Engineered Printed Propulsion Technology: A Study on Geometry-Based Thermal Management

Tungsten-based materials such as pure tungsten and tungsten-rhenium alloys are attractive hot-walled material options for solid rocket motor components, but they possess a high thermal diffusivity and can present some design challenges for thermal management. These challenges manifest themselves where geometric constraints, such as small thicknesses/volumes, coupled with long burn times and high temperature/pressure propellants utilization push materials to steady-state thermal conditions. The specific thermal management technique sought after in this effort is the redesign of the internal construction of a pintle to reduce the axial heat flow while maintaining structural integrity through coupled theoretical thermal-structural modeling. The overall goal of the Phase II program is to build on the favorable Phase I results to further explore and mature geometry-based thermal management for solid rocket motor applications. This technology will offer improved thermal management / resistances compared to solid components by defining internal thermal paths to control / limit direct axial heat flow. This advanced concept will be demonstrated during the Phase II research and development work plan by completing tasks related to: design and analysis; additive manufacturing maturation and material fabrication; material characterization and experimentation; data Evaluation and material improvements; static testing; post-test data correlation studies and design improvements; and reporting and travel. Approved for Public Release | 22-MDA-11340 (16 Dec 22)