Influence of Aluminum Content and Agglomerates Initial Velocity on Erosion in Solid Rocket Motor

Despite the aluminized propellants offering a high specific impulse, the challenge of nozzle erosion adversely impacts the rocket's performance and its reusability potential. This study presents a numerical model aiming to predict the mechanical erosion of the propulsion chamber nozzle. The model employs an Eulerian–Lagrangian approach to simulate the complexity of the flow field within the rocket combustion chamber and the interactions between the continuous phase and particles. The model also emphasizes the importance of the aluminum particle combustion process and the secondary breakup phenomena in the erosion process. Experimental and numerical data from the literature were used to validate the numerical model. Subsequently, the model was utilized to explore the impacts of increasing propellant aluminum content and varying particles' injection velocities on the nozzle's mechanical erosion. The outcomes indicated that higher aluminum content leads to a 4–10% increase in nozzle erosion compared to the 15% content case. Furthermore, the aluminum particles tend not to fully burn within the combustion chamber and contribute to the nozzle's erosion. Lastly, particles with higher initial velocity at the inlet of the combustion chamber increase the nozzle mechanical erosion despite the observed decrease in incident mass flux.