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Monday, December 23, 2019

Raptor (rocket engine family)

 
Raptor
Raptor-test-9-25-2016.jpg
First test firing of a Raptor development engine on 25 September 2016 in McGregor, Texas.
Country of originUnited States
ManufacturerSpaceX
ApplicationMultistage propulsion
StatusReady
Liquid-fuel engine
PropellantLiquid oxygen / liquid methane
Mixture ratio3.8
CycleFull-flow staged combustion
Pumps2 × multi-stage
Configuration
Chamber1
Nozzle ratio40
Performance
Thrust2,400 kN (550,000 lbf)
Thrust-to-weight ratio>170 (goal) 
Chamber pressure300 bar (30 MPa; 4,400 psi),
 anticipated value
Isp (vac.)380 s (3,700 m/s) (goal)
Isp (SL)330 s (3,200 m/s)
Dimensions
Length3.1 m (10 ft)
Diameter1.3 m (4 ft 3 in)
Dry weight1,500 kg (3,300 lb) (goal)
Used in
Starship, Super Heavy

Raptor is a full-flow, staged combustion, methane-fueled rocket engine manufactured by SpaceX. The engine is powered by cryogenic liquid methane and liquid oxygen (LOX), rather than the RP-1 kerosene and LOX used in SpaceX's prior Merlin and Kestrel rocket engine families. The earliest concepts for Raptor considered liquid hydrogen (LH
2
) as fuel rather than methane. The Raptor engine has about two times the thrust of the Merlin 1D engine that powers the current Falcon 9 launch vehicle.

Raptor will be used in both stages of the two-stage-to-orbit, super heavy-lift launch vehicle Starship.

The Raptor engine is a highly reusable methalox staged-combustion engine that will power the next generation of SpaceX launch vehicles designed to replace all existing SpaceX vehicles, including the Falcon 9 and Falcon Heavy launch vehicles and the Dragon spacecraft. Raptor engines are expected to be used in various applications including existing Earth-orbit satellite delivery market, the exploration and colonization of Mars.

Raptor engines began flight testing on the Starship prototype rockets in July 2019 and became the first full-flow staged combustion rocket engine ever flown.

Description

Raptor engine combustion scheme
 
Full-flow staged combustion rocket engine
 
The Raptor engine is powered by subcooled liquid methane and subcooled liquid oxygen using a more efficient staged combustion cycle, a departure from the simpler 'open cycle' gas generator system and lox/kerosene propellants that current Merlin engines use. The Space Shuttle Main Engines, with hydrolox propellant) also used a staged combustion process, as do several Russian rocket engines including the RD-180 and the 25.74 MPa (3,733 psi) chamber pressure RD-191. The stated design size for the Raptor engine varied widely during 2012–2017 as detailed design continued, from a high target of 8,200 kN (1,800,000 lbf) of vacuum thrust to a more recent, much lower target of 1,900 kN (430,000 lbf). In its 2017 iteration, the operational engine is expected to have a vacuum Isp of 375 s (3,680 m/s) and a sea-level Isp of 300 s (2,900 m/s).

The Raptor engine is designed for the use of deep cryogenic methalox propellants—fluids cooled to near their freezing points, rather than nearer their boiling points which is more typical for cryogenic rocket engines. The use of subcooled propellants increases propellant density to allow more propellant mass in tanks; the engine performance is also improved with sub cooled propellants. Specific impulse is increased, and the risk of cavitation at inputs to the turbopumps is reduced due to the higher mass flow rate per unit power generated. Engine ignition for all Raptor engines, both on the pad and in the air, will be by spark ignition, which will eliminate the pyrophoric mixture of triethylaluminum-triethylborane (TEA-TEB) used for engine ignition on the Falcon 9 and Falcon Heavy.

Raptor has been claimed to be able to deliver "long life ... and more benign turbine environments". Specifically, Raptor utilizes a full-flow staged combustion cycle, where 100 percent of the oxidizer—with a low-fuel ratio—will power the oxygen turbine pump, and 100 percent of the fuel—with a low-oxygen ratio—will power the methane turbine pump. Both streams—oxidizer and fuel—will be mixed completely in the gas phase before they enter the combustion chamber. Prior to 2014, only two full-flow staged combustion rocket engines had ever progressed sufficiently to be tested on test stands: the Soviet RD-270 project in the 1960s and the Aerojet Rocketdyne Integrated Powerhead Demonstrator in the mid-2000s.

Additional characteristics of the full-flow design, projected to further increase performance or reliability include:
  • eliminating the fuel-oxidizer turbine interseal, which is a potential point of failure in more traditional engine designs
  • lower pressures are required through the pumping system, increasing life span and further reducing risk of catastrophic failure
  • ability to increase the combustion chamber pressure, thereby either increasing overall performance, or "by using cooler gases, providing the same performance as a standard staged combustion engine but with much less stress on materials, thus significantly reducing material fatigue or [engine] weight".
SpaceX aims at a lifetime of 1000 flights for Raptor.

The turbopump and many of the critical parts of the injectors for the initial engine development testing were, as of 2015, manufactured by using 3D printing, which increases the speed of development and iterative testing. Forty percent (by mass) of the 2016 1 MN (220,000 lbf) test stand engine was manufactured by 3D printing.

The Raptor engine uses a large number of coaxial swirl injectors to admit propellants to the combustion chamber, rather than pintle injectors used on the previous Merlin rocket engines that SpaceX mass-produced for its Falcon family of launch vehicles. Raptor uses "dual redundant torch igniters."

