Problems with Blue Origin’s engine force more delays of ULA’s new Vulcan rocket

In a detailed and very informative review of the partnership between ULA and Blue Origin yesterday, Eric Berger at Ars Technica noted these unfolding facts:

For years, United Launch Alliance chief executive Tory Bruno had been saying the new Vulcan rocket, powered by two [Blue Origin] BE-4 engines, would launch in 2021. However, he recently told Aviation Week the first launch would slip into 2022. Bruno said this was due primarily to the mission’s customer, Astrobotic, whose Moon lander was not ready. Technically, Bruno said, Vulcan still had a chance to be ready for a 2021 launch.

This seems highly unlikely because it is already July, and United Launch Alliance (ULA) still does not have a pair of flight engines. After receiving the flight engines from Blue Origin, ULA needs to attach them to the Vulcan rocket, roll it to the launch pad, and conduct a lengthy series of tests before a hot-fire ignition. After this hot-fire test, the rocket will be rolled back to the hangar and prepared for an actual launch attempt. As of January, Bruno was saying this hot fire test with the flight engines would take place this summer. That will no longer happen.

In December both companies promised delivery of those flight engines by this summer, but so far nothing has arrived. Moreover, both companies have remained very tight-lipped about the cause of the most recent delays. In October 2020 Bruno said that an issue with the engine’s turbopumps had been identified and fixed, but if so why has the engine not arrived as promised?

A GAO report released last month had described issues with the engine’s “igniter and booster capabilities,” but Bruno himself has denied the igniter was a problem.

Regardless, Blue Origin’s inability to deliver this engine is causing problems at both companies. Both have been forced to delay the launch of their new orbital rockets. Both rockets were initially scheduled to launch in 2020, were delayed to 2021 about two years ago, and now are likely not to launch until 2022.

While ULA can still switch to its Atlas 5 rocket for some planned Vulcan launches (and has already done so), that rocket is more expensive and thus eats into the company’s profit margin. Using the more expensive Atlas 5 in bidding also makes it more difficult for ULA to compete with SpaceX in any head-to-head competition.

Blue Origin does not even have this option. Its proposed New Glenn rocket is grounded until it gets its engine operational.

All told, the failure of Blue Origin to deliver here is essentially grounding all of SpaceX’s potential American competition, a situation that is not healthy for the American rocket industry.

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ULA to temporarily stop using new engine nozzle because of vibration issue

Capitalism in space: Because of an unexpected vibration issue seen during its first launches, ULA engineers have decided to temporarily stop using a new engine nozzle developed for the upper stage of both its Atlas 5 and new Vulcan rocket.

ULA’s CEO Tory Bruno said June 23 that the company is studying the data from the flight and has not yet decided what corrective action, if any, it might take. In the meantime, the new version of the RL10 [engine] with the carbon nozzle extension will not be used in upcoming Atlas 5 missions, Bruno said during a talk at the Secure World Foundation’s Summit for Space Sustainability.

Concerns about vibrations in the engine led ULA to delay the launch of the Space Force STP-3 mission that had been scheduled for June 23 and was planned to fly with the enhanced RL10. The company has not announced a new launch date for STP-3. ULA first plans to launch Boeing’s Starliner Orbital Flight Test 2 mission to the International Space Station scheduled for July 30. “It’ll be several missions, probably next year” before ULA decides whether to fly the RL10 configuration with the nozzle extension, said Bruno. The company wants to be “fully satisfied that we understand it.”

Below the fold is the live stream from that May launch, cued to show that vibration. It is their intention to go back to the older nozzle configuration for the next few launches.
» Read more

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GAO: Problems with Blue Origin’s BE-4 engine threaten ULA’s Vulcan rocket

Capitalism in space: According to a new report [pdf] issued by the Government Accountability Office (GAO) on June 8th, on-going technical issues with Blue Origin’s BE-4 rocket engine threaten ULA’s planned inaugural launch of its new Vulcan rocket later this year.

