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Copyright © 2011 United Launch Alliance, LLC. All Rights Reserved.File no.
ULA Briefing toNational Research Council
Launch Propulsion Systems Roadmap
March 23, 2011
Bernard Kutter
ManagerAdvanced Programs
ULA Briefing toNational Research Council
Launch Propulsion Systems Roadmap
March 23, 2011
Bernard Kutter
ManagerAdvanced Programs
File no. | 2
Historic Launch Vehicle Development
O22P1-478
X43
NASP
0203066
9500883
9906391
2001-00432
9610538
RLVVenture Star
TSTOSLI
ED04-0320-16
Numerous breakthrough efforts by NASA, DoD and private sector have met with minimal success
– Revolutionary technology
– Revolutionary systems
– Typically not achieving first flight
Pictures Credit: NASA
Predicting Future Launch Vehicles and Predicting Future Launch Vehicles and Their Required Technologies is a Challenge Their Required Technologies is a Challenge
File no. | 3
Booster Engine
Brand new technology for large main engines not required– Chemical engines are essentially at their theoretical maximum Isp– Human Rating has minimal impact on engine design or technology– Reusability for multiple reuses drives need for added margin
• Isn’t a big technology driver– However, importing, and domesticating Ox-Rich Staged Combustion (ORSC)
Kerosene/LOX technology for US designed engines is a long standing need ORSC offers substantial benefits
– ORSC 30 sec Isp improvement over gas generator engines– ORSC engine no more costly than GG (PWR and Aerojet)– PWR and Aerojet pursuing ORSC engine technology
Cost and industrial base are current propulsion drivers– Technology priority: lower cost and increase operability
Enhanced Propulsion is On-going Common RequirementEnhanced Propulsion is On-going Common Requirement
Courtesy PWR and AerojetRS-68RS-68 RD-180RD-180 SSMESSME X-33X-33 ORSCORSC
File no. | 4
2nd Stage Engine Development
Thrust dependant on application– ~25 klb : EELV class
– ~100 klb: Cross cutting use
– J2X or SSME: HLV class
High ISP (>450 sec) Reliable Producible Affordable
– Shared infrastructure cost can be beneficial (e.g. Xcor piston pump)
Engine out – Single largest reliability improvement
Continuous US Propulsion InvestmentContinuous US Propulsion Investment
Courtesy Xcor
Courtesy PWR
0
50
100
150
200
1 of 1 2 of 2 3 of 4RL10 Engine Operation
Sta
ge
Fa
ilure
Ra
te
Engine-Out
File no. | 5 United Launch Alliance (ULA) Proprietary Information
Integrated Vehicle Fluids (IVF)
Utilize hydrogen and oxygen to replace: – Hydrazine for attitude control – Helium for pressurization – Large Vehicle Batteries Power
Provides mission flexibility– Upper stage disposal– Reduced cost– Increased performance – Enhanced pressurization
HP GO2 HP GH2Internal
Combustion Engine
Electrical Generator
LO2 Tank
LH2 Tank
Battery
Drive Motor
O2 Pump
Settling Thruster O2 & H2
Vaporizer/Heater
Drive Motor
H2 Pump
H2 Engine Bleed
Attitude Thrusters
Tank Pressurization Controls
H2/O2ThrusterCourtesy IES
File no. | 6
Key to Launch Vehicle Advancement is Demand
Without Demand Pull Advanced Technology
Will Remain on the Shelf
File no. | 7
Launch Market
Fragmented launch market– Atlas V– Delta IV– Delta II– Shuttle– Falcon 9– Taurus II– HLV?– Ariane– H2A– Long March – Proton– Sea Launch– Soyuz
Commercial launch is not a successful business venture
Courtesy Lockheed Martin
2004: 54 Launches24 Vehicles Active
2.2 Launches per Family
1984: 129 Launches14 Vehicles Active
9 Launches per Family
Lack of Demand Limits Opportunity for Lack of Demand Limits Opportunity for Advanced Technology InsertionAdvanced Technology Insertion
File no. | 8
Medium Class Intermediate Class
Delta II Delta IV Delta IV HeavyAtlas V
Heavy Class
United Launch Alliance (ULA)