History

The engine development from 2009 to 2015 was funded exclusively through private investment by SpaceX, and not as a result of any funding from the US government. In January 2016, SpaceX did agree with the US Air Force to take US$33.6 million in defense department funding in order to develop a particular Raptor model: a prototype of a new upper-stage variant of the Raptor engine designed for potential use as an upper stage on Falcon 9 and Falcon Heavy, with SpaceX agreeing to fund at least US$67.3 million on the same upper-stage development project, on a minimum 2:1 private-to-government funding basis.

Initial concept

An advanced rocket engine design project named Raptor—then a hydrolox engine—was first publicly discussed by SpaceX's Max Vozoff at the American Institute of Aeronautics and Astronautics Commercial Crew/Cargo symposium in 2009. As of April 2011, SpaceX had a small number of staff working on the Raptor upper-stage engine, then still a LH
2
/LOX concept, at a low level of priority. Further mention of the development program occurred in 2011. In March 2012, news accounts asserted that the Raptor upper-stage engine development program was underway, but that details were not being publicly released.

In October 2012, SpaceX publicly announced concept work on a rocket engine that would be "several times as powerful as the Merlin 1 series of engines, and won't use Merlin's RP-1 fuel", but declined to specify which fuel would be used. They indicated that details on a new SpaceX rocket would be forthcoming in "one to three years" and that the large engine was intended for the next-generation launch vehicle using multiple of these large engines, that would be expected to launch payload masses of the order of 150 to 200 tonnes (150,000 to 200,000 kg; 330,000 to 440,000 lb) to low Earth orbit, exceeding the payload mass capability of the NASA Space Launch System.

Methane engine announcement and component development

In November 2012, Musk announced a new direction for the propulsion division of SpaceX: developing methane-fueled rocket engines. He further indicated that the engine concept, codenamed Raptor, would now become a methane-based design, and that methane would be the fuel of choice for SpaceX's plans for Mars colonization.

Potential sources and sinks of methane (CH4) on Mars.
 
Because of the presence of water underground and carbon dioxide in the atmosphere of Mars, methane, a simple hydrocarbon, can easily be synthesized on Mars using the Sabatier reaction. In-situ resource production on Mars has been examined by NASA and found to be viable for oxygen, water, and methane production. According to a study published by researchers from the Colorado School of Mines, in-situ resource utilization such as methane from Mars makes space missions more feasible technically and economically and enables reusability.

When first mentioned by SpaceX in 2009, the term "Raptor" was applied exclusively to an upper-stage engine concept—and 2012 pronouncements indicated that it was then still a concept for an upper stage engine—but in early 2014 SpaceX confirmed that Raptor would be used both on a new second stage, as well as for the large (then, nominally a 10-meter-diameter) core of the then-named Mars Colonial Transporter (subsequently, in 2016, on both stages of the even larger ITS launch vehicle concept and then, in 2017 and 2018, on the currently-in-development 9-meter diameter BFR).

The earliest public hints that a staged-combustion methane engine was under consideration at SpaceX were given in May 2011 when SpaceX asked if the Air Force was interested in a methane-fueled engine as an option to compete with the mainline kerosene-fueled engine that had been requested in the USAF Reusable Booster System High Thrust Main Engine solicitation.

Public information released in November 2012 indicated that SpaceX might have a family of Raptor-designated rocket engines in mind; this was confirmed by SpaceX in October 2013. However, in March 2014 SpaceX COO Gwynne Shotwell clarified that the focus of the new engine development program is exclusively on the full-size Raptor engine; smaller subscale methalox engines were not planned on the development path to the very large Raptor engine.

In October 2013, SpaceX announced that they would be performing methane engine tests of Raptor engine components at the John C. Stennis Space Center in Hancock County, Mississippi, and that SpaceX would add equipment to the existing test stand infrastructure in order to support liquid methane and hot gaseous methane engine component testing. In April 2014, SpaceX completed the requisite upgrades and maintenance to the Stennis test stand to prepare for testing of Raptor components, and the engine component testing program began in earnest, focusing on the development of robust startup and shutdown procedures, something that is typically quite difficult to do for full-flow staged combustion cycle engines. Component testing at Stennis also allowed hardware characterization and verification of proprietary analytical software models that SpaceX developed to push the technology on this engine cycle that had little prior development work in the West.

October 2013 was the first time SpaceX disclosed a nominal design thrust of the Raptor engine—2,900 kN (661,000 lbf)—although early in 2014 they announced a Raptor engine with greater thrust, and in 2015, one with lower thrust that might better optimize thrust-to-weight.

In February 2014, Tom Mueller, the head of rocket engine development at SpaceX, revealed in a speech that Raptor was being designed for use on a vehicle where nine engines would "put over 100 tons of cargo up to Mars" and that the rocket would be more powerful than previously released publicly, producing greater than 4,400 kN (1,000,000 lbf). A June 2014 talk by Mueller provided more specific engine performance target specifications indicating 6,900 kN (1,600,000 lbf) of sea-level thrust, 8,200 kN (1,800,000 lbf) of vacuum thrust, and a specific impulse (Isp) of 380 s (3,700 m/s) for a vacuum version. Earlier information had estimated the design Isp under vacuum conditions as only 363 s (3,560 m/s). Jeff Thornburg, who led development of the Raptor engine at SpaceX 2011–2015, noted that methane rocket engines have higher performance than kerosene/RP-1 and lower than hydrogen, with significantly fewer problems for long-term, multi-start engine designs than kerosene—methane is cleaner burning—and significantly lower cost than hydrogen, coupled with the ability to "live off the land" and produce methane directly from extraterrestrial sources.

SpaceX successfully began development testing of injectors in 2014 and completed a full-power test of a full-scale oxygen preburner in 2015. 76 hot fire tests of the preburner, totaling some 400 seconds of test time, were executed from April–August 2015. SpaceX completed its planned testing at NASA Stennis in 2014 and 2015.

