Tag: Aerojet Rocketdyne

Aerojet Rocketdyne satellite power units are chronically failing

9:53 am

According to space insurers, problems on power units built by Aerojet Rocketdyne on four different satellites are going to cost the industry about $50 million in claims this year.

According to multiple insurance sources, Yahsat’s Al Yah 3, Avanti Communications’ Hylas 4, and Northrop Grumman’s two Mission Extension Vehicles (MEV-1 and MEV-2) are operating with reduced power to their thrusters following a problem with onboard Power Processing Units (PPUs).

The PPUs from Aerojet Rocketdyne provide the electrical power their thrusters need for station-keeping in geostationary orbit (GEO). One of the sources said Al Yah 3, Hylas 4, and MEV-2 have each lost one of two onboard PPUs since the issue emerged in 2022. The youngest of these spacecraft, MEV-2, launched in 2020.

While the article at the link focuses on the impact to space insurers for these additional claims, what I see are serious quality control problems at Aerojet Rocketdyne, now part of the company L3Harris after a summer acquisition. The new management of L3Harris better aggressively address this, or else it will find its $4.7 billion acquisition a big waste of money.

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FTC will not block the purchase of Aerojet Rocketdyne by L3Harris

10:03 am

How nice of them! The Federal Trade Commission (FTC) said yesterday that it will not block the planned purchase of Aerojet Rocketdyne by L3Harris, which the company expects to now complete in mere days.

The deal, if finalized, would place L3Harris on a solid footing to achieve Kubasik’s long-stated goal of positioning the company as the sixth major defense prime.

The forthcoming acquisition has also garnered support from an unlikely source: RTX, the parent company of missiles giant Raytheon. Executives from the company, which rely on Aerojet to deliver crucial parts, have been open in recent weeks that while they don’t love strengthening a competitor, they feel Aerojet is in desperate need of new leadership. “We’ve obviously always been concerned about Aerojet. But I would say some of these things have been magnified by all these external inputs,” Wes Kremer, Raytheon president, told Breaking Defense during last month’s Paris Air Show.

Aerojet has had problems for years, especially because the rocket engines it makes are very expensive. It has failed to garner any market share in the new emerging rocket industry, remaining dependent entirely on very generous government contracts and the older big space contractors. But even here, it lost out to Blue Origin when ULA was looking for engines for its new Vulcan rocket.

It is likely that after this merger, the name Aerojet Rocketdyne will vanish, a sad end to a company whose roots go back to the very beginning of the space age.

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Aerojet Rocketdyne wins contract from Lockheed Martin to build more Orion engines

8:22 am

Aerojet Rocketdyne announced yesterday that it has been awarded a new $67 million contract from Lockheed Martin to build the Orion propulsion engines for Artemis missions six though eight.

This contract option includes delivery of three additional sets of Orion’s service module auxiliary engines and three additional jettison motors. The eight auxiliary engines each produce 105 pounds of thrust to help maintain Orion’s in-space trajectory and position, and supplement the Orion Main Engine. The jettison motor, located on Orion’s Launch Abort System (LAS), generates 40,000 pounds of thrust to separate the LAS from the crew module during both nominal operations and abort scenarios, allowing the spacecraft to continue on its journey. The jettison motor is the only motor on the LAS that fires during every mission.

These Artemis missions are not expected to occur until very late in this decade, by which time Starship will likely be making regular commercial trips to the Moon. At that time Orion will look increasingly ridiculous next to Starship, and will demonstrate starkly the difference in what government can do versus a free private sector.

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L3Harris to buy Aerojet Rocketdyne for $4.7 billion.

10:02 am

The space and defense contractor L3Harris Technologies has announced a deal to buy Aerojet Rocketdyne for $4.7 billion.

L3Harris is buying Aerojet at $58 per share in an all-cash transaction. Aerojet shares traded at $54.89 on Dec. 16. The deal is expected to close in 2023, pending regulatory approvals.

Aerojet Rocketdyne, based in Sacramento, California, manufactures rocket engines and propulsion systems for space vehicles, ballistic missiles and military tactical weapons. The company generates approximately $2.3 billion in annual revenue. L3Harris, headquartered in Melbourne, Florida, is a global defense and aerospace firm with $17 billion in annual revenue.

This deal could in the end save Aerojet, which in recent years has had problems both making and selling its rocket engines, while facing increasing competition from many new rocket engine startups. As an old space company, its engines have tended to be too expensive, and often produced behind schedule. L3Harris now has the opportunity to clean house and streamline operations there, thus making the engines it produces more competitive in the emerging new space market.

