Identified Company (CompositeX) to manufacture Custom Composite Pressure Vessel ● Working pressure 1000psi ● Holds 8 kg Nitrous Oxide ● 700 cubic inch volume ● HDPE lined ● 1.4 lbs Composite Pressure Vessel (Chalice Concept) Liquid Nitrous Oxide Nitrous Oxide Vapor

Composite Pressure Vessel (Chalice Concept) Helium Gas Liquid Nitrous Oxide

Composite Pressure Vessel (Chalice Concept) ● Ideal gas law used to model helium pressure ➔ p=m*R*T/V ● Verified from pressure/ temperature data that Helium will remain gaseous ➔ Compressibility factor ~1, so ideal gas assumption valid ● Tank weights listed estimated from quote of 700ci=1.4 lbs ➔ Also includes weight of Helium (case dependent)

Aluminum/Titanium Comparison Aluminum alloy Titanium Alloy Property7075-T6 (ww-T-700) drawn tubing7075-T6; 7075-T651Grade 5 Ti6Al4V% Different SourceCasing.xlsMatweb Yield Strength (Mpa) % Ultimate Strength (Mpa) % E (Gpa) % 0.33 Density (g/cc) % Melting Temp ( o C) % Thermal Conductivity (W/m-K) % Specific Heat (J/g-K) %

Mass Calculation Short Grain HTPB Mass(kg)N2O Vol (m^3) Structure Mass Allowable (10:2) Multiplier Long Grain HTPB Mass(kg)N2O Vol (m^3) Structure Mass Allowable (10:2) Multiplier

Mass Calculation Chalice Design, 7075-T6 Al 240mm OD, 1.75mm Thickness, FS 1.25 Short Grain Low Height (cm)Low Mass (g)% All. MassHigh Height (cm)High Mass (g)% All. Mass % % % % % % % % % % % % Long Grain Low Height (cm)Low Mass (g)% All. MassHigh Height (cm)High Mass (g)% All. Mass % % % % % % % % % % % %

Mass Calculation Embedded Outer Shell Design, 7075-T6 Al 180mm OD, 61mm ID, 1.3mm Thickness, FS 1.25 Short Grain Low Height (cm)Low Mass (g)% All. MassHigh Height (cm)High Mass (g)% All. Mass % % % % % % % % % % % % Long Grain Low Height (cm)Low Mass (g)% All. MassHigh Height (cm)High Mass (g)% All. Mass % % % % % % % % % % % %

Mass Calculation Embedded Inner Shell Design, Grade 5 Titanium 61mm OD, 0.5mm Thickness Short Grain Low Height (cm)Low Mass (g)% All. MassHigh Height (cm)High Mass (g)% All. Mass % % % % % % % % % % % % Long Grain Low Height (cm)Low Mass (g)% All. MassHigh Height (cm)High Mass (g)% All. Mass % % % % % % % % % % % %

Inner Shell (fuel grain housing) Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Outer radius: 2.40” (~61mm) Inner radius: 2.36” (~60mm) Height: 21.46” (~545 m) Mat’l: Aluminum 7075 T6 Outer radius: 1.75” mm ( m) Inner radius: 1.25” ( m) Height: 1.5” ( m) Mat’l: Al 7075 T6 with Composite over-wrap Composite: IM7 Carbon (fiber) / PEEK (matrix) Model Geometry Outer Shell (NOS/rocket housing)

Material Properties Al 7075-T6 (Modeled as Isotropic) Density: 2810 kg/m 3 Longitudinal Mod., E1: 71.7e9 Pa Poisson’s Ratio, v12: 0.33 PEEK (matrix) Density: 1376 kg/m 3 IM7 Carbon Fiber (12,000 filaments) (Modeled as Orthotropic) Density: 1780 kg/m 3 Longitudinal Mod., E1: 278e9 Pa Poisson’s Ratio, v12: 0.20 Carbon/PEEK Composite (Modeled as Isotropic) Density: 1600 kg/m 3 Longitudinal Mod., E1: 71.7e9 Pa Transverse Mod., E2: 10.2e9 Pa Poisson’s Ratio, v12: 0.30 Shear Modulus, G12: 5.7e9 Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept )

