Optimization Methodology for Unconventional Rocket Nozzle Design

Several current rocket engine concepts such as the bell-annular tripropellant engine, and the linear aerospike being proposed for the X-33, require unconventional three-dimensional rocket nozzles which must conform to rectangular or sector-shaped envelopes to meet integration constraints. These types of nozzles exist outside the current experience database, therefore, development of efficient design methods for these propulsion concepts is critical to the success of launch vehicle programs. Several approaches for optimizing rocket nozzles, including streamline tracing techniques, and the coupling of CFD analysis to optimization algorithms are described. The relative strengths and weaknesses of four classes of optimization algorithms are discussed: Gradient based methods, genetic algorithms, simplex methods, and surface response methods. Additionally, a streamline tracing technique, which provides a very computationally efficient means of defining a three-dimensional contour, is discussed. The performance of the various optimization methods on thrust optimization problems for tripropellant and aerospike concepts is assessed and recommendations are made for future development efforts.