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https://ntrs.nasa.gov/search.jsp?R=20090014109 2019-08-30T06:39:32+00:00Z

Ares V and RS-68B

Steve Creech, NASA MSFC Jim Taylor, NASA MSFC Lt. Col. Scott Bellamy, AFSPC Fritz Kuck, Pratt & Whitney

JANNAF Liquid Propulsion Subcommittee (LPS) JANNAF LPS Technical Steering Group RS-68/-68A/-68B Specialist Session

8-12 December 2008 Orlando, Florida

ARES V and RS-68B

Abstract

Ares V is the heavy lift vehicle NASA is designing for 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25… lunar and other space missions. It has significantly more ExplorationExploration andand ScienceScience LunarLunar RoboticsRobotics MissionsMissions LunarLunar OutpostOutpost BuildupBuildup lift capability than the vehicle used for the Research and Technology DevelopmentDevelopment on ISS missions to the moon. Ares V is powered by two Commercial Orbital Transportation Services for ISS recoverable 5.5 segment solid rocket boosters and six RS-68B engines on the core stage. The upper stage, SpaceSpace ShuttleShuttle OperationsOperations SSPSSP TransitionTransition designated as the , is powered by a and OrionOrion Development

Operations CapabilityCapability Development single J-2X engine. This paper provides an overview of (EVA(EVA Systems,Systems, GroundGround Operations,Operations, MissionMission Operations)Operations) Ares I-X andand Ares I Production andand Operation Test Flight the Ares V vehicle and the RS-68B engine, an upgrade April 2009 to the Pratt & Whitney Rocketdyne RS-68 engine Development developed for the Delta IV vehicle. Ares VV && EarthEarth Departure Stage SurfaceSurface SystemsSystems DevelopmentDevelopment 032408 Figure 2. NASA’s Exploration Roadmap The Constellation Program includes the Ares I & V launch vehicles, the Orion , the Ares V Altair lunar lander and their associated missions. Ares I launches the Orion and its crew, and Ares V launches The Ares V is built upon a foundation of proven the earth departure stage (EDS) and Altair with the technologies from the , Ares I and Saturn crew’s supplies. The Ares V earth departure stage and V vehicles as shown in Figure 3. The reusable solid the Orion vehicle rendezvous and mate in earth orbit, rocket motors are derived from the Space Shuttle and and the EDS propels the vehicles to the moon or other Ares I boosters. The core stage tank includes destination. The Constellation Program vehicles are technologies from the but will be depicted in Figure 1. built to the larger 33 foot diameter used on the Saturn V tanks. The J-2X engine, that powers the earth departure stage, has restart capability and will be a variant of the Ares I upper stage engine that was derived from the J-2

Earth engine that powered the Saturn V S-II and S-IVB stages. Departure Stage Building on a Foundation of Proven Technologies Launch Vehicle Comparisons 122 m (400 ft) Orion Crew Exploration Ares V Crew Ares V Vehicle Altair Cargo Launch Vehicle 91 m Lunar (300 ft) Orion Earth Departure Lander Stage (EDS) (1 J-2X) Altair 253.0 mT (557.7K lbm) LOX/LH2 S-IVB Lunar (1 J-2 engine) Upper Stage 108.9 mT Lander (1 J-2X) Lander (240.0K 137.0 mT 61 m LOX/LH (200 ft) (302K lbm) 2 LOX/LH 2 S-II (5 J-2 engines) 453.6 mT 5-Segment Core Stage

Overall Vehicle Height, m m (ft) Height, Vehicle Overall (1,000.0K lbm) Reusable (6 RS-68 Engines) Ares I Solid Rocket 1,587.3 mT LOX/LH2 30 m Booster (3,499.5K lbm) Crew Launch (100 ft) S-IC (RSRB) LOX/LH2 Vehicle (5 F-1) 2 5.5-Segment 1,769.0 mT RSRBs (3,900.0K lbm) LOX/RP-1 Figure 1. Constellation Program Vehicles 0 Space Shuttle Ares I Ares V Saturn V Height: 56.1 m (184.2 ft) Height: 99.1 m (325 ft) Height: 116.2 m (381.1 ft) Height: 110.9 m (364 ft) Gross Liftoff Mass: Gross Liftoff Mass: Gross Liftoff Mass: Gross Liftoff Mass: 2,041.1 mT (4,500.0K lbm) 927.1 mT (2,044.0K lbm) 3,704.5 mT (8,167.1K lbm) 2,948.4 mT (6,500K lbm) Payload Capability: Payload Capability: Payload Capability: Payload Capability: Ares I and Orion are currently in full scale development 25.0 mT (55.1K lbm) to 25.5 mT (56.2K lbm) 44.9 mT (99K kbm) to TLI (LEO) to LEO 71.1 mT (156.7K lbm) to TLI (with Ares I) 118.8 mT (262K lbm) to LEO DAC 2 TR 6 62.8 mT (138.5K lbm) to Direct TLI with first operational flight scheduled for spring of LV 51.00.48 ~187.7 mT (413.8K lbm) to LEO 2014. The Ares I project has completed preliminary Figure 3. Ares V Technical Foundation design (PDR), while the Orion project will conduct PDR in mid 2009. Ares V is currently in systems The versatile, heavy-lift Ares V is a two-stage, vertically architectural definition study phase, and full scale stacked launch vehicle that is capable of delivering development is planned to start in October 2010 with 414,000 pounds (188 metric tons) to low-Earth orbit. test flights beginning in 2018. NASA’s Exploration Working together with the Ares I crew launch vehicle, roadmap is shown in Figure 2. the Ares V can send nearly 157,000 pounds (71 metric tons) to the moon. The Ares V payload capability is

