Ablative Cooling in Rocket Engines
Ablative Cooling in Rocket Engines
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International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue VIII August 2022- Available at [Link]
Abstract: This essay investigates the use of ablative cooling in solid propellant rocket engines. It begins by exploring the
mechanisms by which ablation occurs. It then demonstrates how heat transfer to an ablator can be modelled, and how this can
be used to find ablator recession rate and hence the necessary ablator thickness for a rocket engine. It does so by considering
simplified mathematical models.
These are then compared to the more complex models that have recently been developed. The different variables involved and
how they might be used or calculated are discussed.
The next section of the essay ties this theoretical knowledge and modelling into practical engineering use by considering the
impact ablation has on performance.
MATLAB is used to demonstrate how an expanding throat diameter of the nozzle can decrease thrust and specific impulse, and
that this can greatly decrease payload capacities. Other variables involved in creating a thrust profile for a solid propellant
rocket engine are considered.
Finally, the essay will look at how to choose an optimal ablator. It goes through the universally desirable characteristics and
uses the Space Shuttle SRMs as an example of disadvantages that may not initially be considered when selecting an ablator.
I. INTRODUCTION
Rocket engines are some of the most complex pieces of machinery humans have constructed. They essentially control high energy
explosions in order to provide the thrust required to lift a payload into space.
The combustion temperatures as a result of the reactions between the fuel and oxidiser typically range from 2700K to 3600K;
substantially higher than the melting point of the metals from which the rocket nozzle is made. In order to preserve the structural
integrity of the nozzle wall, the wall temperatures must be far below the melting points of the metals. Various cooling techniques
have been implemented to rapidly cool the engine and prevent rocket failure, the most common of which are regenerative cooling
and ablative cooling. 1 2
Regenerative cooling is currently the most common method used for liquid propellant rocket engines. It works by flowing propellant
(which is often cryogenic) through the walls of the combustion chamber to transfer heat away rapidly. It enables the walls of engine
to be fairly thin, which reduces the weight, hence increasing the specific impulse of the engine. It will also continue to function until
the propellant runs out.
Furthermore, it can be integrated into an expander cycle. This is where the fuel boils while passing through the combustion chamber
walls, and then spins a turbine, harnessing extra energy. 2
Ablative cooling is a much simpler way of cooling an engine, as there is simply a layer of ablative material coating the engine wall,
which vaporises as the hot exhaust gases pass by it, taking heat with it.
This method is much simpler to implement in an engine as there are no moving parts, however it does have several disadvantages.
As the ablative layer erodes away, the nozzle expansion ratio changes, reducing the thrust output of the engine. This also means that
these engines are not reusable, which can add significant risk to a mission as the same engine can’t be tested and then flown. A
notable example of this is the Apollo Lunar Ascent engine which wasn’t fired until it was actually on the moon. Despite this, it’s
simplicity makes it extremely useful for smaller engines such as those on missiles, and also solid propellant rocket engines as there
is no propellant to run around the combustion chamber. 2
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International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue VIII August 2022- Available at [Link]
The three main types of rocket engine are liquid, solid, and hybrid. Liquid rocket motors
have both the fuel and oxidiser in liquid form, which are stored in fuel tanks. The liquids
are then sprayed by injectors into the combustion chamber where they react together.
These are the most complex and expensive types of engine, because the liquid
propellants must be forced into the combustion chamber so the chamber pressure is high
enough. With smaller engines, an inert pressuring gas such as N2 or He can be used, but
this is impractical on a larger scale. Larger motors usually use turbo pumps to pump the
propellants into the combustion chamber, however energy is required to start this when
the rocket takes off. As a result, pre burners are needed, which means staged combustion
cycles are needed. Figure 1 shows a full-flow stages combustion cycle which has both an
oxidiser rich and a fuel rich pre burner. In summary, liquid propulsion is optimal for
large scale launchers, but brings many complexities with it. 3 4 5
Solid propellant rockets are vastly more simple. They consist of a grain
of fuel and oxidiser blended together in solid state. This is then ignited
(like a firework) and combustion occurs. These produce very high 6
thrust, but have a smaller specific impulse (essentially efficiency) than
liquid motors. There are no moving parts making them much more
reliable and cheaper. They are most commonly used for boosters (such
as the space shuttle or SLS), and missiles.
