Tag: Vulcan

Blue Origin expands its rocket engine factory in Alabama

9:04 am

Capitalism in space: Blue Origin yesterday revealed that it is hiring 300 more engineers and expanding the rocket engine factory in Alabama in order to produce flight worthy BE-3 and BE-4 engines.

Blue Origin in Huntsville spent the pandemic supporting the company’s main engine plant in Kent Washington with parts for the company’s BE-3 and larger BE-4 engines, [site lead Nathan] Harris said. “We are now actually in the process of building our first set of complete engines through our facility,” he said. Those first engines will be produced this year.

…“We’re getting very close,” Harris said. “They’re still doing quite a bit of retrofitting. As you learn, anytime you retrofit something that’s over 60 years old, it takes a little bit more and there’s a little bit more that you unearth that was undiscovered.”

Harris said he expects to be testing the BE-3 “in the next couple of months followed shortly by the BE-4.” [emphasis mine]

This may be good news for both ULA’s Vulcan rocket as well as Blue Origin’s own New Glenn rocket. Both need the BE-4 engine, and both have been delayed years because it has not been ready on time. While the engine problems appear to have been resolved, Blue Origin had not put any thought into developing a practical and affordable manufacturing process that would allow it to build enough engines to serve both itself and ULA.

This expansion at the engine factory suggests the company is finally moving into its production phase. The highlighted sentence above however also tells us that the first flight worthy BE-4 engines are still months away, which will further delay launch of Vulcan and New Glenn. It is now certain that neither will launch this year, putting both rockets more than three years behind schedule.

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Russia blocks future rocket engine sales to U.S.

1:45 pm

Dmitry Rogozin, head of Roscosmos, today announced that Russia will no longer sell any rocket engines to U.S. companies.

The head of Roscosmos, Dmitry Rogozin, announced the new policy in an interview with the Russia 24 TV channel. “Today we have made a decision to halt the deliveries of rocket engines produced by NPO Energomash to the United States,” Rogozin said in the interview, according to Russia’s state press site Tass. “Let me remind you that these deliveries had been quite intensive somewhere since the mid-1990s.” Rogozin also added: “Let them fly on something else, their broomsticks, I don’t know what,” according to Reuters.

Russian engines are used on two American rockets, ULA’s Atlas-5 and Northrop Grumman’s Antares. The Atlas-4 however is being phased out, and has already received all the engines it needs for all of that rocket’s remaining flights. ULA plans to replace it with its new Vulcan rocket, using Blue Origin’s (long delayed) BE-4 engine.

Antares however is a more serious issue. Northrop Grumman uses this rocket to launch Cygnus freighters to ISS. It depends on two Russian engines for its Ukrainian-built first stage. The Ukraine War now probably makes building more Antares rockets impossible, which means at some point Northrop Grumman will no longer be able to supply ISS with cargo using Cygnus. Furthermore, NASA’s plan to use Cygnus’ engines to maintain ISS’s orbit will be impacted if Cygnus launches to ISS cease.

There is an option, though it too has issues. ULA has already launched one Cygnus to ISS using its Atlas-5. Though this rocket is going away, ULA could probably use its Vulcan instead — assuming Blue Origin finally gets the BE-4 engine operational so that Vulcan can finally launch.

Overall, Russia’s decision might cause a temporary blip in the American space effort, but if the government doesn’t get in the way I think that competition will force a solution. As Aesop said, necessity is the mother of invention.

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

9:35 am

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.

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BE-4 engine delayed until ’22

9:36 am

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.

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

3:59 pm

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.

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ULA to no longer sell Atlas-5 launches

9:36 am

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.

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ULA rolls Vulcan core first stage to launchpad for tank tests

9:26 am

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.

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Blue Origin BE-4 engine delayed again

10:14 am

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.

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

12:09 pm

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.

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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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Delays force ULA to replace Vulcan rocket with Atlas 5 on military launch

11:08 am

Because the development of ULA’s new Vulcan rocket is behind schedule, the Space Force has agreed to allow the company to replace it with an Atlas 5 rocket on a ’22 launch.

That mission, known as USSF-51, was awarded to ULA in August 2020 and is scheduled to launch in late 2022. The company had bid its newly developed Vulcan to fly that mission but the vehicle is not going to be ready on time. As a result, the Space Force agreed to allow ULA to launch USSF-51 on the company’s legacy vehicle the Atlas 5.

