Blog - Castle Point Rocketry

Ignitor Team: Go!

October 29, 2019June 5, 2020
by Dakota

[This is an update from the Ignitor Senior Design team.]

Welcome back! This week, we will walk you through our preliminary plans.

Chosen Method:

After weighing out the risks and benefits of all potential methods, our team chose an industry standard ignition method known as the augmented spark plug system. In short, a portion of the fuel will be diverted from the combustion chamber and injected into a smaller sub-chamber for ignition via spark plug. This resulting fireball will then travel down a channel into the primary combustion chamber and create the thrust necessary to get our rocket off the ground and up to the Karman Line.

Below is an extremely simplified initial diagram:

A block diagram showing the team’s proposal for an augmented spark plug system.

As you can see, this system will require quite a bit of design overhaul on original build. However, we hope that the hours of sweat and tears we put into this system will result in a reusable, economical, and safer rocket.

Project Updates:

Currently, we are working on the first iteration of this new injector. Recently, we started modeling the new sub-chamber which will house the augmented spark igniter system. We are simultaneously working on the chamber geometry, injection elements, and creation of the spark plug itself.

Each of these tasks offer their own set of chanllenges, but we can’t wait to solve them. Past them, we will move on to finalizing the first iteration using SolidWorks. We will then move onto inert water flow tests before actual combustion.

We can tell this project will be a lot of work which will push us to our technical limits. Particularly, crunching all the numbers associated chamber geometry and flow characteristics will take some time. But we plan to give this project everything we have to develop an innovative injector/ignitor system — and get this rocket to space.

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(Remix to) Ignition

October 24, 2019June 5, 2020
by Dakota

[This is an update from the Ignitor Senior Design team.]

Our Team

Hello everyone! We’re a team of four dedicated and driven individuals trying to make this rocket as reusable and as efficient as possible by improving the injection and ignition system.

Lucas Franz (CHE)
Kenneth Otten (ME)
Rachel Gart (ME)
Nicholas Lavigne (CHE)

Lucas is both the Team Lead and Propulsion Specialist. Kenneth’s focus is CAD Specialist and the Design Lead. Rachel is the Manufacturing Specialist, Outreach Coordinator, and Team Manager. Nicholas specializes as Propulsion and Materials Specialist.

You might be asking yourself, “Why did you choose this crazy hard project over some much easier ones?” For us, the answer is easy: We all have passion for space and rocketry, and we all wanted to do something more with our senior design project.

We believe this project provides one of the best ways for us to make an impact, and we’re excited to tell you how we plan to do just that.

Our Goal

Our goal is simple: To incorporate an ignitor into the rocket’s injector. The idea may be simple, but there is some complexity in integrating the ignitor into the rocket.

We also want the ignitor to be reusable. Long-time readers of the blog will know how the first ignitor worked. Every time the ignitor was used, it was consumed. This means a costly reprint every time we ignite the rocket. The ignitor integration team plans to change this and reduce impediments to getting our rocket into the air.

Our Considerations

Briefly, here are a few designs which didn’t make it past the first design stage. Still, they are interesting solutions to the problem at hand.

Laser ignition, while very cool sounding, was impractical for what we were looking for. Lasers are delicate and difficult to work with. Minimum ignition energy also works differently with lasers, since ignition comes not from a spark but instead from exciting the fuel until it ignites.

Image result for laser ignition — A depiction of laser-assisted ignition. (Source: Nature)

We’re working with pretty extreme conditions and would need to have a powerful laser to actually achieve ignition. The time and research costs would be too high, so we need to do something simpler.

We turned to pure chemistry. The image below shows triethylaluminum, an extremely unstable compound which will spontaneously burn when exposed to oxygen. It’s very difficult to work with, but it would certainly simplify design.

Triethylaluminum, a volatile, hypergolic chemical. (Source: Wikipedia.)