In January 2015, Elon Musk stated that the thrust they were currently targeting was around 230 tonnes-force (2,300 kN; 510,000 lbf), much lower than older statements mentioned. This brought into question much of the speculation surrounding a 9-engine booster, as he stated "there will be a lot of [engines]". By August 2015, an Elon Musk statement surfaced that indicated the oxidizer to fuel ratio of the Mars-bound engine would be approximately 3.8 to 1.

In January 2016, the US Air Force awarded a US$33.6 million development contract to SpaceX to develop a prototype version of its methane-fueled reusable Raptor engine for use on the upper stage of the Falcon 9 and Falcon Heavy launch vehicles, which required double-matching funding by SpaceX of at least US$67.3 million. Work under the contract is expected to be completed in 2018, with engine performance testing to be done at NASA's John C. Stennis Space Center in Mississippi and Los Angeles Air Force Base, California.

Engine development and testing

Testing of the Raptor's oxygen preburner at Stennis Space Center in 2015.
 
Initial development testing of Raptor methane engine components was done at the Stennis Space Center in Hancock County, Mississippi, where SpaceX added equipment to the existing infrastructure in order to support liquid methane engine testing. Initial testing was limited to components of the Raptor engine, since the 440 kN (100,000 lbf) test stands at the E-2 complex at Stennis were not large enough to test the full Raptor engine. The development Raptor engine discussed in the October 2013 time frame relative to Stennis testing was designed to generate more than 2,900 kN (661,000 lbf) vacuum thrust. A revised, higher-thrust, specification was discussed by the company in February 2014, but it was unclear whether that higher thrust was something that would be achieved with the initial development engines. Raptor engine component testing began in May 2014 at the E-2 test complex which SpaceX modified to support methane engine tests. The first items tested were single Raptor injector elements, various designs of high-volume gas injectors. The modifications to the test stands made by SpaceX are now a part of the Stennis test infrastructure and are available to other users of the test facility after the SpaceX facility lease was completed. SpaceX successfully completed a "round of main injector testing in late 2014" and a "full-power test of the oxygen preburner component" for Raptor by June 2015. Tests continued at least into September 2015.

By 2016, SpaceX had constructed a new engine test stand at their site of McGregor in central Texas that can handle the larger thrust of the full Raptor engine.

By August 2016, SpaceX confirmed that a Raptor engine had been shipped to the testing site in McGregor for development tests, and the 1,000 kN (220,000 lbf) development Raptor did an initial 9-second firing test on 26 September 2016, the day before Musk's talk at the International Aeronautical Congress. The 2016 development engine had "an expansion ratio of just 150, the maximum possible within Earth’s atmosphere" to prevent flow separation problems.

By August 2016, the first integrated Raptor rocket engine, manufactured at the SpaceX Hawthorne facility in California, shipped to the McGregor rocket engine test facility in Texas for development testing. The engine had 1 MN (220,000 lbf) thrust, which makes it approximately one-third the size of the full-scale Raptor engine planned for flight tests in 2019/2020 timeframe. It is the first full-flow staged-combustion methalox engine ever to reach a test stand.

On 26 September 2016, Elon Musk tweeted two images of the first test firing of an integrated Raptor in SpaceX's McGregor test complex. On the same day Musk revealed that their target performance for Raptor was a vacuum specific impulse of 382 s (3,750 m/s), with a thrust of 3 MN (670,000 lbf), a chamber pressure of 300 bar (30 MPa; 4,400 psi), and an expansion ratio of 150 for an altitude optimized version. When asked if the nozzle diameter for such version was 14 ft (4.3 m), he stated that it was pretty close to that dimension. He also disclosed that it used multi-stage turbopumps. On the 27th he clarified that 150 expansion ratio was for the development version, that the production vacuum version would have an expansion ratio of 200. Substantial additional technical details of the ITS propulsion were summarized in a technical article on the Raptor engine published the next week.

By September 2017, the development Raptor engine—with 200 bars (20 MPa; 2,900 psi) chamber pressure—had undergone 1200 seconds of test fire testing in ground-test stands across 42 main engine tests, with the longest test being 100 seconds (which is limited by the capacity of the ground-test propellant tanks). As of September 2017, the first version of the flight engine is intended to operate at a chamber pressure of 250 bars (25 MPa; 3,600 psi), with the intent to raise it to 300 bars (30 MPa; 4,400 psi) at a later time.

By September 2017, the 200 bars (20 MPa; 2,900 psi) sub-scale test engine, with a thrust of 1 meganewton (220,000 lbf) and "a new alloy to help its oxygen-rich turbopump resist oxidization, ... had completed 1200 seconds of firings across 42 tests."

While plans for Raptor flight testing have consistently been on the new-generation fiber-composite-material construction flight vehicles since 2016, the specific vehicle was not clarified until October 2017, when it was indicated that initial suborbital test flights would occur with a BFR spaceship. In November 2016, the first flight tests of the Raptor engine were projected to be on the very large 12-meter (39 ft)-diameter ITS launch vehicle, no earlier than the early 2020s. By July 2017, the plan had been modified to do flight testing on a much smaller launch vehicle and spacecraft, and the new system architecture had "evolved quite a bit" since the very large ITS launch vehicle design concept from 2016. A key driver of the 2017 architecture was to make the new system useful for substantial Earth-orbit and Cislunar launches so that the new system might pay for itself, in part, through economic spaceflight activities in the near-Earth space zone.

Elon Musk announced in September 2017 that the initial flight platform for any Raptor engine would be some part of the BFR launch vehicle. BFR is a 9 m (30 ft)-diameter launch vehicle. In October 2017, Musk clarified that "[initial flight testing will be with] a full-scale 9-meter-diameter ship doing short hops of a few hundred kilometers altitude and lateral distance ... [projected to be] fairly easy on the vehicle, as no heat shield is needed, we can have a large amount of reserve propellant and don’t need the high area ratio, deep-space Raptor engines."