…Switching vehicles financially penalizes ULA. According to the company, the Atlas 5 is more expensive than Vulcan. Phase 2 provisions allow ULA to change vehicles but at no cost penalty to the government.

This story however is important because of what it tells us about the state of Blue Origin’s BE-4 rocket engine, required by both Vulcan and Blue Origin’s New Glenn rocket.

At this moment ULA is saying that the first launch of Vulcan is still scheduled for late this year, launching Astrobotic’s Peregrine lander to the Moon. However, for that launch to happen the rocket requires working BE-4 rocket engines for its first stage. In January Blue Origin announced it had finally completed a full throttle test of that engine after problems lasting several years, and would soon be delivering flight-worthy engines to ULA.

It is now late May, and the article at the link revealed this very significant and somewhat shocking detail buried in the text:

Blue Origin in 2020 delivered pathfinder engines for ground tests but has yet to provide a flight-qualified engine for Vulcan’s first flight. A spokeswoman for Blue Origin said May 20 the company is “on track to deliver BE-4 engines this year.” [emphasis mine]

It seems completely impossible for ULA to launch that lunar lander on Vulcan this year if it does not yet have any flight-worthy engines on hand to incorporate and test in the rocket. Worse, it appears that Blue Origin might not deliver those engines for months yet.

This story thus suggests that we will not see launches of either ULA’s new Vulcan rocket or Blue Origin’s New Glenn rocket for a considerable time.

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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!
» Read more

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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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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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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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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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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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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’s Vulcan rocket: problems with Blue Origin’s rocket engine

10:04 am

Based on a detailed update today at NASASpaceFlight.com on the status of ULA’s new Vulcan rocket, it appears that while everything is proceeding as scheduled for a 2021 launch debut, the big issue that might cause a delay is Blue Origin’s BE-4 rocket engine, to be used in Vulcan’s first stage.

Speaking to the Denver Business Journal yesterday, ULA CEO Tory Bruno noted an ongoing issue with BE-4’s turbopumps but voiced his confidence that the issue would soon be resolved and that it would not impact Vulcan’s schedule at this time.

…Development of the BE-4 has long been seen as the critical path for Vulcan. ULA exercised an option within the U.S. Space Force’s National Security Space Launch (NSSL) Phase 2 award proposal and bid Atlas V as a backup vehicle for Vulcan in case the latter ran into development or certification issues.

When asked when ULA would have to inform the Space Force of its desire to switch one of the first awarded NSSL missions from Vulcan to Atlas V under a purely hypothetical BE-4 or Vulcan issue, Mr. Peller [VP of Major Development for ULA] did not comment directly, instead affirming ULA’s confidence that all of their NSSL missions would fly on Vulcan. [emphasis mine]

From the Denver Business Journal article:

Blue Origin is still troubleshooting the 75,000-horsepower pumps that bring fuel to the BE-4’s main combustion chamber, Bruno said, adding that he’s confident the issues will soon be solved. “There’s very little technical risk,” he said. “It isn’t easy, but we know we can do it.” [emphasis mine]

This is the first public admission I’ve seen anywhere of a specific problem with the BE-4 engine. It also suggests strongly that the problem has been long-standing, and has not yet been solved.

Both articles also make it clear that ULA is prepared to continue using both the Atlas 5 rocket and the Russian engines (that the BE-4 is supposed to replace) until 2027, if necessary.

While it could very well be that the BE-4’s turbopump issues are on the way to being solved and there will be no delays, the careful wording by Bruno and his head of development strongly suggests that they are aware of an issue and are trying to deflect press interest in it. In fact, the timing of this revelation, only six weeks after Blue Origin delivered to ULA its first BE-4 engine (a test version not flightworthy), suggests that ULA has only now become aware of the issue, and is now working to help solve it.

Stay tuned. I suspect all will become very clear within the next few months.

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Air Force terminates development contracts to ULA, Blue Origin, Northrop Grumman

9:44 am

In awarding ULA and SpaceX exclusive launch rights for all launches through 2026, the Air Force also decided to end prematurely the development contracts to ULA, Blue Origin, and Northrop Grumman aimed at helping these companies develop new rockets.

An issue at hand is the termination of the Launch Service Agreement contracts that the Air Force awarded in October 2018 to Blue Origin and Northrop Grumman, as well as to ULA. The purpose of the agreements was to help Phase 2 competitors pay for launch vehicle development and infrastructure. Blue Origin received $500 million; Northrop Grumman $792 million and ULA $967 million. The funds were to be spread out through 2024, and the Air Force from the beginning said the LSAs would be terminated with those companies that did not win a Phase 2 procurement contract.