Maybe not so “simple,” though. The bonds between the ethyl groups readily and explosively break down in contact with oxygen. We ruled this out due to the red tape and safety concerns of working with such a volatile compound.

Our next blog will outline our current plan.

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…This is Ground Control

October 22, 2019June 5, 2020
by Dakota

[This is an update from the Ground Control Senior Design Team.]

Greetings from Castle Point Rocketry’s Ground Control team! The team consists of five team members: Martin Gilmartin (MechEng), John Hamill (MechEng), Ed Minnix (CySec), Nicholas Yarbrough (CompEng), and Charles Zwicker (CompEng).

We’re currently working on Revision 2.0 of the Ground Infrastructure Support and Control Systems in order to increase its capabilities, make it more reliable and redundant, and make its operations more logical and streamlined.

Here are some of the improvements we’re making.

Ground Control Station (GCS)

This is the main station that we will use to control the launch sequence, view our camera feeds and telemetry from the rocket (velocity, altitude, etc.), and manually actuate any valves in the event of emergency.

This subsystem will be an upgrade over last year’s setup. We are integrating the control and monitoring into a single unit as opposed to last year’s iteration which was handled by a separate laptop. The combination of these systems with a more powerful computer will lead to easier setup and transport. Furthermore, the new computer will run an enterprise-grade Linux distribution, providing further stability.

The GCS will be upgraded to redundantly store all of the data being streamed in realtime from the Ground Support Station and run for over eight hours on battery power, with a backup generator we can switch to without interruption. We will also waterproof the entire case and its connections so rain won’t hinder our progress.

We’re also constructing an antenna rotator in order to accurately track the rocket as it is airborne and achieve a more reliable signal.

Ground Support Station (GSS)

The GSS will roll all of the pre-launch hardware, which needs to be near the rocket, into one enclosure, streamlining it from its previous iteration. In addition, a large number of the GSS’s computational systems will be integrated directly into the GCS, reducing the hardware required at this location. We will upgrade the cameras and tripods in order to receive a higher quality video. This subsystem will also be battery powered for over eight hours.

Conclusion

We’re currently working with Nathan and Ben in the design and planning phase, ironing out the details before we pull the trigger and begin our first round of purchases. Our next steps include designing initial prototypes in CAD which we will then build and test followed by detailing the components of each system down to the minutia.

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“When is Launch?”

October 17, 2019June 5, 2020
by Dakota

We get that question a lot. So, rather than keep everybody waiting, here is a quick update.

The short answer is, “Coming soon.” The long answer is much more complicated and balances quite a few variables.

The biggest factor in play is our lack of components. When the team finished testing this summer, it was due to a hairline fissure in our liquid oxygen (LOX) tank. Though barely noticeable to the naked eye, this defect could have caused a catastrophic explosion with further testing. We returned the tank to its manufacturer for analysis and remanufacture, which can be a lengthy process. Additionally, the fins and nose cone arrived after testing. Though not necessary for testing, they need to be added to the rocket before we can launch.

Castle Point Rocketry is also in the middle of a transition. Since the founders are no longer Stevens undergraduates, we are navigating the challenges associated with acquiring real estate and transferring funds. (All while pursuing graduate school or full-time jobs!) Luckily, we have three great senior design teams to help tackle further engineering projects.

The final challenge to a set launch date is the same as last year: permits. Until the rocket passes our eight-step testing process, we cannot apply to launch. Even after applying, we will need to wait for approval — and maybe return for more tests.

The primary objective is still to put a liquid-fueled rocket beyond the Karman Line. We have some more help getting there, but testing is still in a temporary holding pattern.

So all that is to say: “Soon. Very soon.”

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New Senior Design Teams

October 17, 2019June 5, 2020
by Dakota

Last month, we mentioned the most exciting news from Castle Point Rocketry. In short, the company is sponsoring three new senior design teams to work on the rocket.

