→ TECHNOLOGIES FOR EUROPEAN LAUNCHERS An ESA Communications Production

Publication Technologies for European launchers (ESA BR-316 June 2014) Production Editor A. Wilson Design/layout G. Gasperoni, Taua Publisher ESA Communications ESTEC, PO Box 299, 2200 AG Noordwijk, The Netherlands Tel: +31 71 565 3408 www.esa.int ISBN 978-92-9221-066-3 ISSN 1013-7076 Copyright © 2014 European Space Agency

Cover image: ESA–S. Corvaja Contents

→ INTRODUCTION 02

→ AVIONICS 04

→ PROPULSION 14

→ STRUCTURES 26 AND MECHANICAL ENGINEERING Introduction

Technologies for European launchers and new market requirements For decades, the development of new launch systems has demonstrating new technologies in materials, structural and focused on increasing lift capability and reliability. Programmes mechanical components, as well as advanced avionics, under conducted on behalf of ESA have supported industry in acquiring flight conditions. and mastering the basic and advanced technologies required to develop, manufacture and operate the most successful launch – The Intermediate Experimental Vehicle (IXV) is a testbed vehicles of their times. for technologies required for atmospheric reentry and recovery. These include highly autonomous and modular Although Ariane has been setting the standard for the launch subsystems that will help to expand the flight envelope able industry worldwide for more than 25 years, new challenges will to be accessed in the future. have to be met in the coming years to ensure the viability of Europe’s autonomous access to space and to keep the – As the ESA launcher technology programme, FLPP is maturing competitiveness of the European space transportation industry, technologies to enable and sustain the development and whose skills are recognised at international level and have evolution of current and future launchers. It is also already led to major export contracts with vehicle prime investigating advanced launch vehicle concepts and contractors in the US and Japan. technologies in the longer term. Special attention is being paid to preserving the expertise and evolution of the Future European launch systems will not only have to deliver the industrial setup in the launcher sector, as well as minimising right masses to the right orbits, but they will also have to be able the environmental impact of launch vehicles through to do it for any mass and any orbit, even if it requires complex technology matured in line with ESA’s Clean Space Initiative. manoeuvres. They will have to comply with new space regulations, in particular regarding debris mitigation through the deorbiting of This brochure highlights 44 examples of new advanced upper stages. Most of all, they will have to provide reliable, flexible technologies developed or being developed by ESA’s industry and timely launch services at a fraction of today’s cost. partners for these five programmes for future launch vehicles: propulsion (liquid, solid and hybrid), mechanical and structural In order to prepare to face these challenges, ESA has started a components, and avionics. series of new programmes in space transportation: These are 44 ways of demonstrating the knowhow of European – Adapted Ariane 5 ME (Midlife Evolution) aims at improving industry and its efforts to innovate to ensure the long-term the capacity of the Ariane 5 launcher to increase its payload viability of Europe’s access to space. For each one, ESA and its capacity and enable it to perform complex deployment partners have identified the needs, confronted the technology manoeuvres to a range of orbits where the current version challenges and made the best of existing experience in order to cannot deliver payloads in an efficient way. define, develop and qualify competitive solutions that will be applicable to future European launchers. They could even, – Ariane 6 aims to become Europe’s workhorse for sometimes, be exported to support our international partners’ institutional missions together with Vega in the next own efforts. This would be win–win cooperation, with European decade. Ariane 6 is building on 10 years of activities carried systems benefitting from the scale effects to reduce their own out under the Future Launchers Preparatory Programme production costs. (FLPP). It aims at continuing to guarantee access to space for Europe, improving the competitiveness of the launch These efforts illustrate the importance of the strategic asset systems without the need for Member State accompaniment represented by European savoir-faire in multiple fields, funding for launcher exploitation. It will benefit from including thermo-structural materials, electric valves, advanced synergies with common elements developed through the propulsion subsystems and smart avionics, born from years of ongoing activities of Adapted Ariane 5 ME, in particular for research and development efforts, fostered by continuous the upper stage, and through Vega evolution. support from ESA and national agencies. This unique expertise is key to Europe maintaining its leading position in – Vega is ESA’s new vehicle for lightweight missions. It autonomous access to space, a prerequisite for the success of addresses the lower segment of the launch market while all other European space ventures.

Background image: ESA–S. Corvaja → AVIONICS ESA–S. Corvaja → INTELLIGENCE INSIDE

Future space vehicles will have to be by new-generation processors and able to complete less generic and more the impressive advances made in complex missions with many new new sensor technologies. The alliance requirements. To perform these at a of the two will help a vehicle to competitive cost, they will need new monitor the status and health of its flexible, adaptable and robust avionics, own subsystems in real time and in easier and safer to operate in order to flight, and to adapt its performance streamline mission management and accordingly. Moreover, the use of reduce human intervention. Modular smarter, lighter, smaller and less power- designs will be key to achieving this consuming avionics will reduce the mass capability, taking benefit from the of equipment bays and thus increase rapid rise in computing power made payload capacity.

→ VEGA ONBOARD COMPUTER

RUAG Space

■ Programme ■ Other applications vega ariane 5 ariane 6

■ What is it for? ■ What is European industry’s expertise? The onboard computer is the launcher’s ‘brain’. It integrates the RUAG Space (formerly SAAB Space) has developed all of the mission’s flight software and processes the data from the vehicle’s computers flown on the various versions of the Ariane launchers sensors, including inertial navigation, and delivers commands to for more than three decades. They all feature a robust and fault- the stages and subsystems to achieve the required orbital injection tolerant design, high error detection coverage and components parameters. immune to radiation events.

■ What is the technology challenge? ■ What will be the resulting competitive edge? Compared with the computer used in Ariane 5 before 2012, the A powerful onboard computer can run more sophisticated software Vega computer offers far more processing power, yet is significantly that will improve flight control robustness and enable complex smaller and lighter. missions with multiple payloads to be injected into different orbits.

6 breadboard testing. for reducing the harness mass be will assessed through targeting simplification of software applications, and optical fibres such as Time Triggered new Ethernet, redundancy features The ofapplicability emergingprotocol standards forlaunch systems challenge? technology is the ■ What would likely be obsolete before their firstflight. architecturesbut notpre-development on of actual systems that focus spaceactivitieswill on requirements application and pace.Preparatoryfast very a at evolving are systems,which critical newbased on technologiesin aerospace electronics otherand time- the includes evaluationlaunchers ofinnovative avionics concepts The search for cost efficiency in the design of newa generation of it for? is ■ What → ADVANCED AVIONICS → ADVANCED to the communication systemreport and to the ground. logic by reporting telemetryall and commands itissues receivesand commands power,and withredundancy, while controllingitsown Thehas MFU to ensure efficient and redundant delivery of challenge? technology is the ■ What redundancies powersand electrovalves. 10 Vegait controls totala of pyrotechnic28 functions withtheir power todistribution the different subsystems. Inparticular, on The Multi-Functional Unit (MFU) provides control, monitoring and it for? is ■ What →  ■ Programme ■ Programme

vega MULTI-FUNCTIONAL UNIT flpp CRISA Other ■ Other applications Airbus Defence &Space Other ■ Other applications ariane 6 vega

pride pride

ariane 6 require costly requalification processes during its operational life. robustnessprevent and and of early theNGL, obsolescence that would reliableand state-of-the-art avionics willimprove the capacity, flexibility architecture when designing the Next-Generation Launcher (NGL).Robust This keybe assessment will to decisions themaking sound on avionics ■ What willbe the resulting competitive edge? (Austria, Switzerland, Sweden) and TTTech (Austria). (Ireland), CRISA (Spain), Fiber Sensing (Portugal), RUAG Space consortium includes competences from ACRA Control (Ireland), In Tune managementsystem for the International SpaceStation. Its Ariane 5, the Automated Transfer Vehicle and an onboard data acquired the in development ofnumerous avionics systems, such as isleading Airbus the preparatory its experienceon activities, building ■ performances are critical forthe vehicle’srobustness reliability. and Theis MFU a critical element oflauncher’s the avionics. Its ■ What willbe the resulting competitive edge? payload loops.More have units such than 200 flown. within the launcher, like electrovalves, pyrotechnic devices and actuator drivemostcontrol ofunits the supervision and actuators CRISA has providing been sequential electronics for These 5. Ariane ■ What is European industry’s expertise? What is European industry’s expertise? avionics 7 8 → SAFEGUARD MASTER AND REMOTE UNIT Unit and two Safeguard Remote Units. two independent chains, each consisting ofSafeguard one Master system failure on board the vehicle. For maximum reliability, it has haschain toand remain operational eventhe eventin of major a This criticalsystem is completely segregated fromthe functional challenge? technology is the ■ What couldbecome threata topeople or to the environment. command fromlauncherifthethe veersoff ground course and autonomously casein ofuntimely stage separations orunder The safeguard system enables flight bothtermination it for? is ■ What with the inherent advantage of high multiplexing capability. allow theintroduction of fibreBragg grating sensor technology, for assembly,integration testing and (AIT). In addition,itcould electromagneticenvironmentreducedespecially masscost, and and several major improvements: high data rates, immunity to the Thereplacement of copperby harnesses optical fibres yieldwould challenge? technology is the ■ What bay the equipment through heavy a harness of copper cables. behaviour.launch The network ofis traditionally sensors connected to monitored transmittedand to the ground forprecise monitoring of the This robust. meansand that numerous parameters have to be To achieve success high a rate, launch a system has to beboth reliable it for? is ■ What SENSOR GRATING SYSTEMS BRAGG → FIBRE ■ Programme ■ Programme vega flpp Selex Galileo Fiber Sensing Other ■ Other applications Other ■ Other applications ariane 6 pride

