Tag: engineering

ULA slashes launch prices for Atlas 5

9:12 am

Capitalism in space: In order to compete with SpaceX ULA announced this week that it will cut its launch price for the Atlas 5 rocket by one third.

United Launch Alliance has dropped the price of its workhorse Atlas 5 rocket flights by about one-third in response to mounting competition from rival SpaceX and others, the company’s chief executive said on Tuesday. “We’re seeing that price is even more important than it had been in the past,” Tory Bruno, chief executive of United Launch Alliance, or ULA, said during an interview at the U.S. Space Symposium in Colorado Springs. “We’re dropping the cost of Atlas almost every day. Atlas is now down more than a third in its cost,” Bruno said.

It appears that they have discovered that the prime reason they lost their bid of an Air Force GPS satellite launch to SpaceX was because their price was too high.

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Air Force willing to use re-used Falcon 9 first stages

9:09 am

Capitalism in space: The head of the Air Force’s space division said yesterday that they would be willing to launch satellites using Falcon 9 used first stages.

“I would be comfortable if we were to fly on a reused booster,” General John “Jay” Raymond told reporters at the U.S. Space Symposium in Colorado Springs. “They’ve proven they can do it. … It’s going to get us to lower cost.”

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Hubble snaps close-up of Jupiter

4:08 pm

Jupiter by Hubble

Cool image time! The Hubble Space Telescope has taken a magnificent global view of Jupiter. The image on the right is only a thumbnail. Make sure to go to the link to see the full image, which amazingly compares quite favorably with the images being sent down by Juno in orbit around the gas giant.

This Hubble image once again demonstrates the remarkable advantages of an optical telescope in space. Equipped with the right instruments, it could do much of the research now being done by the planetary missions, and do it from Earth orbit.The research possibilities and the knowledge revealed from the ability to see things clearly in the optical bands is truly endless.

Even more important, we are wired to what we see. Give us a good visual image and many questions can immediately be answered.

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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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Russia proposes extending ISS beyond 2024

7:13 am

The head of Roscosmos said at a space conference this week that his nation is open to extending its ISS partnership with the U.S. beyond 2024 to 2028.

Russia has several good and bad reasons for wanted to do this.

  • Their shortage of cash will make it difficult for them to fly their own station.
  • They need a space station in order to maintain the jobs that exist at their mission control as well as throughout their space industry.
  • There are many good political reasons for them to maintain this space partnership with the U.S. It prevents the U.S. from completely breaking off relations, should Russia do something the U.S. doesn’t like (such as invading a nearby country).
  • They recognize that the ability to do long term research in an orbiting space station is essential for anyone who plans future interplanetary missions.

I will let my readers decide which of these reasons are the good reasons, and which are bad.

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Orbital ATK developing new rocket

6:38 am

Capitalism in space: Orbital ATK is developing a new rocket, based on the solid rocket technology it provided for the space shuttle, to compete with SpaceX and ULA.

Two versions of the rocket are planned. The medium-lift variant will have a two-segment, solid-fuel first-stage motor and a single-segment, solid second. The heavy lifter will have a four-segment first stage and a single-segment second. Both versions can be outfitted with strap-on boosters for extra lift capacity, Orbital representatives said.

To complete the rocket’s development the company says it needs to win a follow-up contract that the Air Force has been issuing to help ween the U.S. from the use of Russian rocket engines.

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ULA reduces workforce at Vandenberg

9:23 pm

Capitalism in space: In an effort to save costs ULA is reducing its workforce at Vandenberg by 48.

The company has been aggressively trying to streamline its operations to better compete against SpaceX. This reduction was expected, and based upon what I saw when I toured Vandenberg a few years ago, entirely justified. While SpaceX’s operations then looked lean and simple, ULA’s set up appeared a bit inefficient.

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ULA gets three launch contracts

8:41 pm

Capitalism in space: ULA last week won three launch contracts, two from the Air Force and one from NASA.

