Grain characterization difficulties

and aging
• Grain materials(propellant, liner, and insulator) are rubber-like materials that are nearly
incompressible.
• They typically have a bulk modulus around 1400 MPa in compression
• For properly casted grain there are very few voids giving it good compression strength and very low
strains. But stresses are 3d as load and propellant geometry is 3d.
• Also, the propellant is easily damaged by applied tension and shear loads
• Propellants exhibit non linear visco-elastic behavior. Max stress and strain levels diminishes for
each cycle of loading making it weaker.
• Chemical deterioration and aging as well, degrades propellants
• Hence, it is difficult to characterize and predict (properties ) behavior in engineering terms
• Lab test are conducted for uni-axial loading rather complex 3d loading with uniform temperature
instead of thermal gradient
• Lab test results are applied with several assumption and empirical correction factors to actual grain
• Most common preferred test is uni-axial tensile test at constant strain rate
• Sample cut from different parts of temperature cycled grain gives different test results
• Hence data from various uni-axial test is manipulated to arrive at permissible safe stress strains
• Bi-axial tests are also carried, however meaningful 3d load test are difficult in lab and usually not
carried
• Several other test as endurance test, constant stress test, fracture test with cracks defects, test to
measure thermal coefficient of expansion, tests under various chamber pressures etc are
conducted
• For elastic materials essentially stress is proportional to strain implying, when load is removed
original geometry is regained.
• But for visco-elastic material stress – strain relation is non linear. Essentially it is time related
dependency and relation is influenced by rate of strain. Grain do not regain its original geometry
after load removal.
• Most of structural analysis carried are based on elastic theory model for 1d,2d, 3d. However ideally
the analysis must be based on non linear visco-elastic theory that is still being under development
• To compensate elastic design, non elastic behavior is
characterized by
– Considering degraded allowable stresses and
– Effective modulus that uses complex approximation based on
laboratory strain test data.
– Typically modified modulus called stress relaxation modulus
(extracted from master curve against temperature compensated time
to failure that is drawn from data of series of uni-axial test at constant
strain rate and different temperature test )
• Solid propellant behavior
– Weak in tension and shear
– Semi elastic
– Grows softer and weaker at elevated temperatures
– Becomes hard and brittle at low temperatures
– Becomes brittle as strain rate rise at a given temperature
– Easily absorbs and stores energy when being under vibration
– Degrades during long term storage due to decomposition and
crystalline changes
– Accumulates structural damage
• Important variables effecting shelf life of grain
– Time –temperature cycles
– Propellant mass composition
– Stress due to gravity for large motors
– Shock and vibration
– Failure due to cumulative damage due to cracks and unbonds
Propellant aging
• Aging refers to deterioration of properties with time
• It is done by cumulative damage and chemical changes
• Cumulative damage done due to thermal cycling and load applications during storage transportat.
ion and operation
• Chemical changes refers to
– Change in chemical composition
– Evaporation(moisture absorption) of liquid plasticizers
• Cumulative damage also reduces propellants ability to allow elongation (stress carrying capacity)
• Ageing limit is estimated time when motor is no longer able to perform safely
• Depending on propellant and grain design motor life could be between 8-25years
• Before limit is reached motors are deactivated and propellants are removed and replaced
• For tactical missiles ageing is determined by full scale motor firing tests conducted at various time
periods(2-3 years of manufacturing)
• To reduce time needed, accelerated temperature(repeated thermal cycle), accelerated mechanical
pulse loads, and over stressing are often used.
Propellant life
Typically life of propellants depends on
Typical life varies from 5-25 years.
Shelf life can be altered by
– Choosing compatible chemical compounds
– Stable ingredients
– Minimizing vibration loads
– Temperature limit