ariane 6 new generations oflaunch systems. systems, designed for worst-casescenarios, willberequired for all Guiana and are likely to become an international standard. Safeguard New regulations launcheron safety have introduced been French in ■ What willbe the resulting competitive edge? systems for space applications,both satellites on launchers. and experienced provider of power distribution pyrotechnicand control Involved space in activities since is Selex Galileo an the 1960s, ■ What is European industry’s expertise? conventionaltechnologies available. health monitoring, having become the natural substitute for all reliable suitable and technology forlong-term structural sensing and FibreBragg grating sensor technologyis considered tobe themost ■ What willbe the resulting competitive edge? offor risks futurethethedesign assess advantages and launcher avionics. AIT. Abreadboard harness will be tested in the laboratory environment to optimisation anddata acquisitionsystem and analysis,particularin for technology under the FLPP programme, emphasising harness the energy,rail oil, and aerospace Itindustries. has studying been this advancedsystemsmonitoring Bragg fibre on based grating technology for Fiber is Sensing leadinga company the in development production and of ■ What is European industry’s expertise? avionics

→ TELEMETRY ANTENNA

Rymsa

■ Programme ■ Other applications ixv vega pride ariane 6

■ What is it for? resulting radiation pattern complies with the stringent conditions The need to relay information from the launch vehicle’s system and imposed by the limited visibility windows and the presence of the sensors requires a set of antennas for reliable transmissions to the thermal protection layer. ground in various flight configurations. On Vega, these are classic conical S-band transmission antennas. IXV relies on aperture- ■ What is European industry’s expertise? coupled microstrip patches with a multilayer structure. Rymsa has more than 30 years of experience in the design, manufacture and supply of onboard antennas and passive ■ What is the technology challenge? microwave equipment for satellites. Vega’s antennas have their own thermal protection to combat the thermal fluxes during the ascent phase of the flight. IXV will have ■ What will be the resulting competitive edge? to withstand much higher aerothermal conditions so the antenna is The proposed patch technology for the IXV antenna design is designed to operate under a fibreglass dome covered with thermal highly efficient and effective because it is simple and easy to insulation. The antenna’s design is optimised to cope with the mount, while offering a high bandwidth. signal degradation caused by this protection and to ensure that the

→ ONBOARD BATTERIES

Saft

■ Programme ■ Other applications ixv vega pride ariane 5 ariane 6

■ What is it for? upper stage, one for thrust vector control and the other for the During flight, all the electrical power to feed a launcher’s vehicle’s guidance, navigation and control systems. They supply subsystems is provided by batteries, which have to deliver power at a lower rate but for a much longer time. continuous and stable performance in all kinds of dynamic and thermal conditions. These batteries support vital launch vehicle ■ What is European industry’s expertise? systems, including safeguard and pyrotechnic subsystems, thrust Saft has over 40 years of experience in the design, development, vector control, pump activation, avionics and telemetry. manufacture and supply of onboard battery systems for satellites, launchers and other space vehicles. On Ariane, Saft batteries are ■ What is the technology challenge? found in the solid-propellant boosters, the cryogenic core stage, the On Vega, the batteries play a key role by powering the cryogenic upper stage and the vehicle equipment bay. electromechanical actuators for the thrust vector control system on each stage, and in particular on the P80, the largest solid stage ■ What will be the resulting competitive edge? ever to use such actuation. Saft has developed innovative Li-ion The high performance and reliability of European space-qualified battery systems for this purpose. One type of cells has been batteries have already guaranteed their export to international prime selected for the first three stages, which require high current contractors, telecom operators and space agencies. Their continuous delivery. Another type is used in the two sets of batteries on the improvement will increase their market share.

9 10 TheOBSW willbe first validated onSoftware a Validation Facility ■ What is European industry’s expertise? perfectlyperform forof duration. mission the all and upgraded in flight. It will have to be highly autonomous and phase. This means that OBSW its notwill be able to bemaintained dynamic,evolving flight conditions, especially during the reentry Unlikeother spacecraft, IXV will fly a short mission with highly challenge? technology is the ■ What errorhandling. taskswell as applicationsoftware as GNC and for MVM packagesupport deviceand drivers, thewhile servicelayer the supports two layers: the basic layer provides the operating system, board a (MVM) as well as guidance,navigation and control(GNC). It consistsof incorporatesvehiclemanagement for and mission the algorithms the The IXV onboard software (OBSW) isunder development by GMV and it for? is ■ What TECHNOLOGY SOFTWARE → ONBOARD with the IXV vital functions, telemetry sensors and links. constraints the on development of thenew interface capabilities Power Management System flown on Proba-2, imposes challenging The highly modular scheme, adapted from the Advanced Data & challenge? technology is the ■ What to reentry missions,it was configuration. in single-chain a designed comply with themass stringent thermal constraintsand inherent tasks from release its by the launcher to recovery its at sea. To bein command of ofall the vehicle’s functions and data-handling complex as mission a as IXV’s,On onboardthe computer will (OBC) it for? is ■ What →  ■ Programme ■ Programme

ixv ixv COMPUTER ONBOARD IXV QinetiQ GMV, GTD Sistemas de Información Other ■ Other applications Other ■ Other applications pride pride SVF configuration files Test procedure script files script highly autonomous interplanetary exploration probes. where a high level of reliability and robustness is required, and for way for more demanding missions, inparticular inhuman spaceflight, Europeanindustry’s capacity to develop such systemspave will the Europe terms in of complexity, reliability, autonomy robustness.and The OBSWIXV is newa step in flight software developmentin ■ What willbe the resulting competitive edge? segments. ground and for space applications,monitoring control especiallyand in systems Información has become leading a company software in development projects, missions platforms.and In the last decade, GTD Sistemas de onboard software and theirmaintenance systems, for kindsall of validationinvolved development, verificationthe design, and in of verification and validation. Since its creation in1984,GMV has been Test Bench. In parallel, GTD will conduct an independent software developed on theby project’s IXV thenqualified GMV and Avionics satellites applications. and compatibility of QinetiQ modular OBCs with a much wider range of The new interface capability, based on a 1553bus, will ensure the ■ Proba-1satellites.-2 and interplanetarythe missions,including highly and autonomous systemsthan100 delivered for spacemanned stations, satellites 40 years of experience as spacea systemintegrator, morewith (formerly Belgium QinetiQ Verhaert) benefits from more than ■ What is European industry’s expertise? What willbe the resulting competitive edge? Software Facility Validation (SVF) Supervisor Test TSIM CommsManager SVF Controller OBSW Image OBCSim Sensors &Actuators)Sensors IXV-Avionics Models IXV-Avionics VehicleDevicesIF IXV-Vehicle (Devices) RWSim OBCI/O Boards (DKE, Test results files Test report files record theloads at splashdown.The drop test required also orderin instrumented tomonitor the descentparameters and to beintegrated tested.and The prototype was extensively thebeacons the and ablativeprotection thermal system, whichhad assembly, the parachute and flotation panels, the flotationballoons, The prototypeIXV incorporated modelsflight of the parachutemain challenge? technology is the ■ What an altitude of 3000min June 2013 and safely splashed down. prototypeA full-scale real flight. dropped was helicopterbya from vehicle, have been assessed in conditions as close as possible to the trigger these events, as well as therecovery procedures for the of theperformance themission, of the softwareflight designed to inflate flotationballoons andactivate beacons. Toensure thesuccess deploy parachute main a immediatelyand after splashdown it will of At descenttheend its following reentry,atmospheric will IXV it for? is ■ What →  DATA-HANDLING SYSTEM DATA-HANDLING ETHERNET-BASED MODULAR AND → SMART toolsthe spaceand in used industry. compatibilitywith the assembly,integration testing and processes with space constraintshas tobe tested as its qualified, well as and innovativehighly space approachcompliance in its applications and theAlthough Ethernet protocol on the isuniversal itis ground, still a challenge? technology is the ■ What back at acceleratedvisible.stationis ground when a speed datathespacecraft when play and intozones no-visibility them flies protocolEthernetthe on tuneablecore to a store and able algorithm, ACRA Control is developing innovativean modular systemand based encodeprocess and these data to the transmitterback to the ground. thusrequire an efficient data-handling system to acquire, store, heterogeneoussubsystems. data,sensors and from multiple It will Duringitsmission, IXV will collect verylarge amountsof it for? is ■ What ■ Programme ■ Programme

ixv DESCENT AND LANDING SYSTEM SYNTHESIS TEST TECHNOLOGY ixv CIRA ACRA Control Other ■ Other applications Other ■ Other applications pride ariane 6

pride future projects involving reentry unmanned vehicles. reinforceEuropeanindustry’s attractiveness partneron valuable asa the descent phase. landing Masteringand this technology will projects by other national internationaland space agencies during highly critical, as demonstratedby the failure of somesimilar fidelity the conditions of thefinalpart of themission,whichis IXV With this testing technology, itispossible to reproduce with high ■ operationalrecovery and scenario thetest same within range. Vehicleprogramme. These droptests were conducted similar under a drop test campaigns in2007 and 2010under the Unmanned Space the ItalianCIRA, aerospaceresearch centre, has alreadyconducted ■ What is European industry’s expertise? control mission centrerecovery a and team. complex coordinated operations between helicopter, military a the orbit spacecraft to deep-spaceprobes. missions withlimited accessto groundstations, fromlow-Earth and-play’ concept for applyto will datahandling range wide a of imposing strict timing or transmission order.This modular ‘plug- very high-bandwidth requirements (up to several Gbit/s) without bundles, thusreducing therisk ofhuman error, and can support of complexintegrated systems. It the ofamount limits serial cable The Ethernet protocol facilitates the integration design, testingand ■ What willbe the resulting competitive edge? industry. realtimeas dataprocessing ground stations to the aerospace datarecording networksairborne acquisition and systems well as ACRA Control has accumulated 20 years of experience in supplying ■ What is European industry’s expertise? What willbe the resulting competitive edge? avionics 11 → PROPULSION ESA/CNES/Arianespace/Service Optique CSG → THE THRUST YOU NEED AT THE BEST COST

