Tag: Orbital ATK

DOJ settles with company that faked tests which caused two Taurus launch failures

9:07 am

The Justice Department has reached a settlement with the company that had faked test results which caused faulty components to be installed on Orbital ATK’s Taurus rocket, eventually causing two consecutive launch failures.

SPI agreed to plead guilty to one count of mail fraud while SEI entered into a deferred prosecution agreement. SPI will pay $34.1 million in combined restitution to NASA, the Missile Defense Agency (MDA) and commercial customers, and forfeit $1.8 million in “ill-gotten gains.” The company will also pay an additional $6 million to NASA and $5 million to MDA as part of a separate civil settlement.

The companies acknowledged that SPI altered test results for nearly two decades, starting in the mid-1990s, such that aluminum extrusions that had failed mechanical properties testing instead appeared to have passed. Dennis Balius, a testing lab supervisor at SPI who led the effort to falsify test results for a number of years, pled guilty on separate charges in 2017 and was sentenced to three years in prison.

Those aluminum components were sold to a number of companies, including those who had contracts with NASA and MDA. The Justice Department statement noted that the components were used in frangible joints in launch vehicles and missiles. Such joints are used in vehicle separation systems.

“NASA maintains that SPI’s manufacturing processes lacked sufficient controls and produced extrusions unable to pass mechanical properties testing,” the Justice Department stated. “NASA further maintains that it identified SPI’s out-of-specification extrusions as the cause of two failed rocket launches, which resulted in the loss of important scientific missions.” SPI disputed those claims, although NASA has barred the company from contracting.

The worst part of this story is that it likely ended up destroying Orbital ATK, an innocent party to this fraud. Though the company lives on now as a division within Northrop Grumman, it never quite recovered from the two Taurus launch failures in 2009 and 2011. Customers went elsewhere, and the company’s launch business dried up. The only customer Orbital ATK was able to muster afterward was NASA, and the number of launches this provided was not enough, causing company’s eventual absorption by Northrop Grumman.

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Northrop Grumman purchase of Orbital ATK approved

9:24 am

Capitalism in space: Northrop Grumman’s acquisition of Orbital ATK has been approved by the Federal Trade Commission.

With this purchase, the name Orbital ATK will recede into history. This division of Northrop Grumman will now be called Northrop Grumman Innovation Systems. Here at Behind the Black I will simple call it Northrop Grumman.

The FTC ruling carried with it one caveat:

As a condition for the approval of the merger, the company will have to supply solid rocket motors “on a non-discriminatory basis under specified circumstances,” the FTC ruled.

Ensuring competition in the solid rocket motors industry is a key issue for the Defense Department because only two manufacturers remain in the business, Orbital ATK and Aerojet Rocketdyne. The Air Force plans to acquire a new strategic intercontinental ballistic missile, the so-called Ground Based Strategic Deterrent, with Northrop Grumman and Boeing competing for the award. The intent was for both Orbital ATK and Aerojet to supply both prime contractors. The FTC decision requires Northrop Grumman to separate its solid rocket motors business with a firewall so it can continue to support Boeing.

It will be up to the Defense Department to ensure compliance with the firewall mandate.

It is unclear from the press report what this firewall accomplishes. It sounds like there was fear that Northrop Grumman would not have sold its solid rocket boosters to competitor Boeing, but I don’t see that happening. This acquisition was designed to put Northrop Grumman back in the rocket business just as that business is booming. Part of that business is selling solid rockets.

Either way, the company that David Thompson started in the early 1980s to challenge the big space companies, Orbital Sciences, has now completely vanished into one of those big space companies.

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Stratolaunch to make first flight later this year

9:13 am

Capitalism in space: Paul Allen said at a space conference today that Stratolaunch will likely make its maiden flight later this year.

Actual satellite launches will have to wait until around 2020, however, as the giant plane will first have to be certified by the FAA, a process expected to take one and a half to two years.