Both rockets are part of the existing EELV Block Buy between the Air Force and United Launch Alliance. The mission assignments were announced Friday by the Pentagon. The missions exceed the lift performance of the SpaceX Falcon 9 rockets that has been certified by the Air Force for national security payloads, making ULA the only provider available to execute these heavy launches.

In other government-launch news, NASA said last month that the second satellite in the next-generation era of U.S. civilian weather observatories will be launched atop an Atlas 5-401 rocket. The Atlas 5 beat out the Falcon 9 in a competition to win the rights to launch the Joint Polar Satellite System spacecraft No. 2 in 2021 from Vandenberg Air Force Base.

For SpaceX to truly compete with ULA they need to get the Falcon Heavy flying.

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Bad solder joints cause of Russian Proton engine defects

8:49 am

The problem that has forced the Russians to recall all Proton second and third stage engines has been identified as the use of the wrong materials in solder joints.

According to specifications, the structural walls and the nozzle chamber of the gas generator had to be fused together with the help of the solder designated G70NKh, which employs nickel, chromium and manganese alloy (Ni-Cr-Mn). However the investigation revealed that due to mismanagement of the raw material usage at the Voronezh Mechanical Plant, the required alloy had been replaced with the PZhK-1000 solder comprised of palladium, nickel, chromium and silicon (Pd-Ni-Cr-Si). Because the replaced solder did not meet specifications, it could lead to structural disintegration of the nozzle head during the firing of the gas generator.

The discovery of the problem with the solder triggered inspection of other engines and revealed that all RD-0210 and RD-0212 engines from the second and third stages that had been manufactured during 2015 and 2016 had been equipped with defective gas generators. In order to re-certify these engines for flight, each of them would have to be disassembled, the gas generator would have to be removed and replaced, followed by the re-assembly and re-testing of each engine!

The article also notes that the next Angara rocket is also “unfit for flight” due to unspecified defects. It also notes widespread corruption and mismanagement throughout the Russian aerospace industry.

Sadly, the decision by the Putin administration to consolidate their industry into one huge corporation run by the government, and thus eliminate any competition, is only going to make solving this problem more difficult. What Russia needs is competition, with many different companies free to challenge each other for business. It also needs to allow companies to fail and go out of business.

Instead, everything is controlled from above, and thus no competition can happen. Rather than finding a new company to build these engines, the government is going to provide the company “economic aid” in order to modernize it. This is like putting a band-aid on a broken bone.

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SpaceX recovers fairing of upper stage of Falcon 9

8:34 am

The competition heats up: Even as SpaceX made history yesterday in its successful use and recovery of a used first stage, it also recovered for the first time the fairing that protected the satellite.

For the first time, SpaceX also recovered the payload fairing, the conical shaped structure on top of the rocket that surrounds and protects the spacecraft during launch. The fairing separates from the spacecraft in two sections during the launch sequence — in this case, 3 minutes and 49 seconds after launch — and usually falls into the ocean and breaks into pieces. SpaceX outfitted these two fairing sections with parachutes so they could be recovered, which apparently will become standard practice.

Musk also indicated that they are now going to begin an effort to recover the second stage. “What’s the worst that could happen? It blows up? It would anyway.”

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Rush – Countdown

6:01 pm

An evening pause: The video focuses on a shuttle launch, but I think the words apply to all launches, and especially to those that break new ground.

Excitement so thick you could cut it with a knife
Technology…high, on the leading edge of life

Hat tip Commodude.

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SLS faces more delays

5:34 pm

Delays by ESA in the construction of the service module for Orion, plus the tornado damage at the Michoud facility in Louisiana, could force NASA to delay the first unmanned test launch of the SLS rocket, presently planned for late in 2018.

NASA is also considering delaying the flight further should the agency decide to make this first unmanned test flight a manned one. They also say they will need more money if they have to put people on the first flight. I guess $43 billion and almost 15 years wasn’t enough.