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Aerojet Rocketdyne reprimands its executive chairman for trying to oust CEO

10:16 am

During the failed effort of Lockheed Martin to buy Aerojet Rocketdyne late last year, it appears Aerojet’s executive chairman, Warren Lichtenstein, made improper public and private attempts to enlist others to replace the company’s CEO, Eileen Drake, even though the board had not authorized a search for a new CEO and had in fact issued a memo telling Lichtenstein not to look for one.

Yesterday a formal investigation [pdf] came to that conclusion, and reprimanded Lichtenstein for those actions.

Mr. Lichtenstein acted improperly in taking those actions, including by failing to follow the directives given to him in the Guidance Memo. This memorandum is a formal reprimand for that conduct, and a
mandate to Mr. Lichtenstein that he comply with the Company’s Code of Conduct and make no statements or communications to persons external to the Company concerning the Company’s CEO, any search for a new CEO, management tenure or succession generally, or the strategic direction of the Company, unless (i) specifically pre-approved by the Board, (ii) the statements or communications are made to stockholders as part of his efforts concerning the election of directors at the next annual meeting, or (iii) the statements or communications are made as part of his efforts seeking suitable persons to serve as CEO of the Company in the event his nominees are elected.

While most of this is typical corporate office politics, it does reflect badly on the management at Aerojet Rocketdyne. It appears the board is not working together well. For example, Lichtenstein claimed he had these discussions because he was concerned the merger — which he supported — would fail, and wanted to take actions to address those concerns. Apparently the board did not. Another example is the fight with Boeing over the valve problems in Starliner.

Since the merger failed, this rocket engine company is now on its own again. Though for awhile it seemed to be struggling, the recent deal with ULA for 116 engines appears to have put it on its feet again.

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Boeing and Aerojet Rocketdyne fight over cause of Starliner valve problem

6:01 pm

In a Reuters story today, it was revealed that Boeing and Aerojet Rocketdyne are in a fight over the cause of Starliner valve problem, where thirteen valves failed to work and caused the scrub of a launch attempt last summer, delaying almost a year to next week.

A team of Boeing and NASA engineers is in general agreement that the cause of the stuck valves involves a chemical reaction between propellant, aluminum materials and the intrusion of moisture from Starliner’s humid Florida launch site.

Aerojet engineers and lawyers see it differently, blaming a cleaning chemical that Boeing has used in ground tests, two of the sources said.

It appears that Aerojet is attempting to put the blame on Boeing because it might be liable for the cost of redesigning the valves, as well as other costs associated with the delays since last year.

The article also reveals that the valves being used in the Starliner capsule to be launched next week have only a temporary fix for the problem, and that Boeing intends to redesign them to prevent the problem in the future.

All in all, this whole fiasco does not speak well for either Boeing or Aerojet. It remains completely inexplicable for any spacecraft to be built with this kind of valve problem, now, after six decades of launches from wet and humid Florida. The problem reeks of bad design or poor quality control procedures by both companies.

The article further confirms these quality control problems by this tidbit in its last paragraph:

In 2017, Starliner had an accident during a ground test that forced the president of a different subcontractor to have his leg medically amputated. The subcontractor sued, and Boeing subsequently settled the case.

That this accident has been kept out of the news is somewhat shocking. For it to happen at all reveals a lot about the sloppy way Boeing operates these days.

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ULA orders 116 rocket engines from Aerojet Rocketdyne for its Vulcan upper stage

10:33 am

Capitalism in space: In order to meet its contract with Amazon to launch a lot of Kuiper satellites, ULA has now ordered 116 rocket engines from Aerojet Rocketdyne for the Centaur upper stage of its new and as-yet unlaunched Vulcan-Centaur rocket.

Aerojet said this was the company’s largest ever contract for the RL10 engine. The large purchase of rocket engines comes on the heels of Amazon’s announcement April 5 that it selected Arianespace, Blue Origin and ULA to launch up to 3,236 satellites for its Project Kuiper broadband constellation.

CEO Tory Bruno said ULA plans to fly Vulcan’s first mission late in 2022. Winning the Amazon deal would more than double the annual rate of Vulcan launches to as many as 25 per year, and ULA will ramp up production to meet the demand, Bruno said last week at the Space Symposium.