The profitability of this launch system at the moment remains an unknown. The only rocket presently set to launch on Stratolaunch is Orbital ATK’s Pegasus, which is designed to launch small to mid-size satellites. Stratolaunch will therefore have to compete with the slew of new smallsat rocket companies that should be becoming operational in the next two years. It will be interesting to see if this air-launched system will be able to compete with them.

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Orbital ATK renames its Next Generation Launcher OmegA

8:32 am

At a space conference yesterday Orbital ATK announced that OmegA is the new name for its proposed Next Generation Launcher, based on solid fuel technology and set for launch in 2021.

They also outlined the rocket’s proposed capabilities.

In its intermediate three-stage configuration, OmegA will be powerful: About 2 million pounds of thrust at liftoff with no side-strapped solid rocket boosters. But with the added flexibility of sporting up to six SRBs [solid rocket boosters], that number could more than double and enter heavy-lift territory with around five million pounds of thrust. To provide perspective, SpaceX’s much-vaunted Falcon Heavy rocket launched in February with slightly more than 5 million pounds of thrust.

They are initially focused on winning military contracts.

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A detailed look at Orbital ATK’s Next Generation Launcher (NGL)

8:44 am

Link here. Based on the solid rocket technology developed for the shuttle and then for Ares, they hope to make the first launch in 2021, and actually do two flights that year to get certified by the Air Force so that they can bid on military launch contracts.

Development money for this rocket has come mostly from the Air Force, not from private funds raised by Orbital ATK. It also seems to me that it has taken far longer to get it built than it should if they really wanted to get a rocket up and running to compete for business. Moreover, they expect the Air Force to certify them after only two launches, while it took SpaceX a lawsuit and far more launches to get the same certification.

Thus, all told there is a bit of crony capitalism involved here. NGL might turn out to be a good deal, in the long run, but forgive me if I reserve my opinion.

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Orbital ATK unveils new satellite servicing robots

9:14 am

Capitalism in space: At a satellite conference yesterday Orbital ATK unveiled a new robotic satellite servicing system utilizing two new robots, the Mission Robotic Vehicle (MRV) and Mission Extension Pods (MEP), simpler yet also more sophisticated versions of its Mission Extension Vehicle (MEV) which is already planned for launch later this year.

Under the new approach, a Mission Robotic Vehicle, based on the MEV design, will carry 10 to 12 Mission Extension Pods. The Mission Robotic Vehicle would approach a customer’s satellite and use a robotic arm to attach a pod to that satellite. The pod would then take over stationkeeping, proving up to five years of additional life. The Mission Robotic Vehicle and Mission Extension Pods are intended to provide new solutions to customers that don’t need the full-fledged capabilities of the MEV. The pods have a shorter lifetime than an MEV and do not provide attitude control capabilities.

The new system, designed to be ready for service in 2021, largely incorporates existing technology. The Mission Robotic Vehicle is a version of the MEV and the Mission Extension Pods is based on Orbital ATK’s ESPASat small satellite bus.

One new technology will be the robotic arm. Tom Wilson, president of SpaceLogistics, the Orbital ATK subsidiary offering the satellite life extension program, said the company was considering technology from NASA as well as Europe. “We’ve got a couple of different options,” he said, but hasn’t yet made a decision on the specific technology.

Orbital ATK’s new design will certainly cost its customers a lot less, since its design that will allow them, with one launch, to place a robot in orbit capable of servicing up to twelve different satellites. You want to extend the life of your communications satellite by five years? You call Orbital ATK, and they use their already orbiting Mission Robotic Vehicle to install an extension pod on your satellite. This way they can spread the cost of the launch across a dozen different customers.

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Stratolaunch completes initial taxi tests

6:24 am

This past weekend Stratolaunch successfully completed its second series of taxi tests, reaching a speed of 40 knots (46 miles per hour) as it moved down the runway.