Despite political pressure to not end the LSAs, the agreements will be terminated, Assistant Secretary of the Air Force for Acquisition Will Roper said Aug. 7 during a video conference with reporters. “We will work with those two companies to determine the right point to tie off their work under the LSA agreements,” Roper said. The intent of the LSAs “was to create a more competitive environment leading into Phase 2,” he said. “The point is not to carry them indefinitely.”

LSA funds supported the development of Blue Origin’s New Glenn rocket and Northrop Grumman’s OmegA launch vehicle. ULA will continue to receive funds for its Vulcan Centaur vehicle.

Almost immediately after the award of these contracts was announced in 2018, ULA and Blue Origin announced one year delays in the development of Vulcan and New Glenn. Apparently, meeting the additional requirements of military’s bureaucracy in exchange for getting the cash slowed development.

Now they won’t be getting a large part of that cash, making the decision to take it a deal with the devil. The delay in development has definitely hurt both companies in their competition with SpaceX. First, it likely has raised the cost and complexity of their new rockets, making it harder to compete in price. Second, the delay has given SpaceX more time to grab more customers while improving its own rockets.

SpaceX initially protested not getting a share of this development money, but has subsequently chosen to no longer pursue such government money for Starship because it doesn’t want itself hampered by obtuse government officials and their mindless requirements.

Meanwhile, Northrop Grumman’s Omega rocket is almost certainly dead. That company took the old big space company approach, structuring development around government cash. Without it there is no R&D money at Northrop Grumman to continue work. Furthermore, Omega was designed to serve only once customer, the military. Without any launch contracts there are no customers for Omega, especially because it likely has too high a launch price.

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Blue Origin delivers its first BE-4 rocket engine

10:42 am

Capitalism in space: Blue Origin this week delivered its first BE-4 rocket engine to ULA, for use in ULA’s new Vulcan rocket.

This engine is still a test article and is not yet flight-worthy.

“The engine delivered is the first pathfinder engine to be mated with the Vulcan Centaur and will support ULA’s testing,” a Blue Origin spokesperson told SpaceNews. “We are planning on delivering the second engine in July.” A pathfinder is a development engine. Blue Origin has not said when a flight-qualified engine will be delivered.

…ULA set a 2021 target to fly its first Vulcan Centaur mission and needs two production-quality engines to build the launch vehicle for that mission. Flying Vulcan Centaur in 2021 is an imperative for ULA as it tries to win one of two contracts that the U.S. Space Force will award this summer to launch dozens of national security satellites between 2022 and 2027.

According to sources, frustration has been mounting at ULA as the company’s future is tied to the success of Vulcan Centaur and there is no room for error when it comes to the main engine.

I empathize with ULA’s frustration. The pace of development at Blue Origin has seemed incredibly slow in the past two years. They had begun static fire tests in 2018, and then — beginning with ULA’s decision to buy the BE-4 for Vulcan in May 2018 — for more than a year there was no news. It wasn’t until August 2019 that they announced completion of the first full power test. Even then, it took another whole year before they got to this point now, where they were willing to deliver a first test engine to ULA.

Building a new rocket engine is not simple, so these delays could be entirely reasonable. At the same time, the company’s overall pace in accomplishing anything has been glacial. For example, in the past three years it has repeatedly not delivered on its promises to start flying humans on its New Shepard suborbital capsule. Four months ago, in their most recent promise, they said they would need three more unmanned test flights of New Shepard before they’d put humans on it, and that all those flights (including the manned one) would occur this year. Yet nothing has happened since.

While I truly want Blue Origin to succeed, one must cast a cold eye on what is really happening. If they wish to really compete with SpaceX they have got to pick up their pace.

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ULA on schedule for maiden flight of Vulcan in early 2021

9:49 am

Capitalism in space: According to ULA, the development program for its new Vulcan rocket remains on schedule, and will make its maiden flight in early 2021 as initially planned.

The launch will send Astrobotic’s privately built Peregrine lander to the Moon, carrying NASA science instruments.

The article provides a good overview not only of the status of construction, but also the political history that forced the development of Vulcan, that being the insistence by Congress that ULA stop using Russian engines in its rockets.

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Blue Origin to deliver first BE-4 engines to ULA this summer

8:42 am

Capitalism in space: Development of Blue Origin’s BE-4 engine, to be used in both its New Glenn rocket as well as ULA’s new Vulcan rocket, appears to be finally reaching its conclusion with the planned delivery this summer of two operational engines to ULA.