7
Hybrid rocket motors have one propellant in solid form, and the other in liquid form. This tends to be a solid fuel and liquid
oxidiser. Their main advantage is that they are much simpler than liquid engines to design, but are still throttleable as the engine can
be shut down in the same way as a liquid motor.
Sources:
1: [Link]
methodes/#:~:text=Ablative%20cooling%20is%20one%20of,an%20extremely%20high%20melting%20point
2:[Link]
3: [Link]
a-fourth/
4: [Link]
12/rocket/[Link]#:~:text=There%20are%20two%20main%20categories,the%20nozzle%20where%20burning%20occurs.
5: [Link]
6: [Link]
7: [Link]
8: [Link]
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International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue VIII August 2022- Available at [Link]
Sources:
9: [Link]
10: [Link]
11: [Link]
12: [Link]
13: [Link]
17
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Sources:
14:
[Link]
%20are%20considered,ablation%20applications%20(Shi%20et%20al.
15: [Link]
16: Ablative Thermal Protection Systems: Pyrolysis Modelling by Scale-Bridging Molecular Dynamics. Abhilash Harpale, Saurabh
Sawant, Rakesh Kumar, Deborah Levin and Huck Beng Chew. 2017
17: [Link] .
The total heat flux (rate of heat transfer from the combustion products to the ablator per unit area) is hence given by:
̇ = ̇ + ̇ + ̇
=ℎ
where
= heat transfer
A = surface area
ℎ = convective heat transfer coefficient
dT = difference in temperature between the surface and the bulk fluid
̇ =ℎ −
where
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International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue VIII August 2022- Available at [Link]
The value of ℎ can be calculated using various different methods, including computational modelling. For a rigorous approach to
calculating heat flux, sections of the nozzle where flow separation occurs should be considered separately. In these areas, ℎ
should be decreased as the local flow velocity will be lower. 18 19
q= σ
where
σ = The Stefan-Boltzmann Constant (5.6703*10-8 W/m2K4)
Unfortunately, as the solid propellant combusts, it forms a metallic oxide cloud, which must be treated as a grey body. This means
that some of the thermal radiation is reflected.
̇ = εσ
where
ε = the emissivity coefficient of the body (0 < ε < 1)
In order to calculate the overall heat flux from the combustion products to the wall, we treat them both as grey bodies. We will also
assume a view factor = 1.
is given by the direct radiation from surface 1 onto surface 2, divided by the total radiation emitted by surface 1. 20
Hence, the heat flux is given by the standard equation for radiation transfer between two grey bodies:
σ( − )
̇ =
1 1
+ −1
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Sources:
18: [Link]
19: [Link]
20: [Link]
21: [Link]
22: [Link]
̇
̇ = ∗
As shown by the above equation, it is assumed, that ̇ ∝ ̇ . This would only cause a significant error if Q* is measured under
conditions which are too different from the actual operating conditions of the rocket engine. 23
Sources:
23: [Link]
Ablative cooling is extremely difficult to model, since it is not even understood that well, and most models use advanced software to
produce estimates. I will outline what different variables must be considered to produce such a model.
A surface energy balance (SEB) is usually formed to show what physical and chemical processes are accounted for. This will
determine the thermochemical ablation. Mechanical erosion (due to large particles, usually metal from the solid propellant) is
calculated separately. These are summed to get the total ablator surface recession rate. 24
̇ = ̇ + ̇
A. SEB
An expression for the SEB of an ablator would be based on conservation of energy. It would take a control volume at the surface
and assess the incoming and outgoing flux. 25
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International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue VIII August 2022- Available at [Link]
The calculations for the first three were shown in the Q* method. Conduction in this case is going to be unsteady state, meaning it
varies depending on both time and distance into the ablator. The ablator wall is assumed to be a long cylinder, so a lumped system
analysis (used for approximating conduction to small, highly conductive bodies) can’t be used. A partial differential equation is
formed as temperature is a function of position and time, T(x,t). 26
It is hence given as =
Solving then applying the appropriate boundary conditions (temperature at x=0, temperature at t=0) gives an infinite series solution.
The first term of this should be used (the others are insignificant).
To calculate the rate of pyrolysis, a form of the Arrhenius relation is usually used 27
=
= rate constant
= activation energy
= frequency factor
= gas constant
= temperature
Mass flux of solid and gaseous pyrolysis products leaving the ablator must be accounted for when finding a SEB expression. These
would be found using the Arrhenius relation, and other known variables such as specific heat capacity, thermal conductivity,
density, enthalpy of pyrolysis, and phase change enthalpy
Re-radiation is included when calculating radiative heat flux between the two grey bodies as mentioned previously.
