Tag: ULA

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

10:28 am

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

9:31 am

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

9:30 am

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

10:37 am

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

10:56 am

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

5:15 pm

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

4:51 pm

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

9:20 am

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

10:08 am

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

10:32 pm

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

9:31 am

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

11:17 am

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

3:54 pm

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.

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Space Force ends development contracts with Blue Origin and Northrop Grumman

9:33 am

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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Northrop Grumman successfully test solid rocket booster for ULA’s Vulcan

10:45 pm

Capitalism in space: Northrop Grumman today announced that it has successfully test fired the strap-on solid rocket booster, qualifying it for flight, for use on ULA’s new Vulcan rocket.

In the Jan. 21 static test, the motor fired for approximately 90 seconds, producing nearly 449,000 pounds of thrust to validate the performance capability of the motor, the company said. The firing also verified the motor’s internal insulation, propellant grain ballistics and nozzle in high temperatures.

If all goes right Vulcan will make its inaugural flight later this year.

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First flightworthy BE-4 engine delivery now expected in summer ’21

9:22 am

Capitalism in space: Tory Bruno, the CEO of ULA, revealed yesterday that Blue Origin will finally deliver two flightworthy BE-4 engines for ULA’s Vulcan rocket this coming summer.

ULA, the Pentagon’s top launch contractor for national security satellites, had initially expected the shipment in 2020 for a debut flight in early 2021, but this was delayed by development hurdles.

The installation of Blue Origin’s reusable BE-4 engines into ULA’s next-generation Vulcan rocket will keep it on track for the debut launch of a moon lander dubbed Peregrine at the end of 2021, ULA Chief Executive Tory Bruno said. The Vulcan rocket has won a slate of key U.S. defense missions through 2027.

“That is now our expectation, that Peregrine will go to space in the 4th quarter of 2021,” Bruno told reporters during a call on Thursday.

Peregrine is a commercial lunar lander being built by Astrobotic for NASA.

More information here.

It appears that ULA thinks the long delay in engine development and delivery from Blue Origin will not delay the planned first launch of Vulcan later in ’21. It appears their long range plan to recover and reuse these engines has caused them to design Vulcan so that they can easily swap out engines, which will allow them to complete that new rocket’s development with the test engines that Blue Origin has already provided, and then switch engines and launch within months.

During Bruno’s press briefing he also noted that they have done a thorough refurbish of the Delta launchpads and have instituted a new policy requiring regular launchpad dress rehearsals, in order to make sure the series of problems that delayed the launch of a Delta-4 Heavy earlier this year will not reoccur.

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ULA’s Delta-4 Heavy successfully launches reconnaissance satellite

6:18 pm

Capitalism in space: After a several month delay, ULA’s Delta-4 Heavy tonight successfully launched a reconnaissance satellite for the National Reconnaissance Office.

The leaders in the 2020 launch race:

33 China
23 SpaceX
13 Russia
6 ULA
5 Rocket Lab
5 Europe (Arianespace)

The U.S. now leads China 37 to 33 in the national rankings. The U.S. launch total this year matches the number of launches achieved in 1969, and is the most launches by the U.S. in a single year since then.

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Watch ULA try again to launch its Delta-4 Heavy

9:09 am

Capitalism in space: ULA will today try once again, after numerous scrubbed and aborted attempts in August and September, to launch its Delta-4 Heavy rocket carrying a National Reconnaissance Office spy satellite.

The mission is set to take off at 6:15 p.m. EST (2315 GMT) Thursday from pad 37B at the newly-renamed Cape Canaveral Space Force Station in Florida. Forecasters predict near-ideal weather with a 90% chance of favorable conditions during the launch window Thursday evening.

Many of the launch problems earlier this year were due to issues in the launch pad. The article at the link describes the major refurbishing that ULA has done since then to fix them.

I have embedded their live stream of the launch, below the fold. It is set to go live at 5:55 pm (Eastern).

Note also that the next few days will be very busy for the American rocket industry. Tomorrow (Friday) both SpaceX and Astra have launches scheduled, with the latter making its second attempt to complete its first orbital launch. Then Rocket Lab has another Electron launch from New Zealand scheduled for the next day (Saturday).

That’s four launches in three days. If just two succeed, it will raise the total U.S. launches in 2020 to 38, which would be the most American launches in a single year since 1969, the year the country put men on the Moon.
» Read more

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ULA successfully launches reconnaissance satellite with Atlas 5

3:42 pm

Capitalism in space: ULA today successfully launched a military reconnaissance satellite using its Atlas 5 rocket.

