Paper Session II-A - Delta III Reaches out to the Commercial Market

1997 (34th) Our Space Future - Uniting For The Space Congress® Proceedings Success

Apr 30th, 1:00 PM

Paper Session II-A - Delta III Reaches Out to the Commercial Market

William S. Files Jr. McDonnell Douglas Aerospace

Michael C. Laker McDonnell Douglas Aerospace

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Scholarly Commons Citation Files, William S. Jr. and Laker, Michael C., "Paper Session II-A - Delta III Reaches Out to the Commercial Market" (1997). The Space Congress® Proceedings. 2. https://commons.erau.edu/space-congress-proceedings/proceedings-1997-34th/april-30-1997/2

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William S. Files, Jr. and Michael C. Laker McDonnell Douglas Aerospace 5301 Bolsa Avenue, Huntington Beach, CA 92647-2099 (714) 896-5208 / 896-5118

The dramatic growth in demand for world-wide communication has driven the requirement for lower cost, higher reliability launch services to drastically increase over the past decade. This need has developed due to the advent of commercial communication satellites and cellular com- munications. This loss created a void in launch services that has been filled since 1987 by the introduction of commercial launches on Atlas, Delta, Long March, H-1 and H-2, Titan, Proton, and Zenit. The introduction of numerous launch vehicles has created an extremely competitive market- place, and the explosion of the commercial market places ever increasing demand on the launch vehicle manufacturers to continually increase vehicle capability while maintaining or decreasing the cost of payloads to orbit. To satisfy this requirement, McDonnell Douglas has built on the reliability and cost effectiveness started in the 1950’s on Thor and the enhanced and improved performance of Delta and Delta II to develop the new Delta III system. Delta III offers increased performance and affordability, more efficient operations, and a true responsiveness to the requirements expressed by commercial launch customers. The McDonnell Douglas Aerospace (MDA) commitment to providing improved capability launch services is demonstrated by the history of the Delta vehicle family. (Figure 1) The Delta II has led the way and with 104 successes in our last 107 launches our performance stands at better than a 97% success rate. The Delta III will build on this heritage and its capabilities and benefits are as follows: •8,500 lbs (3,863 kgs) to GTO (This capability is greater than the Atlas IIAS and double the capability of the Delta II) •Operational efficiency equal to or better than the Delta II •Reliability equal to or greater than the Delta II •Competitive commercial prices The current National Space Policy states that it is in the best interest of the United States security, civil and commercial sectors to stimulate and sustain growth of space activity at the earliest possible time. In pursuit of this strategy, MDA launched the Delta III and with it provides the world a highly reliable internationally competitive launch system. In conjunction with the Delta II, MDA provides affordable access to space for over 80% of the world’s payloads projected through 2010. (Figure 2)

MDA’s approach to the Delta III is the result of a developing strategy created with the help of our commercial customer base and our existing government users. The capabilities and requirements being built into the new system have been developed by continually meeting with our customers and understanding their requirements and expectations. Internal trade studies are per- formed to evaluate the affordability of all changes and the ones that support both our customers requirements and our affordability expectations are being implemented in the Delta III launch system. Utilizing an evolutionary approach from our Delta II to our Delta III provides reduced cost and assured reliability in the new system. This evolution dates back to the 1960’s and will continue well into the 21st century. Our heritage has been as MDA has developed new launch systems, 3863 (8500) Delta III 2359 (5200) Avionics Upgrades, 10-ft-dia Fairing, Ordnance Thrusters, Extended Air-Lit GEMs Nozzles 2177 (4800) RS-27A Main Engine, Graphite/Epoxy SRMs 1995 Delta II (4400) 9.5-ft-dia Payload Fairing, 12-ft Stretch for Propellant Delta II 7925 Tank, Castor IVA SRMs 7925 1814 (4000) Payload Assist Module 3rd Stage New 2nd Delta Redundant Inertial Measuring System Stage 1633 Engine Servo-System Electronics Package (3600) RS-27 Main Engine, 8-ft Payload Fairing, Isogrid Main System Delta II 6925 1451 9 Castor SRMs, Delta Inertial Guidance System (3200) Castor IV 3920/ 6 Castor SRMs SRMs 1270 Stretched Propellant Tank PAM-D (2800) Upgraded 3rd Stage 3910/ PAM-D 1088 3 Castor II SRMs (2400) 5-ft-dia Payload Fairing Revised MB-3 Main Engine 3914 807 Payload to GTO Payload Kilograms GTO (lb) in to 3 Castor I SRMs (2000) Revised MB-3 726 Main Engine and 2914 (1600) 3rd Stage M M6 904 Delta 544 C D E J (1200)

364 (800) 181 (400)

0 1960 1963 1964 1965 1968 1969 19701971 1973 1975 1980 1982 1989 1990 1995 1998 Figure 1. Delta Modification and Growth

Annual Payload Mass Distribution COMSTAC Stable and Continued Mass Growth Model 40

30 HLV > 9,000 lbs 25

20 ILV or HLV

Number of Payloads 10 ILV 4,000 - 9,000 lbs

5 MLV 2,000-4,000 lbs 0 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 Launch Year

Figure 2. COMSTAC Mission Model 1996 Update (June 24, 1996) our reliability has been maintained or improved and our systems have continued to become more affordable. The side-by-side comparison of the Delta II and Delta III vehicle shown in Figure 3 demonstrate how we maximize the use of existing flight-proven hardware to reduce development risk. DELTA III EVOLVED TO MINIMIZE RISK