[I]n December Stratolaunch capped off the year with a successful low-speed taxi test. During the taxi, the vehicle reached a top speed of 28 miles per hour (45 kilometers per hour) as it headed down the runway. Following the test, Aircraft Program Manager George Brugg stated, “This was another exciting milestone for our team and the program. Our crew was able to demonstrate ground directional control with nose gear steering, and our brake systems were exercised successfully on the runway. Our first low-speed taxi test is a very important step toward first flight.”

Last weekend, Sratolaunch kicked off 2018 with two days of additional taxi tests. Most notably, the tests included reaching the maximum taxi speed of 40 knots (46 miles per hour). According to Allen, these tests allowed the team to “verify control responses.”

There is a tiny 35 second video of this last test at the link.

The article provides a lot of details about Stratolaunch and its future, including the suggestion that the giant airplane could become the main launch platform for Orbital ATK’s Pegasus rocket. Pegasus presently has only one launch listed on its manifest, using its L1011 Stargazer airplane.

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SSL lawsuit against Orbital ATK to move forward

8:48 am

A judge has ruled that a lawsuit brought by SSL against Orbital ATK, two companies competing for satellite servicing work, can go forward.

The case stems a December 2016 incident where NASA officials notified SSL that there had been unauthorized access to SSL documents related to a NASA “Tipping Point” technology development award on a server at the Langley Research Center. SSL had received that award earlier in the year to work on technologies related to in-space satellite servicing.

That unauthorized access was traced to an Orbital ATK employee, who was subsequently fired by the company. However, SSL said in its suit that as many as six Orbital ATK employees viewed the documents. SSL filed the suit in March 2017 seeking an injunction to prevent Orbital ATK from using any of those documents in its own projects, as well as “other and further relief the Court may deem just and appropriate.”

Both companies have satellite servicing missions planned. What I want is for both to succeed, to provide some competition in the field. Though I suspect this is doubtful, this lawsuit has the possibiliity of killing Orbital ATK’s effort.

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Orbital ATK gets its second contract for its satellite repair robot

11:09 pm

Capitalism in space: Orbital ATK has signed a second contract to build another Mission Extension Vehicle (MEV), designed to robotically extend the life of old but usable satellites.

The vehicle was ordered by Intelsat S.A. to provide life extension services for an Intelsat satellite. Orbital ATK is now producing MEV-1, the industry’s first commercial in-space satellite servicing system, for Intelsat with launch scheduled for late 2018. Under this new agreement, Orbital ATK will manufacture, test and launch MEV-2 and begin mission extension services in mid-2020. The production of the second MEV is part of Orbital ATK’s longer-range plan to establish a fleet of in-orbit servicing vehicles that can address diverse space logistics needs including repair, assembly, refueling and in-space transportation.

“Work on MEV-1 is progressing rapidly toward a late 2018 launch with system-level testing beginning this spring,” said Tom Wilson, President of Orbital ATK’s Space Logistics, LLC subsidiary. “With the launch of MEV-2, Orbital ATK will continue to pioneer in-space satellite servicing for commercial operators. Intelsat’s commitment to a second MEV demonstrates not only the market demand for our servicing vehicles, but also the customer’s confidence in our product.”

Through its Space Logistics subsidiary, Orbital ATK will introduce in-orbit commercial satellite servicing with MEV-1 late this year. The MEV is based on the company’s GEOStarTM spacecraft platform, and controlled by the company’s satellite operations team. The MEV uses a reliable, low-risk docking system that attaches to existing features on a customer’s satellite, and provides life-extending services by taking over the orbit maintenance and attitude control functions of the client’s spacecraft. Each MEV vehicle has a 15 year design life with the ability to perform numerous dockings and repositionings during its life span.

What Orbital ATK here is doing is creating a entirely new cottage industry with the satellite industry, providing satellite companies an inexpensive way to maintain their satellite networks without building and launching a whole new communications satellite. Once Orbital has placed a number of these in orbit, they will be available to move from satellite to satellite. Once their first repair job is finally finished, they will then move on to another at relatively little cost.

