More delays for Blue Origin’s BE-4 rocket engine

Capitalism in space: According to a report yesterday at Ars Technica, more delays are expected in the delivery of Blue Origin’s BE-4 rocket engine to ULA, possibly preventing the first launch of Vulcan from occurring in ’22.

Testing suggests the engine itself is functioning well. However:

Blue Origin is unlikely to deliver two flight-ready versions of the BE-4 rocket engine to United Launch Alliance (ULA) before at least the second quarter of 2022, two sources say. This increases the possibility that the debut flight of ULA’s much-anticipated new rocket, Vulcan, could slip into 2023.

Vulcan’s first stage is powered by two BE-4 engines, which burn methane and are more powerful than the space shuttle’s main engines. The sources said there recently was a “relatively small” production issue with fabrication of the flight engines at Blue Origin’s factory in Kent, Washington. [emphasis mine]

Translation of the highlighted words: We have built the engine, it is working great, but we have suddenly discovered we haven’t figured out the mass production process for building it quickly and in large numbers so as to support numerous launches by both ULA’s Vulcan and Blue Origin’s New Glenn rockets.

ULA claims it can get Vulcan off the ground only a few months after getting those flightworthy BE-4 engines because it has done most of the design work using the dummy “pathfinder” BE-4 engines Blue Origin provided last year. Don’t believe it. The company is going to have to install working engines on Vulcan, and then do static fire tests to validate not only the rocket but its entire launch process. Such testing usually takes months, and is rarely completed in less than half a year, even by SpaceX.

These problems at Blue Origin means that both Vulcan and New Glenn will likely launch more three years behind schedule. Instead of 2020, both will fly no earlier than 2023, at best.

ULA and China complete launches

Two launches were successfully completed in the past twelve hours.

First ULA’s Atlas-5 rocket successfully launched two Space Force military satellites and a NASA ultraviolet telescope into orbit on a launch that had been repeatedly delayed since February.

Next, one of China’s pseudo-private companies, Galactic Energy, completed its second launch of its Ceres-1 rocket, putting five smallsats into orbit. As the Ceres-1 rocket uses solid rocket motors, its initial development was for the military, and thus everything Galactic Energy does is carefully supervised by that Chinese military.

The leaders in the 2021 launch race:

46 China
27 SpaceX
20 Russia
6 Europe (Arianespace)
5 ULA

China now leads the U.S. 46 to 43 in the national rankings. The 118 total launches this year is now the most since 1985. And this number is only temporary, with two more launches scheduled in the next 24 hours.

BE-4 engine delayed until ’22

Capitalism in space: The CEO of ULA, Tory Bruno, admitted yesterday that the first production versions of Blue Origin’s BE-4 rocket engine, required for his company’s new Vulcan rocket, will not be delivered until until early ’22.

Bruno had previously said he expected the engines in late 2021 but on Friday he confirmed the BE-4s will not arrive until early 2022. “I was hoping to get those engines for Christmas. I had giant stockings at home waiting for them,” Bruno quipped in the CNBC interview.

“I’ll say it’s taking them a little longer to fabricate my production engines. They’re in the factory now being built at Blue Origin,” said Bruno. “The COVID epidemic has affected them and their supply chain and it’s just taking a little bit longer, but they’re doing very, very well,” he added. “There’s been no problems with them and in fact, we’re doing the final testing, or what we call certification testing. And that is just going really, really well.”

It appears that Blue Origin is dealing with the difficulties of production, not design, at this point, the same kind of issue that SpaceX recently revealed with its Raptor engine. Blue Origin needs to be able to manufacture these engines at a somewhat high pace, as both ULA’s Vulcan and Blue Origin’s New Glenn rocket use it. It appears that in designing it Blue Origin didn’t think about the manufacturing until very late in the game.

Bruno also said that he plans on flying Vulcan twice in ’22. We shall see.

Amazon picks rocket startup ABL to launch 1st two prototype Kuiper satellites

Capitalism in space: Amazon has chosen the smallsat startup rocket company ABL to launch its first two prototype Kuiper satellites, with that launch targeted for ’22.

KuiperSat-1 and KuiperSat-2 will reach orbit via the RS1, a new rocket developed by California-based ABL Space Systems. Amazon also announced today that it has signed a multi-launch deal with ABL to provide these early Project Kuiper launches.