Delta II 7925 Delta III

2.9-m/9.5-ft Composite Payload Fairing 4-m/13.1-ft Common Elements Payload Fairing Avionics

2.44-m/8-ft Isogrid Single Cryogenic Fuel Tank Engine 4-m/13.1-ft Isogrid Isogrid First-Stage First-Stage Fuel Tank Liquid Oxygen Tank

Stretched Graphite Epoxy Strap-On Motors (TVC on 3 GEMs)

Graphite Epoxy Strap-On Motors Rocketdyne RS-27 Main Engine

GTO Payload (kg/lb) 1870/4120 GTO Payload (kg/lb) 3810/8400 LEO Payload (kg/lb) 5140/11,330 LEO Payload (kg/lb) 8290/18,280

Figure 3

The second step in assuring the success of the Delta III program is the approach to development and qualification testing as risk mitigation actions. The success of all tests to date provides even more confidence that MDA is going to successfully complete this development cycle and begin launching Delta III’s in 1998. Each critical hardware and software element of the Delta III system was analyzed to determine whether the Delta III should be qualified for flight by similarity, demonstration, analysis or test. Significant development testing was conducted for aerodynamics, environmental level validation, manufacturing process improvements and thermal insulation characterization. A full structural qualification test, payload fairing separation, tank cycle and burst tests, liquid rocket engine and solid rocket motor qualification tests, stage demonstration, and launch base pathfinder operations are planned to demonstrate our readiness for first flight. Examples of the successful test program include the vehicle wind tunnel test, the burst test of the solid rocket motor, RL-10 engine chill down, SRM static firing, and acoustic tests on the first stage equipment shelf and the payload fairing. Interstage Fairing Acoustic Acoustic PLF and Test Test Interstage Fairing Fairing & Fwd Second Sep Stage Structural Test Test

Stage 2 Modal Outboard Survey Test Structural Second Loads Eq Shelf LOX tank Test Struct Cycle & Burst Stage Test Stage 2 Stage 2 Sep Shock Stage Fire Test (X Stage) Acoustic

First Stage Engine Section Acoustic Test Centerbody 4M Tank Cycle Structural & Burst Engine Section Sep Test Shock Test Engine Section Structural Test

Figure 4. Comprehensive test plan in place

In addition to these development tests, we have demonstrated through program performance that we have the capability to meet both schedule and cost goals in development programs. An example of this point is the Delta III upper stage development and the SSRT program which have many similar characteristics as demonstrated in Table 1. Both programs attempted to utilize existing hardware, modify existing RL-10 engines, and develop several new components. One of the differences between the two programs is the production requirement of the Delta III. At the end of the program, Delta III must be capable of being repetitively built within required quality levels and cost targets. Table 1. Previous Stage Development Programs Support Delta III Objectives Task / Approach Delta III Upper Stage SSRT Use of Existing Available Hardware Yes Yes Development of Cryogenic Tankage Yes Yes Modification of RL-10 Engines Yes Yes Development of a new Boattail 1 Engine 4 engines Development of a composite aeroshell Fairing Yes Production processes and qualification testing Yes No Development period 30 months 18 months Another example of a development program that has similar objectives to the Delta III is the Air Force Medium Launch Vehicle I (MLV I) program. These objectives, Table 2, are to develop a launch vehicle that is more operable and has greater performance than the existing systems. The modifications necessary include improved engine performance and reliability, increase in first- stage tankage size, and the development of a new fairing. The similarity in the requirements for these equivalent activities provides MDA with a high degree of confidence in its development of the Delta III system on schedule. Table 2. System Evolution supported by previous programs Task / Approach Delta III Upper Stage MLV I Delta 6925 & 7925 Engine Modification RL-10B-2 New Nozzle RS-27A New Nozzle Increase in 1st stage tankageYes Yes Add new SRMs Yes Yes New Fairing Yes Yes Development period 30 Months 24 Months

The over 35 years of launch vehicle experience that MDA has provides the confidence for meeting the government and commercial customer requirements into the 21st century. Having increased the capability of the Delta from a 400 lb to LEO capability with an on-pad time in excess of 40 days to the existing Delta II system with a 11,000 lb to LEO capability and 24 days on-pad time, MDA continues to demonstrate a commitment to our customers needs and the execution of our program plans. Finally, involvement of our commercial customers in our process and keeping them informed on program progress through the mission integration program for their satellite has yielded customer satisfaction time and again. Figure 5 shows our process which provides, via a MDA mission manager, a single point of contact for the customer on all spacecraft integration activity.

Authority to Proceed Requirements Definition

IntegrationIntegration ProcessProcess Release Initial Mission Specification

Review/Study Spacecraft Requirements Engineering Compatibility Analysis Production Planning Loads/Thermal/Mission/Controls Joint Agreements

Environment Test Plans ProductionProduction andand LaunchLaunch ProcessProcess Range Safety Documentation Fabrication Range Network Documentation

Assembly and Checkout Flight Software Launch Processing Flight Readiness Reviews L-24 months L-12 months Launch Operations

Figure 5. Proven mission integration process As is evidenced above, the Delta III launch system is well into production. The 4 meter hardware has been demonstrated on production tooling. The remainder of 1997 provides the test bed for mitigating risk and by year end, all the major component tests will be completed. Addition- ally, the pad modifications necessary for Delta III are proceeding and are on schedule to support a second quarter 1998 first launch. The Delta III is on plan to be a highly competitive launch system that will maintain the Delta heritage of mission success.