Assessing the thermal safety of solid propellant charges based on slow cook-off tests and numerical simulations

Abstract A method is proposed to assess the thermal safety of solid propellant charges by measuring the temperature and pressure of propellant specimens during cook-off tests and determining the reaction kinetics. In this work, two propellants—ammonium perchlorate/hydroxy-terminated polybutadiene/aluminum (AP/HTPB/Al), and ammonium perchlorate/hydroxy-terminated polyether/aluminum (AP/HTPE/Al)—are taken as examples to demonstrate this method in detail. Specifically, by implementing two kinds of cook-off tests—viz., multipoint temperature monitoring, and combustion pressure measurement—the thermal reaction temperature before ignition and the combustion pressure after ignition of the two propellants were respectively determined. Then, the kinetic parameters of the thermal decomposition reaction model and the parameters of the combustion reaction model were numerically simulated and calibrated to achieve mathematical descriptions of the entire process of cook off of two solid propellant charges. On this basis, the technology of grid-node separation calculation was employed to simulate and predict the rupture of a solid rocket motor case, thereby quantitatively describing the severity of the cook-off reaction. The results demonstrate that, at a heating rate of 1 K min−1, the ignition positions of the two propellant charges in the solid rocket motor are located in the annular area where the side wall and the front of the casing are joined. Compared with those of the AP/HTPE/Al charge, the ignition time of the AP/HTPB/Al charge is longer (12,714 s for AP/HTPB/Al vs. 9701 s for AP/HTPE/Al), the temperature of the casing before ignition is higher (501.5 K for AP/HTPB/Al vs. 466.2 K for AP/HTPE/Al), the reaction after ignition is more intense, and the deformation of the casing is more serious.