The 88-foot-tall (27 meters) RS1 is capable of launching 2,975 pounds (1,350 kilograms) of payload to LEO, according to its ABL specifications page. ABL is charging $12 million for each launch of the two-stage rocket. The RS1 has not flown yet, but ABL has said that it aims to conduct a debut launch from Alaska’s Pacific Spaceport Complex before the end of 2021.

Earlier this year, Amazon announced that it had signed a deal with United Launch Alliance (ULA), whose Atlas V rocket will loft operational Project Kuiper craft on nine different launches.

Does anyone notice what rocket company has not won these contracts, even though its owner is also Amazon’s founder and biggest shareholder? That’s right, as far as I can tell, Blue Origin’s New Glenn rocket has apparently not won any contracts to launch Amazon’s Kuiper satellites. Notice also that the deal with ULA uses its Atlas-5 rocket, not its new Vulcan rocket, even though ULA wants Vulcan to replace the Atlas-5 beginning in ’22.

Since both New Glenn and Vulcan depend on Blue Origin’s troubled BE-4 rocket engine, these contracts strongly suggest that the engine’s technical problems have not yet been solved, and that neither rocket will be flying in ’22 as both companies have promised.

Today’s blacklisted American: ULA fires leader of protest against its COVID shot mandate

The religious banned at ULA
The religious banned at ULA

They’re coming for you next: The rocket company United Launch Alliance (ULA) yesterday fired Hunter Creger, the man who organized public protests against its COVID shot mandate.

Creger, a Laser Weld Technician at ULA, reported for his day shift at the rocket parts manufacturing plant on Wednesday for the first time this week. On Monday and Tuesday, Creger organized a protest with other employees to raise their voices in unison over the company’s COVID-19 vaccination mandate.

The mandate requires the federal workers at the plant to be vaccinated by Friday, October 29, or face termination. Creger asked his supervisors if the suspension is related to his role in the protests. He said they would not clarify that, but he has his own suspicions. “Even after all of this, after walking me out of the facility for my role that I played in the protest, at the root of all of this is because I’m a Catholic and that’s why they fired me. They denied my religious accommodation. That’s what started this whole thing.” [emphasis mine]

According to the story, more than two hundred employees filed for a religious exemption to the mandate. All were denied.
» Read more

ULA’a Atlas-5 successfully launches the Lucy asteroid probe

ULA’a Atlas-5 rocket early this morning successfully launched the Lucy asteroid probe on a 12 year mission to study eight Trojan asteroids over a period from 2025 to 2031. One tidbit about the mission is especially creative:

Scientists named the Lucy mission after the fossilized remains of a human ancestor, called Lucy by the scientists who discovered her in Ethiopia in 1974.

The leaders in the 2021 launch race:

36 China
23 SpaceX
17 Russia
4 Northrop Grumman
4 ULA

The U.S. and China are once again tied in the national rankings, at 36 each.

ULA successfully launches Landsat 9

Capitalism in space: Using its Atlas-5 rocket ULA today successfully launched Landsat 9, built by Northrop Grumman.

At the time of writing, the rocket and payload are in orbit and in a 60-minute coast phrase prior to payload deployment.

This was only the third launch this year by ULA, tying them with Rocket Lab but still too few launches to make the leader board. The leaders in the 2021 launch race remains the same:

33 China
23 SpaceX
15 Russia
4 Northrop Grumman

The U.S. now leads China 35 to 33 in the national rankings. In 2020 the U.S. completed 40 launches total, the most since 1968. At the moment there are sixteen more U.S. launches scheduled for launch in 2021. If all occur as planned, that would make 51 launches, making ’21 the fifth best launch year for the U.S. ever, exceeded only by four years in the mid-1960s.

For ULA, the low number of launches so far this year continues a slow downward trend since 2014, when the company completed fourteen launches. ULA still has four launches listed for ’21, but one, the unmanned Starliner demo launch, is likely to get delayed till ’22. The dates of two other launches remain “too-be-determined”, which also makes them questionable.

News flash! Union lobbyists wants to influence Biden against non-union SpaceX

In the past two days probably a dozen of my readers have sent me a link to this story at the Washington Examiner,
The Anti-SpaceX lobbying campaign casts new light on Elon Musk’s Biden beef.

The story reveals some private emails between a union lobbyist and a vice president at ULA, outlining their mutual effort to discredit Elon Musk and SpaceX because of its long term success in preventing its workforce from unionizing.

Everyone who has sent me this story somehow thinks it reveals a major breaking story.