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Orbital ATK gets first FCC license approval for space repair mission

9:38 am

Capitalism in space: Orbital ATK has gotten its first FCC license approval for its Mission Extension Vehicle 1 (MEV-1) robotic space repair mission, set to launch late in 2018.

Space Logistics [a subsidiary of Orbital ATK] has a contract with fleet operator Intelsat of Washington and Luxembourg to provide in-orbit servicing with MEV-1 — the first in a proposed fleet of satellite servicers Dulles, Virginia-based Orbital ATK intends to build — with service beginning in early 2019.

In a public notice issued Dec. 8, the FCC authorized Space Logistics to use four different frequency bands for telemetry, tracking, and command (TT&C) of MEV-1 as the servicer completes post-launch maneuvers, reaches the graveyard orbit for decommissioned geostationary satellites some 300 kilometers above the geosynchronous arc, and attaches to Intelsat-901.

Space Logistics’ MEVs works by connecting to a satellite and taking over station-keeping, using fuel onboard the servicer to propel the satellite and extend its life. Most geostationary satellites are forced into retirement after 15 years or more due to a shortage of fuel. “It is in our plan for Intelsat-901 that at the end of the five-year life extension mission that we would return the IS-901 to the graveyard orbit and release them there. After that release the MEV would then proceed onto our next client,” Anderson said, adding that the next client has not yet been identified.

They will still need to obtain additional permits from both the FCC (for future operations) and from NOAA (because the spacecraft’s cameras, needed for docking, might also look at the Earth).

Why NOAA has this permitting power astonishes me, but then, in today’s government-run America, I probably should not be surprised. If we were trying to settle the west today we would likely have a whole range of government agencies requiring wagon train approval, route approval, and scheduling approval.

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Minotaur-C successfully launches 10 commercial smallsats

5:51 pm

Capitalism in space: Orbital ATK’s Minotaur-C rocket today successfully launched 10 commercial smallsats.

It appears that they have upgraded the accused Taurus rocket in renaming it Minotaur-C.

After Orbital ATK suffered a series of launch failures with the Taurus rockets — which led to the loss of NASA’s Orbiting Carbon Observatory as well as its Glory climate-monitoring satellite — the company redesigned the Taurus. The new and improved rocket uses newer and more reliable technologies that Orbital ATK had built for its other Minotaur rockets.

This success is a very good thing for Orbital ATK, as the rocket likely gives them a strong position in the emerging smallsat market.

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Orbital ATK to launch first Minotaur-C in six and a half years

8:25 am

Capitalism in space: Orbital ATK will try today to successfully launch its renamed Taurus rocket, six and a half years after its previous two launches had ended in failure.

The rocket is now called Minotaur-C and will attempt to launch ten Planet Lab smallsats. As Taurus, the rocket failed 3 times out of 9 launches, and from what I could tell watching the launch industry, was basically a dead product. I am now astonished that it is coming back to life. Apparently, Planet Lab got a good launch price, and can take the risk since its smallsats represent a relatively small investment and can be replaced much more easily than the two research satellites (Orbiting Carbon Laboratory and Glory) that NASA lost in the rocket’s previous two launches more than half a decade ago.

The article outlines nicely the history of this rocket, and how its failures significantly set back the growth of Orbital ATK. Hopefully, it will succeed now, and provide the U.S. another player in the increasingly competitive global launch market.

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Stratolaunch tests engines on giant plane

5:41 pm

Capitalism in space: Stratolaunch announced today that it has successfully tested the six engines that will fly on the giant plane that it will use as a first stage.

This isn’t that big a deal, since the engines were built for the 747s that were scavenged by Stratolaunch to assemble their giant plane. If those engines didn’t work I would have been very surprised.

The most interesting part of this story is this:

Despite the plane’s giant size, Stratolaunch plans to initially use the aircraft as a platform for Orbital ATK’s Pegasus XL rocket, which is currently launched from a much smaller L-1011 airplane. The Stratolaunch plane will ultimately have the ability to carry three Pegasus rockets that could be launched one at a time on a single flight. An initial launch, the company said in May, could take place as early as 2019.