This launch was the first Atlas 5 using these particular Northrop Grumman solid rocket boosters.

Because this was a military launch, the live broadcast ended at the moment the fairings were released, exposing the satellite. Final announcement of the satellite’s successful deployment will come later, assuming all goes well.

The leaders in the 2020 launch race:

30 China
19 SpaceX
5 ULA
4 Russia
4 Europe (Arianespace)
4 Rocket Lab

The U.S. now leads China 31 to 30 in the national rankings, with two more launches scheduled for the next two day. SpaceX is first with its second manned Dragon mission tomorrow, followed by Rocket Lab’s next launch from New Zealand on November 15.

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Blue Origin pinpoints problem with BE-4 engine

9:34 am

Capitalism in space: According to ULA’s CEO Tory Bruno, Blue Origin has identified and fixed the issue with the turbopumps of its new BE-4 rocket engine.

United Launch Alliance Chief Executive Tory Bruno said Friday that the problem was “sorted out,” and that the full-scale, flight-configured BE-4 engine is now accumulating a lot of time on the test stand. Bruno made his comments about one hour into The Space Show with David Livingston.

Bruno’s company, ULA, is buying the BE-4 engine to provide thrust for the first stage of its upcoming Vulcan-Centaur rocket. This booster may make its debut next year, although ULA is still awaiting delivery of BE-4s for the first flight. Two of these large engines—each providing about 25-percent more thrust than the RS-25s used on the Space Shuttle—will power each Vulcan rocket.

Here’s what I think happened: Blue Origin struggled to fix the problem for several years. ULA, suspecting problems, got increasingly impatient at the lack of delivery of an operational engine, and threatened to dump the BE-4 in favor of Aerojet Rocketdyne’s engine unless it was given a test engine to analyze. Blue Origin finally complied in July, and very quickly ULA pinpointed the problem and the solution.

While this is good news for the development of both ULA’s Vulcan and Blue Origin’s New Glenn rockets, it does not speak well for the development team at Blue Origin. Nonetheless, the engine is always the big hurdle for designing a rocket, and that hurdle has now been passed.

During Bruno’s interview he also said that ULA still intends to recover and reuse these engines when it flies its Vulcan rocket, but gave no timeline for when that might happen. Initially, and probably for several years at least, expect those engines to be expendable and tossed into the ocean with each flight.

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Delta 4 Heavy launch now delayed indefinitely due to launchpad issues

3:16 pm

ULA has now delayed indefinitely the launch of a military reconnaissance satellite using its Delta 4 Heavy rocket because of ongoing issues in the swing arms on the launch tower.

According to ULA’s CEO, Tory Bruno:

..ULA was “working through an issue with pad hydraulics” associated with the swing arm retraction system at the Delta 4 launch pad. Three swing arms feeding propellants and conditioned air to the rocket and its satellite payload are designed to retract as the Delta 4-Heavy lifts off.

“Fixing is always easy,” Bruno tweeted. “Making sure something stays fixed takes more work and lots of discipline.”

This launch has been delayed numerous times in the past two months, almost always because of a variety of different problems, most related to the launchpad, with two scrubs occurring as launch aborts at launch. As the article at the link correctly notes,

The repeated problems with different parts of the Delta 4-Heavy’s launch pad have raised questions about aging infrastructure at pad 37B, which was originally built to support Saturn rocket launches in the 1960s, then mothballed until Boeing took over the facility in the 1990s for the Delta 4 program.

Boeing built the towering mobile gantry for the Delta 4 rocket, along with a then-new fixed umbilical tower with huge swing arms designed to pull away from the launcher as it climbs away from the pad.

The age of the launchpad, combined with the expensive complexity of the Delta 4 Heavy that results in very few launches spread over many years, cannot result in reliable operations.

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Endless technical issues force Delta 4 Heavy launch scrubs

9:10 pm

BUMPED and revised to include the September 30th launch abort.

Can we count the ways? For what has become a string of seemingly endless technical issues, ULA on September 29th was forced to once again scrub the launch of a military reconnaissance satellite because of a technical issue with its Delta 4 Heavy rocket and launchpad.

Apparently when they tried to move the launchpad’s mobile gantry away from the rocket they discovered “a hydraulic leak in the ground system.”

On the evening of September 30th (tonight) they tried again, only to have an abort at T-7 seconds, just as the engines were to ignite as planned.

