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Launch Propulsion:
SMC/LR Perspectives
Presented to
Launch Propulsion Workshop
Caltech
Pasadena, CA
Presented by
Lt Col Toby Cavallari
Chief Engineer
Launch and Range Systems Directorate
Space and Missile Systems Center
23 March 2011
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ELV History (1958 – Present)
 Powered first US ICBMs
 Evolved into launch vehicle systems, opening the door to
space
 Continued with improvements in performance, reliability,
and operability
 However, more than 40% of all historical
launch vehicle failures caused by propulsion
subsystem malfunctions (#1 contributor)
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Drawing courtesy of Boeing
 In past 50 years, propulsion enabled ballistic
and spacelift capabilities
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Historical USAF Development & Industrial Base
 More than 50 years, USAF has been a key player in rocket development
1954
1957
1961
1967
1979
SSD
Gen. Schriever
(1st Commander)
WDD
Atlas ICBM,
Titan I ICBM
AFBMD
Atlas ICBM,
Titan I ICBM,
Minuteman I,
Satellites &
related Space
Systems
Satellites &
related
Space
Systems
Atlas ICBM,
Titan I/II ICBM,
Minuteman I,
Minuteman II,
Minuteman III,
1989
SD
SSD
Satellites & related
Space Systems
SAMSO
All ICBMs
& Space
Systems
(Titan III
Delta, etc.)
1992 1993
1995
SMC
Atlas I, II, IIA, IIAS
Delta II, Titan III/IV
EELV
WDD = Western Development Division
AFBMD = AF Ballistic Missile Division
BSD = Ballistic Systems Divisions
SSD = Space Systems Divisions
SAMSO = Space and Missile Systems Organization
BMO = Ballistic Missile Organization
SD = Space Division
SMC = Space and Missile Systems Center
All ICBMs,
(& Peacekeeper,
Small ICBM)
BSD
(1989-1990)
BMO
BSD BMO
SMC Det 10
 Today, only
several U.S.
companies
are active
Rocketdyne
Thiokol
Pratt & Whitney
TRW
General Electric
American Pacific Corp
Rocket Research Corp
Hamilton Standard Div.
Reaction Motors
Atlas V
Delta IV
Peacekeeper & Small
ICBM Close-out,
Sustainment Effort 526th
ICBM
SPO
U.S. Propulsion Companies
From 1941
Liquid
Today
Solid
Hercules
Aerojet
Atlantic Research Corp
Grand Central Rocket Co.
Today
Liquid
Solid
Pratt & Whitney
Rocketdyne
Rohm & Hass Co.
Northrop
Grumman
United Technology
Center
Space-X
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ICBM
Systems
Group
Aerojet
ATK
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EELV Families
 Two families of launch vehicles (Atlas V and Delta IV)
Atlas V Family
Delta IV Family
GTO Capability
(lbs)
30,000
25,000
PWR
RL10B-2
Engine
PWR
RL10-A2 Engine
20,000
15,000
10,000
GEM-60
SRB
Russian
RD-180
Engine
PWR
RS-68
Engine
5,000
IOC
Atlas V
Atlas V
Atlas V
Atlas V
Delta IV
Delta IV
Delta IV
Delta IV
(401)
(4XX Series)
(5XX Series)
(Heavy)
(Med)
(Med+ 4 series)
(Med+ 5
series)
(Heavy)
8/02
7/03
3/03
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11/02
12/04
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Current EELV Propulsion Environment


Escalating engine cost growth
Must ensure engine availability for EELV until 2030
 Supplier obsolescence
 Reliance on foreign suppliers for EELV mission assurance and sustainment



Payload mass-to-orbit expected to continue on an upward trend
Declining U.S. industry capability in engine development and
production
Some specific concerns:
 EELV Upper Stage Engines:
 50-year-old craftsman-based manufacturing
 Currently flying at reduced confidence margins
 Running at twice original engine chamber pressure
 Requiring highly selective screening per USG standards
 Increased mission assurance costs
 No further growth opportunity without major redesign
 Kerosene Booster Engine:
 DoD reliance on Russian designed and built engine
 Limiting opportunity for technology transfer to new U.S. engine effort
 Also, ITAR restricts U.S. technology transfer into RD-180 program
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RL10 Engines





LOX/LH2 engine built by Pratt-Whitney Rocketdyne
Expander cycle
1st RL10 flight in 1963 (RL10A-3 on Centaur)
RL10A-4-2 and RL10B-2 first flown in 2002
Atlas V and Delta IV 2nd stage engines
 More than 40% component commonality between Delta
and Atlas RL10 variants
RL10A-4-2
(Atlas V)
RL10B-2
(Delta IV)
Thrust, vac (lbf)
22,300
24,750
Chamber
Pressure (psia)
610
640
Isp, vac (sec)
450.5
464
MR
5.5
6.0
Expansion Ratio
84
285
RL10A-4-2
(Atlas V)
RL10B-2
(Delta IV)
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Upper Stage Engine History & Future Paths
Qual.
Year
1961
1963
1966
Model
A-1
A-3
A-3-1 A-3-3
1967
1985
1991
1994
1998
A-3-3A
A-4
A-4-1
B-2
• 15k lbf
• Pc=300 psia
• Isp = 422 s
RL10A-3-3A
RL10A-3
• 16.5k lbf
• Pc=475 psia
• Isp = 444.4 s
• 15k lbf
• Pc=300 psia
• Isp = 427 s
2000
A-4-1A A-4-2
(Atlas V)
(Delta IV)
RL10A-1
1999
RL10B-2
• 24.7k lbf
• Pc=640 psia
• Isp = 464 s
RL10A-4-2
• 22.3k lbf
• Pc=610 psia
• Isp = 451 s
Possible Upper Stage Engine Paths
• Converting existing RL10B-2 inventory
• No further growth opportunity without major redesign
• Fly RL10C on Atlas V
RL10C
RL10A
&
RL10B-2
Next
Generation
Engine (NGE)
• True common, new upper stage engine
• Greater designed-in reliability/performance margins
• Fly on both Atlas V and Delta IV
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Upper Stage Next Generation Engine (NGE)

