Ideas Powering Freedom Eduardo Casillas Manager, Mission Architecture Engineering Rocket Propulsion Chabot College E10 Guest Lecture

Ideas Powering Freedom

Eduardo Casillas Manager, Mission Architecture Engineering

Rocket PropulsionChabot College E10 Guest Lecture

A GenCorp Company

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Education Community College: San Jose City, Evergreen Valley B.Sc. Mechanical Engineering - San Jose State University, 1979 Graduate Studies in Mechanical Engineering, San Jose State University,1980-1985 Various Professional Courses (AIAA, Launchspace, etc)

Work Experience 25+ Years of Experience in Lead, Support, or Managing Capacity of Systems Analysis and Preliminary

Propulsion Design and Trade Studies (CSD and Aerojet) Large Launch Vehicles (Shuttle, Titan IVA-IVB, ASRM, Delta II-III, Atlas II-III) Orbital Vehicles (Inertial Upper Stage, Various Apogee and Perigee Motors) Small Launch Vehicles (Athena, Pegasus, Multiple Ground / Air Launched Small Launch Vehicle) Strategic Missiles (Minuteman III, SICBM, Trident II, LBSD, SLIRBM) Missile Defense (THAAD, SM3 Boost / DACS, GMD, CorpSAM) Miscellaneous (Scramjet Booster, Tomahawk Underwater Booster, Hybrid Boosters, Launch Abort)

Significant Achievements Numerous Letters of Recognition Two Patent Awards (Dual Action Solid Hybrid Rocket, 1.5 Stage Symbiotic Hybrid Vehicle) Key Technical Member of Numerous Successful Proposals

How I Became Interested in Propulsion Local Rocket Company (CSD, San Jose, Ca) Specialized in Solid Rocket and Ramjet Propulsion Design / Development Trials & Tribulations Bow Down When Your Motor Flies Exploring the Universe and Defense of Freedom are Among the Noblest of Professional Endeavors

Eduardo Casillas Biographical Information

Eduardo Casillas RocketPropulsion ChabotCollege E10 110812.pptx

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3Eduardo Casillas RocketPropulsion ChabotCollege E10 110812.pptx

Agenda

Rocket Propulsion Emphasis on Solid Propulsion

Aerojet Company Overview

Videos Aerojet 70th Anniversary Video Mars EDL 7 Minutes of Terror Video

Summary

Questions?

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Agenda




Summary

Questions?

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Rocket Propulsion

Type Propellants

Solid Combined solid mix of fuel and oxidizer

Liquid Bipropellant

Separate liquid fuel and oxidizer

Liquid Monopropellant

Decomposable fuel

Hybrid Separate solid fuel and liquid oxidizer (other combinations possible)

Gas Blow-down High pressure gas

Supersonic Solid or liquid fuel and air

Hypersonic Liquid fuel and air

Electric Inert ionized gas

Nuclear Thermal Liquid fuel


Accelerate medium to create thrust (mostly gas medium)

http://history.nasa.gov/conghand/propulsn.htmhttp://www.ricknewlands.webspace.virginmedia.com/pages/engines/what-is-a-hybrid.htmhttp://www.answers.com/topic/ramjet

Figures provided courtesy of the following web sites:

http://history.nasa.gov/conghand/propulsn.htm

http://www.ricknewlands.webspace.virginmedia.com/pages/engines/what-is-a-hybrid.htm

http://www.ricknewlands.webspace.virginmedia.com/pages/engines/what-is-a-hybrid.htm

http://www.answers.com/topic/ramjet

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SRM Type Mission Examples Characteristics

Rocket Munitions

Propel small warheads and / or penetrators to a few miles’ range

Hellfire, Javelin, Stinger, EFOGM, TOW

Weight < 100-lb, 3-7 in diameter, robust / rugged, produced in the hundreds of thousands

Tactical Rockets

Propel large warheads from tens to hundreds of miles

MLRS, ATACMS, Hawk, Mk-111, Mk-104, Mk-72, AMRAAM, Sidewinder,

Weight ~ 100-2000-lb, 5-24-in diameter, robust / rugged, produced in the tens of thousands

Missile Defense

Boost kill vehicles from local to continental defense coverage

PAC-3, THAAD, SM-3, GMD Weight ~ 500-30000-lb, 10-50-in diameter, composite case / TVC, produced from a few thousand to a “handful”

Kill vehicle terminal guidance propulsion

PAC-3 ACM, SM-3 DACS [THAAD DACS and GMD EKV- are liquid propulsion]

Weight ~ 30-150-lb, 10-24-in diameter, thrust-managed, responsive, produced from a few thousand to a “handful”

Strategic Missiles

Boost ballistic re-entry vehicles to intermediate - intercontinental range

Trident, Poseidon, MM-III, Peacekeeper, Pershing

Weight ~ 5-100-klb, 40-92-in diameter, composite case / TVC, produced in the hundreds, fire-ready for decades

Re-entry vehicle range extension and precise maneuvering

Trident, Poseidon SGG [MM-III, Peacekeeper are liquid, Pershing is aero-controlled)

Weight < 1000-lb, SGGs feed exhaust gas into manifold / valve system for steering, produced in the hundreds

Space Boosters

Boosters / upper stages that part of a space launch vehicle launch satellites / spacecraft

Ariane-V, Atlas-V, Shuttle, Titan-IV, Delta, Taurus, Pegasus, H-IIA, Vega

Weight ~ 2-1100-klb, 38-146-in diameter, metal, composite, segmented cases / TVC / thrust shaping, produced from a few to dozens per year

Space Motors

Orbital transfer, Interplanetary travel propulsion

IUS SRM-1 and SRM-2, STAR Motor Series

Weight ~ 1-20-klb, 27-92-in diameter, titanium, composite cases / TVC, spin / space environments, produced 1-2 per year