They have been trying to get this bird off the ground now for more than a month. Here is a chronology of the launch scrubs, with all the various technical issues described.

August 26: Scrub because of “several problems,” the primary cause being a “pneumatics system issue.” This same countdown also had a long hold because of two blown fuses in a launchpad heater.

August 29: Aborted at T-3 seconds, due to “a torn diaphragm in one of three pressure regulators” in the launchpad. During the countdown they also had holds to deal with a fuel valve issue, a fuel sensor issue, and a temperature payload issue.

September 26: Scrubbed because of issue with the launchpad “swing arm retraction system.”

September 27: Scrubbed because of a continuing issue with the launchpad “swing arm retraction system.”

September 29 (just after midnight): A lightning strike forced a scrub. This was the only scrub not caused by technical issues.

September 29 (just before midnight): Scrubbed because of a hydraulic leak in the ground system.

September 30: Aborted at T-7 seconds. Under investigation. No new launch date yet announced.

This string of seemingly minor and apparently easy-to-fix problems does not reflect well on the quality control systems at ULA. I understand that this is rocket science, and thus difficult. At the same time engineers have now been doing launches for more than a half century, and this tale of woe above is more reminiscent of the early days of rocketry in the 1960s, when you might have a dozen or more scrubs because of these kinds of technical issues. You’d think by now ULA’s launch engineers would have worked these kinks out.

From a customer perspective this list of issues is also troubling, considering that the Delta 4 Heavy costs the customer more than any other commercial rocket. Granted it can put up a lot of payload, but the Falcon Heavy can put up more, and do it for less than half the cost and far more reliably. If I was ULA’s customer I would not be very satisfied with the product I am getting, even if the launch turns out to be a complete success.

The delays are also impacting other launches. SpaceX has had to repeatedly delay the launch of a GPS satellite on its Falcon 9 because for scheduling reasons the ULA launch must come first.

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China and Russia launch a bunch of satellites

8:40 am

Russia today used its Soyuz-2 rocket to launch three communication satellites plus 19 commercial smallsats.

This was the first time Russia used the Soyuz-2 for these particular small communications satellites, as previously they had been launched by a variety of smaller rockets.

China in turn today used its Long March 4B to place two Earth resource satellites into orbit.

The leaders in the 2020 launch race:

25 China
15 SpaceX
10 Russia
4 ULA
4 Europe (Arianespace)

China has moved ahead of the U.S. 25 to 24 in the national rankings.

These numbers should change again in the next few days. The U.S. has had a number of scrubs and launch delays in the past few days. ULA has been repeatedly pushing back the previously delayed launch of a National Security Agency reconnaissance satellite due to a variety of problems related to its Delta 4 Heavy rocket. The launch is now set for just after midnight tonight (Monday night). [UPDATE: Launch scrubbed due to lightning and poor weather. Tentatively rescheduled for 11:58 pm (Eastern) on September 29.]

SpaceX meanwhile had to scrub a launch this morning (September 28) of another 60 Starlink satellites due to weather. No new launch date has yet been announced.

Northrop Grumman also has had to scrub tomorrow’s Antares launch of a Cygnus cargo freighter because of poor weather at Wallops Island. It is now set for the evening of October 1st.

SpaceX also has a scheduled launch tomorrow morning of a GPS satellite on its Falcon 9 rocket. This is also threatened by weather. There is also no word whether the ULA launch scrub will cause this launch to be delayed.

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ULA reveals Chinese-owned company attempted to steal rocket data

3:42 pm

In an interview yesterday ULA’s CEO Tory Bruno revealed that a Chinese-owned software company tried to infiltrate the supply chain being set up to build their next generation Vulcan rocket.

Bruno said the Chinese-owned vendor identified in ULA’s supply chain was a provider of software for tools used to manufacture the company’s next-generation rocket Vulcan Centaur. Because the issue was detected quickly, no sensitive information was extracted by that supplier, Bruno said.

The company flagged as a risk was a tool supplier working with KUKA Robotics. According to ULA, KUKA had no access to ULA’s intellectual property. “ULA envisions no further future work involving KUKA or KUKA products,” the spokesperson said. “There was no evidence they attempted to obtain data, however, we have an obligation to our customers as well as our company to ensure we have taken all necessary steps to protect our IP as well as information the government has entrusted us with.”

