Look Out Below! China’s Heavy-Lift Rocket Due For Uncontrolled Reentry Within Days

April 30, 2021 by Tom Nardi 57 Comments

On April 28th, China successfully put the core module of their Tianhe space station into orbit with the latest version of the Long March 5B heavy-lift booster. This rocket, designed for launching large objects into low Earth orbit, is unique in that the 33.16 m (108.8 ft) first stage carries the payload all the way to orbit rather than separating at a lower altitude. Unfortunately, despite an international effort to limit unnecessary space debris, the first stage of the Long March 5B booster is now tumbling through space and is expected to make an uncontrolled reentry sometime in the next few days.

The massive booster has been given the COSPAR ID 2021-035-B, and ground tracking stations are currently watching it closely to try and determine when and where it will reenter the Earth’s atmosphere. As of this writing it’s in a relatively low orbit of 169 x 363 km, which should decay rapidly given the object’s large surface area. Due to the variables involved it’s impossible to pinpoint where the booster will reenter this far out, but the concern is that should it happen over a populated area, debris from the 21 metric ton (46,000 pound) booster could hit the ground.

This is the second launch for the Long March 5B, the first taking place on May 5th of 2020. That booster was also left in a low orbit, and made an uncontrolled reentry six days later. During a meeting of the NASA Advisory Council’s Regulatory and Policy Committee, Administrator Jim Bridenstine claimed that had the rocket reentered just 30 minutes prior, debris could have come down over the continental United States. Objects which were suspected of being remnants of the Long March 5B were discovered in Africa, though no injuries were reported.

China’s first space station, Tiangong-1, made an uncontrolled reentry of its own back in 2018. It’s believed that most of the 8,500 kg (18,700 lb) burned up as it streaked through the atmosphere, and anything that was left fell harmlessly into the South Pacific Ocean. While small satellites are increasingly designed to safely disintegrate upon reentry, large objects such as these pose a more complex problem as we expand our presence in low Earth orbit.

An Attempt At 3D Printing A Hybrid Rocket Engine

April 29, 2021 by Lewin Day 6 Comments

Liquid fuelled engines are throttleable and monstrously powerful, but highly complex. Meanwhile, solid rocket engines are simple and cheap, but once you light them, they’re going full-bore until burnout. Hybrid rocket engines offer perks from both worlds, with simple solid fuel and the ability to throttle down by regulating oxidizer flow. Naturally, [Integza] decided he should try and 3D print one.

The build came about somewhat by accident, as the 3D printed casing of one of [Integza’s] liquid-fuelled rockets continued burning once the fuel was turned off. This prompted the realization that he could 3D print rocket fuel, and simply supply oxygen, creating a hybrid rocket. Thus ensued much experimentation, going so far as to create custom sugar-loaded resin for more power and experimenting with ABS as a potential fuel.

Most of the rockets self-destructed within a few seconds and thrust was minimal, but the basic concept should be a goer. As always, [Integza] is struggling with the thermal limitations of plastics, but we fully expect he’ll one day get to a flight ready engine. His previous experiments show he certainly doesn’t give up. Video after the break.

Continue reading “An Attempt At 3D Printing A Hybrid Rocket Engine” →

3D Printed Vortex Cooled Rocket Needs To Stop Leaking

March 23, 2021 by Lewin Day 27 Comments

Rocket engines are known for one thing above all else, and that’s getting hot. It’s this very property that makes them such a challenge to build and run from a materials engineering standpoint. It’s hard enough to build one with advanced metal alloys, but [Integza] presses on with trying to make one on a 3D printer. Progress is being made, but success remains elusive. (Video, embedded below.)

To try and mitigate the thermal effects of burning propellants in his engine design, [Integza] looked to vortex cooling. This is where oxygen is swirled around the outer edge of the combustion chamber in a vortex, acting as a buffer layer between the burning fuel and the chamber walls. With 3D printed chamber components, keeping temperatures as low as possible is key, after all. Unfortunately, despite using a special ceramic-laden resin for printing and lathering the rocket components in various refractory materials, it wasn’t possible to stop the chambers leaking. Solid combustion was possible for a few seconds at a time, but eventually each motor tested turned into a ball of flames as the walls broke down.

Thankfully, nobody was hurt in testing, and [Integza] has a clear idea of the problems that need to be fixed in the next iteration. We’ve featured other vortex cooled rockets before – the theory is sound. As always, the devil is in the implementation.

Continue reading “3D Printed Vortex Cooled Rocket Needs To Stop Leaking” →

Experimenting With 3D Printed Rocket Nozzles

March 17, 2021 by Lewin Day 7 Comments

Rocketry is an exacting science, involving a wide variety of disciplines, encompassing everything from fluid mechanics to thermodynamics and materials engineering. As complex as it sounds, that doesn’t mean it’s beyond the purview of the average maker. [Sciencish] demonstrates this with a series of experiments on rocket nozzles in the home lab. (Video, embedded below.)