Notably, Musk also announced that the new Raptor-powered BFR launch vehicle was planned to entirely replace both Falcon 9 and Falcon Heavy launch vehicles as well as the Dragon spacecraft in the existing operational SpaceX fleet in the early 2020s, initially aiming at the Earth-orbit market, but SpaceX is explicitly designing in substantial capability to the spacecraft vehicles to support long-duration spaceflight in the cislunar and Mars mission environment as well. SpaceX intends this approach to bring significant cost savings which will help the company justify the development expense of designing and building the new launch vehicle design. In addition to orbital spaceflight missions, BFR is being considered for the point-to-point Earth transportation market, with ~30–60-minute flights to nearly anywhere on the planet.

The first flight version of the Raptor engine planned for the Starship hopper arrived in McGregor, Texas in late January 2019.

On 3 February 2019, SpaceX performed the first test of a flight version engine. The test lasted two seconds with the engine operating at 60 percent of rated thrust at a chamber pressure of 170 bars (17,000 kPa). Just four days later, the test engine achieved the power levels needed for use in Super Heavy and Starship. The engine reached 172 tonnes-force (1,690 kN; 380,000 lbf) thrust with a chamber pressure of 257 bars (25.7 MPa). The test was conducted using warm propellant, with expectations of a 10% to 20% increase in performance when switching to deep cryogenic temperatures for the propellant. On 10 February 2019, Musk announced on Twitter that the flight version engine had attained the chamber combustion pressure of 268.9 bars (26.89 MPa) on a test stand.

By March, serial number 2 (SN2) of the flight version Raptor engine had been delivered to the SpaceX South Texas launch site east of Brownsville, Texas for system integration testing on the Starship flight test rocket, the first test article of Starship, approximately one year ahead of schedule. SN2 was used for two tethered integration tests of the flight test "hopper" in early April. Serial numbers 3, 4, 5 and 6 had all made it to the test stand by early July, but the first three had issues of various sorts and SpaceX did not try any flight tests of the Starhopper test vehicle. SN6 was still under test on the ground test stand as of 8 July 2019.

The first flight test of a Raptor engine occurred on 25 July 2019 at the SpaceX South Texas Launch Site. Unusually, for initial flight tests of orbital-class rocket engines, this was not a full-duration burn but just a 22-second test. SpaceX is developing their next-generation rocket to be reusable from the beginning, just like an aircraft, and thus needs to start with narrow flight test objectives, while still aiming to land the rocket successfully to be used subsequently in further tests to expand the flight envelope.

Another flight test of a Raptor engine (probably SN6) occurred on 27 August 2019 from Boca Chica, Texas, test facility. The starhopper test vehicle reached an estimated altitude of 150m (FAA approved). A side step and a perfect landing on a nearby landing pad terminated the roughly 1 minute flight. 

Versions


IAC 2016 proposed designs

At the IAC meetings September 2016, Musk mentioned several Raptor engine designs that could be used on the ITS launch vehicle by late in the decade. In addition, a much smaller subscale engine had been built for test and validation of the new full-flow staged-combustion cycle engine. At that time, this first "subscale" Raptor development engine had been tested on a ground test stand for only one brief firing.
"Raptor subscale development engine"
In order to eliminate flow separation problems while being tested in Earth's atmosphere, the test nozzle expansion ratio was limited to only 150. The engine began testing in September 2016 on a ground test stand. Sources differ on the performance of this engine. In reporting during the two weeks following the Musk reveal on 27 September, NASASpaceFlight.com indicated that the development engine is only one-third the size of any of the three larger engine designs planned for the 2016-design flight vehicles, approximately 1,000 kN (220,000 lbf) thrust.
Raptor 2016 with expansion ratio 40
With an expansion ratio 40 nozzle, 42 of these engines were planned to power the 2016 high-level design of the ITS booster stage. 3,050 kN (690,000 lbf) of thrust at sea-level, and 3,285 kN (738,000 lbf) in vacuum. In addition, three gimbaled short-nozzle engines were to be used for maneuvering the 2016-design ITS launch vehicle second-stages; and these engines were to be used for retropropulsive landings on Mars (with mean atmospheric pressure on the Martian surface 600 Pa (0.0060 bar; 0.087 psi)), as well as, potentially, other Solar System objects.
Raptor 2016 with expansion ratio 200
Like the SpaceX Merlin engine, a vacuum version of the Raptor rocket engine design was shown which would target a specific impulse of 382s, using a larger nozzle giving an expansion ratio of 200. Six of these non-gimbaled engines were planned to provide primary propulsion for the 2016 designs of the Interplanetary Spaceship and the Earth-orbit ITS tanker. As designed, both of those vehicles were to play a short-term role as second stages on launches to Earth orbit, as well as provide high-Isp efficiency on transfer from geocentric to heliocentric orbit for transport to beyond-Earth-orbit celestial bodies. 3,500 kN (790,000 lbf) thrust at vacuum, the only conditions under which the six ER200 engines were expected to be fired.