These interdisciplinary teams incorporate students from all across Stevens Institute of Technology. Chemical (CHE), Computer (CPE), Electrical (EE), and Mechanical (ME) Engineers will work with Cyber Security (CS) students to help us reach the Karman Line.

As with last year’s marathon goal, a diverse set of subsystems is on the docket. Here is a quick look.

Flight Computer Team

Redundant hardware is beneficial for most projects. If one component on a flight computer fails, the entire system may shut down. (Or, in the case of a rocket, end catastrophically.) This team will incorporate fallback systems into the current computer in order to make a more robust rocket.

The Flight Computer Team will design a leaner flight computer for Castle Point Rocketry. Composed of two EEs and a CPE, they are well-equipped for the task.

Ground Systems Team

The Ground Systems Team will remodel the ground infrastructure required to launch the rocket. Suitably, two CPEs, two MEs, and one CS are tackling this sprawling project.

Most radically, upgrades will be made to on-site telemetry systems and relay boxes. These changes will allow the team to communicate with the rocket more reliably and more securely. This is necessary both pre- and post-launch.

Given the time, the team will also build a stronger ground control center to provide instant feedback on the rocket.

Igniter Team

Expanding on last year’s prototype, the Igniter Team is designing a new igniter. After all, our current igniter is not reusable — though it looks spectacular in action. The goal of this project is to make it reusable and safer.

Two CHEs and two MEs will make it happen. Already, a series of meetings has been very productive. If all goes well, it could even be on the next injector model!

Future Blogs

In the future, both the company and these new teams will provide blog updates. That way, we can keep everyone informed of the latest news at Castle Point Rocketry!

News

Paying It Forward

September 11, 2019June 5, 2020
by Dakota

Over the last year, Castle Point Rocketry has learned a lot. We built a rocket, created a company, and maintained a brand — all while keeping afloat in school. Now, it’s time to look to the future.

The eight founders of Castle Point Rocketry have graduated from Stevens Institute of Technology, but the relationship is far from over. This year, Castle Point Rocketry is sponsoring three more year-long senior design groups at Stevens. They will each work on a small section of the rocket, iterating on the current design to make a better vehicle overall. The goal is still the same: To create and launch a liquid-fueled rocket to the Karman Line.

We look forward to what this partnership holds in store. The mere fact that the project has generated interest in Stevens graduates-to-be is promising in and of itself!

News

Recent Developments

August 2, 2019June 5, 2020
by Dakota

The rocket you’ve seen in photos isn’t complete. In the weeks since testing, we have received good news regarding our remaining parts. Three main pieces of the rocket remain in fabrication: (1) the nose cone (2) the fins (3) the fuselage.

Nose Cone

In order for our rocket to reach the Karman Line, it needs to pierce the atmosphere. A flat top is inconducive to flight, since particles of air would slam into the top of the rocket and slow it down. On the other hand, an inverted cone would shed air particles like a boat’s hull through water.

Our cone, which is being turned out of a titanium sheet, is currently in the final stages of completion. Though we don’t have photos of it, the cone will be ready by next week.

Fins

As the rocket goes upwards, a certain amount of spin will be added to its flight. Spin is necessary to guide it in a general upwards direction — a flight without rotation could easily complicate and meander off course. However, since spin requires energy, too much spin can shorten the rocket’s distance traveled. In order to find middle ground, we designed fins to assign a fixed amount of spin.

These fins will live at the bottom of the rocket, 90 degrees from one another, just above the engine. Designed with a very slight tilt, they will ever so slightly nudge the rocket into a slow spin. They were precision-machined for us on a 5-axis CNC machine. (That’s pretty expensive stuff.)

Fuselage

The fuselage, the “skin” of the rocket, is the single largest component. Essentially a really wide pipe, this carbon fiber composite cylinder was designed to slide over the outside of our aluminum air frame. (The air frame can be seen in various photos of our rocket.) Since it is both large and rigid, the fuselage also houses our antenna.