Propulsion is one of the primary cost propellant consumption), while reducing drivers in any launch vehicle design. recurrent manufacturing costs. This can So, the quest for higher competitiveness be achieved through the introduction has to pass through the search for the of new propulsion cycles (expander or highest efficiency levels in liquid and staged-combustion), optimised designs solid propulsion systems. The goal is not for subsystems, new materials and necessarily to get the highest thrust at the best use of decades of industrial the least cost, but to deliver increased investment in technological knowhow, in performance in terms of reliability, order to develop not the most powerful availability, throttle and restart capacity liquid engines and solid motors but those as well as specific impulse (efficiency in that best fit the needs.

→ THRUST CHAMBER TESTING AT SIMULATED ALTITUDE

Airbus Defence & Space

■ Programme ■ Other applications ariane 5 ariane 6

■ What is it for? which allows improved performance and higher engine reliability, Since it is based on an expander cycle, which uses its cryogenic operations of the thrust chamber required five control loops propellant to cool its thrust chamber and then the resulting operating in parallel, which had never been done by Airbus before. gaseous propellant to drive its turbopumps, the Vinci engine’s performance requires a perfect knowledge of its thrust chamber ■ What is European industry’s expertise? behaviour under flight conditions. Airbus and DLR have four decades of experience in conducting thorough firing test campaigns in Lampoldshausen. For this ■ What is the technology challenge? campaign, following four acceptance hot firing tests, To conduct such characterisation tests on the ground, the P3.2 high- 28 development firing tests through November 2011 logged pressure cryogenic test facility in Lampoldshausen, Germany had to 2605 seconds of cumulated thrust chamber firing time monitored undergo major modifications from 2009 to mid-2011 with a complex by over 240 sensors and completed the validation of the Vinci arrangement of feed lines and control valves to adapt to the 380 bar thrust chamber design. of the liquid hydrogen inlet. As for the development of the HM-7 engine in the 1970s, it also required the installation of a ■ What will be the resulting competitive edge? vacuum chamber to simulate high-altitude operations and a This campaign also demonstrated the possibility of adapting the supersonic diffuser to maintain a low-pressure environment while existing testing facilities for highly complex test campaigns for the thrust chamber was performing. However, due to the new cycle, future programmes. 14 RuagSpace Austria took benefit of three decades of expertise ■ What is European industry’s expertise? temperatureand ofinterface plates. strainof itsstructure, angles andcycles, forces torque and loads torqueloads,deformation clearance and ofCardan the well as as enableand flight accurateendure during measurement of friction developed that would simulate theharsh conditionshave it will to To demonstrate the joint’s performance, a special test had rig to be challenge? technology is the ■ What high-stress conditions. the stage. Ithas to operateunder verylow temperature and (120K) steering of order thein Vinci to engine orientate thrust its guide and The ball-bearing joint – or Cardan –is the articulation that allows it for? is ■ What low-voltage the lines, and high voltage required to produce the toplume ignite the engine.The spark systemplug is fedby two (supportedby redundant electronic systems) to generate hot a from blowdown a system twoand redundant sparkplugs The Vinci Ignition System uses gaseous (VIS) oxygen hydrogenand challenge? technology is the ■ What restart capability is a new ignition system developed by APP. trajectories. ofOne the features that givewill the itsVinci engine delivery ofpayloads transferinto high-perigee or orbits escape from the deploymentAriane 5 ECA, of satellite constellations to the complex manoeuvres that cannot currently beperformed by the capability to toperformup five and thus burns to conduct Unlike its predecessor HM7, the cryogenic Vinci engine will have it for? is ■ What → RESTARTABLE CRYOGENIC ENGINE IGNITION SYSTEM IGNITION ENGINE CRYOGENIC → RESTARTABLE JOINT TEST RIG TEST JOINT →  ■ Programme ■ Programme

ariane 5 LOW-TEMPERATURE BALL-BEARING ariane 5 Aerospace Propulsion BV Products Ruag Other ■ Other applications Other ■ Other applications ariane 6 ariane 6 performancepropulsion system. system, required to integrate the Vinci engine into a high- measurement and systemskeyis to the qualification of this critical This combinationmechanisms,thermal controlof demanding highly ■ What willbe the resulting competitive edge? accuracy the data. highest in the platform, maintained atwhichis temperature ambient to ensure rig’s structure. Friction moment is measured with a quartz insulation flowing and thermal from pipes throughthe embedded plates temperatures are precisely adjusted nitrogen with liquid load combinations theinterfacejoint while theball-bearing on computer-controlledhydraulic actuatorsto applyrequired all 3-axis tosupport equipment design an advanced testbench thatuses in complexspace mechanisms for satellites, groundlaunchers and system that used forhas been of all the Vinci testing engine to date. This isnowdesign available to replace the non-redundant ignition ■ What willbe the resulting competitive edge? particularin work conducted on sparkplugs since2008. developed by APP on redundant ignition systems since 1998, and toup five sequences,incorporates ignition knowhowthe all Vegaand robustThisnewto vehicles.highly able design, conduct cryogenicpropulsion systems solid-propellant and flownAriane on (formerlyAPP Stork) has already produced hundreds of igniters for ■ much like in traditional internal combustion engines. electric arc is generated by two ignition coils – oneper plug What is European industry’s expertise? propulsion 15 16 → HIGH-PRESSURE BISTABLE ELECTROVALVE DEPLOYABLE→ COMPOSITE NOZZLE To achieve such constraints, the innovative proposeddesign by ■ costs. recurring low with together temperatures, technical requirements include limited mass and size In toaddition bar pressure 400 levels and very low operating challenge? technology is the ■ What stage commandsystem in flight. theon theground, otherand to todistribution ensurehelium the poppet electrovalves, oneto ensure or emptying of filling the tanks developing load a plate thatdesign incorporates two identical on the pad. tanks, filled To support this system, TechspaceAero is of Adapted Ariane 5MEhas to carry a set of high-pressure helium To pressurise propellant its tanks, the new cryogenic upper stage it for? is ■ What largemass savings. systems. The use of composite materials instead of metal yields oxidationprotection two and carbon–carbon cone-to-conelatching conicalrings coated withthermostructural carbon–carbonradiative 2180 mm. It consistsof three carbon–carbon/silicon carbide increases thenozzle’s exhaust diameter to mm from 700 nozzle m-long extensionThe 2.85 developed by Herakles for Vinci challenge? technology is the ■ What mass interstageand length at launch. However, not it should translate into a tremendous increase in betterhigher– specificthrust perunit impulse mass of propellant. nozzle to channel the gas flow.Such an extension translatesinto a by canbe obtained increasing thelength of section exhaustand its A significant improvement in engine performance at high altitude it for? is ■ What ■ Programme ■ Programme What is European industry’s expertise? ariane 5 ariane 5 Techspace Aero Herakles Other ■ Other applications ■ Other applications ariane 6 ariane 6 industry as well as in ground-based gas management ground-based gas in systems.as well industry as the be space in will also applicable design toother purposes, multiple benefit will also from economy of more scale–the all since this With two electrovalves similar toperform the tasks,Techspace Aero ■ What willbe the resulting competitive edge? mass. integration of stop end impact the on overall limited sensors with massof thesize actuator.the and Theconcept the allows also helium-assistedtopoppetreducemanufacturing well asa cost, as architecture toreduce of thenumber parts thusthe and closing the valve. It includes innovativean bistable solenoid through the valve to assist the electrical actuator or opening in operational reliability, use thewill pressure of flowingthe helium industry with more than 12000 flights units flown with 100% TechspaceAero, provider long-time a of valves for the space performance of Vinci-basedupper stages. technologies, bekeywill in achieving the targeted payload Thisrobust effective flight-proven basedon and design, ■ What willbe the resulting competitive edge? in vacuum conditions. engine. More than 30 deployments were three performed, including transient sustaining and loads shutdownatignition and of the up to sevenlife durations,reaching temperatures of over1700K extensionshave testedbeen under simulated altitude conditions to full-scale developmentmodelsof Since2006, nozzle Vinci extension systems flowninternationaland on them launch vehicles. Herakleshas already developed deployable compositenozzle development of nozzles, inparticular for Ariane 5booster stages, A leader in thermostructural composite materials and in the ■ What is European industry’s expertise? adjustment to ensurelife duration fast optimisation, thermal heat-resistant materials in conjunction with inner wall heat exchange stability. Itis also studying cooling channel layout anddesign and toinjector maximise designs combustionefficiency liquid–liquid and Ariane 5 Vulcainengines fortwo decades,isstudying liquid–gas and providing hasbeen whichthe combustionAirbus, of chambers challenge? technology is the ■ What SCORE-D (Staged Combustion Rocket Demonstrator) Engine project. thewhile staged combustion cycleunder evaluationis through the inherently reliable, has introduced been with the Vinci engine, technology effort space in propulsion. The expander cycle, which is elementofimportant cryogenicis an theresearch engines and thanthe gas-generatorimpulse cyclecurrenton European used The mastering of new combustion cycles providing higher specific it for? is ■ What AND STAGED COMBUSTION ENGINES STAGED COMBUSTION AND →  ■ Programme