Raptor 2017

At the IAC meetings of September 2017, Elon Musk announced that a smaller Raptor engine—with slightly over half as much thrust as the 2016 proposed designs—would be used on the BFR rocket than had been used on the ITS launch vehicle design unveiled a year earlier. Additionally, fewer engines would be used on each stage. BFR would have 31 Raptors on the first stage and 6 on the second stage, whereas the ITS launch vehicle design had 42 larger Raptor engines on the first stage and 9 of that same large size on the second stage. The engine design remains full-flow staged combustion cycle design using subcooled liquid-methane/liquid-oxygen propellant, just like the larger 2016 engine design. Version 1 of the flight engine is designed to operate at 250 bars (25,000 kPa; 3,600 psi) chamber pressure; but SpaceX expects to increase this to 300 bar (30,000 kPa; 4,400 psi) in later iterations. The flight engine is designed for extreme reliability, aiming to support the airline-level of safety required by the point-to-point Earth transportation market.
  • The sea-level model Raptor engine design, with a nozzle exit diameter of 1.3 m (4.3 ft), is expected to have 1,700 kN (380,000 lbf) thrust at sea-level with an Isp of 330 s (3,200 m/s) increasing to an Isp of 356 s (3,490 m/s) in vacuum.
  • The vacuum model Raptor, with a nozzle exit diameter of 2.4 m (7.9 ft), is expected to exert 1,900 kN (430,000 lbf) force with an Isp of 375 s (3,680 m/s).

Raptor 2018

In the BFR update given in September 2018, Musk showed video of a 71-second burn of a Raptor engine, and stated that "this is the Raptor engine that will power BFR, both the ship and the booster; it's the same engine. ... approximately a 200 short tons-force (1,800 kN; 400,000 lbf) engine aiming for roughly 300 bars (30,000 kPa; 4,400 psi) chamber pressure. ... If you had it at a high expansion ratio, has the potential to have a specific impulse of 380 s (3,700 m/s)." The update also included a redesigned Starship with seven sea-level Raptor engines instead of the three sea-level and four vacuum on the previous design.

Later versions will be split into a sea-level design and a vacuum-optimized design again.

Applications

As of September 2016, the Raptor engine was slated to be used in three spaceflight vehicles making up the two launch stages of an ITS launch vehicle stack. The first stage is always an Interplanetary booster while the second stage may be either an Interplanetary Spaceship (for beyond-Earth-orbit missions) or an ITS tanker (for on-orbit propellant transfer operations nearer to Earth).

The SpaceX 2016-design of the Interplanetary booster was announced with 42 sea-level optimized Raptors in the first stage of the ITS launch vehicle with a total of 128 MN (29,000,000 lbf) of thrust. The SpaceX Interplanetary Spaceship—which made up the second stage of the ITS launch vehicle on Earth launches was also an interplanetary spacecraft carrying cargo and passengers to beyond-Earth-orbit destinations after on-orbit refueling—was slated in the 2016 design to use six vacuum-optimized Raptors for primary propulsion plus three Raptors with sea-level nozzles for maneuvering.

The SpaceX 2017-design is a much smaller launch vehicle, 9 meters in diameter rather than 12 meters for the ITS launch vehicle, and is known as Starship. The Starship first stage was originally planned to have 31 sea-level optimized Raptors with a total of 48 MN (11,000,000 lbf) of thrust. The Starship will use three vacuum-optimized Raptors for primary propulsion plus three sea-level Raptors for maneuvering. SpaceX will build the flight-article Starship vehicles at the SpaceX South Texas build site.

National Security Space Launch

From Wikipedia, the free encyclopedia
 
Delta IV Heavy liftoff from SLC-6. Delta IV was one of the rockets developed under the initial EELV program.
 
National Security Space Launch (NSSL) is a program of the United States Air Force (USAF) intended to assure access to space for United States Department of Defense and other United States government payloads. 

Started in 1994 as the Evolved Expendable Launch Vehicle (EELV) launch system program, the initial program goal was to make government space launches more affordable and reliable, leading to the development of the Delta IV and Atlas V EELV families. As of 2019, these launch vehicles are the primary methods for launching U.S. military satellites, along with the Falcon 9 developed by SpaceX under NASA's CRS program.

On 1 March 2019, the program changed its name from EELV to National Security Space Launch (NSSL) to better reflect the changing nature of launch contracting, including the retirement of STS and the inclusion of reusable vehicles. The NSSL program launches the nation's most valuable military satellites; contracts to launch lower value payloads, such as those of the Space Test Program, are awarded using different methodologies.

History


Initial program goals

The USAF began the EELV program in 1994, following many years of government-funded studies into improved systems and architecture. The intent was to replace legacy vehicles, including Delta II, Atlas II, and Titan IV. EELVs were to reduce costs by being based on standardized fairings, liquid core vehicles, upper stages, and solid rocket boosters. A Standard Payload Interface bus was also proposed as a way to save money and improve efficiency.

Reducing the cost of launches and ensuring national access to space were the two main goals of the USAF space launch/EELV program. Some of the reasons why assured access to space is a priority for the United States are stated in National Presidential Directive Number 40, which reads:
Access to space through U.S. space transportation capabilities is essential to:
  1. place critical United States Government assets and capabilities into space;
  2. augment space-based capabilities in a timely manner in the event of increased operational needs or minimize disruptions due to on-orbit satellite failures, launch failures, or deliberate actions against U.S. space assets;
  3. support government and commercial human space flight.
The United States, therefore, must maintain robust, responsive, and resilient U.S. space transportation capabilities to assure access to space.
Procurement of EELV boosters for military space launch was to evolve to more closely match commercial practice. The initial bids came from four major defense contractors: Lockheed Martin, Boeing, McDonnell Douglas, and Alliant Techsystems. Each of the bids included a variety of concepts. Boeing initially proposed utilizing the RS-25 Space Shuttle main engine (SSME). When McDonnell Douglas merged with Boeing in 1997, the latter put forth the Delta IV as their EELV proposal. Both the Delta IV and Lockheed Martin's Atlas V eventually entered service. 