B. Mechanical Erosion
Particle impingement
Spallation
Particle impact can be modelled computationally. The fuel used, as well as ablator material will be needed for this to be modelled.
This has been detailed previously.
Spallation is defined as the ejection of fragments of material from a body due to impact or stress. Particle impingement can cause
fragments of the ablator to break off which results in ablator recession. It is important to note that this process can result in moving
boundary conditions when solving for heat flux in the SEB. These are referred to as the Stefan problems and a Stefan condition must
be calculated to solve the PDE. This condition expresses the velocity of the moving ablator surface as a function of the rate of latent
heat release for this particular case. 28
Evidently, there are other variables that could be accounted for to improve the model, but fairly reliable predictions can be made if
all of these are combined into a model.
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Sources:
24: [Link]
25: [Link]
26: [Link]
27:
[Link]
and_Theoretical_Chemistry)/Kinetics/06%3A_Modeling_Reaction_Kinetics/6.02%3A_Temperature_Dependence_of_Reaction_Rat
es/6.2.03%3A_The_Arrhenius_Law/[Link]%3A_Arrhenius_Equation
28:Error! Hyperlink reference not valid.
The aim of the nozzle is for the combustion products to reach Mach 1 at the throat. At this speed, compressibility can no longer be
ignored, and the relationship is the opposite, ∝ .
Therefore, to accelerate the fluid further to supersonic speeds, the nozzle must expand, hence the diverging section of the nozzle.
The faster the exit velocity of the fluid, the more thrust produced.
29
= ̇ +( − )
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B. Flow Expansion
When the combustion gases travel through the divergent section of the nozzle, they expand. Their pressure and temperature decrease
while their speed increases, maximising thrust. Nozzles can either be under-expanded, over-expanded, ideal, or grossly over-
expanded.
Under expansion occurs when exit pressure is greater than ambient pressure > , so the gas will continue to expand even after
leaving the nozzle, which isn’t optimal as the gas didn’t reach it’s maximum velocity.
Over expansion occurs when the exit pressure is too low. This is more efficient than overexpansion as the gases do reach maximum
velocity, but if the pressure is around 30-45% smaller than ambient, flow separation can occur. This means that the gases do not
stick to the nozzle wall, causing unpredictable and unstable flow, which can damage the nozzle. At this point, it is described as
grossly over-expanded.
Ideal is where = , which can only occur at a certain altitude.
Flow expansion is important to consider when assessing the impact of ablation on thrust and specific impulse.
C. Impact of Ablation
Ablative material is needed to cover the entire nozzle, as if any part of it melts it would cause engine failure. This means that ablator
recession occurs across the nozzle, which impacts the thrust produced as it widens the nozzle.
Considering the throat of the nozzle, this is designed to be the perfect diameter for fluid flow to reach Mach 1, meaning that as it
widens, the flow is not fully choked (doesn’t quite reach Mach 1. This means the thrust produced decreases as the ablator recedes
because the exit velocity decreases.
There is no clear, widely used mathematical model showing how ablator recession rates impact thrust. Therefore, I will use
modelling software to demonstrate the significance of the impact it can have. I will demonstrate this relationship for a solid
propellant rocket engine because ablative cooling is most commonly used for these as regenerative cooling is not an option.
The calculation of ablator recession rate ( ) was described previously. Using the model developed by Wendell A. Stephen and
Thomas E. Frakes for a carbon-phenolic ablator, a possible recession rate would be in the range of 0.12mm/s. 31
Below is a demonstrative calculation for a generic small solid propellant engine with a carbon-phenolic ablator.
The following parameters have been established (not based off any existing rockets):
Parameter Value
Chamber pressure (Pa) 3*10^6
Chamber temperature (K) 1500
Desired thrust (N) 5000
Mass flow rate (kg/s) n/a
Max altitude (m) 10,000
Coefficient of heats 1.4
R 355
Burn time (s) 100
Throat diameter (cm) 40
NB the thrust equation shows that mass flow rate and thrust are functions of each other so only one of them can be inputted.
A MATLAB analysis using these values has been used to show how the fluid flow would change based on the receding throat
diameter. The 100 second burn time would suggest a 1.2cm recession (uniform hence 2.4cm total). Figure X shows the initial flow,
and Figure Y shows the flow at the end of the burn where the throat diameter has increased to 42.4cm.