By the way, it took less than four years to win World War II. From Kennedy’s speech to the Apollo 11 landing was only eight years. One wonders when we, as a nation, will finally wake up and realize that SLS is not a rocket to the Moon, but an never-ending jobs program unable to accomplish anything in space.

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Practically every Russian Proton rocket engine defective

4:36 pm

The investigation of the Russian supply of rocket engines for its Proton rocket has discovered that practically every engine, numbering over seventy, had defects that needed repair.

71 engines, mostly used to power the second and third stages of the Proton rocket, require complete overhauls to remove defects. Arbuzov did not specify what was wrong with the engines. In January, Interfax reported on an investigation into high-quality metals swapped by a plant manager for cheaper alternatives. “Most of the work will be done in 2017, but we understand that some portion will inevitably slip into 2018,” Arbuzov said. “Our main goal is to avoid disrupting the government space program’s launch schedule, or the schedules of the Defense Ministry and commercial customers.”

There is also the possibility that these defects will be found in Soyuz rocket engines as well. Stay tuned.

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A tour of Vector Space Systems

4:31 pm

Jim Cantrell and cars

[UPDATE: I have been informed by Vector’s PR department that they have recently changed the company’s name, dropping “Space Systems” from the title. I can’t really change the title here, but I thought I note this fact for my readers.]

Today I got a quick tour of Vector Space System’s very blue collar but active rocket factory in Tucson, Arizona. My tour guide was Jim Cantrell, the CEO of the company.

Cantrell, shown on the right in front of one of his side businesses fixing and refurbishing race cars and rare luxury sports cars (also located in this factory), started out with a love of race cars, which he still builds and races. As he said to me, “Long endurance car racing is still my thing.”

However, he has also spent his life in the space business. He has worked for government agencies and numerous private businesses, including SpaceX at its very beginning. Vector Space Systems is an effort put together by him and several other people to capture the smallsat market, a market he truly believes is going to explode with activity in the coming years. If things go as he wishes, they hope to launch at least one hundred times a year, from multiple launch sites. Their goal is simplicity and quick turnaround at an inexpensive cost.

The company is presently in the testing phase leading up to their first orbital launches, which they hope to start in 2018. Right now they are building a series of full scale versions of their Vector-R rocket with a dummy second stage. The idea is to do a string of suborbital test flights, the first of which will fly in about a week from Mohave in California, with the second flying from the Georgia spaceport in Camden County. The image below is the first stage of that first test rocket.

Vector test first stage

Vector first stage engine

second test rocket

For this flight their main goal is to test the engine, which Cantrell is showing me in the picture to the right. I was astonished at how small and simple the engine was. In fact, the rocket itself was amazingly small. It looked like it could almost fit inside a typical moving truck.

Below and to the right is the first stage for their second test flight, presently being assembled. They hope it will be ready for flight in only a few weeks after the first flight. They plan five suborbital test flights, with the last capable of getting about 90% to orbit. Along the way they will test their avionics, the rocket’s balancing systems, and its computer and tanks. Once these tests are complete they will then move to testing the orbital version in 2018.

Obviously, all this depends on every test flight being successful. But then, even if something goes wrong they will learn something and move on. For example, they recently transported an engineering version of the rocket to the visitor center at Kennedy. As Cantrell explained, “We learned things new just making that move.”

bumper sticker

In the end, I think the bumper sticker to the right, attached to the window of Vector Space System’s office, sums everything up. The people at Vector want to make money in space, but they — like everyone in the space business — also love making rockets and engines and going fast. What better combination from life could you ask for?

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Atlas 5/Cygnus launch delayed until mid-April

3:17 pm

ULA has delayed its next Atlas 5 launch to send a Cygnus cargo capsule to ISS until mid-April.

Gatens said NASA was now expecting the Cygnus to launch to the station no earlier than the middle of April. “The Orbital launch, the next launch, has slipped due to an investigation of a hydraulic leak in the booster engine compartment that’s in work,” she said. “There are some components being replaced. The investigation is going on and we’re currently targeting no earlier than, probably, a mid-April launch.”