Outer Shell (w/ composite) Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 1: Outer Shell of Imbedded Fuel Grain Design (Meshed Elements – 8node93)

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Outer Shell (w/ composite) Figure 2: Outer Shell of Imbedded Fuel Grain Design: Plot Results  Contour Plot  Element Solution  Stresses  von Mises stress

Outer Shell (w/ composite) Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 3: Outer Shell of Imbedded Fuel Grain Design: Plot Results  Deformed Shape  Def + undeformed

Outer Shell (w/ composite) Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 4: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints – Rotated view)

Outer Shell (w/ composite) Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 5: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints - Front View)

Outer Shell (w/ composite) Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 6: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints - Side View)

Inner Shell (All Aluminum) Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 7: Inner Shell of Imbedded Fuel Grain Design (Meshed Elements – 8node93)

Inner Shell (All Aluminum) Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 8: Inner Shell of Imbedded Fuel Grain Design: Plot Results  Contour Plot  Element Solution  Stresses  von Mises stress

Inner Shell (All Aluminum) Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 9: Inner Shell of Imbedded Fuel Grain Design: Plot Results  Deformed Shape  Def + undeformed

Inner Shell (All Aluminum) Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 10: Inner Shell of Imbedded Fuel Grain Design: (Pressure & Constraints – Rotated view)

Inner Shell (All Aluminum) Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 11: Inner Shell of Imbedded Fuel Grain Design: (Pressure & Constraints – Front view)

Inner Shell (All Aluminum) Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 12: Inner Shell of Imbedded Fuel Grain Design: (Pressure & Constraints – Side view)

Outer Shell (Aluminum only) Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 13: Outer Shell of Imbedded Fuel Grain Design (Meshed Elements – 8node93)

Outer Shell (Aluminum only) Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 14: Outer Shell of Imbedded Fuel Grain Design: Plot Results  Contour Plot  Element Solution  Stresses  von Mises stress

Outer Shell (Aluminum only) Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 15: Outer Shell of Imbedded Fuel Grain Design: Plot Results  Deformed Shape  Def + undeformed

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Outer Shell (Aluminum only) Figure 16: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints – Rotated view)

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Outer Shell (Aluminum only) Figure 17: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints - Front View)

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Outer Shell (Aluminum only) Figure 18: Outer Shell of Imbedded Fuel Grain Design: (Pressure & Constraints - Side View)

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 19: ELEMENT LAYERS

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 20: LAYER ORIENTATION AND THICKNESS

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 21: LAYER ORIENTATION AND THICKNESS continued…

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 22: COMPOSITE PROPERTIES

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 23: ALUMINUM PROPERTIES

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 24: FAILURE CRITERIA FOR COMPOSITES

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 25: INVERSE TSAI-WU STRENGTH RATIO INDEX

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 26: X-COMP OF STRESS

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 27: Y-COMP OF STRESS

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 28: X-COMP OF STRESS

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 29: SHEAR XY-DIR

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 30: SHEAR YZ-DIR

Inner and Outer Shell ANSYS Stress Modeling ( Embedded Fuel Grain Concept ) Figure 31: SHEAR XZ-DIR

Top and Bottom Fixture Solidworks Stress Model (Embedded Fuel Grain Concept) Model Geometry Mass = kg Volume = m 3 Geometry is the same for both the top and bottom fixture

Material Properties, Loading, and Meshing Al 7075-T6 Density: 2810 kg/m 3 Modulus of Elasticity: 71.7 GPa Shear Modulus: 28 GPa Top and Bottom Fixture Solidworks Stress Model (Embedded Fuel Grain Concept) 1000 psi Meshing done with Solidworks and Cosmos finite element analysis Elements: Nodes:49277

Factor of Safety Results Top and Bottom Fixture Solidworks Stress Model (Embedded Fuel Grain Concept)