Two World-Class Launch Systems– 50/50 Joint Boeing/Lockheed Martin Ownership
ULA Formed due to Low Launch DemandULA Formed due to Low Launch Demand
File no. | 9
100% Mission Success48 for 48
ULA Launch History
National Security - 26 NASA/Civil - 12 Commercial - 10
NROL-21 - 12/14/06 - Delta II
THEMIS - 2/17/07 - Delta II
STP-1 - 3/8/07 - Atlas V
COSMO-1 - 6/7/07 - Delta II
NROL-30 - 6/15/07 - Atlas V
Phoenix - 8/4/07 - Delta II
Worldview-1 - 9/18/07 - Delta II
Dawn - 9/27/07 - Delta II
WGS-1 - 10/10/07 - Atlas V
GPS IIR-17 - 10/17/07 - Delta II
DSP-23 - 11/10/07 - Delta IV
COSMO-2 - 12/8/07 - Delta II
NROL-24 - 12/10/07 - Atlas V
GPS IIR-18 - 12/20/07 - Delta II
NROL-28 - 3/13/08 - Atlas V
GPS IIR-19 - 3/15/08 - Delta II
ICO G1 - 4/14/08 - Atlas V
GLAST - 6/11/08 - Delta II
OSTM - 6/20/08 - Delta II
GeoEye - 9/6/08 - Delta II
COSMO-3 - 10/24/08 - Delta II
NROL-26 - 1/17/09 - Delta IV
NOAA-N' - 2/6/09 - Delta II
Kepler - 3/6/09 - Delta II
Most Recent LaunchesGPS IIR-20 - 3/24/09 - Delta II
WGS-2 - 4/3/09 - Atlas V
STSS-ATRR - 5/5/09 - Delta II
LRO/LCROSS - 6/18/09 - Atlas V
GOES-O - 6/27/09 - Delta IV
GPS IIR-21 - 8/17/09 - Delta II
PAN - 9/8/09 - Atlas V
STSS Demo - 9/25/09 - Delta II
Worldview-2 - 10/8/09 - Delta II
DMSP-18 - 10/18/09 - Atlas V
Intelsat-14 - 11/23/09 - Atlas V
WGS-3 - 12/5/09 - Delta IV
WISE - 12/14/2009 - Delta II
SDO - 02/11/10 - NASA
GOES-P - 03/04/10 - Delta IV
OTV-1 - 04/22/10 - Atlas V
GPS IIF-1 - 05/27/10 - Delta IV
AEHF-1 - 8/14/10 - Atlas V
NROL-41 - 9/20/10 - Atlas V
COSMO-4 - 11/5/10 - Delta II
NROL-32 - 11/21/10 - Delta IV
NROL-49 - 1/20/11 - Delta IV
OTV-2 – 3/5/11 – Atlas V
NROL-27 – 3/11/11 – Delta IV
Delta IICOSMO-411/5/10
Atlas VOTV-23/5/11
Delta IVNROL-273/11/11
File no. | 10
NASA Exploration HLV Demand
Low Demand Plagues Future Technology Insertion EffortsLow Demand Plagues Future Technology Insertion Efforts
File no. | 11
Launch Rate Influence
Launch business is very capital intensive
$0/mT
$5/mT
$10/mT
$15/mT
$20/mT
$25/mT
$30/mT
0 2 4 6 8 10 12 14 16 18 20
Launch Rate (#/year)
$ in
Mil
lio
ns
/ m
T
Infrastructure Dominated
Recurring Dominated
LE
O L
aun
ch C
ost
($M
/mT
)
Launch Rate (#/year)
HLV
Fixed cost amortization
Multi year block buy
Technology Advancement
HLV $54M/mT @ HEFT 1 launch per 2 years rate
HLV
Del
ta IV
Atla
s V
Launch Rate Currently Bigger Cost Driver than TechnologyLaunch Rate Currently Bigger Cost Driver than Technology
File no. | 12
Supply Base Health
Supply base health of great concern
Two opportunities for improvement
– NASA launch vehicle decision
• NASA – DoD (EELV) supply base sharing
– Increased EELV order quantity & annual build rate
Stable, healthy supply base encourages new innovative solutions
Increased Rate Supports Healthy Supplier BaseIncreased Rate Supports Healthy Supplier BasePrerequisite for Technology Innovation/AdoptionPrerequisite for Technology Innovation/Adoption
File no. | 14
Reuse of Expensive Hardware
Is Reusability Cost Effective?Is Reusability Cost Effective?
Booster engine reuse has best potential to demonstrate cost reduction at low launch rate
ATS SeparationHypercone Deployment Parafoil
Deployment
Mid Air Capture
Barge Recovery
InspectionATS Integration on new Booster
Vehicle Launch
Campaign
2nd Stage SepEngine Fluid Isolation
File no. | 15
Summary
Focus propulsion investment on cost and operability– Robust engine out offers single largest opportunity for
reliability enhancement
Need demand pull to encourage new technology adoption
It is not clear whether high rate production is more beneficial economically than re-use– Forecast is for low demand
Uncertainty in optimum future launch vehicle – Invest in cross cutting, broad use technologies