ULA spokeswoman Jessica Rye said March 28 that a new launch date has not been set yet for the mission. “Additional information will be provided once testing to resolve the booster hydraulic issue is complete,” she said.

The launch was initially planned for mid-March. This delay has forced NASA to delay a spacewalk because it involves installing equipment that the Cygnus capsule is bringing to ISS.

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Vector signs deal with Georgia spaceport

8:46 am

Vector Space Systems has signed a deal with a Georgia spaceport to conduct one suborbital test flight there of its Vector-R rocket.

The agreement covers only one flight, but considering that Vector is also planning to launch from Kennedy, I think they are doing this to test their rocket’s ability to easily launch from multiple launch sites. It is a small mobile rocket, and they are probably designing its launch systems to be very mobile as well.

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A look at Blue Origin’s upcoming plans

8:38 am

Two stories today give us a peek at Blue Origin’s future plans.

The first outlines how the company plans to launch its orbital rocket, New Glenn, from Florida. The second provides a photo tour of the company’s suborbital New Shepard capsule, as designed for tourist flights.

I must mention that I have been disappointed at the lack of test flights for New Shepard in recent months. Their last flight was in October, almost six months ago, when their test of the capsule’s launch abort system was supposedly a success. No tests since, even though they have said they planned the first manned test flights this year. I am beginning to wonder if they have decided to shift resources to the orbital system and thus slow the suborbital program down.

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ESA narrows landing site choice for ExoMars 2020 to two

10:02 pm

The European Space Agency has narrowed its choice of landing sites for its ExoMars 2020 rover mission.

Two ancient sites on Mars that hosted an abundance of water in the planet’s early history have been recommended as the final candidates for the landing site of the 2020 ExoMars rover and surface science platform: Oxia Planum and Mawrth Vallis.

A primary technical constraint is that the landing site be at a suitably low level, so that there is sufficient atmosphere to help slow the landing module’s parachute descent. Then, the 120 x 19 km landing ellipse should not contain features that could endanger the landing, the deployment of the surface platform ramps for the rover to exit, and driving of the rover. This means scrutinising the region for steep slopes, loose material and large rocks.

Oxia Planum was selected in 2015 for further detailed evaluation. Although not yet complete, the investigation so far indicates that the region would meet the various constraints.

They will spend the next year evaluating both sites, though based on the press release it sounds as if Oxia Planum is the favorite.

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Reused first stage static fire dress rehearsal today

9:03 am

Update: The countdown and static fire test has been completed, apparently successfully. The launch however is now set for Thursday.

SpaceX today plans to do the first static fire dress rehearsal countdown of a Falcon 9 rocket using an already used first stage.

The static fire process for SpaceX and its Falcon 9 rocket is one of the last critical components in the pre-launch flow ahead of liftoff. For SES-10, the Falcon 9 and mated second stage will be moved to the launch pad on top of the TEL (Transporter Erector Launcher) and will be taken to vertical at historic launch complex 39A. Once the Falcon 9 is vertical, technicians and engineers will complete all of the connections between the TEL/launch mount and LC-39A and proceed into countdown operations on Monday morning.

For this particular static fire, SpaceX has up to an eight-hour window.

If all goes well, they plan to do the actual launch on Wednesday.

The article by the way also provides a nice detailed history of the first stage.

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X-37B sets new orbital record

8:57 pm

The X-37B presently in orbit this weekend set a record for the longest in-orbit flight for the Air Force’s fleet of two ships.

As of today (March 25), the X-37B has spent 675 days on its latest Earth-circling mission, which is known as Orbital Test Vehicle-4 (OTV-4). The previous record was 674 days, set during OTV-3, which lasted from December 2012 to October 2014. It’s unclear what the new duration record will end up being; most X-37B activities and payloads are classified, and the Air Force has historically been tight-lipped about landing plans.

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Next Proton launch tentatively set for May

9:05 am

The Russians have tentatively scheduled their next Proton launch for May, contingent on the repair work being done on the rocket’s engines.

