A Comprehensive Optimization Study for Increasing Output Velocity and Minimizing Erosion in Small Caliber Two-Stage Gas Guns

Abstract A critical imperative arises for the refinement of space debris impact simulations on diverse space vehicles. The velocities associated with space debris impacts can reach up to 14 km/s. However, the current tools at our disposal, specifically conventional two-stage light gas guns utilizing moderately heavy saboted projectiles, are constrained to launch velocities within the range of 7-8 km/s. Significantly improving these launch velocities is pivotal for achieving simulations that faithfully mirror the upper-velocity range for debris impacts, as well as for enhancing the durability of gun components. This objective can be achieved through the reduction of maximum gun and projectile base pressures, coupled with mitigating the rate of gun erosion. A computational fluid dynamics (CFD) study on the NASA White Sands Test Facility (WSTF) 17-Caliber (Cal) gun aims to optimize performance through systematic variations in gun parameters. Predictions suggest increased muzzle velocities beyond 9 km/s and reduced gun erosion. Experimental validation supports the reliability of the study, showing potential velocities of up to 9 km/s. Gun erosion remains a challenge, prompting ongoing experimental efforts with novel materials to align actual performance with theoretical expectations.