flpp FOR TECHNOLOGY EXPANDER COMBUSTION Airbus Defence &Space Other ■ Other applications new new 7 July 2010 7 July Le Figaro CEO Space of Astrium Transportation Charmeau Alain live. to adventure awonderful it is development ariane 6 technologies Working on a new launcher, it’s finding the finding it’s launcher, anew on Working

future launchers and operations costs. For the teams, teams, the For costs. operations and of tomorrow and mastering the the mastering and tomorrow of launcher industry. launcher improve maintain and the competitiveness ofEurope’s space increase An the efficiencyin of propulsion systems help would to ■ What willbe the resulting competitive edge? characteriseand the operatingbefore domain testing.full engine nozzle extension technologies.These tests validatewill the design full-scaletesting subsequent of the combustion chamber and representativeness of subscale test conditions support ofin The consolidation of thephysical modelsis essential to ensure the ■ What is European industry’s expertise? consolidateSCORE-Dimprovedesigns. Vincithe and and to testreal thesetechnologiesin hot-firing conditions atlow cost, to combustion chambers are being manufactureddesigned and order in condensation and avoidance.equilibrium demonstratorSubscale propulsion 17 18 → SANDWICH TECHNOLOGY NOZZLE EXTENSION FOR STAGED TURBOPUMP → HYDROGEN ENGINE COMBUSTION The inner cone features machined byducts automated ultrasound- The hundreds of havetubes replaced been by two sheet-metal cones. ■ process tomanufacture patentedusing thema sandwich technology. cryogenic nozzles for three decades ithasand developed newa AerospaceGKN (formerly Volvo Aero) has Europe’s been leader in challenge? technology is the ■ What aroundmandrel. a withmany hundreds of thin tubesmanually welded together However, it requires complex and costly manufacturing processes, nozzles withstand temperatures thehigh of the exhaust gases. structureis a commonly used approach to ensure that engine Regenerative coolingby the circulationof the cold propellantinside it for? is ■ What helium-free orderin sealing to or suppresslimit theneed for helium This advancedincorporates turbopump new approaches termsin of ■ What is European industry’s expertise? the SCORE-D project. maturedparticularin throughFLPP to develop such a turbopump for for Ariane 5’s Vulcain engines, is using innovative technologies Snecma, which designed manufacturesand the hydrogen turbopumps challenge? technology is the ■ What stronglyin a cost-constrained approach. compressiblea Moreover, cryogenic fluid. these challengesare met and(20K) pressure (up to 380bar) conditions, while operating with reliabilitywithin limited a volume under andextreme temperature hydrogen turbopump, which has to deliver high power and high In a cryogenic oneof engine, themost critical subsystemsis the it for? is ■ What ■ Programme ■ Programme What is European industry’s expertise? flpp flpp Snecma Other ■ Other applications Other ■ Other applications Aerospace,Force GKN Institute ariane 5 future launchers

ariane 6

future launchers contouring, curvedsurface weldingor ultrasonic control. processes have been developed, especially to improve nozzle programmes, upgraded sandwich nozzle extension manufacturing international To partners. ensure readiness for future European Itis also applicable to other Europedeveloped engines in orby Vulcain 2 engine and as part of the FLPP High-Thrust Engine project. This new technology has already hot-fire been tested5’sAriane on ■ What willbe the resulting competitive edge? result is a substantially stiffer moreand robust sandwich nozzle. which also introduced new non-destructive testing processes. The welding technique was developed by the Force Institute Denmark, in realtimeusing X-rays that Thisdetect innovative the hidden weld joint. outer cone is welded onto the inner oneby automated laser welding millimetre in sheet metal with a minimum thickness of 0.6mm.The tocontrolled milling achieve precision a ofhundredths some of a systems. launch future European would play a significant role inimproving the competitiveness of vehicle,increase efficiency an in the keeping while costs down Since propulsion accounts for largea partthe in cost of launcha ■ What willbe the resulting competitive edge? which translates into a reduced size and manufacturing cost. demanding overallpressure requirements with only a two-stage design, level of pressure perstage, rise pump thus meeting the engine’s highly technologyimpeller – inherited also from TPX– ensures the highest rotationalrotorspeeds withgood dynamics.Finally, newthe open TPX programme are replacing traditional ball bearings to allow higher new clutchable axial bearings, hydrostatic bearings developed under the resistant tohydrogen For embrittlement. rotor guidance, together with flow in the subsonicenvironment as well asuse the of materials aerodynamic new design, blade profilesare proposed forhigh mass gas ventingbefore In start. the engine turbine’s mechanical and generalisationof control electric valvessensors and position with actuation requirements. Efforts have made been also on the cryogenic environments, forboth secured operationsreduced and retraction system, toimprove static and dynamic sealingin These valvesincorporate new technologies, such as seala ■ What is European industry’s expertise? SCORE-D project. propulsion applications,has developedsetof a valves for FLPP the Techspace Aero, Europe’s leader long-time regulation in valves for space Toincrease theperformance of such valves as well as toreduce cost, challenge? technology is the ■ What hottemperatures. gases athigh and very valves tubing and with forbothpropellant at cryogenictemperatures The staged-combustion cycle performing harsh conditions, implies it for? is ■ What →  ■ Programme

flpp VALVES ENGINE STAGED-COMBUSTION Techspace Aero December 2011 December Périodique bimestriel de l’uWe CEO Techspace of Aero Prete Yves it makes you proud. you makes it Suffering acollective it’s so top, the to pulled are staff technology advanced an In market. the on difference the make to us enables engineers skilled many so more the all and engineers, many so have we that fact The Other ■ Other applications future launchers together to achieve your final goal is pleasant, and pleasant, is goal final your achieve to together

and particularly and suited to first stage or sustainer stageapplications. based the on staged-combustionEngines cycle arehighly efficient ■ What willbe the resulting competitive edge? especially for gearsealing and systems. effortsSimilar have made been with hot-gas valve technologies, designs, adapted cryogenictest benches were developed.also valves’ mechanical design. To validate and qualify these new to torquelimit loads and attenuate order shocksin to the optimise positioning accuracy. New electronic controls have introduced been torque – thus and the power consumption – increasingwhile the optimised gear ratio order in tothe requested minimise actuation apply linear forces has improved been through transmission with externalpower supply.The use of rotating electric actuators to by the propellant pressure itselforder in tothe need for minimise of propellant-aided valves, where part of the actuation isprovided systemstechnology, and monitoring, associatedhealth engine with venture, all the the all venture, success. success.

propulsion 19 20 PROPULSION STORABLE → HIGH-PERFORMANCE MMH (monomethylMMH hydrazine) propellant flow. This has to be its combustion First, chamberis too to small be cooledby the sole Several technology challengeshave tometbe for of engine an that size. ■ What is European industry’s expertise? advanced engine in the 3–8kNrange programme, is Airbus assessing new technologies to develop an bothengine, developed byGermany. in Airbus Under the FLPP thrusters for geostationary satellites and Ariane 5’s 29kNAestus Such engine an would have to Nfit between apogee 500 the challenge? technology is the ■ What not covered that is currently industry.of by thrust European the use of high-performance storable propulsion systems in rangea transferenhancedmissions with orbital some require capability will In the future, the development ofnew ‘smart’ upper stages or of it for? is ■ What ■ Programme flpp Airbus Defence &Space 2009 release press Nammo Products Executive Vice President, Missile Nammo Brandtzaeg Morten market space the in compete demanding active an with years, many for Norway in anational been has technology space that fact The important important Norwegian of success the utmost of is Agency, Space European the Other ■ Other applications vega milestones Division customers and demonstrate our capability demonstrate and customers in our continuous our in space industry space . spacecraft, developed Europe in or underinternational cooperation. manoeuvrableupper stages tointerplanetaryprobes or servicing to used powerThis couldbe engine futuresmart vehicles, from highly ■ What willbe the resulting competitive edge? lower-cost metallicradiative nozzleusing skirts cooling. innovative processes are being matured to manufacture lightweight and orderin to test large a array of configurations tunings. and In addition, have introduced been as modular a feature the in demonstration engine complete injector plates. Systems todesigned prevent high frequencies testedhot-firingunder as firstconditions, single elements, then as inspection and cleanliness requirements. Several havedesigns been The size ofis theinjectors a challenge too termsin of manufacturing, has been be designed testedand will hot-firing under conditions. characterisation the in laboratory, NTO-cooledan combustion chamber which has a lower margin in temperature before boiling. After complemented by regenerative cooling NTO using (nitrogen tetroxide), effort to satisfy to effort importance for for importance . Our contracts are are contracts . Our