Auxiliary Systems

Crew escape, stage separation, attitude and roll control, spin impulse, shroud removal, TVC-GGs

GMC ACS / staging motors, Apollo LES, ICBM shroud removal / roll control / TVC gas generator / RV spin

Wide variation in design configuration, sizing, and technologies, produced in unit numbers depending on vehicle application

Planet Exploration

Assist in extra-terrestrial retro, landing, and launch functions

MER retro rockets / air bag gas generators / horizontal velocity adjusting rockets

Weight ~ 5-35-lb, 3-12-in diameter, titanium cases / space environments, produced 1-2 sets per mission (every 5-10 years)

Wide ranging applications require SRMs with many shapes & functions

Solid Rocket Propulsion


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Program StartPreliminary Ballistics Analysis

Preliminary Mechanical Design Layout

Detailed Analyses

Drawing Generation

ThermalBallistics

Structures

Design Reviews

Mech. Design

Development & Qualification Testing

Functional Configuration Audit (Customer Acceptance)

Customer Specification Requirements and SOW

Interactions between components must be accounted for in the design process – usually by iteration until the design converges Grain design affects the internal insulation (flame exposure) and motor case (pressure)

Nozzle design affects the case (aft opening dia), propellant grain (submergence), and thrust vector actuation system (gimbaled configuration)

Attach structures affect the case (skirts, thrust structure) and nozzle (blast tubes, hot-fly out)

Second-level interactions (ordnance & avionics mounting, etc)

Solid Rocket Propulsion – Design Flow

Eduardo Casillas RocketPropulsion ChabotCollege E10 110812.pptx 7

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Typical Solid Rocket Design Team

Chief Engineer Project Engineers Systems Engineers Ballistic Design Engineers Design Engineers Propellant Chemists Analysts - CFD, Stress, Thermal, Dynamics Controls Engineers Electronic Avionics Engineers Materials & Processes Engineers Configuration Management Manufacturing Engineers Test and Instrumentation Engineers

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Agenda




Summary

Questions?

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Overview

Over 3,000 employees across 13 states

2011 Revenues of $918M Key Capabilities Enabling

Space and Launch Systems

Tactical Systems Missile Defense Systems Advanced Programs

Significant Real Estate Holdings

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Ascent Main Engine

THAAD Static Test

PAC-3

Tactical Systems

Real Estate

Advanced Programs

Space & Launch Systems

Missile Defense and Strategic Systems

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Broad Portfolio of Programs Across Diverse Mission Areas

THAAD

HAWK

SM3 TDACS

EKV

Minuteman

Missile Defense and Strategic Systems

Tactical Systems

Space and Launch Systems

Advanced Programs

F-22

Standard Missile

Tactical Tomahawk

GMLRS

PAC-3

Fragmentation Devices

Kinetic Energy Penetrators

Warhead Liners

M829A3Cartridge, 120mm, APFSDS-T

AOT Specialty Metals

Atlas

Space Thruster

AJ26

Orion

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Northern Virginia Operations

Tactical & Technology325 Employees

Washington, D.C.Gainesville, VA

Orange, VA

Field Offices

Operating Locations

Engineering Center

Product-Focused Manufacturing Centers and Customer-Focused Support

Product-Focused Manufacturing Centers and Customer-Focused Support

Over 3,000 Employees Across13 States

Vernon, CA

Socorro, NM Huntsville, AL

Hill AFB, UT

Denver, CO

Eglin AFB, FL

Orlando, FL

Picatinny Arsenal, NJ

Tucson, AZ

Dallas, TX

HeadquartersSacramento, CA

High Value Propulsion1,650 Employees

HeadquartersSacramento, CA

High Value Propulsion1,650 Employees

Moscow

Tokyo

London

Edwards AFB, CA

Jonesborough, TNUnique Specialty Materials

110 Employees

Redmond, WAPrecision Liquid

Engines350 Employees

Camden, ARTactical Low Cost

High Volume Production550 Employees

Woodland Hills, CA

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Broad Spectrum of New Opportunities

Hydrocarbon Boost

Standard Missile Phased Adaptive Approach Axial

and Divert Launch Standard Missile

Commercial E-Space

Taurus II / Bigelow

JAGM

Advanced Materials

Standard Missile

Shielding

Warhead Liners

HyFly

Tactical Propulsion for

today’s war fighter

PAC-3 MSE

SM3 TDACS

Aeronautical Components

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Summary

Questions?

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Example – Mars Science Laboratory

NASA’s Mars Science Laboratory (MSL)

Aerojet engines assisted with entry, descent,

and landing. Aerojet thrusters also provided

attitude control and trajectory correction

maneuvers during the MSL’s transit to Mars.

MSL carried eight Aerojet MR-111C 1.0 lbf thrusters, eight Aerojet MR-107U 68 lbf thrusters, and eight Aerojet MR-80B 800 lbf thrusters with a throttleable thrust range of > 100:1.

68 lbf and 800 lbf thrusters supported the actual landing.

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Agenda




Summary

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Rocket Propulsion - Summary

Rocket propulsion is an exciting, challenging, and rewarding engineering field Tough challenges for high energy propellants, high temperature /

lightweight materials, fast acting / high precision control actuation, and systems integration

All challenges and tribulations bow-down when your rocket is developed to perform successfully and reliably

Rocket propulsion enables some of our most noble endeavors Study of our planet – protect our island

Space exploration – expand human presence to other islands

Defense of human freedom – protect our way of life now and for future generations

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Agenda




Summary

Questions?

Documents

Ideas Powering Freedom Eduardo Casillas Manager, Mission Architecture Engineering Rocket Propulsion Chabot College E10 Guest Lecture