A monopropellant thruster according to an exemplary aspect of the present disclosure includes, among other things, a first part having a catalyst bed, a thrust chamber, and a nozzle. The first part is integrally formed via a single additive manufacturing process. The thruster further includes a second part, which is a closeout. A method is also disclosed.

A catalytic thruster includes a reaction chamber that extends between first and second opposed chamber ends. The first chamber end includes a thermal standoff cup. There is a catalyst bed in the reaction chamber, and a feed tube extends into the reaction chamber through the thermal standoff cup.

A catalytic thruster includes a reaction chamber that extends between first and second opposed chamber ends. The first chamber end includes a thermal standoff cup. There is a catalyst bed in the reaction chamber, and a feed tube extends into the reaction chamber through the thermal standoff cup.

A catalyst chamber with a catalyst bed embedded therein for a monopropellant thruster of a rocket engine. The catalyst chamber comprises an inlet having a first cross-sectional area through which a propellant can be introduced into the catalyst chamber and an outlet having a second cross-sectional area through which the propellant and/or resulting reaction products can be introduced into a combustion chamber of the thruster. The outlet is connected to the inlet via a catalyst volume of the catalyst chamber. At least one helical wall member is arranged within the catalyst chamber and is dividing the catalyst volume into two or more segments such that an effective length of the catalyst bed of each segment passed through by the propellant and/or its reaction products is larger than a geometrical length of the catalyst chamber defined between the inlet and the outlet along a direction of extension of the catalyst chamber.

A catalyst chamber with a catalyst bed embedded therein for a monopropellant thruster of a rocket engine. The catalyst chamber comprises an inlet having a first cross-sectional area through which a propellant can be introduced into the catalyst chamber and an outlet having a second cross-sectional area through which the propellant and/or resulting reaction products can be introduced into a combustion chamber of the thruster. The outlet is connected to the inlet via a catalyst volume of the catalyst chamber. At least one helical wall member is arranged within the catalyst chamber and is dividing the catalyst volume into two or more segments such that an effective length of the catalyst bed of each segment passed through by the propellant and/or its reaction products is larger than a geometrical length of the catalyst chamber defined between the inlet and the outlet along a direction of extension of the catalyst chamber.

A rocket engine having a co-axial, bidirectional flow arrangement is described herein. The rocket engine receives fuel and an oxidizer into the rocket engine in a first direction, whereby a portion of the fuel is combusted in a pre-burner. The flow direction of the partially combusted fuel/oxidizer mixture is reversed, whereby the mixture is introduced into a combustion chamber. The fuel and oxidizer are combusted in the combustion chamber. The combustion products exit a throat and an expansion plenum in a direction similar to the first direction, whereby the combustion products exit a nozzle of the rocket engine, providing thrust.

A rocket engine having a co-axial, bidirectional flow arrangement is described herein. The rocket engine receives fuel and an oxidizer into the rocket engine in a first direction, whereby a portion of the fuel is combusted in a pre-burner. The flow direction of the partially combusted fuel/oxidizer mixture is reversed, whereby the mixture is introduced into a combustion chamber. The fuel and oxidizer are combusted in the combustion chamber. The combustion products exit a throat and an expansion plenum in a direction similar to the first direction, whereby the combustion products exit a nozzle of the rocket engine, providing thrust.

According to one contemplated embodiment of the rocket engine invention, water is first pumped from a water tank through a rocket nozzle cooling heat exchanger wherein it is evaporated into said superheated steam. A generator supplies electricity to an electrolyzer that electrolyzes superheated steam into gaseous hydrogen and gaseous oxygen. The gaseous hydrogen and gaseous oxygen is employed for forming an annular curtain of secondary combustion in a divergent rocket engine. The secondary combustion gas surrounds a central thrust of combustion gas produced in an upstream combustion chamber by a primary injection of hydrogen/oxygen supplied from a liquid hydrogen tank and liquid oxygen tank. The rocket liquid hydrogen tank and liquid oxygen tank are pressurized by gaseous hydrogen and gaseous oxygen generated by the electrolyzer.

Devices and methods of rocket propulsion are disclosed. In one aspect, a staged combustion liquid rocket engine with preburner and turbopump unit (TPU) integrated into the structure of the combustion chamber is described. An initial propellant mixture is combusted in a preburner combustion chamber formed as an annulus around a main combustion chamber, the combustion products from the preburner driving the turbine of the TPU and subsequently injected into the main combustion chamber for secondary combustion along with additional propellants, generating thrust through a supersonic nozzle. The preburner inner cylindrical wall is shared with the outer cylindrical wall of the engine's main combustion chamber and the turbine is axially aligned with the main combustion chamber. Liquid propellants supplied to the engine are utilized for regenerative cooling of the combustion chamber and preburner, where the liquid propellants are gasified in cooling manifolds before injection into the preburner and main combustion chamber.

Various embodiments of a vortex thruster system is described herein that are configured to create at least three discrete thrust levels. In some embodiments, the vortex thruster system includes a catalyst bed configured to decompose a monopropellant at more than one flow rate and deliver the decomposed monopropellant into a vortex combustion chamber for generating various thrust levels. In some embodiments, the catalyst bed includes a screen assembly positioned within the inner chamber of the catalyst bed. The screen assembly can include alternating reactive screens and inert screens. The reactive screens can include a catalytic coating for assisting with decomposing the monopropellant, and the inert screens can provide structural support for the screen assembly. Related systems, methods, and articles of manufacture are also described.