Particle breakup phenomena are commonly observed during the operation of solid rocket motors and have a pronounced influence on the evolution of the combustion flow field and the prediction of motor performance, yet quantitative treatments remain limited. This study introduces a comprehensive aluminum particle combustion model that integrates the classical Wave Breakup theory to investigate the breakup behavior of aluminum/alumina droplets across motors of varying scales. Numerical results reveal that in high-shear regions, particularly the nozzle convergent section, molten droplets undergo substantial aerodynamic breakup, producing finer child droplets that shift the particle size distribution toward the micron scale and trigger secondary combustion. The attendant increase in specific surface area enhances aluminum combustion efficiency and modifies the reactive flow structure, producing localized temperature rises and broader particle dispersion. Notably, the breakup characteristics exhibit strong scale-dependent behavior, with both motor size and initial particle diameter governing the location, intensity, and consequent combustion enhancement of the breakup process. Relative to simulations ignoring breakup, the model predicts higher particle-phase velocity and thrust, a slight reduction in gas exhaust velocity due to intensified interphase momentum exchange, and a net increase in total thrust—effects that are particularly pronounced in smaller-scale motors. These findings offer a physical basis for improving the design, performance forecasting, and energy utilization of solid rocket motors.
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