This shows how within the space of the nozzle, the flow can’t optimally expand. With the increased throat diameter, optimal flow
expansion would a divergent section of the nozzle that is longer by 14.68cm and wider by 5.53cm. As the ablator recedes, the flow
becomes increasingly under-expanded. The expansion of the flow is what enables it to reach its highest velocity, so a lower exit
velocity is recorded for under-expanded flow.
= ̇ + ( − ) shows that the lower exit velocity decreases thrust.
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International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
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In general, engineers consider 5% to be the maximum acceptable throat enlargement, so the 1.2cm (3%) enlargement of this
example would be allowed. However, it is clearly not optimal. Using the space shuttle as an example, erosion at the throat was the
second largest source of thrust and specific impulse loss. Overall, it reduced the specific impulse of the motor by 0.9s, which could
account for up to a 340kg loss in payload capability. The impact on a smaller motor such as the above example would be even
worse, due to the inevitable larger percentage throat enlargement. 32
Sources:
29: [Link]
30: [Link]
31: [Link]
32: [Link]
See Appendix A for the code used
A. Altitude 34
As the rocket moves up into the atmosphere, the air pressure decreases according to the
/ 33
barometric formula: =
= pressure at the ground
= pressure at height h
= Boltzmann’s constant
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International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
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B. Grain Geometry
In solid propellant engines, the thrust is determined by the shape of the solid propellant.
Saint-Robert’s Law shows us that chamber pressure is directly linked to propellant regression rate. 35
̇=
̇ = recession rate
= burn rate coefficient
= pressure exponent
= chamber pressure
36
Chamber pressure is also linked to thrust, meaning that the
propellant recession rate affects the thrust profile of the rocket.
Sources:
33: [Link]
34: [Link]
35:
[Link]
amber%20pressure.
36:
[Link]
IX. SELECTING THE OPTIMAL ABLATOR FOR A SOLID PROPELLANT ROCKET ENGINE
The choice of ablator is extremely important when designing a rocket engine. The ablator should have the following characteristics:
A. Different Types
1) Asbestos-silica-filled acrylonitrile butadiene rubber (ASNBR): This was used as the main ablator for the reusable solid rocket
motors for the Space Shuttle. While it is extremely effective, asbestos is extremely dangerous as it is carcinogenic. This also
makes producing the asbestos fibres very expensive.
2) Kevlar-filled ethylene propylene diene monomer (KF/EPDM): This was developed as an asbestos-free insulator, but in initial
testing NASA encountered two key problems.
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International Journal for Research in Applied Science & Engineering Technology (IJRASET)
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B. Electrostatic Energy
KF/EPDM created high levels of electrostatic energy on the surface, which did not readily dissipate. This is because it is a very
good electrical insulator as well as a thermal insulator, so static charge builds up. The sudden discharge of this energy could cause
damage to the nozzle and is a safety hazard. Several rocket failures have been recorded as a result of static charge build up. To
prevent this, a Hypalon paint with a high concentration of Electro-Conductive powders was used. The structure of the ablator has
been modified to enable it to dissipate some charge without losses of thermal-ablative properties.
C. Bondline Corrosion
This is where the adhesive between different materials in the ablator is worn away, weakening it. The adhesives initially used were
Chemlok® 205 and Chemlok® 236X. The factors discovered during testing that contributed to bondline corrosion were: cure
temperature, cure time, adhesive age, adhesive thickness. Through testing, the optimal adjustment seemed to be altering the cure
temperature and time.
Sources:
37: [Link]
38: [Link]
X. CONCLUSION
Overall, it is clear that regenerative cooling is the method of choice for liquid propellant engines for a reason. It is far simpler to
model and much more accurate predictions can be made. Ablation is still not particularly well understood, and the lack of a clear
mathematical model is evidence for this. Many models, such as the Q* method rely on experimental data which comes with several
disadvantages. The more sophisticated models often don’t consider certain processes, and there is a large difference in models used
by different engineers. However, advances in computational modelling seem to provide close enough estimates that engineers are
still able to safely implement ablative cooling systems. With the use of a model evaluating a greater number of physical and
chemical processes, more data can be produced, enabling performance to be optimised. The drawbacks of ablation can hence be
lessened by assessing it’s impact of a rocket’s thrust profile, and making necessary changes to minimise these.
APPENDIX A
MATLAB code based off code written by Vinayak Deshpande
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