The fuselage runs the entire length of our rocket — from nose cone to fins. It keeps all of the guts of the rocket inside the air frame. Most importantly, it provides a smooth outer surface to reduce vibration and aerodynamic drag.

News

Testing Review

July 18, 2019June 5, 2020
by Dakota

[This is a long article, but it has some very important updates.]

Over the last ten days, Castle Point Rocketry tested our proof-of-concept rocket. We traveled from HQ in Hoboken to our test site in southern New Jersey on July 9th and returned on the 18th.

Here’s what you need to know.

Setup

The preliminary phases of our testing schedule took longer than anticipated. Though this was the team’s third visit to the site, more infrastructure needed to be laid out. We ordered chemicals, installed the truss, and established ground control. We spent Wednesday through Saturday making sure everything was perfect.

Tank Testing

As mentioned in Ready to Test, validating the liquid oxygen (LOX) tank was the first step of our testing procedure. Infinite Composites Technologies manufactured our LOX tank, and they asked that we do preliminary tests for them.

On Sunday, July 14, an advisor approved us to start testing.

Time lapse footage of our LOX tank going up.

TT.01: COPV Cryogen Validation

Composite overwrapped pressure vessels (COPV) such as our LOX tank have been proven capable of withstanding high pressures. COPVs provide a burgeoning market for lightweight tanks by eliminating the need of an internal metal liner. The manufacturer expected that their formula would withstand low temperatures, too. But putting both together… That was our job.

After retreating 100 meters to Ground Control, we opened valves in a unique sequence to begin the test. First, cryogenic liquid nitrogen (LN2) filled the tank 4/5 full. Then we squeezed pressurized gaseous nitrogen (GN2) into the space that remained, elevating the tank pressure to 500 psi. (Air pressure at sea level is ~15 psi.)

From our perch in Ground Control, we couldn’t see exactly what was happening. But we had an array of sensors and cameras on-site that processed live data back to us.

The team watches the LOX tank closely… from afar.

The LN2 in the tank caused a thin layer of water to condense — and then freeze — on the tank. This temporarily turned the tank from black to a cloudy white, then back to black when the ice melted.

After holding for several minutes with no drop in pressure, the team agreed there were no leaks present. Ben actuated the dump valve, releasing the remaining LN2 in a plume of white steam, and we approached the tank to inspect the tank. No cracks, vents, peeling, or patching were found. We concluded that the Infinite tank could withstand cryogenic temperatures at high pressures.

TT.02: COPV LOX Compatibility Validation

TT.01 took less time than expected. On the order of hours. We planned the day with 4 hours for each test, yet TT.01 only took 34 minutes from start to finish. Too easy. Upon consensus from Nathan (Team Lead), Monica (Safety Officer), and Luke (Industry Advisor), we moved swiftly into TT.02.

Following TT.01, there wasn’t much to do in terms of preparing for the next test. After all, we simply needed to swap out an LN2 cylinder (called a dewar) for a LOX dewar. This required new hoses, too, but we came prepared. Within 30 minutes, we were back at Ground Control.

A screenshot from the program recording our incoming camera feeds. CCW from top: Infrared thermal imaging, test site visual, and dump valve close-up.

We took our time with this test. Though LOX boils at a slightly higher temperature than LN2 (-297°F instead of -320°F), it is much more dangerous. When LN2 boils off, it creates GN2. GN2 makes up 70% of the air we breathe — it is stable, is non-reactive, and plays well with others. LOX, however, boils off into gaseous oxygen (GOX). GOX is incredibly reactive, as oxygen is the driving force of any combustion reaction. With the slightest disturbance, a thimbleful of LOX can create a dazzling explosion. Should either GOX or LOX chemically react with the experimental COPV, a hole would release all oxygen at once, providing the basis for a massive fireball.

Luckily, we did not deal with any such eruption. Though the tank off-gassed a lot more than expected, much more than the LN2 run, we rang in yet another success. A holding time of 10 minutes proved our tank held an adequate amount of LOX to launch with.