From page 106 of the report:

A U.S. produced rocket engine [BE-4] under development [by Blue Origin] for ULA’s Vulcan launch vehicle is experiencing technical challenges related to the igniter and booster capabilities required and may not be qualified in time to support first launches beginning in 2021. A joint program office and ULA team is tracking these challenges, and NSSL officials told us Vulcan remains on track to support first launches and certification in 2021. However, if ULA cannot complete engine qualification before the 2021 flight certification, the program might continue to rely on ULA’s Atlas V—which uses engines manufactured in the Russian Federation—to support ULA’s 2022 launches, despite a nearly $2.9 billion investment in new launch system development. [emphasis mine]

ULA has a limited number of Russian engines in its inventory. At some point it must move on to American-built engines, and if Blue Origin’s BE-4 cannot be fixed then the company will be forced to look for other options.

Both ULA and Blue Origin maintain that the first Vulcan launch will occur in the fourth quarter of this year, launching Astrobotic’s lunar lander Peregrine to the Moon, but no date has been announced. If this GAO report is describing problems that still remain as of June 2021 and have not been fixed, then expect a further delay to be announced, probably by September.

These technical issues with the BE-4 engine also impact Blue Origin’s plans to begin launching its orbital rocket, New Glenn, next year. That rocket is already two years behind schedule, delays caused partly by these engine issues and partly due to the requirements imposed by the military under the above-mentioned $2.9 billion program to develop new launch systems. Without that new engine, Blue Origin’s much-touted effort to compete with SpaceX for commercial launches will go up in smoke.

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SpaceX grabbing 90% of the launch contracts to the Moon

Capitalism in space: The announcement yesterday by Firefly that it has awarded SpaceX the launch contract for its Blue Ghost lunar lander mission (scheduled for launch in ’23) is significant because it continues a remarkable pattern of dominance by SpaceX of the lunar launch market.

Right now, of the seven scheduled robot missions to the Moon, SpaceX will launch all but one. The full list, in no particular order:

In addition, SpaceX launched Israel’s Beresheet lander in 2019 on a Falcon 9.

Furthermore, SpaceX has won the contract from NASA for the agency’s first manned lunar lander, using Starship. It has also won the contract to launch the initial components of NASA’s Lunar Gateway space station on a Falcon Heavy.

There are other lunar missions in the works (by Russia, China, and others), but these are all the launches awarded as commercial contracts to private rocket companies in recent years. Thus, of these ten lunar missions, SpaceX has launched or is launching nine. That’s a 90% market share!
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ULA successfully launches military reconnaissance satellite

screen capture from ULA's live stream
Screen capture from ULA’s live stream.

Capitalism in space: ULA successfully launched a Space Force military reconnaissance satellite using its Atlas 5 rocket. It also deployed two cubesats.

This was the first Atlas 5 launch in 2021. The satellite has now been deployed into its transfer orbit taking it to its final geosynchronous orbit.

The leaders in the 2021 launch race:

15 SpaceX
12 China
7 Russia
2 Rocket Lab
2 ULA

The U.S. now leads China 21 to 12 in the national rankings. Note also that though we are still six weeks short of the year’s halfway point, the U.S. is already more than halfway to its total from all of 2020, 40 launches. If this pace continues the U.S. has a good chance of reaching launch totals that were only routine during the mid-1960s, at the height of the beginnings of the space race.

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ULA’s Delta-4 Heavy successfully launches NRO spy satellite

ULA today successfully used its most powerful rocket, the Delta-4 Heavy, to place a National Reconnaissance Office (NRO) surveillance satellite into orbit.

ULA now only has three Delta-4 Heavy’s in its inventory. After those launch the rocket will be retired, to be replaced by the most powerful versions of its new Vulcan rocket.

The leaders in the 2021 launch race:

11 SpaceX
8 China
7 Russia
2 Rocket Lab

The U.S. now leads China 16 to 8 in the national rankings.

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Amazon signs ULA’s Atlas 5 for first 9 Kuiper satellite launches

Capitalism in space: Amazon today announced that it has signed a launch contract with ULA to use its Atlas 5 rocket for the first 9 Kuiper satellite launches.

The announcement did not say when these flights will take place, nor how many Kuiper satellites will be on each. Amazon’s license with the FAA requires that it launch half its 3,200 satellite constellation by ’26. Also ULA intends to retire the Atlas 5 in only a few years, replacing it with its Vulcan rocket. This suggests that the launches will occur in the next three years.

