Solid Rocket Motor Design and Applications

DURATION: THREE DAYS
COURSE NO.: 5090

This seminar provides a detailed look at solid rocket motors and the sensitivity of system performance requirements on their design, reliability and cost. It will also provide insight into their limitations and a general understanding of solid propellant motor and component technologies, design drivers and critical manufacturing process parameters as well as providing a comparison with liquid and hybrid motors. All current types of motors are included, with emphasis on those recently developed for the emerging small-to-medium commercial and government launch vehicles, such as the Lockheed Martin Athena, Orbital Science’s Pegasus XL and Taurus series, as well as other existing motors, including strap-on motors for the current Delta II (GEMs) and the larger (46 and 60-inch) diameter GEM motors for the Boeing Delta III and Delta IV. Numerous case studies and examples are included, e.g., lower and upper stages and strap-ons. Attendees will gain an understanding and insight into solid motor design and development processes.

COURSE MATERIALS:
Include extensive notes and reference materials.

This course is designed for technologists, launch vehicle designers, systems engineers and other users of solid rocket motors needing an in-depth understanding of solid rocket motor selection, engineering and application.

Solid rocket motor design procedures. Solid motor design drivers and technology trade-offs. Survey and understanding of propellant selections. Parameters which effect the motor manufacturing process. Motor transportation and handling considerations. Recent developments in solid rocket motor adaptation to small and medium-sized launch vehicles. Motor/vehicle interfaces and requirements.

1. Introduction to Solid Rocket Motors (SRMs).
   

   Motor definitions and terminology. Survey of motor functions and applications. Summary of SRM types.

2. Principles of SRM Design and Application.
   

   Fundamental principles of solid rocket motors, key ballistic and other performance parameters used to define usage and application. Comparison of SRMs to liquid rocket engines. Limitations on SRM applications.

3. Sensitivity of SRM Requirements.
   

   Impact of customer/system imposed requirements on motor design, reliability and cost.

4. Design Drivers and Technology Trade-Offs.
   

   Thrust profile shaping and grain design. Motor and component design trades vs. cost and maturity of technology.

5. Key SRM Component Design and Materials.
   

   Detailed description and philosophy of state-of-the-art vs. advanced technology designs and materials. Propellant formulations. Motor case, nozzle, thrust vector actuation and motor ignition ordnance. Flight termination systems. Attachment hardware for strap-ons.

6. Motor Manufacturing Processes.
   

   Description of critical manufacturing operations for motor loading and component fabrication. Grain pouring and test samples. Nozzle materials and fabrication processes. Case and insulation materials.

7. Motor Transportation and Handling Considerations.
   

   Explosive classifications. Licenses and regulations. Understanding the requirements and solutions for transporting, handling and processing different motor sizes with different explosive classifications.

8. Motor/Launch Vehicle Interfaces.
   

   Key physical (mechanical and electrical) and functional interfaces between the SRM and the launch vehicle. Comparison of interfaces for both the straight stack and strap-on applications.

9. SRM Development Requirements and Processes.
   

   Processes and timeline for developing new SRMs. Description of a demonstration and qualification program. Impact of decisions regarding design philosophy (state-of-the-art vs. advanced technology, design safety factors, etc.). Motor sizing studies (using computer design models). Customer oversight and quality program (vis-a-vis ISO 9000). Motor cost reduction approaches.