Design of a sounding rocket upper stage based on the hybrid rocket engine VISERION

Abstract

In the context of the AHRES (Advanced Hybrid Rocket Engine Simulation) program of the German Aerospace Center (DLR), an upper stage for the Brazilian sounding rocket VSB-30 is designed. This third stage is based on the hybrid rocket engine VISERION. The pre-design is mainly focused on the fluid and pressurization system using common European design standards. Real gas simulations were conducted to quantify the required pressurant mass and to analyse operating parameters. Subsequently, all additional subsystems are described and analysed. Initial requirements such as the maximum outer diameter and limits of the overall mass were given due to the launch system. Further requirements for each module and the main components are identified and examined. Available modules for the service or recovery system and commercially off-the-shelf components were considered to reduce the overall complexity and costs. Preliminary flight stability and aerodynamic loads were evaluated using numerical fluid simulations on different characteristic ascent points. The dimensioned system demonstrates the ability of hybrid rocket engines to be used as propulsion modules for upper stages. This enables the combination of several advantages of common propulsion systems as the main intention in hybrid rocket development.