The engine repairs are required because of corruption in the factory that made them. Previously, the Russians had hoped to get Proton off the ground by April. That is no longer likely.

The link above includes a manifest of Russian launches through next year. Interestingly, it only includes three commercial launches. A quick review of the launches listed at this site only includes another three or so commercial launches much farther in the future. All in all, it appears that the Russians are getting less business for this rocket. I also suspect this will remain the case until they get things fixed and begin launching again, though they will need to cut their prices significantly to match SpaceX’s.

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More problems for Russian ISS module

10:37 pm

A Russian module intended for ISS, delayed for years because of technical problems, appears to have more issues that could delay it further, and might even prevent its launch entirely.

As its original 2007 launch date came and went, more and more delays pushed back the MLM’s launch. Then, in 2013, engineers discovered a leaking fueling valve as well as contamination in the propulsion system. At the time, reports said repairs and cleanup would take nearly 10 months.

Those months stretched into years. During the last four years, engineers have been working diligently replacing a jungle of pipelines, valves, and thrusters—part of Nauka’s sophisticated propulsion system—in an effort to get rid of the sawdust contamination introduced during botched upgrades. Because the spacecraft has stayed earthbound much longer than intended, parts of Nauka have also slipped out of warranty.

Fighting off political and logistical concerns surrounding the project—as well suggestions that they ground the MLM entirely until it can serve as the first module of Russia’s own space station—the tedious cleanup and repair effort entered its final phase this year, and the module finally appeared on track for launch at the end of this year or, at the very latest, the first half of 2018.

Then things went from bad to worse. In the past few weeks, engineers found the same contamination they’ve been fighting for years inside the module’s propellant tanks. The repair team tried to wash off these contaminants, but so far all efforts to cleanse the vessels have failed.

Read the whole article. The situation is not good.

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SSL sues Orbital ATK over proprietary in-space servicing technology

10:33 pm

Space Systems/Loral has filed a lawsuit against Orbital ATK over that company’s improper access to proprietary information concerning its in-space servicing plans.

At least four confidential SSL documents were viewed and distributed by an Orbital ATK employee working at NASA’s Langley Research Center in Hampton, Virginia, where the data is stored as part of an ongoing SSL partnership with the U.S. space agency, according to the complaint filed in U.S. District Court for the Eastern District of Virginia.

Orbital declined to comment.

SSL, a subsidiary of Canada-based MacDonald, Dettwiler and Associates Ltd., said it was informed of the data breach by NASA in December 2016. Orbital acknowledged the unauthorized access of SSL’s data and fired the employee, but did not respond to questions about the scope of the breach or about five other Orbital employees whom NASA said may have read the SSL documents, the lawsuit said.

The two companies are in direct competition for doing in-space robotic servicing of satellites. Last month Orbital ATK sued DARPA for its contract with SSL for this work, claiming the contract violated U.S. policy that forbids DARPA from competing directly against commercial companies. It appears that this new lawsuit is a bit of tit-for-tat.

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Labor strikes force Arianespace to suspend all French Guiana launches

3:48 pm

Arianespace today announced that it is suspending all launches from French Guiana indefinitely while it works out the labor problems that surfaced this week with wildcat strikes.

Arianespace chief executive Stephane Israel tweeted Wednesday that officials will set a new target launch date as soon as possible.

The delay will likely cause Arianespace to push back the following launch from French Guiana. Once the Ariane 5 takes off, a Russian-made Soyuz rocket is next in line at the tropical space base, slated to loft the Boeing-built SES 15 communications satellite into orbit to provide in-flight Internet connectivity for airline passengers, and support government, networking and maritime customers across North America. SES 15 also hosts a payload for the FAA’s Wide-Area Augmentation System to enhance airline navigation and safety across the United States.

Liftoff of SES 15 was scheduled for April 4, but it takes nearly two weeks to reconfigure the French Guiana spaceport and downrange tracking stations between launches.

These problems play into the hands of Arianespace’s competitors, SpaceX, the Russians, and ULA.

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