Discussion of Results This model demonstrates how the top and bottom fixtures will hold up against the required loads. The loading is purely theoretical at this point, but the model is made, and all that needs to be done is substitute the correct loads for the theoretical ones. Top and Bottom Fixture Solidworks Stress Model (Embedded Fuel Grain Concept)

External Shell Solidworks Stress Model (Embedded Fuel Grain Concept) Model Geometry Mass = kg Volume = m 3

Material Properties, Loading, and Meshing Meshing done with Solidworks and Cosmos finite element analysis Elements: Nodes:87448 External Shell Solidworks Stress Model (Embedded Fuel Grain Concept) 1000 psi Al 7075-T6 Density: 2810 kg/m 3 Modulus of Elasticity: 71.7 GPa Shear Modulus: 28 GPa

Factor of Safety Results External Shell Solidworks Stress Model (Embedded Fuel Grain Concept)

Discussion of Results External Shell Solidworks Stress Model (Embedded Fuel Grain Concept)

Internal Shell Solidworks Stress Model (Embedded Fuel Grain Concept) Model Geometry Mass = kg Volume = m 3

Material Properties, Loading, and Meshing Al 2024 Density: 2780 kg/m 3 Modulus of Elasticity: 73.1 GPa Shear Modulus: 28 GPa Meshing done with Solidworks and Cosmos finite element analysis Elements: Nodes:68256 Internal Shell Solidworks Stress Model (Embedded Fuel Grain Concept) 1000 psi

Factor of Safety Results Internal Shell Solidworks Stress Model (Embedded Fuel Grain Concept)

Discussion of Results Internal Shell Solidworks Stress Model (Embedded Fuel Grain Concept)

Al 2 O 3 Post Combustion Chamber Post Combustion Chamber ANSYS Thermal Model (Embedded Fuel Grain Concept) Outer radius: 1.25” ( m) Inner radius: 1” ( m) Height: 1.5” ( m) Outer radius: 1.75” mm ( m) Inner radius: 1.25” ( m) Height: 1.5” ( m) Al 7075-T6 Housing (0.5 mm) Model Geometry

Post Combustion Chamber ANSYS Thermal Model (Embedded Fuel Grain Concept) Material Properties Al 2 O 3 Density: 3970 kg/m 3 Specific Heat: J/(kg- K) Thermal Conductivity: variable Al 7075-T6 Density: 2810 kg/m 3 Specific Heat: 960 J/(kg-K) Thermal Conductivity: 130 W/(m-K) Assumptions Constant Aluminum properties Chamber ends are adiabatic Constant film coefficients Constant bulk temperatures

Post Combustion Chamber ANSYS Thermal Model (Embedded Fuel Grain Concept) Meshed Model Nodes: 9,589 Elements: 5,602 Volumes meshed using ANSYS SmartSize 1 with tetrahedral elements

Post Combustion Chamber ANSYS Thermal Model (Embedded Fuel Grain Concept) Boundary Conditions Outer Surface Film coefficient, h = 5 W/(m-K) Bulk temperature, T ∞ = 298 K Simulates free convection of N 2 0 on Al housing Inner Surface Film coefficient, h = 300 W/(m-K) Bulk temperature, T ∞ = 3000 K Simulates convection of the propellant gas inside the combustion chamber All nodes initially set to 298 K

Post Combustion Chamber ANSYS Thermal Model (Embedded Fuel Grain Concept) Transient Results

Post Combustion Chamber ANSYS Thermal Model (Embedded Fuel Grain Concept) Discussion of Results This model demonstrates heat transfer across multiple ANSYS volumes, which will be necessary to derive a film coefficient from thermocouple data A transient analysis was also performed by hand using ANSYS input conditions with results matching ANSYS output to within 100 Kelvin. The transient model is considered validated for this test case.

Post Combustion Chamber ANSYS Thermal Model (Engine Core) Future Models A model of the post combustion chamber and nozzle is being developed to utilize data that will be collected by the test stand team. The model will be used to back out an average film coefficient and to determine if the engine structure will meet the Guidance burn time of 50 seconds.