Technical Approach

Design and manufacturing of dimpled, Mach 0.64 rocket nosecone.

Our engineered applications involve dimples, swirl, grooves, and fore and aft geometry refinements. The methodology leverages bio-mimetics, fundamental turbulence theory, AI, and advanced manufacturing, with the end goal of modifying the system’s boundary layer, induce early drag crisis for reduced frictional drag and increased aerodynamic lift, as well as the minimization of boundary layer detachment. Moreover, these advances are known to contribute to quieter systems, reduced flight signature, increased heat transfer, and increased component lifespan.

To speed up design development, ASE uses a continuous-improvement approach:

Apply a novel set of turbulence equations to rapidly obtain a surface-engineered design
Apply AI to refine and optimize the system design
3D-print the design in our facility
Test the device in our wind tunnel to obtain performance data (or use those from collaborating universities, such as the University of New Mexico or the University of Arizona)
If performance metrics are not yet met, repeat Task 1 and continue refining/optimizing the system design

Due to our streamlined and integrated approach, the design-to-testing iteration for Tasks 1 through 4 can be completed within three business days.

Surface-Engineering Application to a High-Powered Rocket Nosepiece

To assess the aerodynamic potential and further validate the surface modification technology, a rocket nosecone was dimpled as per the turbulence models. Unmodified and dimpled rockets were flown at Mach 0.64 during late 2022 and early 2023. Analysis of the post-flight test data indicated that the dimpled rocket had a frictional drag coefficient that was 20.5% lower on average and had a peak reduction of 39.1% vs. the unmodified rocket. The frictional drag reductions were prevalent for Reynolds number (Re) in the range of 500,000 to 1,200,000. Moreover, the analysis showed that the dimpled rocket experienced an early-induced drag crisis, which significantly reduced the rocket’s frictional drag. This research was the subject of a Master of Science Thesis through the University of New Mexico, with the assistance of Sandia National Laboratories and the Albuquerque Rocket Society in New Mexico [Monroe, 2023].