ULA’s engine choice for Vulcan’s upper stage dates back to 2018 when it selected a variant of the RL10, the same engine used to power the upper stages of ULA’s legacy rockets Atlas 5 and Delta 4 Heavy. Over the past 60 years, more than 450 RL10 engines have flown on various ULA heritage vehicles.

Meanwhile, ULA hopes to get its first BE-4 engines from Blue Origin, needed for the Vulcan first stage, this summer. Vulcan-Centaur cannot make its first launch until it gets some flightworthy BE-4 engines, and these are now three years behind schedule.

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Lockheed Martin cancels merger with Aerojet Rocketdyne

8:52 am

Capitalism in space: Faced with a lawsuit from the Federal Trade Commission (FTC) opposing the merger, Lockheed Martin yesterday announced that it is terminating its effort to buy Aerojet Rocketdyne.

Aerojet released a press release at the same time, insisting that the company remains viable and healthy, but there are doubts. While its rocket engines (its main business) remain technically reliable and well-built, they are relatively expensive. Moreover, the shift by rocket companies to build their own engines in the last decade has reduced its customer base significantly.

This loss of market is now compounded by a battle between two factions on the company’s board of directors.

While monopolies do not encourage competition, the merger with Lockheed Martin would have been mostly good for the rocket industry. It would have quickly given Lockheed Martin the skills to make rockets, and kept Aerojet Rocketdyne alive, albeit as part of another company. Now the latter faces extinction, and the former will need more time to develop the capabilities required in its recently-won NASA contract to launch a rocket from Mars to return samples.

And once again, the FTC lawsuit indicates that the Biden administration has decided to take a heavy-regulatory hand when it comes to business. The result however of this approach in this case has not produced more competition, but the likely bankruptcy of at least one company.

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FTC moves to block Lockheed Martin’s acquisition of Aerojet Rocketdyne

9:18 am

The Federal Trade Commission has sued to block Lockheed Martin’s purchase for $4.4 billion the rocket engine company Aerojet Rocketdyne.

The FTC apparently believes that the acquisition would give Lockheed Martin an unfair competitive advantage. It could refuse to sell Aerojet’s engines to the competitors who depend on them. It also would be able to obtain some of its competitors’ proprietary information through Aerojet.

This quote from the article however explains this action more accurately:

Over the past year, Lockheed Martin has argued that the merger should follow the same template as Northrop Grumman’s acquisition in 2018 of solid rocket motors manufacturer Orbital ATK. The Northrop-Orbital deal was approved by regulators on condition that the company agreed to supply motors to its competitors.

“The FTC during the Biden administration has taken a different view on market concentration and vertical integration than the last one, which approved the Northrop Grumman-Orbital ATK deal,” noted industry analyst Byron Callan, of Capital Alpha Partners. [emphasis mine]

This appears to be more evidence that Democratic Party control of the White House is resulting in more regulation and greater interference in the private sector. In this particular case that interference might very well cause Aerojet Rocketdyne to shut down entirely, since its customer base has been disappearing. It isn’t garnering any new customers because its rocket engines cost too much. Folded into Lockheed Martin the company might be reshaped and become productive and competitive again. Unfortunately, the Biden administration thinks it knows better, and might prevent that from happening.

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NASA awards Aerojet Rocketdyne contract to build 20 Orion main engines

10:21 am

NASA announced yesterday that it has awarded Aerojet Rocketdyne the contract to build twenty Orion main engines for capsules on missions running through 2032, with the first to be used on the seventh Artemis launch..

This engine is the one that Orion will use to enter and leave lunar orbit.

Based on the pace that NASA expects to launch SLS, once per year, I expect the last engine in this contract will fly in 2048, not 2032, since it will take about 27 years to put that many Orions into space after SLS’s first launch, expected sometime in the next five months.

In other words, this is a contract to keep the jobs at Aerojet Rocketdyne in existence for the next three decades, even if that company’s engineers build little and accomplish less. Nice welfare work I must say.

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Lockheed Martin buys Aerojet Rocketdyne for $4.4 billion

10:20 am

Capitalism in space: Lockheed Martin officials announced yesterday that it will buy the rocket engine company Aerojet Rocketdyne for $4.4 billion.

James Taiclet, Lockheed Martin’s president and CEO, said the acquisition gives the company a larger footprint in space and hypersonic technology. He said Aerojet Rocketdyne’s propulsion systems already are key components of Lockheed Martin’s supply chain across several business areas. “The proposed acquisition adds substantial expertise in propulsion to Lockheed Martin’s portfolio,” the company said in a news release.

