Injection dynamics of gelled propellants

Gel propellants have been recognized as attractive candidates for future propulsion systems due to the reduced tendency to spill and the energy advantages over solid propellants. One of strong benefits emphasized in gel propellant applications is a throttling capability, but the accurate flow control is more complicated and difficult than with conventional Newtonian propellants because of the unique rheological behaviors of gels. This study is a computational effort directed to enhance understanding of the injector internal flow characteristics for gel propellants under rocket injection conditions. In simulations, the emphasized rheology is a shear-thinning which represents a viscosity decrease with increasing a shear rate. It is described by a generalized Newtonian fluid constitutive equation and Carreau-Yasuda model. Using this rheological model, two injection schemes are considered in the present study: axially-fed and cross-fed injection for single-element and multi-element impinging injectors, respectively. An axisymmetric model is developed to describe the axially-fed injector flows and fully three-dimensional model is utilized to simulate cross-fed injector flows. Under axially-fed injection conditions investigated, three distinct modes, an unsteady, steady, and hydraulic flip mode, are observed and mapped in terms of Reynolds number and orifice design. In an unsteady mode, quasi-periodic oscillations occur near the inlet lip leading mass pulsations and viscosity fluctuations at the orifice exit. This dynamic behavior is characterized using a time-averaged discharge coefficient, oscillation magnitude and frequency by a parametric study with respect to an orifice design, Reynolds number and rheology. As a result, orifice exit flows for gel propellants appear to be significantly influenced by a viscous damping and flow resistance due to a shear thinning behavior and these are observed in each factors considered. Under conditions driven by a manifold crossflow, unsteady and asymmetric flow structures are revealed as a series of vortices generated from the unstable vena contracta. Here, flows are characterized by an orifice design, manifold/core injection velocity ratio, Reynolds number and rheology. A significant decrease of discharge coefficients is noted with increasing the manifold flow. As the manifold crossflow increases, stronger friction losses are exerted on the leeward, and lead to larger hydraulic losses across the injector. In addition, calculations show that discharge coefficients decrease and the unsteadiness is mitigated as the viscosity increases by fluid rheology variations. A larger and more distinct horseshoe vortex is observed, and pulsation magnitude and viscosity fluctuations are mitigated with increasing viscosity. The oscillation frequency, however, remains unchanged even though the viscosity curves at the high shear rate are modified. All these observations confirm the conclusion that the role of viscous damping and flow resistance is more critical in cross-fed injection conditions than in axially-fed one.