Mass Optimization of Rocket Nozzles Using Ablative Materials
A Case Study on Indonesian Sounding Rockets
DOI:
https://doi.org/10.55981/ijoa.2025.11394Keywords:
nozzle, solid rocket, mass optimization, alternative materials, simulation, fabrication technologyAbstract
This study presents a comprehensive redesign of the RX450 sounding rocket nozzle
aimed at reducing mass while maintaining thermal and structural integrity. The baseline
design, characterized by heavy steel casing and monolithic graphite liners, imposes significant
limitations on payload capacity and flight performance due to its weight and thermal
management challenges. The proposed design replaces the divergent section’s steel casing
with a combination of ablative silica-phenolic composite liners and aluminum 6061 structural
support, achieving a substantial mass reduction from approximately 59 kg to 14.5 kg
in this critical region. Thermal simulations demonstrate that the addition of a glass-phenolic
insulation layer effectively limits heat transfer to the metallic casing, allowing for thinner
structural components without compromising safety. Structural analyses confirm that
both steel and aluminum sections maintain high safety factors under operational loads.
Comparative evaluations of alternative configurations further highlight the benefits of advanced
composite materials and innovative structural concepts, with the lightest model
reducing total nozzle mass by around 40% compared to the baseline. While these results
are based on literature-derived properties and simplified assumptions, they underscore the
potential of integrating ablative composites and lightweight metals to enhance rocket nozzle
performance. Future work will focus on detailed thermochemical modeling, experimental
validation, and full-scale testing to confirm thermal-structural behavior and erosion
rates. Overall, this study supports Indonesia’s strategic objective of advancing indigenous
rocket technology through accessible, high-performance materials and design innovations.
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