Regeneratively Cooled Rocket Nozzle using Triply Periodic Minimal Surfaces​

As interest in space travel grows, so does the demand for robust propulsion system design. Advances in additive manufacturing have eliminated many of the limitations that once accompanied the fabrication of highly complex geometries. As the design space continues to expand, so does the ability to produce lighter, cheaper, and more powerful propulsion systems. Engine combustion gases can reach thousands of degrees Kelvin, necessitating powerful cooling systems. One common approach is regenerative cooling, in which the cold fuel flows along channels within the nozzle walls before being burned in the combustion chamber, acting as a counter flow heat exchanger (HEX). Recent research explores the feasibility of Triply Periodic Minimal Surface (TPMS) Structures within HEXs. Current literature indicates that they possess superior cooling performance compared to traditional HEXs. However, there is limited research on their applications within propulsion cooling systems. The goal of this project is to create a regeneratively cooled nozzle using TPMS structures to increase total operation time of a model rocket. Working alongside the Drexel Rocket Team, this senior design team will calculate theoretical thermal performance, generate a new nozzle design, and conduct thermal and structural performance analyses through Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) simulations. After completing the design phase, it will then be manufactured through additive manufacturing methods. Utilizing the Team’s rocket, Ambition 1, testing will be completed to verify the design, where temperature and pressure changes will be observed and documented, and a static fire test will be conducted.