A recent deal could combine two of Stratolaunch’s partners. Scaled Composites, who developed the aircraft for Stratolaunch, is owned by Northrop Grumman, which announced Sept. 18 a deal to acquire Orbital ATK for $9.2 billion.

This might make Pegasus more affordable for smallsat launches, and provide those smallsat companies much greater launch flexibility. Moreover, the purchase of Orbital ATK by Northrop Grumman appears to work to the advantage of Stratolaunch.

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Federal bureaucracy prevents satellite launch

8:33 am

We’re here to help you! A suite of 8 private commercial cubesats that the Air Force had agreed to launch as secondary payloads on the August 26 launch of a Minotaur rocket were blocked from launch by FAA bureaucracy.

The “interagency partner” that appeared to raise objections was the Federal Aviation Administration, which issued the launch license for the mission. “The Federal Aviation Administration (FAA) did not approve Orbital ATK’s request for a license modification to include commercial cubesats on the upcoming ORS-5 launch mission,” Guthrie said. “As a result, Orbital ATK decided not to include commercial cubesats on the launch.”

Asked if the FAA placed any conditions or restrictions on the ORS-5 mission launched on the Minotaur 4, agency spokesman Hank Price said the FAA issued Orbital ATK a license Feb. 10 to launch government payloads on the Minotaur 4 from Cape Canaveral. The launch license contains any and all conditions on the license, Price said, and the FAA does not comment on the “existence or status of launch license applications or modifications until the FAA makes a final decision regarding those requests.”

Industry sources believe the FAA never formally rejected a proposed license modification for the cubesats because it did not go through the official process, but it was informally clear that the agency would have rejected such a modification had it been formally submitted.

Spire officials are trying to figure out why there was any issue at all about commercial cubesats on this launch. “If Spire chose this launch in the place of another commercial offering, I would understand the industry’s concern about fair competition,” Barna said. “But no existing U.S. launch company or new entrant was offering a similar launch. The fundamental intent of the policy is to keep competition fair, and competition just wasn’t a factor here.”

Spire’s problems here demonstrates the difficulties smallsat companies have getting their satellites in orbit, which explains the emergence of a new smallsat rocket industry. The company’s difficulties also illustrates why the launch industry should always be opposed to giving too much regulatory power to government. In this case it really appears that the launch license was denied merely because the bureaucrats involved with approving it at the FAA simply didn’t want to bother dealing with it.

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Northrop Grumman to buy Orbital ATK

9:14 am

Capitalism in space: Aerospace giant Northrop Grumman has made a deal to acquire Orbital ATK for $9.2 billion.

This deal essentially allows Northrop Grumman to return as a player in the space industry. In recent years the company has not been visible in any major way in space. Orbital ATK gives it that.

At the same time, the flexibility and risk-taking seen at Orbital ATK that allowed them to build Antares and Cygnus for crew cargo will likely be more difficult as part of a giant corporation.

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Orbital ATK begins assembly of first orbital repair satellite

8:49 am

Capitalism in space: Orbital ATK has begun the assembly of Mission Extension Vehicle 1, (MEV-1), designed to attach itself to commercial satellites and extend their life.

Controlled by the company’s satellite operations team, the MEV 1 uses a reliable, low-risk docking system that attaches to existing features on a customer’s satellite. The MEV-1 provides life-extending services by taking over the orbit maintenance and attitude control functions of the client’s spacecraft. The vehicle has a 15 year design life with the ability to perform numerous dockings and repositionings during its life span.

They hope to launch before the end of 2018. Meanwhile, the legal battle between Orbital ATK’s effort to build this satellite repair mission and DARPA’s effort to subsidize SSL’s own satellite repair mission continues in Congress with the introduction of two amendments favoring Orbital ATK.