1990s-2000s

In October 1998 two initial launch services contracts (known as Buy 1) were awarded. Along with the award of two development agreements, the total amount was more than $3 billion. Boeing was awarded a contract for 19 out of the 28 launches; Lockheed Martin was awarded a contract for the other 9. Boeing received $1.38 billion, and Lockheed Martin received $650 million for the launches. Boeing and Lockheed Martin were both collectively awarded US$100 million for the final phase of the bid. Boeing developed the Delta IV based around Common Booster Cores (CBC) and the Delta Cryogenic Second Stage, while Lockheed Martin developed the Atlas V based around Common Core Boosters (CCB) and the Centaur upper stage.

In 2003, Boeing was found to be in possession of proprietary documents from Lockheed Martin. The USAF moved 7 launches from Delta IV to Atlas V. To end litigation and competition for a limited market, both companies agreed to form the United Launch Alliance (ULA) joint venture. Each company has a 50% stake in ULA.

2010s

In December 2012, the DoD announced a re-opening of the EELV-class launch vehicle market to competition while authorizing the USAF to proceed with a block buy of "up to" 36 boosters from ULA. At the same time, another 14 boosters were to be procured competitively beginning in 2015, with the initial launches to be performed in 2017.

The USAF signed a contract at that time with SpaceX for two launches in 2014 and 2015 to serve as proving flights to support the certification process for the Falcon 9 v1.1 and Falcon Heavy. In April 2014, after the launches were contracted, SpaceX sued the United States Air Force, arguing that the RD-180 engines, produced in Russia by the government owned NPO Energomash and used by the Atlas V, violated sanctions against the Russian government. The USAF and SpaceX settled the lawsuit in Jan 2015 by opening up more launches to competitive bidding. The USAF certified the Falcon 9 in May 2015, and in 2016 SpaceX won a contract under the EELV program to launch a GPS Block III satellite payload to MEO.

2018 to 2020s

The USAF began the process of competitively selecting the next generation NSSL vehicles in 2018. Announced performance requirements include:

Orbit description Apogee (km) x perigee (km) Inclination (degrees) Mass to orbit (kg) Payload category
LEO 926 x 926 63.4 6,800 A, B
Polar 1 830 x 830 98.2 7,030 A, B
Polar 2 830 x 830 98.2 17,000 C
MEO Direct 1 18,200 x 18,200 50.0 5,330 A, B
MEO Transfer 1 20,400 x 1,000 55.0 4,080 A, B
GTO 35,786 x 190 27.0 8,165 A, B
Molniya 39,200 x 1,200 63.4 5,220 A, B
GEO 1 35,786 x 35,786 0.0 2,300 A, B
GEO 2 35,786 x 35,786 0.0 6,600 C

Category A payloads fit within a 4 m payload envelope, category B payloads fit within a 5 m payload envelope, and category C payloads require an extended 5 m envelope.

The USAF plans to use the next generation NSSL launch vehicles until at least 2030. At least one program was considering follow-on technologies before cancellation in 2012.

Launch vehicles

Currently, there are four vehicles certified to conduct NSSL launches: Atlas V, Delta IV Heavy, Falcon 9 and Falcon Heavy. Delta IV Medium was retired in August 2019. The USAF is currently in the process of soliciting bids for next-generation launch vehicles, with proposals due by 1 August 2019.

Active


Atlas V-certified

Atlas V liftoff from SLC-41

Each Atlas V launch vehicle is based on a Common Core Booster powered by one NPO Energomash RD-180 engine with two combustion chambers and a Centaur upper stage powered by one or two Pratt & Whitney Rocketdyne RL10A-4-2 engines. Up to five Aerojet Rocketdyne Graphite-Epoxy Motor solid rocket boosters can be added to increase vehicle performance, and two diameters of payload fairing are available.

A three-digit (XYZ) naming convention is used for the Atlas V configuration identification. An Atlas V XYZ will have a 4.2- or 5.4-meter diameter payload fairing (X= 4 or 5), Y solid rocket boosters (0-5), and Z RL-10's on the Centaur upper stage (1-2). As an example, an Atlas V 551 has a 5.4 m PLF, 5 SRBs, and 1 RL-10.

Delta IV Heavy-certified

Each Delta IV launch vehicle is based on a Common Booster Core (CBC) powered by a Pratt and Whitney Rocketdyne RS-68 engine and a Delta Cryogenic Second Stage (DCSS) powered by an RL10. Delta IV Heavy is distinguished by two additional CBCs and always flies with a 5 m DCSS and PLF, while Delta IV Medium flew with two or four SRBs on a single CBC.

The DCSS had 4 m diameter and 5 m diameter versions, with matching diameter payload fairings (PLFs). Delta IV CBCs and DCSSs are integrated horizontally before being transported to the launchpad. The 4 m diameter DCSS was retired with the Delta IV Medium after the 22 August 2019 launch of a GPS-IIIA satellite on a Delta IV M+(4,2) with one CBC, two SRBs, and a 4 m diameter DCSS and PLF.

Falcon 9-certified

Falcon 9 liftoff from SLC-4E

The main features of the Falcon 9 in its current Block 5 version include two stages, both powered by LOX and RP-1, with nine Merlin 1D engines on the first stage and one Merlin 1D Vacuum engine on the second stage.

GPS-IIIA USA-289 was the first NSSL-type B5 Falcon 9 launch. The launch occurred on December 23, 2018.

Falcon Heavy-certified

The Falcon Heavy is a heavy-lift rocket developed and produced by SpaceX. It has been certified for the NSSL program after the STP-2 launch completed on 25 June 2019, as confirmed by the commander of the Air Force Space and Missile Systems Center, Lt. Gen. Thompson. He clarified: "I certified them to compete last year" and "[o]ne of the requirements behind certification is to fly three missions." This requirement has been satisfied by the Falcon Heavy test flight in February 2018, Arabsat-6A in April 2019, and the STP-2 launch in June 2019. However, Falcon Heavy has been certified for two Phase 1A reference orbits only and "[i]t's not certified for all of our most stressing national security space orbits," Thompson said. Thus, the USAF is working with SpaceX to mature their Falcon Heavy's design. 