membership

priority to to in in

combinations withdifferent additives. to characterise2003 performance of various fuel/oxidiser has investigating been Ariane 5, hybrid modern propulsion since rocket more solid than1000 motors forbooster separation on Norway’shas which flownspecialist, Nammo,solid-propulsion a challenge? technology is the ■ What propulsion atlowermuch a manufacturing operating and cost. In many ways,it combines the advantages of solid andliquid duringprocessing than traditional solid and storablepropellants. non-toxic and storable oxidiser,both easier to transporthandle and manyits advantages is the capacity to usenon-explosive solid fuel throttle, shutdown and even restart (like liquid propulsion). Among highthrust (like solid propulsion) but with a capacityto control oxidiser to deliverliquid fuel a and solid a uses propulsion Hybrid it for? is ■ What for high-precision manoeuvring. Whenever a stronger boost isneeded, decompose itinto hot gas to deliver low, modulated orthrust pulsed be used as monopropellant by flowing througha catalystunit that will oxidiser, both non-polluting storable.and The hydrogen peroxide will thruster will be fed with high-strength hydrogen peroxide, a powerful thrust levels, with high reliability at reduced cost. The proposed SCATE monopropellantand propulsion to achieve a wide range of modulated integrated ingenious an thruster concept, which combines greenhybrid For Nammo, this purpose, hybrid pioneerpropulsion, hasa in designed challenge? technology is the ■ What phasesprior to reignition. Vinci engine (SCATE), toalso used forbe propellant settling at theof end cruise require stage flexible and reliableattitudewill a control system release of payloads, its the Adapted ME cryogenic 5 Ariane upper To perform complex manoeuvres and accurate positioning for the it for? is ■ What ATTITUDE-CONTROL THRUSTERS MONOPROPELLANT AND → HYBRID →  ■ Programme ■ Programme

flpp DEMONSTRATOR PROPULSION HYBRID ariane 5 Nammo Other ■ Other applications Nammo, SAAB-Dynamics Other ■ Other applications Lander propulsion Nanolauncher rocketSounding ariane 6 in termsin of operationalperformance procurement and cost. tobut propulsion also demonstrate hybrid advantages its quantify and The objective isnot only to increase European industry’s knowhow in ■ What willbe the resulting competitive edge? which could later beintroduced in future rocket sounding designs. demonstratorlead towill the testing of a flightworthy version, With the developmentof dedicatedtools, analysis design thisand demonstratorengine for‘battleship’ full-scale testing. ground A configuration was selectedthen for the development of a hybrid combinations has made been for testing at subscale level. Under ESA’s FLPP a selection of the most promising propellant ■ What is European industry’s expertise? use on future rockets sounding microsatelliteand launch vehicles. under wayhybrid technology on to scale the concept up for possible In toaddition high-flexibility useon a futureupper stages, studiesare ■ What willbe the resulting competitive edge? the monopropellant mode for ME. 5 useAriane on In 2011,more than40 additional tests were conducted to optimise monopropellantconcept, hybrid mode in mode. in 20 29 and Programme, Nammo performed 49 firing tests of its thruster behalfon In of 2010, ESA’s propulsion Hybrid Technology Readiness ■ itcan– andbethrottled, shut down restarted and atwill. highly energetic solid propellant – thus reducing risks during handling propulsion Unlike solid systems, hybrid propulsion notdoes require a orderchamberin tofuel solid a burn deliver and higherthrust. a the decomposed hydrogen peroxide be fedwill into hybrid a propulsion What is European industry’s expertise? propulsion 21 22 → P80 NOZZLE → P80 BENCH → TEST PROPULSION ADVANCED SOLID order to reduce production costs. hasand since upgrading been its towardsdesign fewer in elements producing nozzles for 5’s Ariane EAPs since the programme’s inception Herakles1970s, (formerly Propulsion Snecma has Solide) been EuropeanA leader thermostructural in composite materials since the challenge? technology is the ■ What could bereused for future evolutions of 5’s Ariane boosters. introducingrequirements advanced low-cost and technologiesthat developed another evolution ofnozzle, its adapted to Vega’s diameter 5’sas Ariane booster solid stages (EAPs). Herakles has As Vega’s first stage, solid rocketP80 the motor has the same it for? is ■ What booster configurations for new with to experiment bench test comprehensiveand forneed the propulsionstudies, flexiblea solid constraints full-scale firing testsare and too expensive for flexible testing isnot fully representative owing to numerous physical Ariane 5 upgrades or P120 for Vega upgrades). Since subscale critical in the upgrade of existing motors (P250 and MPS-2 for especially on segmented propellant loads, which can behighly Among the primary concernssimulations. are pressure oscillations, satisfactory evaluation ofnew through designs numerical of propulsion isnotsolid yet fully This prevents modelled. Despite large a ofamount test flight and data, some of physics the challenge? technology is the ■ What demonstratedby selected Vega.the designs for5 and Ariane as stages, forbooster core thrust and high to deliver solution propulsion hasSolid identified longbeen asa cost-effective it for? is ■ What ■ Programme ■ Programme vega flpp Herakles Avio Other ■ Other applications ■ Other applications ariane 5 ariane 5

ariane 6 vega

ariane 6 ofmass, thrust vector controlrobustness. and reducing production costs – and improves the performances in terms This new nozzle architecture boththe simplifies assembly– thus ■ What willbe the resulting competitive edge? and enhanced thermalprotection. thatdesign incorporates new materials for reduced torque moment material,with monolithic a throat innovative and an flex-seal bearing nozzle architecture using cost-effective and lighter carbon phenolic flight in2012, the P80 nozzle features ahigh-performance, simplified Ground qualified 2008 in and flight-proven through the Vega maiden ■ the development of Next-Generation Launcher booster stages. configurations Arianeand for motorupgrades solid Vega as as well for This flexible testarticle used be then to could explore new ■ What willbe the resulting competitive edge? protection, thenozzle or other subsystems. propellant load (segmented or monolithic) as well as internal thermal thatbe canadapted to simulate motor various configurations of demonstrator. POD-X features modular a structure for hot-firing tests underFLPPsince to 2010 develop the POD-X propulsion solid nearly 30 years, has been cooperating with France’s CNES space agency Avio,provider ofboosters solid for theAriane family oflaunchers for ■ What is European industry’s expertise? protection, sensors or low-cost nozzles) was long identified ago. pressureinnovative oscillations and technologies (such as thermal What is European industry’s expertise? The Z23 is loaded with 23.9 tonnes of propellant and delivers 1196 kN ■ What is European industry’s expertise? featuringnew a lightweight filament-wound composite casing. derived fromearlier its Zefiro ground-fired Z16 demonstrator, but for nearly 30 years, has developed a family of motorssolid-propellant Avio, provider of rocket solid boosters for the Ariane family of launchers challenge? technology is the ■ What new motorssolid-propellant have introduced. been in terms of payload lift capacity and recurring production costs, two To achieve theperformance requirements for the Vegalaunch system it for? is ■ What →  ■ Programme

vega MOTORS ROCKET SOLID ZEFIRO Avio boundaries activities R&D our continue to impetus more even us gives also it technology, space future to door new mission successful The fibre. carbon of completely made be to ever first the system, launch development the towards work hard of years eight of result the is Vega’s launch of maiden success The February 2012 February release press Avio Head of Avio Space Division Pier Giuliano Lasagni Other ■ Other applications vega of access to space. to access of system its competitiveness ensuring and the on exportmarket. The two motors are key keeping in the cost down for the Vega launch ■ What willbe the resulting competitive edge? Both weresuccessful onthe Vegamaiden flight 2012. in ground-qualified on 27 March 2008 and the Z9A on 28April 2009. electromechanicalwith actuators forthrust vector control.The was Z23 propylene monomer)diene insulation as well as a flexible nozzle joint 1.9 m-diameter carbon epoxy casing low-density EPDM(ethylene 128.6 seconds. Both are loaded with HTPB1912propellant and use a its 10.1 tonne propellant load delivers 313kN of thrust in vacuum for featuresZ9A the highestmass fraction for motors solid its category: in of thrust at sealevel duration with burn seconds.a ofThe 86.5 smaller not only opens a opens only not and push the the push and of a new anew of out out propulsion 23 → STRUCTURES AND MECHANICAL ENGINEERING ESA–S. Corvaja → LIGHT, STIFF AND CAPABLE

Any gain in the dry mass of a launch has already been recognised and system translates into a higher payload exported widely, while its competence in capacity, more so if the gains are made thermal protection systems and sound in the upper parts of the launcher. This mechanical designs has led to many means an increase in competitiveness, technology firsts. These are tremendous either by launching more payload mass assets from which the design of future with a given design, or by enabling the generation of launch and space vehicles launch of heavier payloads on a smaller will have to benefit in order to get the vehicle. Europe’s expertise in advanced best performance return from propulsion manufacturing processes for metallic systems while being able to adapt to all parts and composite structural elements kind of new mission requirements.

