Goals

Project Goals for Spring 2023

Over the semester of Spring 2023, Stellar aims to test our injector using the full fluid flow rate as well as document and analyze our findings from the result. Another goal is to redesign the chamber and nozzle component to fit within the size constraints of the metal 3D printer in the Additive Manufacturing Lab here at Iowa State and implement cooling channels with accurate wall thicknesses. On the controls side of the project, we will be heavily researching pressure vessels and cryogenic hardware components, documenting our findings, and developing a list of recommended hardware for purchasing in future semesters. Furthermore, the controls team will construct the Fuel side of the fluid feed system, connect the necessary components to the lab view, and test the system. Finally, in preparation for the future of Stellar, we want to start communications with EH&S and the University about developing a testing area and future steps they want us to take regarding hot-fire testing.

Deliverables

The goal of this program is to generate the deliverables listed below.

For the Fall 2021:

  • SolidWorks model of Typhoon 1.0
  • Full SolidWorks model of Path Finder
  • Pressure Vessel Solid Models and Design Specifications
  • Documentation for Code schematics, hardware selection, and wiring diagram
  • Fluid System testing procedures for operation of Pathfinder
  • Chemical equilibrium analysis, theoretical calculations for iterative design process and specifications as well as preliminary research into cooling jacket design and effects on performance.

For the Spring 2022:

  • Manufacture and assemble Path Finder.
  • Design the Pintle Injector, preliminary testing with injector using sink in the lab.
  • 3D Print the Thrust Chamber, Nozzle, and additional components.
  • Set up lab view for existing hardware.
  • Design the regenerative cooling system to mimic a closed engine cycle.
  • Order hardware and electronic components as well as plumbing components and begin assembly

For the Fall 2022:

  • Update theoretical values for pressure & temperature across the fluid feed system & create a visual representation using the P&ID diagram
  • Order the remaining fluid feed components for a single line of flow (not including pressure vessels)
  • Create a report on metal 3D printing companies & materials suitable for the thrust chamber and nozzle
  • Update the Pathfinder CAD model with electrical housing and a converging-diverging nozzle
  • Complete the electrical circuit for one line of the fluid feed system
  • Test & verify that each of the fluid feed components meets the current engine design specifications
  • 3D print and test different pintle injector configurations

For the Spring 2023:

  • Redesign Chamber and nozzle with more accurate regenerative cooling channels and smaller form factor.
  • Conduct and analyze Full Flowrate Cold Flow Injector Tests
  • Create a report on pressure vessel options and recommendations for future purchase
  • Create a report on cryogenic hardware and recommendations for future purchase
  • Assemble 1st half of the fluid feed system in Pathfinder
  •  
  • *Not Started*, *In Progress*, *Complete*

Major Milestones

  • January 30, 2023
    • Onboard new members
    • Begin chamber and nozzle redesign
    • Begin full flow rate injection test research
    • Begin cryogenic hardware and pressure vessel research
    • Resume inner wall thickness of chamber calculations
    • Begin writing a document about the future needs of STELLAR for EH&S and the University
  • February 27, 2023
    • Finish testing all available fluid feed hardware and connect to LabView
    • Finish cryogenic hardware and pressure vessel recommendations
    • Finish design for full-flow injection test
    • Order anything needed for full flow injection test
    • Begin integration of injector and redesigned chamber and nozzle
    • Verify chamber thickness using Ansys simulations
    • Begin assembly of the fluid feed system
  • March 27, 2023
    • Finish document for EH&S and University
    • Finish modifying the injector so that it is compatible with the new chamber
    • Perform Full Flow Injector tests
    • Begin post-processing of injector tests
    • Implement chamber thickness from calculations
    • Verify with AML that the new chamber can be 3D printed using the Metal 3D printer
  • April 24, 2023
    • All deliverables completed

*Not Started*, *In Progress*, *Complete*