The Pentagon has shown growing concern about Chinese ownership of U.S. suppliers and continues to impose cybersecurity requirements on contractors. “But I have to tell you this is just shocking in terms of the scale and ubiquity of this threat and this effort on the part of China to not only gain access to intellectual property through traditional means — hacking or espionage — but through infiltration of the supply chain,” Bruno said.

The article also notes that while the top tier subcontractors ULA might hire are almost all American owned, foreign companies own 70% of the smaller subvendors, and the number of Chinese-owned subvendors has grown 420% since 2010.

China’s effort to steal American technology has been a serious problem that has been ignored for too long.

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ULA pinpoints cause of Delta launch abort, reschedules launch

2:58 pm

ULA has identified the cause of the launch abort of its Delta 4 Heavy rocket on August 29th, and has now aiming for a launch no earlier than September 18th.

A torn diaphragm in one of three pressure regulators at Cape Canaveral Air Force Station’s Launch Complex 37 caused the computer-controlled scrub just three seconds before liftoff on Aug. 29, ULA CEO Tory Bruno said via Twitter on Wednesday. The engines briefly lit on fire, but the rocket remained firmly on the pad.

“Torn diaphragm (in the regulator), which can occur over time,” Bruno said. “Verifying the condition of the other two regulators. We will replace or rebuild as needed, re-test, and then resume towards launch.” [emphasis mine]

The highlighted words illustrate the less than stellar old space rocket design that the Delta 4 Heavy represents, and that ULA is perpetuating as long as it uses this rocket. Rather than redesign so that these torn diaphragms will no longer be a problem, it appears they will simply make sure this design is tested and works, for this launch. Thus, this issue has the possibility of reappearing in a future launch.

Wouldn’t it be better to upgrade and eliminate such a problem, for good, once it is identified? That appears to be SpaceX’s strategy, and the consequence is that their rockets and spacecraft get increasingly more reliable with time.

Anyway, if ULA’s schedule holds, it means there will be two launches at Cape Canaveral in less than 24 hours, as SpaceX is aiming for another Starlink launch the day earlier.

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ULA’s Delta 4 Heavy: Launch abort at T-3 seconds tonight

1:14 am

Delta 4 Heavy immediately after engine shutdown

UPDATE: It appears ULA will need at least a week to analyze the situation before attempting another launch. It also appears that SpaceX is going forward with its two launches on August 30.

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Tonight’s attempt by ULA to launch a National Reconnaissance Satellite on its Delta 4 Heavy rocket was aborted at T-3 seconds when the rocket’s main engines did an automatic abort. The image to the right shows the rocket immediately after the engines shut down, the smoke clearing and the rocket still sitting on the launch pad.

They are presently unfueling the rocket and will not launch tonight. They have not set a new launch date, and there is also no word on whether this launch delay will force delays in the two SpaceX launches set for August 30th. My guess is that the issue tonight will take time to assess, so they will give up their place in line and let SpaceX proceed as planned.

In watching ULA’s broadcast tonight, as well as reviewing the issues that prevented launch two days ago, I was struck by several things. First, ULA’s promo films to tout the wonders of the Delta family of rockets actually made them seem incredibly clunky and complex. There seemed to be too many pieces and complex operations to get the rocket ready for launch, which makes sense as Delta rockets are very costly and not competitive with today’s market. This is the exact reason ULA is in the process of retiring the entire Delta family. They will complete the already purchased and scheduled launches, but in the future will use their new Vulcan rocket for similar future bids.

Second, the number of minor and major technical issues during both countdowns reinforced my impressions above. This is a very complex rocket to launch, and that complexity apparently leads to many issues that make launch difficult.

For the scrub on August 26 they first had two blown fuses in a launchpad heater that had to be replaced, then a pneumatics system issue that was apparently not solved during the countdown. When they scrubbed, however, they said they did it because of “several problems,” not just this one.

On tonight’s launch they first had an issue with a fuel valve, then several fuel sensor alarms gave them problems, requiring them to disable them to proceed, then the temperatures in the payload electronics posed an issue that after some analysis was considered acceptable. These issues caused the launch to be delayed by about an hour and a half.

Finally, the rocket’s main engines shut down at the rescheduled lift-off time.

It might not be fair, but in comparing this ULA launch effort with the numerous countdowns by SpaceX the differences were stark. SpaceX has had comparable few issues during recent launches, with only one launch recently scrubbed due to a technical issue in July. Moreover, the company’s launch team has several times had similar launch aborts at T-0, and still were able to recycle everything and proceed to launch immediately.