I think this story is a tempest in a teapot. It reveals nothing newsworthy. All it shows is that a union lobbyist is trying to influence the Biden administration against SpaceX, a decidedly non-union company. Why should these actions surprise anyone? Unions always go after non-union companies, and they often do it by exerting their political clout.

Nor should be we surprised that one of SpaceX’s biggest competitors is partnering with the union in this effort. There is nothing newsworthy about this. Competitors compete, and that competition can sometimes be quite cut throat.

Furthermore, nothing in these emails appears illegal. The lobbyist’s claims against SpaceX are spurious and shallow, but so what? Unions have the right to lobby politicians, and they have the freedom to make whatever arguments they want, even if those arguments are silly or false.

Finally, to think it is a news story that Biden might be receptive to union lobbyists is kind of silly. Biden is a modern Democrat. In almost all matters he is going to genuflect to the unions. I don’t need to read the private emails of a union lobbyist to find this out.

However, the evidence in the past ten months shows that this lobbying effort has so far been incredibly ineffective. While I certainly do not trust the Democrats running the Biden administration, and fully expect them to take actions eventually to squelch private enterprise, this White House’s actions regarding space has so far generally continued the capitalist policies begun during the Trump administration. Note too that these are the same policies first begun at the end of the Bush Jr. administration, and encouraged strongly throughout the Obama administration. It certainly appears that — in space at least — the Democrats are as much for capitalism as the Republicans.

And these emails have apparently done nothing to change that. Thus, there is no news here.

ULA to no longer sell Atlas-5 launches

Capitalism in space: In an interview ULA’s CEO Tory Bruno has announced that they have contracts on all of the company’s remaining Atlas-5 rockets, and will no longer be offering that rocket for new sales.

“We’re done. They’re all sold,” CEO Tory Bruno said of ULA’s Atlas V rockets in an interview. ULA, a joint venture between Boeing and Lockheed Martin, has 29 Atlas V missions left before it retires sometime in the mid-2020s and transitions to its upcoming Vulcan rocket, Bruno said. The remaining Atlas V missions include a mix of undisclosed commercial customers and some for the Space Force, NASA, and Amazon’s budding broadband satellite constellation, Project Kuiper.

This means that the company is now firmly committed to its Vulcan rocket, which also means it is entirely committed to the repeatedly delayed BE-4 engine that Blue Origin is building for that rocket. This announcement suggests that Bruno is confident that the BE-4’s problems have been overcome, and that Blue Origin is about to begin regular assembly of the many flightworthy engines ULA will need.

If so, this is really good news. It not only means that Vulcan launches will finally begin, but that Blue Origin might also begin flying its New Glenn rocket. Both will give the U.S. some competitive options for getting big payloads into space. Right now the only real choice at a reasonable price is SpaceX, and having one choice is never a good thing.

ULA rolls Vulcan core first stage to launchpad for tank tests

Capitalism in space: ULA yesterday rolled out a test Vulcan core first stage to its launchpad for a variety of tests in preparation for its first launch, now delayed until next year.

The rocket’s core stage will undergo Pathfinder Tanking Tests (PTT) at Space Launch Complex-41 at Cape Canaveral Space Force Station. It is outfitted with two development BE-4 engines that will be replaced by flight engines before launch. The tanking, or fueling, tests will validate launch pad infrastructure, evaluate countdown procedures, and train the launch team.

That these launchpad tests were delayed until now suggests that ULA had hoped to do them with the flightworthy engines, and then follow-up quickly with Vulcan’s first orbital launch in the fall. With the admission this week by both Blue Origin and ULA that the flightworthy BE-4 engines would not be delivered this summer as promised, ULA probably decided it was better to get this testing done now with the development engines, in order to save prep time for when the flightworthy engines finally arrive.

Thus, the delays at Blue Origin are costing ULA money. Once the flightworthy engines are installed, ULA will still need to do static fire launchpad tests, which means they will have to do much of this test program all over again. The extra countdown rehearsals are of course beneficial, but they are an extra expense, and also require extra time.

ULA’s CEO, Tory Bruno, has tried very hard to streamline ULA’s operations so they are more efficient and thus more competitive. Blue Origin’s failure to deliver on time is making Bruno’s effort very difficult.

It also shows that SpaceX’s policy of building as many of its components in-house, instead of depending on outside contractors, makes sense. And that all of the new rocket companies are doing the same proves that others agree. ULA’s dependence on others for its rocket engines will thus in the long run put it at big competitive disadvantage.

