Solid propellant combustion and flow are significantly affected by condensed combustion products (CCPs) in solid rocket motors. A new aluminum agglomeration model is established using the discrete element method, considering the burning rate and formulation of the propellant. Combining the aluminum combustion and alumina deposition model, an analytical model of the evolution of CCPs is proposed, capable of predicting the particle-size distribution of completely burned CCPs. The CCPs near and away from the propellant burning surface are collected by a special quench vessel under 6~10 MPa, to verify the applicability of the CCP evolution model. Experimental results show that the predicted error of the proposed CCP evolution model is less than 8.5%. Results are expected to help develop better analytical tools for the combustion of solid propellants and solid rocket motors.