They better. Starlink is already going operational, and OneWeb is about to. Plus several other internet constellations are in the pipeline. If Amazon wishes to compete it needs to get those satellites in orbit as quickly as possible. Internet customers don’t generally change their servers easily, tending to stick with whom they’ve got. If Starlink and OneWeb scoop up all the best low-hanging internet fruit Amazon will find itself facing an uphill battle getting customers.

The article revealed one tidbit of interest. Rajeev Badyal, Amazon’s VP of technology for the Kuiper project, was one of the managers Elon Musk fired from his Starlink project in 2018 after realizing that that management team was moving far too slowly for his tastes. It appears Jeff Bezos then hired Badyal to run Kuiper.

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Russia hands over last rocket engines to ULA

In a ceremony in Russia yesterday, Roscosmos’s Energomash division completed and handed over ownership to ULA six RD-180 engines, to be used in ULA’s Atlas 5 rocket.

These are the last such engines required as part of the contract. They will also likely be the last Russian engines ULA will ever buy. The company is retiring its Atlas 5 rocket, which requires them, and replacing it with its Vulcan rocket, which will instead use Blue Origin’s BE-4 engine.

Furthermore, as of September 1st, 2021 such commercial space contracts with Russia will be difficult to obtain because of new sanctions imposed on Russia by the Biden administration.

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Space Force awards launch contracts (two each) to ULA and SpaceX

Capitalism in space: On March 9th the Space Force announced that it has awarded four new launch contracts, two each to ULA and SpaceX, for a total cost of just under $400 million, all to launch in ’23.

Under the task orders issued March 9, ULA and SpaceX will each launch two missions. ULA was awarded $225 million to launch and integrate the USSF-112 and USSF-87 missions on its Vulcan Centaur rockets while SpaceX was awarded $160 million to launch and integrate USSF-36 and launch NROL-69 on its Falcon 9 rockets.

Based on these numbers it appears ULA is charging about $113 million per launch for its new Vulcan Centaur rocket, while SpaceX is charging about $80 million using its Falcon 9.

For ULA, that is less that what it would charge using its Atlas 5 rocket, but not by much. For SpaceX this price is high, probably because the military might be demanding the company use new boosters for its launches.

These high prices for both are to me a sign of how little our federal government cares about saving any money for the taxpayer. While the competition brought on by SpaceX’s arrival is saving the military money, the way these contract awards are structured, with both ULA and SpaceX guaranteed to win them, neither company has an incentive to reduce its prices. Instead, they can overcharge and the military can do nothing about it.

In a more sane world the military would use the competition in the launch market to get an ever better deal. Instead, our federal government sees its budget as a blank check, and they are using it.

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Scheduling conflicts at ISS delay Starliner unmanned demo flight till May

NASA and Boeing have been forced to again delay the second unmanned Starliner demo mission to ISS due to scheduling conflicts with Soyuz and Dragon missions in April, forcing the flight to slip to May.

A Russian Soyuz capsule is set for launch April 9 from the Baikonur Cosmodrome in Kazakhstan with two Russian cosmonauts and a U.S. astronaut. The Soyuz MS-18 spacecraft will dock with the space station about three hours after launch, and an outgoing three-person crew will depart and return to Earth on April 17.

SpaceX’s next Crew Dragon flight to the space station is set for launch from NASA’s Kennedy Space Center in Florida around April 20 with astronauts Shane Kimbrough, Megan McArthur, Akihiko Hoshide, and Thomas Pesquet. Their mission, known as Crew-2, will last about six months.

The four astronauts who flew to the station last November on the Crew-1 mission — aboard the Crew Dragon “Resilience” spacecraft — will return to Earth in late April or early May. Both docking ports capable of receiving the Boeing Starliner capsule will be occupied during the crew handover in late April.

They had hoped to launch on April 2nd, but I suspect strongly that Boeing and NASA are glad to have this extra time.

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1st Vulcan test core stage arrives at Kennedy

Capitalism in space: ULA’s first complete Vulcan core stage, meant at this point only for testing launch procedures, has arrived at Cape Canaveral.

After connecting the launch platform and the rocket to gas and electrical systems at the pad, ULA engineers will run the Vulcan booster and the ground infrastructure through a series of exercises, culminating in loading of thousands of gallons of cryogenic liquid methane and liquid oxygen into the rocket.