→ ELECTROMECHANICAL THRUST-VECTORING SYSTEM

SABCA

■ Programme ■ Other applications ixv vega vega pride ariane 6

■ What is it for? stages as well as for the Vulcain 2 engine, has developed Traditionally, large rocket stages rely on hydraulic actuation systems electromechanical TVC systems for all of the Vega stages. Each for thrust vector control (TVC). For instance, solid rockets execute the system is composed of two electromechanical actuators (EMAs), a motor’s nozzle-steering commands issued by the launcher’s onboard battery, an interconnection harness and a power-control electronics computer software to reach the desired trajectory. Hydraulic TVC box, which embeds a computer-based control system to achieve requires a large tank of hydraulic fluid. high-precision and high-speed nozzle motion. SABCA has qualified the four elements as well as designed and manufactured all the ■ What is the technology challenge? components inhouse with the exception of the batteries (from Saft, Replacing the hydraulic TVC with electromechanical TVC allows a France) and the AVUM upper stage’s EMAs (from Moog, US). major reduction in the mass and complexity of stages, and thus an improvement in performance, cost reduction and competitiveness. ■ What will be the resulting competitive edge? The use of electromechanical TVC on Vega’s P80 motor is a first for SABCA’s lightweight EMA technology inherited from Vega is also being a solid motor of that size and opens up new possibilities for future used for controlling the aerodynamic surfaces on IXV, with the developments. addition of a brake mechanism to keep the flaps locked when required.

■ What is European industry’s expertise? SABCA, provider of actuation systems of Ariane 5’s EAP booster 26 passes thealong abutting edgesof twometallicrigidly clamped technology centre. It uses non-consumablea rotating tool that The Welding Institute a British (TWI), independent research and Friction stir welding, a solid-state joining process, was invented by challenge? technology is the ■ What technologies tomanufacture lightweight tanks. a step-by-step technologyroadmap tointroduce and qualifynew complex deployment Aerospace MT missions. is thus implementing complexmechanical requirements thermal and tomore support reduction of structural mass and recurring costs while meeting stage, as well as for Ariane 6,implies a major effort in the performanceof Ariane5, at similar a cost asthe current upper The development of new a cryogenicupper stage toincrease the it for? is ■ What → FRICTION STIR WELDING FOR WELD SEAMS WELD FOR WELDING STIR → FRICTION ■ Programme ariane 5 MT Aerospace MT Other ■ Other applications ariane 6 onboard computer. onboard commands processes which software, the as command developed the but hydraulic longer no are actuators These Ariane. on like motor, the for actuators provided Vega on also we skirt,

La Belgique Libre CEO of SABCA Blondeel Daniel future launchers electro In addition to the launcher’s launcher’s the to addition In sent to the actuators by the the by actuators the to sent -mechanical, and we also hydrogen tank. to two ofm-diameter the5.4 circumferential welds theliquid on reduction ofrecurring costs.AerospaceMT will apply this technology structuralmass efficiency than traditional welding. It also allows a of the process, little alteration of the material properties higher and This technique provides major advantages such robustnessas high ■ What willbe the resulting competitive edge? structuralparts since the very early days ofAriane. MT Aerospace has been designing and manufacturing tanks and ■ pressure. softened state that allows themetal to be mechanical fused using parts.The toolintermixes the twoparts, transforming theminto a What is European industry’s expertise? structures and mechanical engineering box as well well as box the the the the

27 28 welding required by traditional assembly of gore panels. by domes complex eliminating steps such machining as and Thisprocess drastically simplifies the manufacturing of large tank challenge? technology is the ■ What system. launch futureEuropean forthe domes cryotank MT Aerospaceis also carrying out studies on the spin-forming of Adapted Ariane 5MEupper stage’s liquid oxygen tank. Aerospace MT will apply spin-forming toproduce thelower dome on To ensure thelowest possible structural mass cost, optimised with it for? is ■ What →  → ALUMINIUM–LITHIUM ALLOY CRYOGENIC TANK tank using innovative processing and manufacturing techniques. Transfer Vehicleto – demonstratortanks develop Al–Li subscale a with MTAerospace of Germany –provider of Ariane and Automated space-qualified pressure vessels for human spaceflight, has teamed for Delta US vehicles for more than a decade is and a world-leader in Thales Alenia Space Italy, which has been producing propellant tanks challenge? technology is the ■ What high-stiffnessAl–Li alloy. replacementof conventional aluminiumalloysby lightweight and Significant mass and cost reductions can be achieved through the aerothermodynamicpressures andresultant thermal stresses. pressurised cryogen, beinsulated, carry the loads and absorb the of liquid hydrogen requires large tanks that have to contain the performancelift for launch a system. However, the low specific mass The use of high-energy cryogenic propellant iskey to achieve high- it for? is ■ What ■ Programme ■ Programme

flpp ariane 5 TANK DOME THE FOR FORMING SPIN MT Aerospace MT Thales Alenia Space Other ■ Other applications Other ■ Other applications future ariane 6 launchers

future launchers competitive edge forEuropean spaceindustry. recognised by international partners and constitutes a strong Aerospace’sMT patented spin-forming technology has already been ■ What willbe the resulting competitive edge? the Automated Transfer Vehicle propulsion module. production of propellant tanks for ESthe 5 Ariane upper stage and MT Aerospace has already introduced spin-forming in the series ■ What is European industry’s expertise? both forlaunch systems development the exportand of subsystems. industry’s competitive the space edgein transportation business, and technical standardisation, will be key to maintaining European domain of space-qualified tanks, including joint material procurement well as the cooperation between two leadersthe industrial in ofTheuse advanced materialsmanufacturingtechnologies, as and ■ What willbe the resulting competitive edge? eventually up to burst. draining before going for proofa test up to loads the limit and demonstratorbe submitted tank then will to cryogenicand filling leak-before-burst will undergo non-destructive examination. The used for the assembly of theThe various elements. tank fordesigned reinforcement of the tankbarrel panels. Friction stir welding willbe domes, Thales Alenia Space is studying the structure milling for the While MTAerospace is investigating the Al–Li spin-forming of the ■ What is European industry’s expertise? A former national chemical research institute with more than 60 years ■ this has been a showstopper for various advanced projects. because of the very size small ofhydrogen molecules. In thepast, to leakage or even structural damage. The risk of leaks ismore likely well as microcracking caused by very low temperatures leading and material compatibility with liquid oxygen and liquid hydrogen, as Newproblems withcomposite arise cryogenicsuch tanks, as challenge? technology is the ■ What performance of launcha system. structuralin of elements is launchers a good way toimprove the The use of lightweight composite material to replace metallic parts it for? is ■ What → NANOPOLYMER LINER FOR COMPOSITE CRYOGENIC→ FOR TANK NANOPOLYMER COMPOSITE LINER and provider and a of cryogenic insulation for tanks and sinceAriane worldleader cryogenicsLiquide, a in for Air more than centurya ■ What is European industry’s expertise? surface keepand its characteristics while wetted byhydrogen. liquid thatinsulation thermal onto metalliccanbe glued the orthogrid The bulkheadhas to be covered with effectivean but lightweight challenge? technology is the ■ What oxygenphases as liquid subcooling. well excessivehydrogen evaporation, thelong especially coasting during temperature gradientbetween the two might cause tanks oxygen is stored hydrogenat 90K liquid and the is at 20K, between the liquid hydrogen and liquid oxygen tank. Since liquid The upper Adaptedstage ME 5 Ariane has a common bulkhead it for? is ■ What INSULATION →  ■ Programme ■ Programme What is European industry’s expertise?

ariane 5 FORADVANCED COMMON BULKHEAD TECHNOLOGIES flpp Synpo Air Liquide Air Other ■ Other applications Other ■ Other applications ariane 6 future launchers

future launchers lightweightstructures for futurelaunchers. conventional non-cryogenic structures for designing highly integrated allowthe combinationof CFRP cryogenicmoretanks with Once achieved, theproper maturity oftechnologyunique this will ■ What willbe the resulting competitive edge? orderbinder in to achieve very low permeability to cryogenic propellant. compositeinvestigating tanks and the ofaddition nanoparticles to the this, Synpo is developing special polymeric for liners the inner wall of matrixcryogenic carbon under and fibrefiller conditions. To address differences the thermalexpansionin coefficients between the epoxy Microcrackingis causedby thebrittleness of the epoxyresins the and fibre reinforced polymer (CFRP) structures for cryogenicapplications. EADS-CASA – a leader in composite materials –in advanced carbon of expertise polymers, in Synpo is working as a subcontractor to increasepayload its capacity to orbit. structural mass of the upper Adaptedstage ME 5 Ariane thus and Thisreducetechnology will thethe design commonbulkhead and ■ What willbe the resulting competitive edge? favours capillary effectsin the material. behaviourmicrogravityaspects, as well as in conditions, which degradation, environment-friendlyproduction otherand industrial specific stiffeners and X-ring area without performance specific requirements of Adapted Ariane 5ME: compatibility with pressurisation to bar 3 and draining. It isnow adapted to the phases of a standardmission: tank chilldown,propellant filling, validatedand subscale on demonstrators through themain all compared to theirpredecessors. This technologyhas tested been materialsinsulation that reduce heat by losses a factor of three the programme’s inception, has developed advanced thermal structures and mechanical engineering 29 30 → CRYOGENIC MEMBRANE-BASED MANAGEMENT PROPELLANT continuous settlement of the thepropellant coast during phase. has past its on developed, building experience, a concept based on worldleader cryogenica management in fluids morefor thana century, Under the FLPP Cryogenic Upper Stage Technologies Liquide, Air project, challenge? technology is the ■ What management technologies. the developmentof efficient and reliablecryogenic propellant Achieving them with manoeuvrablea cryogenic upper stage requires missions restartsthroughengine multiple long and coasting phases. Futuresystemslaunch be capablemust of complex deployment it for? is ■ What ■ Programme flpp Air Liquide Air 29 October 2012 29 October Liquide’s Air of Sassenage anniversary 50th Roundtable, &CEOChairman Liquide of Air Potier Benoît them. in believe firmly who on people rely way, to need we the along all that means that And years. forty even or twenty ten, over mastered and acquired be to have that competences of made is It asudden. of all blue the of out come doesn’t system Alaunch term. long the in think We to have Other ■ Other applications ariane 5