Aerejet Rocketdyne has been in trouble because it has had problems finding customers for its engines. This acquisition will give Lockheed Martin more technical capabilities should it decide to enter the launch industry with its own rocket.

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NASA buys 18 new space shuttle engines for SLS for $1.79 billion

8:09 am

NASA has awarded Aerojet Rocketdyne a $1.79 billion contract to build 18 new space shuttle R-25 engines for its still unlaunched SLS rocket.

In plain math, that equals $100 million per engine. Since SLS uses four of these engines per launch, and since that rocket is entirely expendable and will thus throw these engines away after each launch, that guarantees each SLS launch must cost no less than $400 million, about four times the price of a Falcon Heavy launch.

But wait, there’s more! Eric Berger at Ars Technica notes

NASA has previously given more than $1 billion to Aerojet to “restart” production of the space shuttle era engines and a contract for six new ones. So, according to the space agency, NASA has spent $3.5 billion for a total of 24 rocket engines. That comes to $146 million per engine. (Or 780,000 bars of Gold-Pressed Latinum, as this is a deal only the Ferengi could love.)

That means each SLS launch must cost a minimum of just under $600 million, and that’s just the price for the four engines. It doesn’t include the rocket itself, the ground systems, its upper stages, or any other component.

But wait, there’s more! Berger also reminds us that SpaceX estimates the cost to build each its Starship Raptor engines to be about $1 million, and each will be used multiple times. He also points out that the Raptor is actually more powerful than the R-25 engine.

That’s okay though. This is the federal government, run by Washington, whose goal for the few decades has been to let no project succeed, and to waste as much money as possible in the process. And if they can squelch the dreams and aspirations of everyone else as they do it, so much the better!

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Firefly to use Aerojet Rocketdyne’s AR-1 engine

10:55 am

Capitalism in space: Firefly has agreed to purchase Aerojet Rocketdyne’s AR-1 engine to use in it larger Beta rocket, presently under development.

Though deal also includes help from Aerojet for the development of Firefly’s smaller Alpha rocket,

…the companies made clear that the centerpiece of the agreement was the potential use of the AR1 on Firefly’s Beta rocket, giving Aerojet a customer for the engine while allowing Firefly to increase the performance of the medium-class rocket.

Beta is intended to fill the niche once served by ULA’s Delta 2. “It has left an opportunity for a modern launcher to come in at perhaps a better price point than Delta 2, and can address some of the new missions coming out,” such as small geostationary orbit satellites, he said.

The target payload capacity of Beta is eight metric tons to low Earth orbit, a size Markusic explained was driven by the market and which, in turn, led to a design change for the rocket. Beta’s original design resembled the Alpha but with two additional first stages as side boosters, a triple-core design like the Delta 4 Heavy or Falcon Heavy. Beta is now a single-core vehicle with an AR1 engine in its first stage.

Aerojet Rocketdyne had gotten a lot of Congressional money to develop the AR-1 with the intent it would be used in ULA’s Vulcan rocket. ULA has instead chosen Blue Origin’s BE-4 engine, leaving Aerojet Rocketdyne high and dry without any customers. This deal might save that company, while making Firefly more competitive and robust. Moreover, because of all that money from Congress, Aerojet has probably been able to offer the engine at cut-rate prices.

A smart deal all around.

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Why ULA picked Blue Origin’s engine over Aerojet Rocketdyne

11:22 am

In an interview of ULA’s CEO Tory Bruno by Eric Berger of Ars Technica, he subtly revealed why his company in the end favored Blue Origin’s BE-4 rocket engine over Aerojet Rocketdyne’s AR-1 in the design of the Vulcan rocket.

Unlike many of the new entrants that you talk about coming in today, we’re not a startup company living off investor capital; we’re a mature business. We have to close a business case on Vulcan itself. So where our strategic partners [Editor’s note: This is a reference to Blue Origin] brought investment as well as schedule, that was a pretty important factor. It became pretty obvious what the right choice was, and we arrived at it with our stakeholders.

In other words, Blue Origin’s willingness to invest its own capital in engine development was a major factor. Aerojet Rocketdyne was using the old model of big space, whereby all development money came from the government. It had been unwilling to commit any of its own funds to engine development. This reluctance implied it wasn’t really committed to the project. If Air Force funding disappeared, they’d back out, leaving ULA in the lurch.

This tidbit from Bruno also suggests that he and the management at ULA are sincerely working to reshape ULA from an old big space company, totally reliant on the subsidies given by the government, into a modern competitive company focused instead on building an affordable product that customers will want to buy.