Once these tests are complete, the stage will be returned to ULA’s facility in Alabama to be refitted with flight worthy BE-4 engines so it can fly on a later mission. The engines presently attached are test engines.

ULA expects the first flightworthy BE-4 engines to be delivered by Blue Origin by the summer. These will then be incorporated into the first Vulcan to fly (hopefully before the end of the year) and carrying Astrobotic’s unmanned Peregrine lunar lander.

That rocket, as will all Vulcan rockets for the foreseeable future, will be entirely expendable. Though ULA says it intends at some point to recover for reuse the engines of the core stage, they have not delineated a time schedule for when that will happen.

At this point the only customer ULA has for this rocket is the government — especially the military. Vulcan cannot compete in price with SpaceX’s rockets, so I doubt any commercial satellite company will be much interested in it. The military will pay the extra bucks, because it wants more than one launch company for redundancy, and it has already committed to buying Vulcans for the next five years.

Of course, that long term commitment to Vulcan by the military will likely change if other cheaper rockets enter the market. At the present the military is limiting bidding on future launches to just SpaceX and ULA. That cannot hold up in court if other viable rocket companies wish to bid. Expect those new companies to do what SpaceX did when the Air Force refused to let it bid on military launches about five years ago, sue, and win in court.

At that point ULA’s an entirely expendable Vulcan will be very vulnerable to losing its last customer. ULA must make this rocket reusable or it will die as a company.

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ULA’s CEO advocates old way of doing things

In a webinar yesterday the CEO of ULA, Tory Bruno, argued that there is too much money being invested in new rocket companies and the money would be better spent developing in-space activities instead.

To be attractive to investors, these new space activities should be dual-use with both commercial and national security applications, Bruno said.

The launch market is becoming dangerously “overheated” for a couple of reasons. One is simply that there are too many launch companies chasing a “more or less fixed size” pool of customers, Bruno said. In the large rocket market, he said, prices are falling and the demand for satellite launches “has remained stubbornly inelastic.”

“It’s down to a third or even a fourth of the cost of what access to space was just a handful of years ago,” Bruno said. “Yet we have seen no increase in the overall size of the launch market nor have we seen a corresponding tripling or quadrupling of space activity.”

While Bruno is correct when he says that there are likely too many new launch companies, he is so wrong about his belief that the customer base “has remained stubbornly inelastic” that he is practically in the wrong galaxy. The lower costs he complains about are exactly why there is so much investment capital being poured into the new launch companies, because those investors see those lower costs attracting many new customers, something that is demonstrated by the growth of the launch rate in the past few years (something that I expect will explode in the next two years).

Many of these new companies will fail, for any number of reasons. No matter. A large number will succeed, and attract more than enough customers to make a profit.

What Bruno really is complaining about are the new lower launch costs. ULA can’t match them, and for this reason faces a crisis in that it might not be able to attract any customers at all in the coming years, even with the introduction of its new Vulcan rocket. And though Bruno has done a good job trying to make ULA competitive in this new market, he appears to have generally failed to change the company significantly. For example, why hasn’t ULA tried to market its Atlas 5 and Vulcan rockets for multi-payload smallsat launches, as SpaceX did with the recent launch of 143 smallsats on one Falcon 9? I can’t think of any reason why ULA’s rockets couldn’t do the same. Yet the company has done nothing to try to market itself to this smallsat industry. Instead, they have let Rocket Lab, Virgin Orbit, and now SpaceX grab it, along with at least four or five new smallsat rocket companies about to do their first launches.

Instead, Bruno advocated during this webinar that the federal government get involved, acting to encourage investors to leave the launch market and instead focus on building companies that only do things in space.

What a deal! The government helps to limit the number of new rocket companies, thus protecting ULA’s market share. ULA in turn can continue to charge its high prices, because the new in-space companies the government subsidized will have few launch options. In fact, the high launch prices that would result from a smaller launch market would likely force the federal government to also subsidize the launch costs for the new in-space companies so they can even afford to get to orbit.

All for the benefit of old big space companies like ULA, who for decades did nothing to innovate or lower the cost to launch.

I think what Bruno is really signaling to us here is that he is not hopeful for the future of his company in today’s present competitive free market, and is thus advocating government intervention to save his company.

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