Objectives





Modern manufacturing techniques
Greater designed-in reliability and performance margins
More sustainable
Lower life cycle cost
Achieve a truly common LOX/Hydrogen upper stage engine
 Incorporates National Security Space & NASA requirements
 Interagency partnership opportunity
 Captures emerging commercial needs
 Creates open competition
 Bolster U.S. liquid propulsion industrial base capability

Leverage advanced design tools matured by AFRL/NASA technology
investment
 e.g. AFRL Upper Stage Engine Technology (USET)

SMC/Aerospace and NASA currently assessing benefits of using the
NGE for
 Evolved Expendable Launch Vehicle (EELV) missions
 NASA’s Cryogenic Propulsion Stage for space exploration
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Potential Partnership Areas

Opportunities for joint propulsion development programs
 Overcome emerging National Security Space challenges and declining budgets
 Lay groundwork for interagency cooperation and commercial partnerships
 Take advantage of NASA’s commitment to advanced tech development and
emerging commercial needs

National Propulsion Strategy for upper stage engine (e.g. NGE) and highthrust kerosene booster engine
 Common engine - not common vehicle architectures
 Improved funding stability
 Accelerated development schedule
 Shared testing and ground certification costs
 Optimal use of national test facilities
 Revitalize declining industrial base capability
 New engine has many cross-cutting mission benefits & capabilities
 Military, civil, and commercial
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Backup Charts
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RD-180 Engine




Atlas V Common Core Booster (first stage) engine
LOX/kerosene engine built by NPO Energomash,
Russia
Oxygen-Rich Staged Combustion (ORSC) cycle
First flown in 2002
Full Power Level
(100% PL)
Min. Power Level
(47% PL)
Thrust, vac (lbf)
933,400
438,700
Thrust, sea level
(lbf)
860,200
365,500
Chamber Pressure
(psia)
3722
1755
Isp, vac (sec)
339.3
335.5
Isp, sea level (sec)
312.7
279.5
MR
2.72 (+/- 7%)
Expansion Ratio
36.87
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RS-68 Engine


Delta IV Common Booster Core (CBC) engine
LOX/LH2 engine built by Pratt & Whitney
Rocketdyne
 Largest LOX/LH2 engine
 Used existing technologies to minimize cost and risk



Gas Generator (GG) cycle
First flown in 2002
RS-68A upgrade certification underway
Full Power Level
(102% PL)
Min. Power Level
(57% PL)
Thrust, vac (lbf)
751,000
432,000
Thrust, sea level (lbf)
656,000
337,000
Chamber Pressure
(psia)
1420
815
Isp, vac (sec)
409
Isp, sea level (sec)
357
MR
6.0
Expansion Ratio
21.6
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Strap-On Solid Motors
Delta IV GEM-60
Atlas V Solid Rocket Booster (SRB)
Delta II
792X
Atlas V
Delta IV
Medium
Delta III
Delta IV Medium+
(5,2)
(4,2)
Delta IV
Heavy
(5,4)
4-m fairing
(Delta III)
5-m fairing
Modified
Delta III
second stage
Stretched
Delta III
second stage
tank
RL10B-2
RL10B-2
Common
booster core
Isogrid
first
stage
LO2 tank
(400 Series)
(0-3 SRBs)
2 GEM
60s
Rocketdyne
RS-27
main
engine
(500 Series)
(0-5 SRBs)
GTO
SRB
1,799 kg
(3,965 lb)
3,810 kg
(8,400 lb)
4,200 kg
(9,255 lb)
5,855 kg
(12,915 lb)
RS-68
main
engine
4,720 kg
(10,405 lb)
4 GEM
60s
6,590 kg
(14,525 lb)
13,425 kg
(29,595 lb)
GEM-60
SRB Characteristics
Diameter (in)
Length (ft)
Gross Weight (lb)
Burn Time (sec)
Total Impulse, Vacuum (lbf-sec)
Isp, Vacuum (sec)
Average Thrust, Vacuum (lbf)
Max Thrust, Vacuum (lbf)
MEOP (psi)
GEM-60 Characteristics
62
67
102,396
88
26,190,000
279.3
270,420
380,000
1600
Diameter (in)
Length (ft)
Gross Weight (lb)
Burn Time (sec)
Total Impulse, Vacuum (lbf-sec)
Isp, Vacuum (sec)
Average Thrust, Vacuum (lbf)
Max Thrust, Vacuum (lbf)
MEOP (psi)
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60
53
74,700
90.8
17,950,000
274
197,540
300,000
1294
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