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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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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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Decision on new Orbital ATK rocket expected in 2018

9:56 pm

The competition heats up? Orbital ATK says it will decide whether it will introduce a new commercial rocket sometime in early 2018.

Orbital ATK has released few details about what is known only as its “Next-Generation Launcher.” The vehicle would use solid-fuel lower stages based on space shuttle solid rocket motor segments developed by the company, as well as solid strap-on boosters. A liquid-oxygen, liquid-hydrogen upper stage would use a version of Blue Origin’s BE-3 engine that company is currently flying on its New Shepard suborbital vehicle.

The rocket’s design has at least superficial similarities to a vehicle concept called Liberty that ATK proposed prior to its merger with Orbital Sciences Corporation. Liberty, with a five-segment shuttle solid rocket booster first stage and a second stage derived from the Ariane 5 core stage provided by Astrium, was itself a commercial spinoff of the cancelled Ares 1 rocket from NASA’s Constellation program. ATK proposed Liberty for NASA’s commercial crew program but failed to win funding.

The decision itself will be based on whether the Air Force remains interested. At the present time the Air Force is investing about half the capital required to develop the rocket. If the Air Force backs out, Orbital ATK will decide against the rocket. If the Air Force support remains firm, they will go ahead with development. Essentially, this story is Orbital ATK lobbying to keep the Air Force support going.

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Orbital ATK prepares Cape Canaveral launchpad for July Minotaur launch

10:05 am

The competition heats up: Orbital ATK crews on Sunday practiced stacking stages on a Cape Canaveral launchpad in preparation for a July Minotaur 4 launch of an Air Force surveillance satellite.

Teams this weekend stacked three inert Peacekeeper missiles stages on a launch stand similar to those that will make up the Minotaur IV rocket’s first three stages. Two more Orion 38 stages will fill out the rocket. On Sunday, the first three stages standing more than 50 feet tall were surrounded by puffy white covers that will keep the right temperature during the launch campaign’s summer heat.

Plans called for the mobile gantry to be rolled back on rails to its launch position before the stages are taken down on Monday.

Orbital ATK has been prevented from expanding its Minotaur 4 market beyond military launches because the rocket uses these available but now unused Peacekeeper missiles and is thus very inexpensive. Their competitors have been their influence in Congress to forbid their use commercially.

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Orbital ATK sues DARPA over its satellite repair program

8:51 am

Orbital ATK has filed a lawsuit against the Defense Department’s DARPA division over its satellite repair program that is apparently going to award a contract to a Canadian company to develop a system for using robots to repair orbiting satellites.

Orbital argues that the federal program, called the Robotic Servicing of Geosynchronous Satellites, would unfairly compete with its own privately funded effort, a system called the Mission Extension Vehicle 1, backed by at least $200 million from investors. The company has set up at a production facility in Northern Virginia, with a launch planned for next year.

DARPA wants to build out a government-funded program of its own, and is close to awarding a contract to a company that Orbital views as a competitor. In a contract announcement briefly posted on the agency’s website, DARPA said it is awarding a $15 million contract to Space Systems/Loral (SSL), a U.S. subsidiary of Canadian aerospace firm MacDonald, Dettwiler and Associates. DARPA spokesman Jared B. Adams said the contract award was posted in error and elements of the deal are still being worked on.

In its lawsuit, Orbital alleges that the contract violates federal policy against creating government space programs that compete with existing commercial ones. “The U.S. National Space Policy explicitly directs government agencies to avoid funding activities that are already in development in the commercial marketplace,” the company said in a statement. “Orbital ATK will continue to pursue all available options to oppose DARPA from moving forward with this illegal and wasteful use of U.S. taxpayer dollars.”

DARPA normally pushes projects that no one is doing, either because the work is too experimental or can’t yet make a profit. In this case however it appears that this is not the case. Worse (from a political perspective), they are awarding the contract to a non-American company. I would not be surprised if Congress soon steps in and shuts this particular DARPA project down.

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