustion chambers.
• * This technology supports the development of polymer-based 3D-printed propulsion systems for space missions.
• * The findings advance additive manufacturing for sustainable and adaptable space propulsion using ISRU.