1 Stan Graves Vice President, Science & Engineering ATK Propulsion Systems 435-863-4062 [email protected] March 23 – 24, 2011 NASA Technology Roadmaps

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Stan GravesVice President, Science & EngineeringATK Propulsion [email protected] 23 – 24, 2011

NASA Technology Roadmaps ATK Commentary

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Assessment Guidelines and Assumptions:

Next generation heavy lift vehicles will employ both liquid and solid propulsion elements to optimize reliability, performance and cost.

Assessment evaluated:1.Total propulsion system performance and reliability2.Ground processing timelines3.Launch delays

Conclusion: ATK endorses NASA technology roadmap and provides guidance for priority and emphasis

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All of today’s heavy lift vehicles use a combination of liquids and solids.The majority of tomorrow’s commercial vehicles of all sizes will also

combine solids and liquids

HLV-001

Delta II Delta IV Atlas VAtlas IIAS Titan LV FamilySpace Shuttle

Japanese H-2ESA Ariane V India LV Family Russian Start-1ESA Ariane IV

Heavy Lift Vehicles Use Both Liquids and Solids

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Design Rule:High power lower stages High Isp upper stages

3rd StagePower (T/W)

Economy (Isp)

TotalVehicle

T/W0.7

TotalVehicle

T/W1.5

1st Stage

Power (T/W)Economy (Isp)

2nd StagePower (T/W)

Economy (Isp)

Relative Importance of Power & Economy

Propulsion Theory:

Solids: Best for initial acceleration

Liquids: Best for high velocity operation

Combination best to achieve orbit

0 5000 10000 150000

0.2

0.4

0.6

0.8

1

Velocity (mi/hr)

Pro

pu

lsiv

e E

ffici

enc

y

SolidLOX H2Optimal Solution

Use Liquids

Range

Alti

tude

Staging

Staging

Rocket Equation Physics

Propulsion Physics

Ideal

The combination of solids and liquids results in the most efficient, cost effective heavy lift solution

Independent Trade Studies:

2-StageConfiguration:1st – 2nd

Solid – SolidLiquid – Liquid (RP-1) (H2).

Solid – Liquid(H2)

Payload (klb) 150 150 150

GLOW (klb) 17,400 5,500 4,600

Total Propellant Volume (ft³)

200,000 112,000 98,000

Failure Rate Estimates 1/483 1/286 1/407

3-Stage Configuration:Boost

1st – 2nd

Liquid Liquid – Liquid

SolidLiquid – Liquid

Payload (mT) 95 97

Relative Cost per Flight 1.08 0.87

Relative DDT&E Cost 1.29 0.96

Reliability; Loss of Mission (PRA) 1/71 1/133

ATK Study

NASAStudy(ESAS)

The Solid/Liquid combination is not just a coincidence– it is a result of the physics, economics, and programmatics of the launch vehicle industry

Solid/Liquid Combination is not a Coincidence

1957-2009 1964-2009 1970-2009 1980-2009 1990-2009 2000-20090

200

400

600

800

Pro

ba

bili

ty o

f S

ucc

ess

(Y

to

1) Propulsion System Historical Reliability Vs. Time (All Stages Considered)

Liquid Propulsion SystemsSolid Propulsion Systems

Impr

oved

Re

liabi

lity

Solid propulsion performance and high reliability increases likelihood of crew survival – optimal designs reduce “lofting” and eliminate “black out” zones

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200 250 300 350 400 450 5000

1

2

3

4

5

6

Specific Impulse - Isp (s)

Thr

ust

to W

eigh

t -

T/W

(lb

f/lb

m)

Key Performance Parameters of Available Industry Stages

Solid PropellantLOX/RP LOX/H2

Bo

ost

/1st

Sta

ge

Eff

icie

ncy

Upper Stage Efficiency

Efficient Rocket

Boost/ 1st

Stage

Up

pe

rS

tag

e

Solids optimize first stage performance (density Isp). Liquids optimize Upper stage performance (Isp). Hybrids are somewhere in between.

Solids Optimum for First Stage, Liquids Optimal for Upper Stage

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Investments in both liquid and solid propulsion ground process technologies are prudent since launch

operations timelines are virtually identical

Space Shuttle Ground Processing Timelines

VAB

Stacking Ops(21 days)

SRBIntegratedOps(11 days)

ETIntegrated

Ops(18 days)

MPS/SSME(5.5 days)

ARF

Fwd Skirt

ARF

Aft Skirt

Jay Jay Siding

Receipt, Transfer

RPSF

Offload, Aft Booster

Turn Basin

Offload, Inspect

Checkout Cell

Checkout

Engine Shop

Checkout

OPF

Checkout

Hangar AF

Transfer to ARF

Solid

Pro

puls

ion

Elem

ents

Liqu

id P

ropu

lsio

n El

emen

ts

Pad

RSRM / SRB(6 days)

External Tank(3 days)

MPS / SSME(13 days)

Manufacturing

Launch Ops

35 days

15 days

18days

Utah

Recovery

Launch Operations Timeline

Solid Propulsion: 73 Days

Liquid Propulsion: 72.5 Days

PRF

Parachutes

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Technology investments should address overarching system level issues that contribute to launch delays.