This story also tells us a lot about Aerojet Rocketdyne’s future, or lack thereof. The rocket industry is changing, and if that company doesn’t change also, it will soon die.

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Has Aerojet Rocketdyne lost engine race with Blue Origin?

2:59 pm

Aerojet Rocketdyne financial documents suggest that it has given up the bidding competition with Blue Origin to supply a rocket engine for ULA’s Vulcan rocket.

The latest financial release from aerospace manufacturer Aerojet Rocketdyne reveals that the company spent none of its own money on development of the AR1 rocket engine this spring. Moreover, the quarterly 10-Q filing that covers financial data through June 30, 2018 indicates that Aerojet may permanently stop funding the engine with its own money altogether—a sign the company has no immediate customers.

Although Aerojet will continue to receive some funding from the US military through next year to develop its large, new rocket engine, this money won’t be enough to bring it to completion. Instead of having a flight-ready engine for use by the end of 2019, the filing indicates that Aerojet now intends to have just a single prototype completed within the time frame.

Essentially this means ULA will have no choice but to pick Blue Origin’s engine, unless the Air Force pulls its weight and demands it take Aerojet rocketdyne, even if that means a significant delay before Vulcan can launch.

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Engine tests for reusable Phantom Express space plane completed

9:22 am

Boeing and Aerojet Rocketdyne have successfully completed ten engine firings in ten days of an rocket engine originally designed for the space shuttle and now being recycled as part of Boeing’s Phantom Express reusable rocket being built for DARPA.

I honestly am not that excited by this. The Merlin engine has been able to do some variation of this now for a half decade. Firing an engine repeatedly is required to get satellites into geosynchronous orbit. This really isn’t news.

Nonetheless, it will be news if they can get this engine installed in a rocket that they actually fly to orbit ten times in ten days.

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Aerojet Rocketdyne completes first rocket engine for DARPA’s quick launch rocket

9:32 am

Aerojet Rocketdyne has completed assembly of the first rocket engine for DARPA’s quick launch rocket, Phantom Express, being built by Boeing.

[The engine] can fly for 55 missions with servicing only every 10. To speed up turnarounds, the engines will be installed in a hinged nacelle for better access and the entire spacecraft will use an operations procedure similar to those developed for aircraft.

The first AR-22 engines will be used for daily hot-fire tests at Rocketdyne’s Stennis Space Center facility in Mississippi to demonstrate that it can handle multi-mission conditions and that the fast turnarounds are both feasible and practical. In addition, Rocketdyne says that the test information will help spaceplane builder Boeing to improve the Phantom Express ground infrastructure.

Boeing and Aerojet Rocketdyne both have it very sweet. They have gotten DARPA to fund the development of their own low-cost reusable rocket, while other private companies have to go it alone.

Still, it appears that Boeing is leveraging its engineering experience from building the X-37B for the Air Force for this project. Whether the company can expand the rocket’s customer base beyond the Air Force remains unclear.

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ULA picks Aerojet Rocketdyne engine for Vulcan upper stage

9:35 am

Capitalism in space: ULA has chosen an Aerojet Rocketdyne engine to power the upper stage of its next generation rocket Vulcan.

The company has not yet made a decision on the engine for the first stage, where Blue Origin’s BE-4 still appears favored over Aerojet Rocketdyne’s AR-1 engine. This decision on the upper stage could partly be a political move, giving Aerojet the upper stage in order to make it easier to give the lower stage to Blue Origin.

ULA is forced to play politics here because politicians are involved. A number of power members of Congress want Aerojet Rocketdyne to get the business, and ULA risks offending these legislators should it abandon that company entirely.

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Air Force reconsiders rocket engine, aims for small rocket launches

3:48 pm

Two stories over the past few days indicated some shifts in the Air Force’s commercial space contracting policies.

The first story has to do with ULA’s Atlas 5 and future Vulcan rockets. The engine that Aerojet Rocketdyne has been building, AR-1, has received significant subsidizes from the government for its construction, even though its only potential customer, ULA, has said it prefers Blue Origin’s BE-4 engine. ULA has not made a decision yet on which engine to use, but my sense of the politics here is that the main reason ULA is considering the AR-1 is because of heavy political pressure. Nonetheless, it makes sense for them to hold off from a final decision when they have two competitors.

