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Technical Report on Different RLV Return Modes' Performances

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Technical Report on Different RLV Return Modes' Performances Formation flight for in-Air Launcher 1st stage Capturing demonstration Technical Report on different RLV return modes’ Performances Deliverable D2.1 EC project number 821953 Research and Innovation action Space Research Topic: SPACE-16-TEC-2018 – Access to space FALCon Formation flight for in-Air Launcher 1st stage Capturing demonstration Technical Report on different RLV return modes’ Performances Deliverable Reference Number: D2.1 Due date of deliverable: 30th November 2019 Actual submission date (draft): 15th December 2019 Actual submission date (final version): 19th October 2020 Start date of FALCon project: 1st of March 2019 Duration: 36 months Organisation name of lead contractor for this deliverable: DLR Revision #: 2 Dissemination Level PU Public X PP Restricted to other programme participants (including the Commission Services) RE Restricted to a group specified by the consortium (including the Commission Services) CO Confidential, only for members of the consortium (including the Commission Services) APPROVAL Title issue revision Technical Report on different RLV return modes’ 2 1 performances Author(s) date Sven Stappert 19.10.2020 Madalin Simioana 21.07.2020 Martin Sippel Approved by Date Sven Stappert 19.10.2020 Martin Sippel FALCon D2.1: RLV Return Mode Performances vers. 19-Oct-20 Page i Contents List of Tables iii List of Figures iii Nomenclature vi 1 Executive Summary ......................................................................................... 1 1.1 Scope of the deliverable ............................................................................................. 1 1.2 Results ....................................................................................................................... 1 1.3 Specific highlights ...................................................................................................... 3 1.4 Forms of integration within the work package and with other WPs ............................. 3 1.5 Problems .................................................................................................................... 3 2 Introduction ...................................................................................................... 4 2.1 Study/investigation logic ............................................................................................. 6 2.2 Tools used ................................................................................................................. 6 3 RLV Return Modes Comparison ...................................................................... 7 3.1 Return Options and Methods ..................................................................................... 7 3.1.1 VTVL with return-to-launch-site (RTLS) ............................................................................. 8 3.1.2 VTVL with Down-range landing (DRL) ............................................................................... 9 3.1.3 Horizontally Landing Autonomous airbreathing-powered fly-back (LFBB) .......................10 3.1.4 “In-Air-Capturing” (IAC) .....................................................................................................11 3.2 Comparison and Design Logic ................................................................................. 12 4 Performance, Mass and Re-entry Analysis .................................................... 14 4.1 Size, Performance & Mass ....................................................................................... 14 4.2 Re-entry Analysis ..................................................................................................... 21 4.3 Summary ................................................................................................................. 26 5 Economic Analysis ......................................................................................... 27 5.1 Recovery Costs ........................................................................................................ 28 5.1.1 In-Air-Capturing Cost Model and Assumptions ................................................................29 5.1.1.1 Aircraft and Flight Performance ....................................................................................29 5.1.1.2 Aircraft Costs Estimation ..............................................................................................33 5.1.1.2.1 Acquisition and Listed Prices .................................................................................... 33 5.1.1.2.2 Aircraft Upgrades and Modifications ........................................................................ 34 5.1.1.2.3 Aircraft Ownership Costs/Indirect Costs ................................................................... 35 5.1.1.2.4 Direct Cash Costs ..................................................................................................... 37 5.1.1.2.5 Limitations Cost Model ............................................................................................. 39 5.1.1.2.6 Indirect and Other Further Ownership Costs ............................................................ 40 5.1.1.3 Cost Breakdown of Recovery Costs .............................................................................41 FALCon D2.1: RLV Return Mode Performances vers. 19-Oct-20 Page ii 5.1.2 VL Downrange Landing, RTLS Cost ................................................................................43 5.1.3 Comparison of Recovery Costs ........................................................................................47 5.2 Total Launch Costs .................................................................................................. 49 5.3 Subscale Scenario Economic Analysis ..................................................................... 52 5.3.1 Premise .............................................................................................................................53 5.3.2 Recovery Costs for Turboprop cargo aircraft ...................................................................54 5.4 Outlook .................................................................................................................... 56 6 RLV Reference Stage .................................................................................... 57 6.1 Assumptions and Stage Design Requirements ........................................................ 57 6.2 RLV stage geometry with moving / folding wings ..................................................... 59 6.3 Aerodynamic performance ....................................................................................... 62 6.4 Performance and Mass ............................................................................................ 63 6.5 Re-entry and corresponding loads ........................................................................... 64 6.6 ASTOS Configuration and Trajectory Optimization................................................... 66 6.6.1 FALCon VTVL Scenario ...................................................................................................66 6.6.1.1 Scenario setup and assumptions .................................................................................67 6.6.1.1.1 Target mission .......................................................................................................... 67 6.6.1.1.2 Stage Data ................................................................................................................ 67 6.6.1.1.3 Engine Data .............................................................................................................. 68 6.6.1.1.4 Aerodynamic Data .................................................................................................... 69 6.6.1.1.5 Mission Phases ........................................................................................................ 70 6.6.1.1.6 Mission Constraints .................................................................................................. 71 6.6.1.1.7 Cost Function............................................................................................................ 71 6.6.1.2 Optimization Results .....................................................................................................71 6.6.1.2.1 Masses ..................................................................................................................... 71 6.6.1.2.2 Constraints fulfillment ............................................................................................... 74 6.6.2 FALCon VTHL Scenario ...................................................................................................82 6.6.2.1 Scenario setup and assumptions .................................................................................82 6.6.2.1.1 Target mission .......................................................................................................... 82 6.6.2.1.2 Stage Data ................................................................................................................ 82 6.6.2.1.3 Engine Data .............................................................................................................. 83 6.6.2.1.4 Aerodynamic Data .................................................................................................... 84 6.6.2.1.5 Mission Phases ........................................................................................................ 85 6.6.2.1.6 Mission Constraints .................................................................................................
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