As of September 2019, it has two manifested classified national security flights for the USAF in 2020 and 2021.

Next generation vehicle competition

As of 2018, a competitive contract award to launch national security spacecraft is underway between ULA, Northrop Grumman Innovation Systems (NGIS), Blue Origin, and SpaceX. Two providers will be selected to launch spacecraft to a number of reference orbits. In October 2018, the USAF awarded funding to ULA, NGIS, and Blue Origin to develop their rockets.

On 12 August 2019, at least three of the four companies submitted their final bids for the launch services competition. SpaceX bid the existing Falcon rockets, while Blue Origin was expected to bid New Glenn, ULA bid Vulcan Centaur, and NGIS's bid status was not reported. Blue Origin also filed a pre-award protest of the request for proposal arguing that the requirements were ambiguous.

New Glenn

Blue Origin was awarded $500 million for development of New Glenn as a potential competitor in future contracts. As of 2019, New Glenn was expected to first launch in 2021. 

OmegA

OmegA is a rocket design by Northrop Grumman Innovation Systems with two main solid stages, a cryogenic upper stage, and the possibility of strap-on boosters. The first flight is expected in 2021.

Vulcan

ULA was awarded phase 1 funding for development of Vulcan as a potential competitor in future contracts. On 12 August 2019, ULA submitted Vulcan Centaur for phase 2 of the USAF's launch services competition. As of that time, Vulcan Centaur was on track for a 2021 launch.

Blue Engine 4

From Wikipedia, the free encyclopedia
https://en.wikipedia.org/wiki/BE-4
 
Blue Engine 4
Country of originUnited States
ManufacturerBlue Origin
PredecessorBE-3
Liquid-fuel engine
PropellantLiquid oxygen / Liquefied natural gas
Under development
Performance
Thrust (SL)2,400 kN (550,000 lbf)
Chamber pressure13,400 kPa (1,950 psi)
Gimbal range±5°
Used in
Vulcan
New Glenn

The Blue Engine 4 or BE-4 is an oxygen rich liquefied-natural-gas-fueled staged-combustion rocket engine under development by Blue Origin. The BE-4 is being developed with private and public funding. The engine has been designed to produce 2,400 kilonewtons (550,000 lbf) of thrust at sea level.

It was initially planned for the engine to be used exclusively on a Blue Origin proprietary launch vehicle, New Glenn, the company's first orbital rocket. However, it was announced in 2014 that the engine would also be used on the United Launch Alliance (ULA) Vulcan launch vehicle, the successor to the Atlas V launch vehicle. Final engine selection by ULA happened in September 2018.

First flight test of the new engine is expected no earlier than 2021.

History

Blue Origin began work on the BE-4 in 2011, although no public announcement was made until September 2014. This is their first engine to combust liquid oxygen and liquid methane propellants. In September 2014—in a choice labeled "a stunner" by SpaceNews—the large launch vehicle manufacturer and launch service provider United Launch Alliance selected the BE-4 as the main engine for a new primary launch vehicle.

As of April 2015, the engine development work was being carried out in two parallel programs. One program is testing full-scale versions of the BE-4 powerpack, which are the set of valves and turbopumps that provide the proper fuel/oxidizer mix to the injectors and combustion chamber. The second program is testing subscale versions of the engine's injectors. Also in early 2015, the company indicated it is planning to begin full-scale engine testing in late 2016, and that they expected to complete development of the engine in 2017.

As of September 2015, Blue Origin had completed more than 100 development tests of several elements of the BE-4, including the preburner and a "regeneratively-cooled thrust chamber using multiple full-scale injector elements". The tests were used to confirm the theoretical model predictions of "injector performance, heat transfer, and combustion stability", and data collected is being used to refine the engine design. There was an explosion on the test stand during 2015 during powerpack testing. Blue Origin built two larger and redundant test stands to follow, capable of testing the full thrust of the BE-4.

In January 2016, Blue Origin announced that they intended to begin testing full engines of the BE-4 on ground test stands prior to the end of 2016. Following a factory tour in March 2016, journalist Eric Berger noted that a large part of "Blue Origin’s factory has been given over to development of the Blue Engine-4".

Initially, both first-stage and second-stage versions of the engine were planned. The second stage of the initial New Glenn design was to have shared the same stage diameter as the first stage and use a single vacuum-optimized BE-4, the BE-4U.

The first engine was fully assembled in March 2017. Also in March, United Launch Alliance indicated that the economic risk of the Blue Origin engine selection option had been retired, but that the technical risk on the project would remain until a series of engine firing tests were completed later in 2017. A test anomaly occurred on 13 May 2017 and Blue Origin reported that they lost a set of powerpack hardware.

In June 2017, Blue Origin announced that they would build a new facility in Huntsville, Alabama to manufacture the large BE-4 cryogenic rocket engine.

The BE-4 was first test fired, at 50% thrust for 3 seconds, in October 2017. By March 2018, the BE-4 engine had been tested at 65% of design thrust for 114 seconds with a goal expressed in May to achieve 70% of design thrust in the next several months. By September 2018, multiple hundreds of seconds of engine testing had been completed, including one test of over 200 seconds duration.

In October 2018, Blue Origin President Bob Smith announced that the first launch of the New Glenn had been moved back to 2021, which will be the first flight test of the BE-4. 