All these impressions once again suggest that ULA is making the right decision to retire Delta. That it is going to take them several more years however to launch several more government surveillance satellites raises questions about the decisions of our government to pay for such a unwieldy and expensive rocket. There now are better and cheaper options available.

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Five American launches in two days!

9:51 am

Capitalism in space: Though the first launches in the string of four American launches that was initially scheduled to begin two days ago and continue through the weekend was delayed because of weather and then technical issues, all these delays have done is pack those scheduled launches into a shorter time period, with the addition of a fifth launch!

If all goes as scheduled (hardly guaranteed), we will see five launches from three spaceports and four private companies in less than two days. The schedule, as of this moment:

August 29th at 2:04 am (Eastern): ULA’s Delta 4 Heavy to launch a military reconnaissance satellite from Cape Canaveral. The company’s webcast of the launch can be seen here.

August 29th at 11:05 pm (Eastern): Rocket Lab’s Electron rocket will launch a commercial radar satellite from New Zealand. The launch can be watched at the company’s live stream channel.

August 30th at 10:08 am (Eastern): SpaceX’s Falcon 9 will launch more of its Starlink satellites from Cape Canaveral. All SpaceX launches are live streamed from SpaceX’s website, though the links are not yet up.

August 30th at 7:19 pm (Eastern): SpaceX’s Falcon 9 will launch an Argentinian Earth observation satellite from Cape Canaveral. All SpaceX launches are live streamed from SpaceX’s website, though the links are not yet up.

August 30th at 10:00 pm (Eastern): Astra will attempt the first orbital test launch of its privately built rocket from Kodiak, Alaska. They will not be live streaming their launch, but will provide updates at their Twitter feed.

All times and dates list only the beginning of the launch windows, which means they might launch, but not exactly at the times listed.

Also, SpaceX is aiming to do its second Starship test hop this weekend, the first for its sixth prototype.

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Delta 4 Heavy launch scrubbed

11:15 pm

Tonight’s launch of ULA’s Delta 4 Heavy was scrubbed due to a variety of technical problems. They have not set a new launch time, though they say they are aiming for the early morning hours of August 28.

This was to have been the first of four American launches in the next four days. The next, a Falcon 9 launch of an Argentinian radar Earth observation satellite, was scheduled for tomorrow, August 27th, at 7:19 pm (Eastern). No word on whether it is going forward as planned, though it might be since the ULA launch has shifted after it, to August 28th.

The third, by Rocket Lab, is presently scheduled also for August 28rd at 11:05 pm (Eastern), launching out of New Zealand.

The fourth, another SpaceX launch of more Starlink satellites, had been scheduled for 10:30 am (Eastern) on August 29th. Once again, this schedule could change due to tonight’s ULA scrub.

Stay tuned. I suspect all three companies are going to aggressively work to get all four launches off as fast as possible, even if not exactly as presently scheduled.

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Four American launches in the four days

9:39 am

UPDATE: Rocket Lab’s launch has been delayed to 11:05 pm (Eastern) August 28 due of weather.

Beginning tomorrow, the next four days will be very busy for the American space rocket industry, with three companies attempting to complete four different launches.

First comes Rocket Lab, which will attempt its first launch of its Electron rocket since its first operational launch failure on July 4. Launch is scheduled for 11:05 pm (Eastern) on August 26th.

Next ULA is scheduled to use its most powerful rocket, the Delta 4 Heavy, to put a National Reconnaissance Office surveillance satellite into orbit. Launch is set for 2:12 am (Eastern) on August 27th. This very expensive rocket (which costs three to four times that of a Falcon Heavy) has only four launches left before being permanently retired.

Then SpaceX will attempt two launches in quick succession. The first will launch at 7:19 pm (Eastern) on August 27th, putting up an Argentinian Earth observation radar satellite. On this launch the first stage is a new one, and will attempt the first landing at Cape Canaveral since March 2020.

SpaceX will then follow with its third Starlink launch this month and twelfth overall, scheduled for 10:30 am (Eastern) on August 29th out of its facility at Cape Canaveral, assuming the other launches at Kennedy go as planned.

Moreover, the startup smallsat rocket company Astra is also aiming to attempt its first test launch before the end of August. The date is not yet set.

Busy times for sure, but note that this is only the beginning. I expect by the end of the 2020s the launch schedule will get increasingly packed. Soon having three three launches per week will seem routine.

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