The story suggests however that Aeroject Rocketdyne itself lacks confidence in the engine. It wants to renegotiate its Air Force contract so that it doesn’t have to invest any of its own money on development. This suggests the company no longer expects to get any contracts for it, and thus doesn’t want to spend any of its own money on it. With that kind lack of commitment, the Air Force would be foolish to change the deal.

The second story outlines how the Air Force is now committing real money for buying launch contracts with smallsat rocket companies, something it has hinted it wanted to do for the past year. The idea is for them to depend on numerous small and cheap satellites, capable of quick launch, givingthem a cushion and redundancy should an enemy nation attack their satellites. It will also likely save them money in the long run.

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Blue Origin’s BE-4 rocket engine still leads race with Aerojet Rocketdyne

5:13 pm

Capitalism in space: An independent assessment of the development work being done by Blue Origin and Aeroject Rocketdyne on their competing rocket engines says that Blue Origin is still in the lead by two years, despite a testing incident in May.

The article also outlines how the present Air Force budget includes language that would prevent the Air Force from financing any part of ULA’s Vulcan rocket, other than the money presently being spent to subsidize Aeroject Rocketdyne’s AR-4 engine.

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Aerojet Rocketdyne trims and reorganizes workforce

9:07 am

Capitalism in space: In an effort to reduce costs and increase efficiency Aerojet Rocketdyne is cutting approximately 300 jobs while closing facilities in California and Virginia.

Rancho Cordova’s nearly 70-year run as a hub of the aerospace industry will soon end. On Monday, Aerojet Rocketdyne Inc. announced that it would relocate or eliminate about 1,100 of its 1,400 local jobs over the next 2 1/2 years and shut down manufacturing operations in the area. The company also said it would close its facility in Gainesville, Va.

Rocket engine manufacturing will be consolidated in a new plant in Huntsville, Ala. In all, 800 jobs will be added in Huntsville by the end of 2018.

The company is faced with stiff competition from Blue Origin and others, and until now has resisted changing its methods of operation, which in the past relied on generous government contracts that were uninterested in lowering costs. That world appears to be ending, and so it appears that the Aeroject Rocketdyne is finally changing as well. This is a good thing, as it increases the chances that the company will survive.

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ULA prepares to choose engine for Vulcan

7:21 am

Capitalism in space: ULA’s CEO Tory Bruno announced at a space conference this week that should Blue Origin’s BE-4 engine pass its testing phase his company will be prepared to select it for their Vulcan rocket.

Bruno also said that no decision has yet been made, and that Aerojet Rocketdyne’s AR1 engine remains an option, though it is 18 to 24 months behind in development.

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Congress micromanages rocket development at ULA

9:16 am

Corrupt Congress: Even though ULA favors Blue Origin’s BE-4 engine for its Vulcan rocket, various elected officials in Alabama are pushing the company to use Aeroject Rocketdyne’s AR-4 engine instead.

At the end of February, two US representatives, Mike Rogers of Alabama [Republican] and Mac Thornberry of Texas [Republican], decided to push a little harder. On February 28, they sent a letter to Lisa Disbrow, the acting secretary of the US Air Force, and James MacStravic, who is performing the duties of the undersecretary of defense for acquisition, technology, and logistics. In addition to reiterating a desire that ULA continue to fly a second rocket, the Delta IV Heavy, the letter urges the Pentagon officials to be skeptical about the BE-4 engine.

“The United States Government (USG) must have a hands-on, decision-making role… in any decision made by United Launch Alliance to down-select engines on its proposed Vulcan space launch system, especially where one of the technologies is unproven at the required size and power,” the letter states. “If ULA plans on requesting hundreds of millions of dollars from the USG for development of its launch vehicle and associated infrastructure, then it is not only appropriate but required that the USG have a significant role in the decision-making concerning the vehicle.” The letter then goes on to say the Air Force should not give any additional funding to ULA, other than for current launch vehicles, until the company provides “full access, oversight of, and approval rights over decision-making” in its choice of contractors for the engines on Vulcan.

The article also mentions porkmaster Senator Richard Shelby (R-Alabama), who also favors Aerojet Rocketdyne because they say they will build it in Alabama. Note also that these elected officials are not only trying to pick the winner in the private competition between these two rocket engines, they also want to force ULA to keep using the Delta rocket, even though it is very expensive and not competitive with the newer rockets being developed by other companies. And their only reason for doing so is because they provide jobs for their districts.

This one story illustrates perfectly the corruption that permeates both parties in Congress. While it is more likely that Democrats will play this pork game, there are plenty of corrupt Republicans who play it as well. These petty dictators all think they have the right to interfere in the private efforts of Americans, whether it involves building a new rocket or buying health insurance. And all we get from this is a poorer nation and a bankrupt federal government.