ariane 6 proposed for Adapted ME’s 5 Ariane upper stage. unnecessary, thus improving the payload lift capacity. It is also reducing the overall stagemass by ullage thrustersmaking This new technology would improve the use of propellant while ■ What willbe the resulting competitive edge? liquid hydrogen. temperature gradient theinside tanks to reduce theheat intoflux the time of thepropellant thelower on preserving side while a wettingand theupper sideofreduce and the tank, the settlement Cryogenicmembranes theprevent inside tanks from theliquid spilling ■ What is European industry’s expertise? site, site, Airbus has been prime has prime contractorAirbus been for ofall Ariane’s upper stages and ■ restartoperating cavitationengine and conditions. under all bubble-freepropellant toliquid feed the turbopumps withoutrisk of tankoutlets using capillary forcesto guarantee a certain amountof management system consists of passivea device mounted at both proper ignition and early powering-up. Airbus’s propellant is so the onlyneed fluids, to deliver propellant enough to ensure Oncerestarted,is the engine thrustissufficientits to settle the challenge? technology is the ■ What complex deployments. coast phases that are often necessary between ignitions engine for solutions forlengthythe cryogenicpropellantmanagement during prime contractor of 5’s Ariane upper stages, is studying alternative Under the FLPP Cryogenic UpperStage Technologies Airbus, project, it for? is ■ What FOR SEPARATOR → GAS performance. payloadextra affectthe as will missions and, dead weight, integrated into the upper stage beunnecessary forwill such required for Theequipment complex additional manoeuvres and challenge? technology is the ■ What remain the traditionalin geostationary transfer(GTO) orbit segment. complex deployments, largea part of the market launch islikely to restartslong coast engine and phasesto ensure the capability for Despite the requirement for high manoeuvrability, with multiple it for? is ■ What →  ■ Programme ■ Programme What is European industry’s expertise? CRYOGENIC PROPELLANT MANAGEMENT CRYOGENIC PROPELLANT flpp JETTISONABLE VERSATILE THERMAL INSULATION flpp Airbus Defence &Space Thales Alenia Space Other ■ Other applications Other ■ Other applications ariane 6 ariane 6

future launchers payloadperformance of a future cryogenic supper stage. manoeuvrability through multiple restart while preserving the This low-cost and lightweight solution would ensure high ■ What willbe the resulting competitive edge? theexperimentwith flights actual cryogenicfluids. constraints. Investigations areunder way forrocket furthersounding nitrogen toperformed liquid easewith cost, safety thermal and validationof models for bothtechnical concepts.Thisflight first was recorded onboard inhigh definition. The results are supporting the microgravity were continuouslymonitored from the ground and The phasesof complex phenomena that flight. appear during microgravityprovided the environment to simulate the different the Texus-48 sounding rocket inNovember 2011.The six minutes of oxygen gasseparator,liquid concepts were developed flown and on maturation experiments to demonstratehydrogen theliquid and manoeuvrable Automated Transfer Vehicle. part As of the technology cryogenic stages, as well as for thehighly on thepropulsionmodule the payload mass performance theand vehicle’s competitiveness oncedumped the atmosphereis clearedGTO on missions to increase propellant long missionsrequiring on coasting phases or simply be This VTI could eitherprovide efficient thermal management of the ■ What willbe the resulting competitive edge? stage toprotect the tanks’ basic atmospheric insulation during ascent. panels attachedjettisonable(VTI): toversatileinsulation thermal the Alenia Space, a specialist inlightweight structures, is investigating Under the FLPP Cryogenic UpperStage Technologies Thales project, ■ What is European industry’s expertise? structures and mechanical engineering 31 32 → DEPLOYABLE VERSATILE THERMAL INSULATION THERMAL VERSATILE → DEPLOYABLE could be adapted to specificmission requirements. Design of lightweighta and flexible thermal insulation system that challenge? technology is the ■ What transferthermal control less demanding requirements. with orbits, tostage is designed serve classicalalso tomissions geostationary mass orreduce the overallperformance, themore all if sothe coastingnot phases significantly should increase the stage’sdry complex deployment ignitions missions engine and with multiple Thermalprotection requirements for cryogenicstagesupper during it for? is ■ What → LIGHTWEIGHT THRUST→ FRAME LIGHTWEIGHT on innovativeon materials structuraland configurations. is studyingengines, new HM-7B and thrust frame concepts based DutchSpace, whichprovides thrust frames forAriane 5’s Vulcain challenge? technology is the ■ What intothem very complexpadturn heavyweight and components. role interfaceas an tomany vehicle subsystems toand thelaunch aerodynamic requirements, inparticular to limit buffeting, and their axisymetric configurations to load ease constraints. Moreover, tend tobe heavy structures,usually relying on quite conventional theproximity of engines and strap-onbooster plumes, thrust frames vehicle’sthermal conditionsstructure harsh from withstanding while toDesigned transferheavy loads from thepropulsion system to the it for? is ■ What ■ Programme ■ Programme flpp flpp Dutch Space RUAG Space RUAG Other ■ Other applications Other ■ Other applications ariane 6 ariane 6

future future launchers launchers while preservingpayloadwhile its performance. thermal controlof futurea manoeuvrable cryogenicstagesupper Thislow-cost andlightweight solution would ensure effective ■ What willbe the resulting competitive edge? to cover the cryogenicpropellant reduce tanks and heat transfers. wouldbe stored ascent during deployed orbit and thein along stage protectionthermal through lightweight a deployable that shield multilayer Ruag insulation, Space is developing a concept of additional thermal systems for ofkinds spacecraft,all mostly based on large its on experienceBuilding space in mechanisms as well as in ■ What is European industry’s expertise? into increasean of payload performance. the in vehicle’sSignificant reductions translatemassdry will directly ■ What willbe the resulting competitive edge? conical part are being manufactured and tested. evaluated.Representative thermoset thermoplasticand panels for the requirements as well as various manufacturing processes have been Differentresins fibre and systems compatible the thermal with levelshigh of internal loads thewithin composite material itself. loadsby caused proximitythe to cryogenicpropellant tanks, as well as metallic They parts. havewill to withstand the large thermomechanical made of compositematerial or of a combination of composite and Theproposed would designs feature lightweightstructures either ■ What is European industry’s expertise? traditional forging processes. In order to reduce mass, inparticular these Y-rings are made of metallic materials, produced through by supporting loads from upper parts. In current launch vehicles, constraints, eitherby transmitting thrust frompropulsion systems or involve Y-rings, whichhave to withstand complexmechanical Theinterfaces between cylindrical and conical or spherical shapes challenge? technology is the ■ What createmechanical stresses. introducebetweenthese variousshapes which discontinuities, support propulsion systems or payload adaptors. Connections cylindrical structures are connected to conical frames, either to togetherby cylindrical or conical theseSometimes, skirts. succession of cylindrical tanks with spherical ends connected The architecture of expendablelaunch vehiclesbased is on a it for? is ■ What →  ■ Programme

flpp Y-RING COMPOSITE 2 December 2011 December 2 Bit&Chips CEO of Dutch Space Reijnen Bart are focus which companies, few become has industry space The Dutch projects European major –for ones –crucial parts building mainly now We are national for time the but projects, national had of of plying Sonaca government complex Space is by definition an international affair. In the past we past the In affair. international an definition by is Space an increasing role in space infrastructures space in role increasing an Other ■ Other applications , led by the European Space Agency or other partners. partners. other or Agency Space European the by , led

future launchers , multidisciplinary and technically , multidisciplinary is far from finished from far is only in the space market. Developments Developments market. space the in only , although private funding is also, private although launch systems spaceand compositeindustry. technology islikely to improve the competitiveness of European producedwith smaller tooling and autoclaves, areselected. This structures and their production cost, inparticular if small segments, Moulding could significantly reduce both the mass of large-diameter Manufacturing a Y-ring through processes like Resin Transfer ■ What willbe the resulting competitive edge? Y-ring specifications.Airbus based on investigatinghas been theiruse for theof design segmenteda materialstructuresfor both aeronautical space and applications, Sonaca, anaerospacecompany with longexpertise a compositein ■ What is European industry’s expertise? lightweight carbon fibre reinforced polymers (CFRPs). for the upperparts of launchers, future Y-rings could bemade of an export market. There are are There market. export an structures and mechanical engineering