TT.03: COPV Pressurize LOX Validation

Though we took our sweet time to make sure all of the GOX had adequately diffused before we drove the van up, we still had a remarkable amount of time left in the day. “Why not do another test?” we thought.

This test required LOX again. Under pressure, this time. We took a collective breath and pushed “Start.”

Once again, we were surprised by the amount of gas released from the system, but we assured ourselves it was nothing to worry about. The pressure did stay constant at ~300 psi for the full test, which indicated we didn’t have a leak.

Full Stack Testing

Following our three successful Tank Tests, we went into overhaul mode. Full Stack Testing required removing the LOX tank from the gantry hoist, placing it back in the rocket, and raising the rocket on the truss. Additionally, we needed to move our ground support relay boxes and fire extinguishers. (These relay boxes are like runners in a relay race. They act as a hand-off of information between Ground Control and the valves and sensors.) This change took the team a full day to complete.

FST.01: Full Stack Pressurization Test

Now comes the part of our story that gets a little bit… sad. On Tuesday, July 16th, we launched into FST.01 with great expectations. But the pressure just wouldn’t build. FST.01 only required the use of GN2. Since GN2 is practically harmless, Luke approved us to stay on-site with the rocket until we reached a pressure of 100psi. But even with our gas cylinders all the way open, we simply couldn’t get above 25psi.

Monica, Will, and Luke descended upon the LOX tank, assuming it (or one of its fittings) was the culprit. After a lengthy, methodical search, they found the problem: A hairline crack had formed on the very bottom of the tank. This was a deal-breaker.

Here’s the deal with cracks: They aren’t good for structural stability. Even at pressures as low as 25 psi, the crack was undoubtedly growing. Undetectably slowly, maybe, but definitely growing as GN2 tried to force its way from high to low pressure. Had we increased the system pressure any more, this effect would have increased dramatically — ending in a catastrophic burst as all of the GN2 left at once.

A tank exploding onboard the rocket was not what we wanted — so we unfortunately had to call off the rest of our testing schedule.

Moving Forward

So, what happens now?

After careful consideration of the data, the team concluded that the hairline fracture had occurred from “temperature cycling” the COPV. The tank went through a series of contractions and expansions as it got subcooled then superheated, which delaminated the layers of the COPV. In much the same way that ruffling a phone book puffs it up, this had introduced space between the “pages” of the tank wall, eventually leading to a full crack.

So, Castle Point Rocketry is still in our Testing Phase. Though we weren’t able to get through all five Full Stack Tests this week, we will soon have another tank. In the meantime, though, it was nice enough just to raise a rocket in the air — depressurized, of course — and look at what we had built.

For ease of access to the internal components, we didn’t add the nose cone, fuselage (skin), or fins. In a launch scenario, the rocket would look different.

News

Projected Testing Schedule

July 12, 2019June 5, 2020
by Dakota

Assuming the final pieces fall into place (a chemical delivery here, rocket fuel there), we will begin our testing procedure soon. We’ve laid out an explanation, but now… Here’s a timeline. Be sure to also check our Facebook page every once in a while for any updates!

Day Three:

Castle Point Rocketry is expecting a delivery of pressurized gas and cryogenic liquids on the morning of Friday, July 12. Once those come through, we will begin pressure testing the subassemblies of pipes and fittings. We have already begun removing small subsections from the full stack in preparation for this.

We have also pulled the liquid oxygen (LOX) composite overwrapped pressure vessel (COPV) from the air frame. In the afternoon, we will have the time to move on to our first official test, TT.01: COPV Cryogen Validation.

Though we are not rushing, we also look forward to having enough time to complete TT.02: COPV LOX Compatibility Validation today.

Day Four:

Following closely on its heels, we are waking up early Saturday morning for more testing.

TT.03: COPV Pressurized LOX Validation will start first, right after we drive to purchase our surrogate rocket fuel from a nearby airport.