By February 2019, the BE-4 had acquired a total of 1800 seconds of hot fire testing on ground test stands, but had yet to be tested above 1.8 meganewtons (400,000 lbf) pounds of thrust, about 73 percent of the engine's rated thrust of 2.4 MN (550,000 lbf).

In August 2019, Blue Origin announced that BE-4 was undergoing full power engine tests.

Blue Origin BE-4 rocket engine powerhead and combustion chamber, April 2018—liquid methane inlet side view. This was the first BE-4 engine to be hotfire tested; test occurred on 18 October 2017.

Applications

As of 2017, the BE-4 was being considered for use on two launch vehicles currently in development. Prior to this, a modified derivative of the BE-4 was also being considered for the experimental XS-1 spaceplane for a US military project, but was not selected.

Atlas V successor - Vulcan

In late 2014, Blue Origin signed an agreement with United Launch Alliance to co-develop the BE-4 engine and to commit to use the new engine on the Vulcan launch vehicle, a successor to the Atlas V, which would replace the single Russian-made RD-180 engine. Vulcan will use two of the 2,400 kN (550,000 lbf) BE-4 engines on each first stage. The engine development program began in 2011.

The ULA partnership announcement came after months of uncertainty about the future of the Russian RD-180 engine that has been used in the ULA Atlas V rocket for over a decade. Geopolitical concerns had come about that created serious concerns about the reliability and consistency of the supply chain for the procurement of the Russian engine. ULA expects the first flight of the new launch vehicle no earlier than 2019.

Since early 2015, the BE-4 has been in competition with the AR1 engine for the Atlas V RD-180 replacement program. While the BE-4 is a methane engine, the AR1, like the RD-180, is kerosene-fueled. In February 2016, the US Air Force issued a contract that provides partial development funding of up to US$202 million to ULA in order to support use of the Blue BE-4 engine on the ULA Vulcan launch vehicle.

Initially, only US$40.8 million will be disbursed by the government with US$40.8 million additional to be spent by a ULA subsidiary on Vulcan BE-4 development. Although US$536 million was the original USAF contract amount to Aerojet Rocketdyne (AJR) to advance development of the AR1 engine, as an alternative for powering the Vulcan rocket, by June 2018, the USAF had renegotiated the agreement with AJR and decreased the Air Force contribution—5/6ths of the total cost—to US$294 million. AJR is putting no additional private funds into the engine development effort after early 2018.

Bezos noted in 2016 that the Vulcan launch vehicle is being designed around the BE-4 engine; ULA switching to the AR1 would require significant delays and money on the part of ULA. This point has also been made by ULA executives, who have also clarified that the BE-4 is likely to cost 40% less than the AR1, as well as benefit from Bezos capacity to "make split-second investment decisions on behalf of BE-4, and has already demonstrated his determination to see it through. [whereas the] AR1, in contrast, depends mainly on U.S. government backing, meaning Aerojet Rocketdyne has many phone numbers to dial to win support".

New Glenn launch vehicle

The engine is to be used on the Blue Origin large orbital launch vehicle New Glenn, a 7.0-meter (23 ft)-diameter two-stage orbital launch vehicle with an optional third stage and a reusable first stage. The first flight and orbital test is planned for no earlier than 2021, although the company had earlier expected the BE-4 might be tested on a rocket flight as early as 2020.

The first stage will be powered by seven BE-4 engines and will be reusable, landing vertically. The second stage of New Glenn will share the same diameter and use two BE-3 vacuum-optimized hydrolox engines. The second stage will be expendable.

XS-1 engine

Boeing secured a contract to design and build the DARPA XS-1 reusable spaceplane in 2014. The XS-1 is to accelerate to hypersonic speed at the edge of the Earth's atmosphere to enable its payload to reach orbit. In 2015, it was believed a modified derivative of the BE-4 engine was to power the craft. In 2017, the contract award selected the RS-25-derived Aerojet Rocketdyne AR-22 engine instead.

Availability and use

Blue Origin has indicated that they intend to make the engine commercially available, once development is complete, to companies beyond ULA, and also plans to utilize the engine in Blue Origin's own new orbital launch vehicle. As of March 2016, Orbital ATK was also evaluating Blue engines for its launch vehicles.

The BE-4 uses liquid methane rather than more commonly used rocket fuels such as kerosene. This approach allows for autogenous pressurization, which is the use of gaseous fuel to pressurize remaining liquid fuel. This is beneficial because it eliminates the need for costly and complex pressurization systems which require storage of a pressurizing gas, such as helium.

Although all early BE-4 components and full engines to support the test program were built at Blue's headquarters location in Kent, Washington, production of the BE-4 will be in Huntsville, Alabama. Testing and support of the reusable BE-4s will occur at the company's orbital launch facility at Exploration Park in Florida, where Blue Origin is investing more than US$200 million in facilities and improvements.

Technical specifications

The BE-4 is a staged combustion engine, with a single oxygen rich preburner, and a single turbine driving both the fuel and oxygen pumps . The cycle is similar to the kerosene-fueled RD-180 currently used on the Atlas V, although it uses only a single combustion chamber and nozzle.

The BE-4 is designed for long life and high reliability, partially by aiming the engine to be a "medium-performing version of a high-performance architecture". Hydrostatic bearings are used in the turbopumps rather than the more typical ball and roller bearings specifically to increase reliability and service life.
  • Thrust (sea level): 2,400 kN (550,000 lbf) at full power
  • Chamber pressure: 13,400 kPa (1,950 psi), substantially lower than the 26,000 kPa (3,700 psi) of the RD-180 engine that ULA wants to replace
  • Designed for reusability
  • Design life: 100 launches and landings
  • Restartable during flight, via head-pressure start of the turbine during coast
  • Deep throttling capability to 65% power or lower

Hebrew Bible

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