2 approximately 50 percent greater than the Saturn V. of tank size, as well as solid booster and RS-68 engine Payload capabilities to various orbits along with the design and performance options. Figure 6 shows some payload envelop information are shown in Figure 4. of the preliminary study results and opportunities for payload margin. The vehicle design has several specific practical limits and constraints. For example, the height of the door in the Vertical Assembly Building (VAB) at the limits the height of the Ares

21.7 m (71.1 ft) V. Additionally, the diameter of 10 meters is considered 10 m (33 ft) ♦ Payload capabilities a practical limit due to fabrication and shipping • LEO (130 x 130 nmi @ 29 deg) ~150 mT 23.2 m (76.2 ft) capabilities. Also, the standard RSRM segment length • GTO (130 x 19323 nmi @ 29 deg) ~75 mT • GEO (19323 x 19323 @ 0 deg) ~40 mT combined with a structural requirement for the 10 m • GEO (19323 x 19323 @ 0 deg) ~40 mT (33 ft) 116.2 m (381.1 ft) attachment point of the RSRB to be between the core ♦ Payload envelop stage hydrogen and oxygen tanks, and, Michoud • 8.8 m diameter 71.3 m • 8.8 m diameter Assembly Facility building limitations constrain the (233.8 ft) 58.7 m • 9.7 m barrel length (192.6 ft) length of the core stage. • 700 m3 approximate volume Ares V LCCR Trade Space

