Reusable Rocket Propulsion

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• Reusable Rocket Propulsion
• John Vilja
• September 29, 2004

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Reusable Launch Vehicle Evolution
Space Shuttle 1980s to Present
Two Stage to Orbit 2000s
Single Stage to Orbit 1990s
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Reliability, Maintainability Supportability
Vehicle Figure of Merit
Engine Figure of Merit
Failure Modes
Reliability
Crit 1
Loss of Vehicle, Loss of Crew
Cat. Failures
Planned Maintenance
Benign Engine Shutdown
Loss of Mission
Crit 1R or 2
Availability Cost/Eng/Flt
Unplanned RR/ Maintainability
Crit 3
Unplanned Maintenance
Maintainability Supportability
Logistics Support Plan
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Analysis Process Improvement

• Hydrodynamic CFD Analysis

3-D Model
Historical Tools Design Process
6 Months/ Iteration
Analysis Model Generation
Pressure Boundary Condition
Analysis
Mesh
Integrated Product Development Process Tools
lt1 Week/ Iteration
Structural Analysis
Time
9705091c.ppt aw
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Cycle Time to 100 Power Level Reduced
SSME
J2
J2
RS-68
RS-68
SSME
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Test Success Comparison
200 150 100 50 0
SSME 1st Flight
Major Failures (SSME) Causing Redesign/Retest
615 Tests
Engine Test Failures
RS-68
183 Tests
No Major Failures
500
1000
1500
2000
2500
Days From 1st Engine Test
RS68-871-35 Druyun/Weiss
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X-33 Aerospike Testing Highly Successful

• Single thruster - 13 tests, 985 seconds
• Multi-Cell - 10 tests, 49 seconds
• Powerpack - 17 tests, 1506 seconds
• Single Engine - 14 tests, 1513 seconds
• Full power achieved in 6 tests
• Dual Engine 3 tests as planned
• Less than 4 years development required

Unprecedented success achieved with extensive
test program
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IPD Engine Provides Reusable Technology
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SLI/NGLT Engine Comparison w/SSME
RS-83 FRSC
RS-84 ORSC
RS-85 Expander
SSME
390 klb, sl
640 klb, sl
1,050 klb, sl
350 klb, vac
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Summary

• RLV engine requirements continue to evolve
• Space Shuttle provides anchor data for cost
  reliability
• Improved engineering tools reduce development
  cost and improve engine quality
• Component technology programs providing results
• NASA NGLT effort ended this year slowing progress
• AFRL/NASA IPD program entering test early 2005
• New propulsion could be available to support 2nd
  generation RLV by 2010