Solid propulsion reliability makes it an attractive element of a highly dependable architecture.

Shuttle Launch Delays

Length of Launch Delays

Cost of Launch Delays*

*NASA estimates that each scrub costs $500,000 in lost fuel, and $700,000 to pay for the extra workforce needed for launch attempts (ref: Space.com). The STS costs about $200M/month operate (ref: Augustine report).

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TA01Composite case damage tolerance detection

Near Term Benefit

TA01Composite case damage tolereance assessment

Near Term Benefit

TA01, TA02Domestic sourcing of SRM materials

Near Term Benefit

TA01Formulation of advanced hybrid fuels

Potential Long Term Benefit

TA01 SRM design and analysis toolsNear Term Benefit

TA13Low loss cryogenic storage and transfer

Near Term Benefit

TA13Corrosion detection / prevention

Near Term Benefit

TA13

autonomous systems and integrated vehicle health management

Near Term Benefit

TA13 Intelligent, self-healing systems


TA13

Multipurpose models enabling distributed control and collaboration

Mid Term Benefit

TA01 Electric TVCMid Term Benefit

TA01Advanced Launch Abort / Range Safety

Near Term Benefit

TA01 Advanced pyrotechnic systemsMid Term Benefit

TA01, TA14, TA03, TA02, TA13

Solar thermal propulsion, solar electric propulsion, air breathing propulsion (SCRAM jets) (high temperature/damage tolerant materials)

Mid Term Benefit

Items in RED are in the roadmaps at a “lesser” level. ATK recommends elevating the priority level of these

items to have equal consideration to the other

items on this list.• Electric TVC• Advanced launch abort and range

safety• Advanced pyrotechnic systems• Solar thermal propulsion, solar

electric propulsion, and air breathing propulsion

Assessment of Ground Processing & Propulsion Technologies

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ATK Assessment of Ground Processing and Vehicle Technologies


Near Term Benefit


Near Term Benefit


Near Term Benefit





Near Term Benefit


Near Term Benefit

TA13


Near Term Benefit



TA13


Mid Term Benefit



Near Term Benefit


TA01, TA14, TA03, TA02, TA13


Mid Term Benefit

The majority of the technologies can benefit commercial vehicles or heavy lift.

Many benefit both solids and liquids.

Recommend higher TRL (4-6) focus for these.

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Near Term Benefit


Near Term Benefit


Near Term Benefit





Near Term Benefit


Near Term Benefit

TA13


Near Term Benefit



TA13


Mid Term Benefit



Near Term Benefit


TA01, TA14, TA03, TA02, TA13


Mid Term Benefit

Highlighted technologies are not applicable to commercial vehicles primarily because of technology / implementation readiness levels.

Recommend lower TRL (1-3) focus for these, with focus on heavy lift applications.

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Near Term Benefit


Near Term Benefit


Near Term Benefit





Near Term Benefit


Near Term Benefit

TA13


Near Term Benefit



TA13


Mid Term Benefit



Near Term Benefit


TA01, TA14, TA03, TA02, TA13


Mid Term Benefit

Integrated vehicle health management:

More than just the health of the liquid systems:

• Solid rocket motor vehicle health management for composites, for logistics, for propellants , for joints and seals, for pyrotechnics…

Electric TVC• Electric TVC lends itself to a propulsion and

power control type system, and enables launch processing efficiencies / synergies


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Near Term Benefit


Near Term Benefit


Near Term Benefit





Near Term Benefit


Near Term Benefit

TA13


Near Term Benefit



TA13


Mid Term Benefit



Near Term Benefit


TA01, TA14, TA03, TA02, TA13


Mid Term Benefit

Domestic Sourcing of SRM Materials:

These technologies should include manufacturability considerations for the entire motor:

• Advanced robotics suitable for low volume, high precision, propellant and ordnance operations

• Certified tooling or processes that enable certification of key characteristics without redundant inspections

• Automated factory models (anthropomorphic /ergonomic) that include QD and logistics considerations specific to the SRM industry


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Conclusion

• Application of both liquid and solid propulsion elements are necessary to optimize the overall system– Reliability– Performance– Cost

• The majority of the technologies identified can benefit both commercial vehicles or heavy lift vehicles– Most benefit both solids and liquids

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Questions?


Documents

1 Stan Graves Vice President, Science & Engineering ATK Propulsion Systems 435-863-4062 [email protected] March 23 – 24, 2011 NASA Technology Roadmaps