Computational Analysis and Regression Laws for Nozzle Erosion Prediction in Hybrid Rockets

The erosion of the nozzle throat can represent one of the major limitations against the future widespread use of hybrid rocket engines (HREs) in the space industry. In fact, nozzle erosion in HREs can be more severe and harder to predict than in solid rockets due to the higher concentration of oxidizing species in the combustion products and to mixture ratio shifts and/or throttling. Therefore, an accurate understanding of the erosion phenomenon is of fundamental importance for the technological advancement of HREs. This work is focused on the investigation of graphite nozzle erosion in HREs burning high-density polyethylene with two different oxidizers, oxygen and nitrous oxide. First, the results of a computational fluid dynamics parametric analysis are used to derive closed-form regression laws for the rapid estimation of nozzle throat erosion and wall temperature depending on chamber pressure and mixture ratio. Then, a one-dimensional transient heat conduction solver is loosely coupled with the aforementioned regression laws, allowing to reconstruct the transient heating process within the solid. The obtained numerical results are validated against experimental data. Finally, the effect of gas-phase reactions on the heterogeneous reactions occurring at the nozzle surface is highlighted when moving from fuel-rich to oxidizer-rich conditions.