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Aerojet Rocketdyne sets record testing new rocket engine

10:06 pm

The competition heats up: In recent static fire tests of its new AR-1 rocket engine Aerojet Rocketdyne set a record for the highest chamber pressure for any American engine using oxygen and kerosene.

They hope to convince ULA to use this engine in its Atlas 5 rocket to replace the Russian engine they presently use. At the moment, though ULA has made no commitment, it appears however that the company is favoring Blue Origin’s engine instead. That Congress favors Aerojet Rocketdyne is their one ace in the hole, since Congress controls the purse strings.

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More evidence ULA will pick Blue Origin over Aerojet Rocketdyne

10:49 am

In a press interview published in late July, a ULA executive confirmed that the company is going to pick Blue Origin’s BE-4 engine for its new Vulcan rocket.

ULA used a Russian engine for its expendable Atlas V booster but has long relied on U.S. suppliers such as Aerojet Rocketdyne. For Vulcan’s reusable engine, ULA is turning to Jeff Bezos’s Blue Origin. The company’s cutting-edge BE-4 is powered by liquid natural gas instead of kerosene or liquid hydrogen.

By partnering with a startup like Blue Origin, ULA gains other advantages. “There is a world of difference between the culture at Blue Origin and the culture at Aerojet Rocketdyne,” said [Dr. George F. Sowers, ULA’s vice president for advanced programs]. “We knew we could absorb some of their culture by osmosis, just by working with them.” That influence shows up in cross-team collaboration. “We are literally breaking down walls to create a ‘Silicon Valley’ workspace,” Sowers said.

Sowers is very careful to say nothing about the Atlas 5 and the engine that will replace the Russian engine in its first stage. ULA originally signed its deal with Blue Origin with the Atlas 5 in mind, but has not made a final decision between Blue Origin and Aerojet Rocketdyne because Congress appears to favor Aerojet Rocketdyne’s engine, and Congress is a very big gorilla you do not upset. However, their development plans for Vulcan are incremental and closely linked with the Atlas 5. They plan to introduce Vulcan piecemeal in various upgrades of Atlas 5 as they go, so if they are set on using Blue Origin’s engine in the Vulcan rocket, it probably means that they plan on using it to replace the Russian engine in Atlas 5. This interview appears to confirm this.

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Aerojet Rocketdyne gets NASA contract for cubesat engine

9:56 am

The competition heats up: Aerojet Rocketdyne has signed a contract with NASA to develop a small thruster engine for use on cubesats.

The MPS-130 green propulsion system will allow CubeSats and SmallSats to increase their capabilities, such as extending mission life, increasing architecture resiliency, maneuvering to higher and lower orbits, and performing complex proximity operations and formation flying. The use of additive manufacturing also reduces the number of parts and amount of time required to fabricate and assemble the modular propulsion system, lowering the cost of small satellites for private and public operators. Under the contract, Aerojet Rocketdyne will deliver a fully-integrated MPS-130 green modular propulsion system for flight demonstration, as well as conduct development and validation testing.

The press release does not say how much money NASA is providing. Regardless, this is a great opportunity for Aerojet Rocketdyne, because the smallsat industry is I think about to take off, and at the moment these tiny satellites lack any useful technology for maneuvering. Up until now they were mostly designed as temporary short term satellites built mostly to teach students. Soon, however, there will be a lot of privately-built commercial smallsats launched, designed to make money. Being able to sell their builders a thruster that could prolong their life and make them more capable will give Aerojet Rocketdyne a product that will certainly sell like hotcakes.

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Congress micro-manages rocket engineering again

9:56 am

In an effort to funnel money to Aerojet Rocketdyne at the cost of every other rocket company in the nation, the House Armed Services Committee has written a bill that tells the Air Force exactly how it will build its future rockets.

“The Committee shares the concern of many members that reliance on Russian-designed rocket engines is no longer acceptable,” the committee said April 25. “The Chairman’s Proposal, as recommended by Chairman Rogers of the Subcommittee on Strategic Forces, denies the Air Force’s request to pursue the development, at taxpayer expense, of new commercial launch systems. It instead focuses on the development of a new American engine to replace the Russian RD-180 by 2019 to protect assured access to space and to end reliance on Russian engines. The Mark also holds the Air Force accountable for its awards of rocket propulsion contracts that violated the FY15 and FY16 NDAAs.”