challenging ambitions is gone. is ambitions . . The role role . The

33 34 AND PAYLOAD ADAPTORS → COMPOSITE INTERSTAGE STRUCTURES with similar structures currently inproduction, by the use of less The objective is to achieve both cost massand reductions as compared ■ What is European industry’s expertise? already providing structural elements for Ariane 5 and Vega. is leadera EADS-CASA in composite structures for space applications, challenge? technology is the ■ What solutions optimised define for applications. various stiffenedor sandwich skin eithermonolithic, technologies, order in to such payloadas adaptors,interstage or skirts cryogenicusing tanks, carbon fibre reinforced in thepolymers design of structural elements EADS-CASA is investigating the use of lightweight and high-stiffness In order to achievemass important costand reduction objectives, it for? is ■ What ■ Programme flpp EADS-CASA Other ■ Other applications ariane 5 the the know-how acquire to Space enable that programs ESA is it all, our September 2012 September SatMagazine CEO of Ruag Space Guggenbach Peter market home our is Europe years. 40 than programs industrial market vega commercial Our company has been amajor been has company Our . We lay the foundations . We the lay from the outset, i.e. for more more for i.e. outset, the from partner in European in partner to go on to enjoy to on go to

ariane 6 success

market. the technologies and the the and technologies the

further competitiveness would benefitalso from major advancesin technology. led to international This export. aspect of European industry’s vehicles’ competitiveness. This field of European expertise hasalready directly into payload capacity increase, which in turn will improve the Mass savingsupperstructures these ofin the vehicles translate ■ What willbe the resulting competitive edge? payloadscale adaptor. subscaleAriane5 andfull-scale a Vega interstage structures or full- a manufacturetest of and representative demonstrators such asa Technicalbe demonstrated feasibility will through the design, theuse of reinforced monolithic elements with stringers frames.and evaluationinclude the elimination of ringsrivets aluminium and and manufactured through more automated processes. Solutions under expensivematerials structural simpler and concepts that couldbe afield. Above Above afield. success on success space space here for Ruag Ruag

This facility willbe used to qualify theperformance of IXV’s ■ What is European industry’s expertise? aerothermodynamicresearch simulation. and centre with a mosttheworld,of along advanced excellencein in Scirocco facility,plasmatunnel wind is considered which tothe be vehicles, Italy’s aerospace CIRA research centre has developed the To simulate the extreme conditions experiencedby reentering challenge? technology is the ■ What reentering the layersdense of the atmosphere. thematerialises formofin aerothermal high veryloads when kinetic energy it acquired at This launch. dissipation usually returning from When a vehiclehas orbit, to dissipate of all the it for? is ■ What →  → PAYLOAD FAIRING Designer and providerDesigner and ofpayload Ariane fairings since the ■ capacity. stiff lightweightorder in and not to degrade the vehicle’s payload jettisonedbeing at high altitude, they need to beboth extremely passing while through the layersdense of the atmospherebefore Sincethey have to dynamic withstandhigh pressurethe conditions challenge? technology is the ■ What aerothermalflux mechanical and loads during ascent. rainbefore extremewell as launch as acoustic conditions, them from temperatures, high solar radiation, moisture dust, and Fairings encapsulate payloads in a controlled environment, protecting it for? is ■ What ■ Programme ■ Programme What is European industry’s expertise? ixv TUNNEL TEST TECHNOLOGY WIND PLASMA vega CIRA Ruag Space Ruag Other ■ Other applications Other ■ Other applications pride ariane 5

vega

ariane 6 atmosphere reentry. developmentsof future vehicles for designed planetary Earthor CIRA’s Scirocco is a strong asset for future European or international ■ What willbe the resulting competitive edge? layers insulation and between the different subassemblies. toit hold as well the ofas on design theinterfaces the– seals theprotection on thermal run be thehot and structure developed marginsthat will define the vehicle’s flight domain. The tests will model checkassumptions verify and criticalelements, design 800 kW/sq m.The test campaign will assess the performance of conditions, at temperatures ofup to2000°C and fluxes of up to thermal protection system under flight-representative aerothermal contributes to the competitiveness ofEuropean the launcherindustry. Ruagpositioned Space as a world leader marketthis in and Vega’s fairing development is the latest in thata series have ■ What willbe the resulting competitive edge? thanks to innovative its design. the fullyoutfitted composite fairing has a mass of only 530 kg fast-moving launch vehicle. Nearly 8mlong and 2.6min diameter, cork insulating tiles to protect it from the heat generated by the carbon fibre reinforced polymer. outerIts surface is covered with madeof honeycomban aluminium core covered withlayers of Atlas as theAriane and fairings. It consists of two sections shell launchers. Vega’sbased the sandwich is on same fairing technology has flown over 220units on Europe’s Ariane and US Atlas beginning of the programme more than 30 years ago, Ruag Space structures and mechanical engineering 35 36 → ABLATIVE THERMAL PROTECTION SYSTEM PROTECTION THERMAL → ABLATIVE technologies. the production use ofand the class of materials relatedand With Ariane and Vega, Avio has acquired a very strong expertise in challenge? technology is the ■ What ceramicsuch as easycomposites, being towell asinstall. as relativelyinexpensive compared to otherprotection thermal materials removed material. Moreover, it has the tremendous advantage of being fluxes at reentry, most with of the energy dispersed with the being Ablative thermal protection is efficientan way todissipate heavy heat it for? is ■ What → CERAMIC THERMAL PROTECTION THERMAL → CERAMIC now oneof the few thecompanies in world with the technical become leadinga provider thermostructural in materials isand launch vehicles, Herakles (formerly Propulsion Snecma has Solide) the in and development of nozzles for European internationaland Thanks to involvement its in various national defence programmes challenge? technology is the ■ What ablativeprotection thermal systems, they arereusable. vehicle thathave will to endure thehighest Moreover, fluxes. unlike particularly suitable forprotection thermal over the areas of a higher temperature environments thanmetallic systems, they are Earth or on another planet. Much lighter and more resistant to systems forto vehicles perform designed reentry, atmospheric on Ceramic composite materials are promising for thermal protection it for? is ■ What ■ Programme ■ Programme ixv ixv Avio Herakles Other ■ Other applications Other ■ Other applications pride pride ambitious vehiclescomplex as ambitious as IXV. low-costreentrysystems, as well as forreducingthe costof more materials assetforis an thedevelopment of future and simple This technology oflow-cost simple and ablativeprotection thermal ■ What willbe the resulting competitive edge? proven ablativeprotectionthermal technologies from inherited Vega. vehicle using efficient and lightweight materials, based on flight- forAssemblies lateral, the theleeward thebase ofand sides the On IXV, Avio manufactured the Ablative Thermal Protection System ■ level, opening new oflevel, domains opening cooperation forEuropean industry. systems, Europe in either or manned or unmanned, at international Thistechnology keybe for will futurereentry developmentsin ■ What willbe the resulting competitive edge? protectionsystem solutions forreentry vehicle.a hasthe possibility of flight-qualifying a full-ceramic composite thermal It providesalso layers insulation stand-offs.and With IXV, Herakles the windward nose and which consistsassemblies, of 30 ceramic tiles. ceramicprotection thermal system such as the single-piece ceramic On IXV, the company developed andmanufactured largea part of the ■ What is European industry’s expertise? materials forspace largesuch dimensions. applicationsin knowhow facilitiesindustrial tothe produce and ceramic composite What is European industry’s expertise? the development, manufacture and qualification of IXV’s Body Flap flap assembly NASA/ESA for the in charge is reentry vehicle, X-38 of MT Aerospace, which designed, manufactured and qualified the body ■ What is European industry’s expertise? flaps will be exposed to very high thermal fluxes and temperatures. bearing, stiff and heat-resistant control surfaces. This pair of body IXV will demonstratesuch a capability withpair a of moveable, load- challenge? technology is the ■ What the dynamiclimit constraints theirpayload on or crew. importance for futurereturnhigh-precisionsystems. It would also speeds reenteringwhile the atmosphere is of paramount The capability to perform controlled manoeuvres at hypersonic it for? is ■ What →  ■ Programme

ixv TECHNOLOGY BODY FLAP MT Aerospace MT Other ■ Other applications pride that can withstand enormous loads. enormous withstand can that materials light also and solid technologies develop to as well as costs minimize to time, same the at issues complex simplify to gradually, products our develop to is us for challenge The years. 10 about averages new launchers for period development The Winter 2009 Winter Tefen Tribune CEO of MT Aerospace J. SteiningerHans

domains will giveEuropean competitivea domains will industry edge. applications. Integrating international industrial teams in these particular for future space orunmanned manned exploration new up for possibilities future developments reentry in systems, in such ceramic basedon compositehigh-temperature material open will Flight demonstration qualificationand of moveable control surfaces ■ What willbe the resulting competitive edge? technology challenge. aerothermomechanicalrepresentconditionswhich major and a resistantbellow, all of which willbe exposed to extreme rod with high-temperature bearings and a flexible high-temperature bearings,protection thermal and for the electromechanical actuator, a body flap, hinged thermal protection with dynamic seals, flap supports ceramicbasedon Assemblies compositematerials. Each consistsof a structures and mechanical engineering

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