Blue Origin BE-4 engine delayed again

In an interview ULA’s CEO Tory Bruno revealed that Blue Origin is not going to deliver the first two flightworthy BE-4 engines this summer, as promised, with delivery now probably not until the end of the year.

“I will not get them before the end of the year,” said Tory Bruno, CEO of ULA, in an exclusive Denver Business Journal interview ahead of this week’s Space Symposium industry gathering in Colorado Springs. “It will be shortly into the beginning of the 2022 calendar year, and anywhere in there will support me being able to build up a rocket and have that Vulcan waiting on my customer, Astrobotic.”

…“We’ve actually be been able to accommodate this, but I’ll be straight with you, the dates we’ve set up for them now— we really don’t have the ability to make any big moves after this,” Bruno said. “I need them to diligently work through the plans we have and get done on time.”

ULA needs to launch its new Vulcan rocket twice in order to get approved for its first military launch, now expected in less than 12 months. They thus no longer have any schedule margin.

The trials and tribulations of Blue Origin’s BE-4 engine

Link here. The article tries to provide some explanations for the delays at Blue Origin that have put the BE-4 engine years behind schedule.

The first and most important fact gleaned from the article is that flightworthy versions of this engine will not be ready this summer as promised, and will likely not get delivered to ULA for its Vulcan rocket before the end of the year, causing its inaugural launch to be delayed to the second half of ’22. This also means that Blue Origin’s own orbital rocket, New Glenn, will likely not launch until late next year, at the earliest.

Moreover, the engines that Blue Origin will deliver to ULA will not be fully tested, and might require replacement if tests on other engines reveal more problems.

The article’s most important revelation about the delays however is this:

One of the most persistent problems, sources said, is that the BE-4 engine testing and development program has been relatively “hardware poor” in recent years. Effectively, this means that the factory in Washington has not had enough components to build development engines, and this has led to extended periods during which no testing has occurred on the stands in Texas.

It was surprising to hear this because back in the spring of 2017 Blue Origin stated publicly that its development program was hardware rich. After arriving as CEO in late 2017, however, [Bob] Smith appears to have focused more on a substantial reorganization of Blue Origin’s leadership rather than hardware development. Other programs were prioritized, too, so the BE-4 team did not get all the resources and freedom it needed to proceed at full throttle. [emphasis mine]

To put it more bluntly, Smith decided it was more important to rearrange the deck chairs rather than launch lifeboats into the water. As a result, Blue Origin has essentially wasted the last four-plus years.

There are signs that the company has changed course away from Smith’s focus, but we shall have to wait and see. The childish press release issued by Blue Origin yesterday, claiming its manned lunar lander was far better than SpaceX’s Starship and should have been chosen by NASA, suggests that the course change has not been as thorough as one would hope. The amount of intellectual dishonesty contained in that release is somewhat disturbing, especially coming from a rocket company:

Blue Origin appears to be, at minimum, cherry picking its comparisons. The graphic notes that the Starship-Super Heavy system hasn’t launched yet. Starship has launched six miles into the air on several occasions, but not with its Super Heavy booster. It also points out that SpaceX’s Starship facilities in Boca Chica, Texas have never accommodated an orbital launch. Blue Origin, though has never launched any rocket to orbit from anywhere.

The graphic doesn’t, however, note the cost of the Starship lunar lander. SpaceX’s proposal estimates that it will cost NASA $2.9 billion, while Blue Origin’s gave a price of $5.9 billion. [emphasis mine]

For the management of a rocket company to not recognize the fundamental facts indicated by the highlighted words above, or to make believe they are unimportant, does not bode well for that rocket company. Rather than focusing on getting its rocket finally off the ground, the management appears instead unwilling to face some hard facts, and fix them.

Meanwhile, SpaceX keeps barrelling along, focused not on petty managment issues or whiny complaints, but on actually building rockets that fly.

Starliner launch scrubbed; no launch date yet set

For reasons that have not yet been revealed, ULA scrubbed today’s unmanned demo test flight of Boeing’s Starliner capsule just prior to launch, rescheduling the launch for tomorrow.

The launch tomorrow wiill occur at 12:57 am (Eastern).

UPDATE: It appears the scrub occurred because of a valve issue in the propulsion system of Boeing’s Starliner capsule.