The video starts with an amusing analogy about nozzle design based on people fleeing a bad pizza. From there, [Sciencish] 3D prints a wide variety of nozzle designs for testing. The traditional bell nozzle is there, of course, along with the familiar toroidal and linear aerospikes and an expansion deflection design. Of course, 3D printing makes it easy to try out fun, oddball geometries, so there’s also a cowbell nozzle , along with the fancy looking square and triangular aerospikes too. Testing involves running the nozzles on a test stand instrumented with a load cell. A soda bottle is filled with rubbing alcohol vapour, and the mixture is ignited, with each nozzle graded on its thrust output. The rockets are later flown outside, reaching heights over 40 feet.

[Sciencish] notes that the results are a rough guide only, as the fuel/air mixture was poorly controlled. Despite this, it’s a great look at nozzle design and all the science involved. It also wouldn’t be too hard to introduce a little more rigour and get more accurate data, either. However, if solid fuels are more your jam, consider brewing up some rocket candy instead.

Continue reading “Experimenting With 3D Printed Rocket Nozzles” →

It Isn’t Rocket Science — Wait, Maybe It Is

January 13, 2021 by Al Williams 22 Comments

We don’t know why, but for some reason, the more dangerous something is, the more hacker appeal it seems to have. We like to deal with high temperatures, high voltages, dangerous chemicals, and powerful lasers. So [Tech Ingredient’s] recent video about homemade rocket motors certainly caught our attention. You may need a little commitment, though. The first video (yes, there isn’t just one) is over an hour long.

Turns out, [Tech] doesn’t actually want to use the rockets for propulsion. He needed a source of highly-ionized high-velocity plasma to try to get more power from his magnetohydrodynamic project. Whatever you want to use it for, these are serious-sized motors. [Tech] claims that his design is both powerful and easy to build. He also has a “secret” rocket fuel that he shares. What is it? We won’t spoil the video for you, but it is a sweet surprise.

Continue reading “It Isn’t Rocket Science — Wait, Maybe It Is” →

SpaceX Starship Replica Attempts The Bellyflop

December 15, 2020 by Lewin Day 20 Comments

SpaceX are perhaps most well known for their vertically-landing reusable rocket technology. The latest such effort is the Starship, which recently underwent a fiery test in the last month to attempt a bellyflop maneuver. [Nicholas Rehm] wanted to attempt a similar flight profile in the local park, and set to building an RC Starship of his own.

The build is like a few we’ve seen before, in which electric power is used to propel a rocket-like craft straight upwards using propellers and active stabilization. In this case, there’s a pair of twin motors with counter-rotating propellers which can pivot to direct their thrust, as well as four external control surfaces. These are all under the command of [Nicholas]’s custom flight controller.

Upon testing the rig, [Nicholas] was able to execute a smooth ascent, followed by a bellyflop, before a smooth return to vertical flight and descent. Landing vertically on the grass was out of the question, due to the rough surface, but we imagine it would be doable with the right landing gear attached.

While flight without wings in this manner isn’t particularly efficient, it’s great to see what can be achieved with smart use of control systems engineering to keep a craft stable. We look forward to seeing [Nicholas]’s next attempts, too. Video after the break.

Continue reading “SpaceX Starship Replica Attempts The Bellyflop” →

SLA 3D Printed Vortex Cooled Rocket Engine

December 8, 2020 by Danie Conradie 16 Comments

3D printing is an incredible tool for prototyping and development, but the properties of the materials can be a limiting factor for functional parts. [Sam Rogers] and colleagues at [AX Technologies] have been testing and developing a small liquid-fueled rocket engine and successfully used vortex cooling to protect a resin 3D printed combustion chamber. (Video, embedded below.)

Vortex cooling works by injecting oxygen into the combustion chamber tangentially, just inside the nozzle of the engine, which creates a cooling, swirling vortex boundary layer along the chamber wall. The oxygen moves to the front end of the combustion chamber where it mixes with the fuel and ignites in the center. This does not protect the nozzle itself, which only lasts a few seconds before becoming unusable. However, thanks to the modular design of the test engine, only the small nozzle section had to be reprinted for every test. While this part could be manufactured using a metal 3D printer, the costs are still very high, especially at this experimental stage. The clear resin parts also allow the combustion observed and more accurate conclusions to be drawn from every test.

This engine intended to be used as a torch igniter for a much larger rocket engine. Fuel is injected into the front of the combustion chamber, where a spark plug is located to ignite the oxygen-fuel mixture. The flow of the oxygen and fuel is controlled by two servo-operated valves connected to a microcontroller, which is mounted with the engine on linear rails. This allows the test engine to move freely, and push against a load cell to measure thrust. The spark is created before the valves are opened to prevent a delayed ignition, which can blow up the engine, and getting the valve sequence and timing correct is critical. Many iterations and destroyed parts later, the [AX Technologies] team achieved successful ignition, with a clear supersonic Mach diamond pattern in the exhaust.

This is just one more example of 3D printing and cheap electronics allowing impressive progress on a limited budget. Another example is [Joe Barnard]’s progress in getting a model rocket to land itself with a solid fuel engine. Companies and organisations have been using 3D printed components in rocket engines for a few years now, and we’ve even seen an open source version.