Additively-manufactured shear tri-coaxial rocket injector mixing and combustion characteristics

A monolithic tri-coaxial propellant injection scheme for enhanced mixing of methane-oxygen in liquid-propellant rocket systems is enabled by additive manufacturing. Mixing and combustion characteristics of the tri-coaxial design are assessed experimentally from 1–69 bar using laser absorption tomography and chemiluminescence imaging, and are compared to a traditionally-manufactured bi-coaxial design. Quantitative two-dimensional images of temperature and carbon monoxide mole fraction are generated from the laser absorption spectroscopy methods, while OH* chemiluminescence provides an approximate metric for combustion heat release defining flame length and injector standoff distance. At similar pressures and oxidizer-to-fuel ratios, the tri-coaxial injector design is shown to enhance mixing and combustion progress, reducing characteristic mixing length scales and achieving improved combustion performance relative to more conventional bi-coaxial designs. Despite enhanced mixing, the tri-coaxial design exhibits more limited reduction in flame standoff distance from the injector face, suggesting that increased heat flux to the injector face can be managed. The tri-coaxial injector highlights the potential to leverage additive manufacturing to enhance performance and simplify the fabrication of liquid-propellant rocket engines.