“During pre-launch preparations for the uncrewed test flight of the CST-100 Starliner spacecraft, Boeing engineers monitoring the health and status of the vehicle detected unexpected valve position indications in the propulsion system,” the company said in a statement. “The issue was initially detected during check outs following yesterday’s electrical storms in the region of Kennedy Space Center.”

…The propulsion system valves in question are inside the Starliner’s service module, which has an array of rocket thrusters designed to propel the spacecraft away from its launcher during an in-flight emergency. Other thrusters on the service module are used for in-orbit maneuvers and spacecraft pointing control.

Boeing cannot afford more failures during this second demo flight. The company has been plagued with numerous debilitating technical failures during the past four years, from Starliner to its airlines. Right now the failure to get Starliner operational is losing them business in the emerging orbital tourist market. They need to get it working, and working reliably.

UPDATE: They have decided to cancel the launch plans for tomorrow, to roll the rocket back into the assembly building so they can do more tests on the capsule’s service module where the troublesome valves are.

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.

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

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.

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!
» Read more

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.

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.

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.

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.

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.

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.

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.

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.

Blue Origin reveals full throttle long duration test of its BE-4 engine

Capitalism in space: Jeff Bezos today revealed that Blue Origin has successfully completed a full throttle long duration test of its BE-4 engine to be used by both its New Glenn Rocket and ULA’s Vulcan rocket.

“Perfect night,” Amazon CEO Jeff Bezos, who created the Blue Origin space venture more than two decades ago, wrote in an Instagram post. “Sitting in the back of my pickup truck under the moon and stars, watching another long-duration, full-thrust hot-fire test of Blue Origin’s BE-4 engine.”

The post featured a shot of Bezos and other spectators looking on at the rising rocket plume from afar, as well as a video with closer perspectives of the firing.

The company has delivered two engines to ULA designed for ground testing, and says it will deliver soon the flight ready engines for Vulcan’s first launch later this year. Blue Origin also needs to get flight ready engines finished this year for New Glenn, which is also supposed to make it inaugural flight in ’21.

Personally, I think both Blue Origin and ULA are cutting it close. I will not be surprised if this tight schedule means that the first launches of both rockets get delayed into ’22.

Nonetheless, it is great news that the BE-4 appears to finally working as planned after what appeared to be problems for the past few years.

Space Force ends development contracts with Blue Origin and Northrop Grumman

The Space Force, having chosen SpaceX and ULA as its sole launch providers, officially ended on December 31, 2020, its rocket development contracts with Blue Origin and Northrop Grumman.

The Air Force awarded Launch Service Agreements to Blue Origin, Northrop Grumman and United Launch Alliance. These were six-year public-private partnerships where both the government and the contractors agreed to invest in rocket development and infrastructure required to compete in the National Security Space Launch program.

The plan from day one was to discontinue the LSAs with companies that did not win a National Security Space Launch procurement contract. Blue Origin and Northrop Grumman lost to ULA and SpaceX, which were selected in August 2020. The Space and Missile Systems Center confirmed in a statement to SpaceNews that the LSAs with Blue Origin and Northrop Grumman ended in Dec. 31, 2020.

From October 2018 through December 2020, Blue Origin was paid $255.5 million. The original six-year agreement was worth $500 million. Northrop Grumman got $531.7 million over that same period, nearly two-thirds of the total value of the LSA which was $792 million.

This whole deal stinks to high heaven. First, it never made any sense for the military to restrict bidding on future launches to just two companies. Such a restrictions smells of a cartel deal designed to play favorites, something the government should not do. It also ends up costing the government more, as it limits competition.

Second, the money handed out sure looks like nice pay-offs to all these big companies, designed to pay company salaries rather than real design work. SpaceX chose not to take it, because it did not want to be beholden to the military’s bureaucracy in how it developed Starship/Super Heavy. That choice has proven wise, as the deal slowed development of both Blue Origin’s New Glenn and ULA’s Vulcan rockets by at least a year, while SpaceX Starship development has moved forward far quicker.

Moreover, its seems very inappropriate for ULA to still be getting this government cash while SpaceX does not. In truth, neither should get a dime unless they actually sign a contract to launch something for the Space Force. Otherwise it is just a form of kickback and a misuse of the taxpayer’s money.

Not that my complaining here will change anything. The big aerospace industry has been addicted to these kind of government payoffs for decades, and apparently will continue to be so addicted for the foreseeable future.

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