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.

A monopropellant rocket engine in which nitrous oxide is the propellant includes a catalyst bed on an end of a diverging combustion chamber to inject a first flow of monopropellant to ignite the monopropellant, followed by a series of additional monopropellant injections along the diverging combustion chamber where the previously injected monopropellant decomposes to be used to ignite the downstream injected monopropellant. When all monopropellant has been decomposed, the monopropellant is passed through a throat and nozzle to produce thrust. A control valve is used to regulate an amount of monopropellant injected at each point in order to regulate an amount of thrust.

A monopropellant rocket engine in which nitrous oxide is the propellant includes a catalyst bed on an end of a diverging combustion chamber to inject a first flow of monopropellant to ignite the monopropellant, followed by a series of additional monopropellant injections along the diverging combustion chamber where the previously injected monopropellant decomposes to be used to ignite the downstream injected monopropellant. When all monopropellant has been decomposed, the monopropellant is passed through a throat and nozzle to produce thrust. A control valve is used to regulate an amount of monopropellant injected at each point in order to regulate an amount of thrust.

A thruster system for use in a spacecraft combines chemical and electric or electrothermal propulsion. To that end a thruster may comprise a cavity including at least one inlet to receive a first fluid and a second fluid configured to chemically react with the first fluid within the cavity to generate a reaction product. Alternatively, the cavity may be configured to receive a monopropellant configured to chemically decompose within the cavity. The thruster system further comprises an energy source coupled to the cavity and configured to heat or ionize material within the cavity by emitting electromagnetic radiation. Still further, the thruster system comprises a nozzle provided at one end of the cavity and configured to direct heated material out of the cavity to generate thrust.

A thruster system for use in a spacecraft combines chemical and electric or electrothermal propulsion. To that end a thruster may comprise a cavity including at least one inlet to receive a first fluid and a second fluid configured to chemically react with the first fluid within the cavity to generate a reaction product. Alternatively, the cavity may be configured to receive a monopropellant configured to chemically decompose within the cavity. The thruster system further comprises an energy source coupled to the cavity and configured to heat or ionize material within the cavity by emitting electromagnetic radiation. Still further, the thruster system comprises a nozzle provided at one end of the cavity and configured to direct heated material out of the cavity to generate thrust.

An aerospike rocket, engine having individually throttleable thrusters arranged in an annular ring around an aerospike, and a bi-propellant system having a catalyst system for combining a solid propellant and a hydrocarbon fuel, and an additional convergent-divergent flow for each thruster which combine into a main combustion chamber for the aerospike.

Various embodiments of a vortex thruster system is described herein that is configured to create at least three discrete thrust levels. In some embodiments, the vortex thruster system is configured to decompose a monopropellant and deliver the decomposed monopropellant into a vortex combustion chamber for generating various thrust levels. In some embodiments, the vortex thruster system includes a secondary propellant valve configured to deliver a secondary propellant into the vortex combustion chamber containing decomposed monopropellant to create a high thrust level. Related systems, methods, and articles of manufacture are also described.

Various embodiments of a vortex thruster system is described herein that is configured to create at least three discrete thrust levels. In some embodiments, the vortex thruster system is configured to decompose a monopropellant and deliver the decomposed monopropellant into a vortex combustion chamber for generating various thrust levels. In some embodiments, the vortex thruster system includes a secondary propellant valve configured to deliver a secondary propellant into the vortex combustion chamber containing decomposed monopropellant to create a high thrust level. Related systems, methods, and articles of manufacture are also described.

Disclosed is a method for forming a catalyst bed for catalytic decomposition of hydrogen peroxide, which uses 3-D printing techniques to form a porous metal backbone and treating the surface of the metal backbone to activate the surface, wherein the metal backbone is formed of a noble metal or a manganese complex. Also disclosed is a rocket engine having a 3D printed catalyst for catalytic decomposition of hydrogen peroxide, a fuel store, an oxidizer store, and a rocket engine, wherein the oxidizer is a stabilized solution of hydrogen peroxide, and a 3D printed catalyst bed.

Disclosed is a method for forming a catalyst bed for catalytic decomposition of hydrogen peroxide, which uses 3-D printing techniques to form a porous metal backbone and treating the surface of the metal backbone to activate the surface, wherein the metal backbone is formed of a noble metal or a manganese complex. Also disclosed is a rocket engine having a 3D printed catalyst for catalytic decomposition of hydrogen peroxide, a fuel store, an oxidizer store, and a rocket engine, wherein the oxidizer is a stabilized solution of hydrogen peroxide, and a 3D printed catalyst bed.