Experimental Validation of a Computational Fluid Dynamics Spray Pattern Simulation for a Bi-propellant Liquid Rocket Engine Injector Plate Assembly

The liquid rocket engine, more specifically, the bi-propellant liquid rocket engine, is a popular type of chemical propulsion system within the propulsion industry due to its relatively high specific impulse and high thrust levels compared to the other chemical propulsion choices. For the purposes of this thesis, a bi-propellant liquid rocket engine system consists of a rocket engine, a set of tanks for the storage and supply of liquid propellants, and everything required in between for thrust-producing operation. Among the hardware in this "in between" necessary for a liquid rocket engine to produce thrust exists an injector, or an assembly of injector elements, whose purpose is to introduce and meter the flow of the fuel and oxidizer of the liquid rocket engine into the combustion chamber. To do this the injector or injector assembly, upon injection into the combustion chamber, must cause the two liquids to break up into small droplets, proportionally and uniformly distribute and mix the liquid into a spray pattern within the combustion chamber, and allow for engine combustion to occur as efficiently as possible. Daedalus Astronautics @ ASU, one of Arizona State University's engineering student organizations, has been working to design, construct, and successfully test a bi-propellant liquid rocket engine of its own. In doing so, Daedalus Astronautics has designed a bi-propellant liquid rocket engine injector assembly consisting of a forward bulkhead and an injector plate. The purpose of this thesis is to experimentally verify the flow of liquid through this injector assembly modeled using computational fluid dynamics methods. During the two semester time line allowed for this thesis project, a mesh was created for a single orifice geometry injector plate and combustion chamber assembly in ANSYS ICEM CFD and an experiment was designed for imaging the spray pattern from the injector plate and forward bulkhead assembly, from which several things about the injector geometry design were discovered.