Experimental investigation of paraffin-based fuels for hybrid rocket propulsion

Solid fuels for hybrid rockets were characterized in the framework of a research project aimed to develop a new generation of solid fuels, combining at the same time good mechanical and ballistic properties. Original techniques were implemented in order to improve paraffin-based fuels. The first strengthening technique involves the use of a polyurethane foam (PUF); a second technique is based on thermoplastic polymers mixed at molecular level with the paraffin binder. A ballistic characterization of paraffin-based hybrid rocket solid fuels was performed, considering pure wax-based fuels and fuels doped with suitable metal additives. Nano-Al powders and metal hydrides (magnesium hydride (MgH2), lithium aluminum hydride (LiAlH4 )) were used as fillers in paraffin matrices. The results of this investigation show a strong correlation between the measured viscosity of the melted paraffin layer and the regression rate: a decrease of viscosity increases the regression rate. This trend is due to the increasing development of entrainment phenomena, which strongly increase the regression rate. Addition of LiAlH4 (mass fraction 10%) can further increase the regression rate up to 378% with respect to the pure HTPB regression rate, taken as baseline reference fuel. The highest regression rates were found for the Solid Wax (SW) composition, added with 5% MgH2 mass fraction; at 350 kg/(m2s) oxygen mass flux, the measured regression rate, averaged in space and time, was 2.5 mm/s, which is approximately five times higher than that of the pure HTPB composition. Compositions added with nanosized aluminum powders were compared with those added with MgH2, using gel or solid wax.