Elaborative collection of condensed combustion products of solid propellants: Towards a real Solid Rocket Motor (SRM) operational environment

A novel constant-pressure and constant-quenching distance Condensed Combustion Products (CCPs) collection system was developed, coupled with a timing control system, to collect the CCPs formed in the course of burning of aluminum-based composite propellants. The effects of adiabatic graphite plating, collection zone, quenching distance, time series of collection, and propellant burning rate on the microscopic morphology, particle size distribution and unburned aluminum content of CCPs were investigated. It was verified that the graphite plating can provide a high-fidelity high-temperature environment for propellant combustion. The combustion efficiency is improved by 2.44% compared to the bare propellant case. The time series of collection has a significant effect on the combustion efficiency of aluminum, and the combustion efficiency of aluminum in the thermal state (1.2–2.4 s) is 2.75% higher than that in the cold state (0–1.2 s). Similarly, the characteristics of the CCPs in different collection zones are different. At the quenching distance of 5 mm, the combustion efficiency of aluminum in the core zone (85.39%) is much lower than that in the outer zone (92.07%), while the particle size of the CCPs in the core zone (172 μm) is larger than that in the outer zone (41 μm). This indicates that the core zone is more likely to produce large-sized and incompletely burned agglomerates during the propellant combustion process. Different burning rates also lead to a significant difference in particle size distribution and combustion efficiency. High burning rates result in higher combustion efficiency. A detailed sequence of the elaborative collection process of CCPs is proposed, mainly including the setting of ignition delay time, burning rate, working pressure, plating length and time series of collection. The findings of this study are expected to provide a reliable tool for the evaluation of the combustion efficiency of solid propellants.