The bulk of the article at the link is mostly a summary of stuff that had already been revealed about the development of the New Glenn rocket. The only new piece of information that I could glean was this engine delivery date. It is significant, however, because no rocket company can ever really design its rocket before it has finished building the rocket’s engines. With the BE-4 now complete, I would expect the development of both New Glenn and Vulcan to proceed with great speed.

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First launch of ULA’s Vulcan on schedule for 2021

10:35 am

Capitalism in space: According to ULA’s CEO, Tory Bruno, the company is on track to transition as planned from its Atlas 5 and Delta rockets to its new Vulcan rocket.

Just five Delta IV Heavy launches remain on the manifest, all NRO launches procured under the block buy Phase 1 methodology. Bruno expects the final Delta launch to occur in 2023 or 2024.

The workhorse of the ULA fleet, Atlas V, is expected to retire on a similar timeframe. Bruno says the launcher could be “done as early as 2022, or as late as 2024.” Atlas V will have to continue operations until its replacement, Vulcan, can be human-rated to launch the Boeing Starliner spacecraft.

…The first flight of Vulcan Centaur is on track for early 2021, with the first flight vehicle under construction, and more vehicles in flow, in ULA’s factory in Decatur, Alabama. Vulcan’s debut launch will carry the Astrobotic Peregrine lander to the moon for NASA’s Commercial Lunar Payload Services (CLPS) program. A second launch is currently planned for later that year, which will satisfy the Air Force certification requirement for Vulcan to launch military missions.

Bruno’s report is also good news for Blue Origin’s New Glenn rocket, since both will use Blue Origin’s BE-4 engine in their first stage. If ULA is on schedule, than Blue Origin also likely to be on schedule, meaning that come 2021 or so the U.S. will have at least three companies (including SpaceX) capable of putting large payloads into orbit. Moreover, Northrop Grumman is developing its OmegA rocket, which will compete for the same business.

The article also talks about the military’s launch procurement program, which supposedly will pick two of these launch companies to provide all military launches through the 2020s. That program however is certain to fail, as it will blacklist all other viable companies from bidding on military launches. I expect those companies will successfully sue and force the Space Force to accept bids from more than two companies.

And that is as it should be. Why the military wishes to limit bidding makes no sense, and is probably illegal anyway. As long as a company has a qualified rocket, its bids should be welcome.

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Blue Origin opens rocket engine factory

8:39 am

Capitalism in space: Blue Origin yesterday cut the ribbon on its main rocket engine factory in Huntsville, Alabama, while also announcing that production of their BE-4 engine for both ULA’s new Vulcan rocket and their own New Glenn rocket will begin in a few months.

In the meantime, made-in-Kent engines are being tested at Blue Origin’s West Texas site. Smith said two flight readiness engines will be delivered in May to United Launch Alliance. They’ll be used for integrated tests of ULA’s Vulcan first-stage booster, which is taking shape not far from Huntsville in Decatur, Ala.

This is excellent news. For the past year and a half the company has released little information about their progress with the BE-4 engine, suggesting that they might be experiencing issues. Yesterday’s news bursts that pessimistic balloon, indicating that both the Vulcan and New Glenn rockets will be flying, maybe as soon as next year.

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ULA backing off from reuseablity and Vulcan upgrades?

9:39 am

Capitalism in space: According to this Space News story today, it appears that ULA is shifting away from building a major upgrade to the upper stage of its Vulcan rocket, even as it also appears to be backing off from pushing plans to recover and reuse its first stage engines.

ULA spokeswoman Jessica Rye told SpaceNews by email that the company still plans to introduce an “advanced upper stage,” but only after Vulcan flies. Rye also declined to provide a specific timeline.

Similarly, ULA officials also refused to give a timeline for when they will begin recovering Vulcan’s first stage engines and reusing them.

Right now the company expects to launch the first iteration of Vulcan, using as Atlas 5 Centaur upper stage, sometime in 2021. It also appears that those first launches will not recover the first stage Blue Origin BE-4 engines.

In the long run, I do not see how ULA can compete. They certainly appear hesitant about introducing any new innovations or upgrades to Vulcan, which will result in an expendable rocket that costs far too much.

In fact, the arrival of this apparent timidity seems to have occurred almost to the day the company accepted a development contract for Vulcan from the Air Force. Thus, it increasingly appears that it is our federal government that is squelching the company’s creativity.

Why am I not surprised?

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