…“The funds would not be authorized to be obligated or expended to develop or procure a launch vehicle, an upper stage, a strap-on motor, or related infrastructure,” says a draft of the 2017 defense authorization bill.

As presently written, the bill would leave the Air Force only one option: use engines built by Aerojet Rocketdyne.

If anything demonstrates the corruption or foolishness of our elected officials, it is this proposal. Not only are they telling the Air Force how to design rockets, they are limiting the options so much that they are guaranteeing that it will either cost us more than we can afford, or it won’t be doable at all. As I say, either they are corrupt (working to benefit Aerojet Rocketdyne in exchange for money), or they are foolish, (preventing the Air Force from exploring as many inexpensive future options as possible).

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Aerojet Rocketdyne pitches its AR1 rocket engine to reporters

9:15 am

The competition heats up: At a space conference this week Aerojet Rocketdyne pitched its AR1 rocket engine, still under development, as the ideal replacement for the Russian engine in the Atlas 5.

The U.S. Air Force awarded Aerojet Rocketdyne a contract in February worth up to $534 million over five years to certify and start delivering flight-ready AR1 engines in 2019. Aerojet Rocketdyne says it already has kicked in $70 million, with its total investment expected to exceed $250 million over the life of the contract.

Van Kleeck, vice president of Aerojet Rocketdyne’s advanced space and launch business unit, said the Air Force contract — the largest of several propulsion-related awards the service has made in recent months — is a sign of the Air Force’s confidence in the AR1’s ability to provide an expedient replacement for the RD-180 engine the Defense Department is under pressure from Congress to stop using.

United Launch Alliance, however, has anointed Blue Origin’s methane-fueled BE-4 engine as the front runner to replace the RD-180 by serving as the main engine for the Denver company’s next-generation rocket Vulcan.

“The AR1 engine can fly both on an Atlas and Vulcan and it’s the only engine that can do so,” Van Kleeck said.

Aerojet has been losing business to the newer commercial space companies like Blue Origin, and desperately needs to find a customer for the AR1. In the long run the Air Force contract won’t suffice, as it really is no more than government corporate welfare and cannot sustain them as a company. This press conference was part of that effort.

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NASA picks Aerojet Rocketdyne engine for SLS upper stage

9:49 am

Government in slow motion: Only six years after program start, NASA has finally chosen Aerojet Rocketdyne’s legacy RL10 rocket engine for the upper stage of the SLS rocket.

The RL10 is an expander cycle liquid hydrogen/liquid oxygen rocket engine typically used on upper stage applications. It was first developed by Pratt & Whitney in the late 1950s and first flown in 1963. It has flown on hundreds of launches, logged approximately 15,000 hot fires, and accumulated more than 2.3 million seconds of hot fire operation time with a demonstrated reliability ratio greater than 0.999 throughout its history. The RL10 – which is used in various forms with Atlas’ Centaur Upper Stage (RL10A-4-2) and Delta IV’s Upper Stage (RL10B-2) – has a history back to the Saturn I’s S-IV Stage.

No other engine exists that can be built in time. Even so, the engine will not be ready for the first SLS launch tentatively scheduled in 2018, but will instead be used on the next two flights. The article also indicates that NASA is planning to delay SLS’s second flight two years to 2023, creating a five year gap which they will use to integrate the RL10 into SLS, while also rebuilding the mobile platform used to move SLS to the launchpad. (For some reason, the reconfiguration installed for the first SLS flight won’t work for later flights.)

The delay to 2023 has not been announced officially, but I have seen too much evidence recently, including statements in this GAO report, that tells me the delay is certain. Furthermore, it seems increasingly likely that the second flight will also be unmanned, and it won’t be until the third flight (as yet unfunded by Coingress) that humans will finally fly on SLS.

The cost? I am doing an analysis of this subject right now for a policy paper I am writing for a Washington think tank, and my preliminary estimate exceeds $41 billion for NASA to fly just one manned flight of SLS. That’s a bit more expensive than the $10 billion NASA is paying SpaceX, Orbital ATK, and Boeing to launch more than a dozen cargo freighters and as many as a dozen manned flights to ISS.

For those elected officials out there who have trouble with math, let’s compare again:

  • SLS: $41 billion for one flight, 15 years development to first flight.
  • Commercial space: $10 billion for two dozen flights, 5 years development to first flight.

Which costs less and gives more bang for the buck? Can you figure that out, Congressmen and Senators? If you need help I can provide you a few more fingers so you can count above ten.

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