That afternoon, we will finish FST.01: Full Stack Pressurization Test.

Day Five:

Sunday will be a long day. We have scheduled both FST.02: Cold Flow Test and FST.03: Ignition Sequence Test, when we first load the fuel tank with actual fuel.

Day Six:

Monday morning, we’ll be up early again to test FST.04: Hot Abort Test. Assuming it goes well, that afternoon will see our first full launch setup with FST.05: Full Stack Hot Fire Test.

Day Seven:

We have reserved some time on Tuesday for a second hot fire test, in case we need it. It also serves as a good spill-over time for any tests which take longer than expected, or a rain date for any other tests.

And then we drive home!

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The Faces of Castle Point Rocketry

July 12, 2019June 5, 2020
by Dakota

It’s high time we re-introduce everyone who makes up this team. After all, once we test this thing and get our big media break, you’ll want to know who we all are.

Team Members

A core group of eight have been with this project since the beginning. We have four Mechanical Engineers (ME), two Chemical Engineers (CHE), one Computer Engineer (CPE), and one Computer Scientist (CS). Pictures and short blurbs below.

Abraham Edens (ME)
Thomas Flaherty (ME)
Faris Ibrahim (CPE)

Abe is our Aerodynamic Design and Mathematics Specialist. He helped solve the regenerative heating problem and worked with Tom and Will on many manufacturing tasks.

Tom also specializes in computer-aided design (CAD). He spent innunerable hours modeling an injector to Monica’s and Dakota’s specifications before tackling other projects.

Faris, working on Electronics, Signals, and Avionics, was integral to designing the team’s circuit boards and developing how those systems fit into the rocket.

Unfortunately, Abe, Tom, and Faris are unable to join the other members of the team for testing. However, we are still very proud to call them members of the Castle Point Rocketry team — we couldn’t have done it without them!

Benjamin Iofel (CS)
William Skwirut (ME)
Nathan Tahbaz (ME)

Ben is Lead Programmer, meaning he has literally written the code for our testing procedure. Recently, Ben has also branched out to become our resident electronic hardware expert.

Will is formally the Machining Specialist, but he has extensive knowledge of (and a quippy remark for) for nearly every facet of the project. He also played a large role in designing the plumbing system.

Nathan is the true Renaissance Man of the group. As Team Lead, it’s his job to ensure every subsystem is stitched together — on top of serving as Point of Contact for purchasing and inquiries.

Monica Traupmann (CHE)
Dakota Van Deursen (CHE)

Monica and Dakota, Propulsion Specialists, collaborate to fill our propulsion and PR needs.

Monica, who is also our Safety Officer, designed our plumbing system with Will and Dakota, manages our social media presence, and interfaces with many of our top donors. Dakota mainly focused on the engine, but he also manages the project’s blogs and attends to the tasks that fall in the ever-present gray areas.

Ben, Will, Nathan, Monica, and Dakota are all on site for this week’s testing procedures.

Team Volunteers

As you may have noticed around campus and online, Castle Point Rocketry has put out a call for volunteers. Two excited Stevens students have come to our aid, and we are very grateful!

Daniel Cooke, Avionics and Telemetry
Rodrigo Nogueira, Fabrication

Rodrigo is a graduate student in ME who joined us in early February. His extensive background in fabrication and manufacturing have come in handy many a late night.

Dan, a rising junior in CPE, joined us at the beginning of the summer. He has been a great help to Ben in preparing our electronic systems for integration and testing.

Rodrigo is on site for this week’s testing procedure, and Dan may be coming down over the weekend.

Industry Advisors

We are also lucky to have had the input of two professional aerospace engineers. Rich Kelly from Valcor Engineering and Luke Colby from Triton Space Technologies have thankfully withstood a barrage of phone calls and emails from the team.

Luke (back row, middle) and Rich (back row, second from right) visiting the team in Hoboken.

Rich and Luke are both on site for this week’s testing procedures.