NOTE: These are MEAN numbers March-June 2008 Core Standard Core Opt. Core Length + Common Design Booster + 5 RS-68B Engines 6 RS-68B Engines Features 51.00.39 +5.0 mT 51.00.46 Spacers: 1 Composite Dry Structures Figure 4. Ares V Capabilities for Other Missions 5 Segment for Core Stage, EDS & PBAN Shroud 63.6 mT 68.6 mT Steel Case 60.2 mT Reusable Metallic Cryo Tanks for Core +6.1 mT Ares V is composed of several elements as shown in mT +6.1 Stage & EDS 51.00.40 +5.0 mT 51.00.47 Spacers: 1 5 Segment RS-68B Performance: I = 414.2 sec HTPB sp Figure 5. The first stage includes the two recoverable Thrust = 797k lb @ vac Composite Case 69.7 mT 74.7 mT f Expendable 61.5 mT 66.3 mT 5.5-segment PBAN-fueled boosters that are derived J-2X Performance: -3.6 mT -2.3 mT Isp = 448.0 sec 51.00.41 +3.7 mT 51.00.48 Spacers: 0 from the 4 –segment Shuttle SRB and 5-segment Ares I 5.5 Segment Thrust = 294k lbf @ vac PBAN Steel Case 71.1 mT Shroud Dimensions: first stage boosters designed and manufactured by ATK. 67.4 mT Reusable 63.0 mT Barrel Dia. = 10 m Usable Dia. = 8.8 m The core stage includes six RS-68B engines derived Barrel Length = 9.7 m Initial LCCR Study Reference Alternative New POD from the Pratt & Whitney Rocketdyne RS-68 engine Recommend for New POD ♦ Current Ground Rules and Assumptions 1.5 Launch TLI Capability Cargo TLI Capability • 4-day loiter/29 degree,130nmi insertion/100nmi TLI departure used on the Delta IV vehicle. • TLI Payload Goal: 75.1 mT The 71.3 meter long core stage has composite structures − Lander (45.0 mT) + Orion (20.2 mT) + Margin ♦ Note: Performance (light blue) is TLI payload in conjunction with Ares I and includes aluminum-lithium tanks that are 10 meters National Aeronautics and Space Administration 7557_AresV_Overview.1 in diameter. The earth departure stage includes an Figure 6. Ares V Trade Study interstage, loiter skirt, aluminum-lithium tanks, composite structure, instrument unit with the primary One of the early vehicle studies planned for the new 6- Ares V avionics system. Other elements of the Ares V engine baseline is analysis of the base heating. The two include the payload shroud and Altair lunar lander. RSRB and six RS-68B engines with their turbine exhaust ducted above the nozzle exit plane create a significant thermal environment. Various engine layout schemes are being studied as shown in Figures 7 and 8. Altair Lunar Stack Integration An example of a key integration trade is the engine Lander • 3.7M kg (8.2M lb) gross liftoff weight First Stage layout for efficient accommodation of thrust loads while • 116 m (381 ft) in length • Two recoverable 5.5-segment EDS optimizing the vehicle performance and outer mold line. PBAN-fueled boosters (derived J–2X Payload J–2X from current Ares I first stage) Fairing Loiter Skirt Factors include favorably handled thrust loads with Core Stage engines on the outer stage circumference (like Saturn V) Interstage • Six Delta IV-derived RS–68 LOX/LH engines (expendable) and the impact of a protective skirt that adds weight and Earth Departure Stage (EDS) 2 • 10 m (33 ft) diameter stage • One Saturn-derived J–2X LOX/LH creates aerodynamic drag. These studies and others will 2 • Composite structures engine (expendable) • Aluminum-Lithium (Al-Li) tanks • 10 m (33 ft) diameter stage be conducted in the architectural concept definition • Aluminum-Lithium (Al-Li) tanks • Composite structures, instrument unit phase over the next two years prior to the official start of and interstage • Primary Ares V avionics system Design Analysis Cycle 1 beginning in October 2010 as shown Figure 9. With a 2011 government fiscal year start for full scale development, the Ares V will have its Vehicle 51.0.48 RS–68 first flight in 2018. Main propulsion test article (MPTA) Figure 5. Ares V Elements (Vehicle 51.00.48) testing of the core stage will prove out the integration of the RS-68B engines with the cores stage. As the Constellation Program has matured, the Ares V requirements and capabilities have evolved. Trade studies have evaluated payload capability as a function

3 RS-68B Engine

6 RS-68 Engine Core Configuration Options ε=30 The RS-68B engine is derived from the Pratt & Whitney

(Current 21.5 expansion ratio) 12.79 ft Footprint diameter for 6 deg. 33.0 ft Vehicle Engine gimbal Rocketdyne engine that is flying on the Delta IV diameter 33.0 ft Vehicle 11.07 ft Footprint diameter diameter for 6 deg. Engine gimbal 8.88 ft Nozzle vehicle. The RS-68B has additional modifications and 7.56 ft diameter Nozzle diameter benefits from the RS-68A development program as Fixed Fixed Engine Engine 1.6 ft overlap between SRB aft skirt and core shown in Figure 10. Ares V requires the thrust and 17.6 ft SRB Aft Skirt diameter base diameter 1.6 ft overlap between SRB aft skirt and core performance of the RS-68A engine 17.6 ft SRB Aft Skirt diameter base diameter ε=40 -or - including the reliability improvements developed under 33.0 ft Vehicle 11.07 ft Footprint diameter diameter for 6 deg. 14.52 ft Footprint Engine gimbal diameter for 6 deg. 33.0 ft Vehicle Engine gimbal the Assured Access To Space (AATS) program. diameter

7.56 ft 10.22 ft Nozzle Nozzle diameter diameter

1.6 ft overlap between RS-68 to RS-68B 1.6 ft overlap between SRB aft skirt and core SRB aft skirt and core diameter 17.6 ft SRB Aft Skirt diameter 17.6 ft SRB Aft Skirt base diameter base diameter

* Redesigned turbine Helium spin-start nozzles to increase duct redesign, along maximum power with start sequence Figure 7. Ares V Engine Layout Study level by approx. 6% modifications, to help minimize pre- ignitionignition freefree Redesigned turbine hydrogen seals to significantly reduce helium usage for pre-launch * Higher element density main injector improvingimproving specificspecific Other RS-68A upgrades or changes 6 that may be included: impulseimpulse byby ~~6 • Bearing material change seconds • New Gas Generator igniter design • Improved Oxidizer Turbo Pump temp sensor • Improved hot gas sensor Increased duration • 2nd stage Fuel Turbo Pump blisk capability ablative crack mitigation nozzle • Cavitation suppression • ECU parts upgrade * RS-68A Upgrades

Figure 10. RS-68A and RS-68B Upgrades

The RS-68A program consists of two major design changes. Engine thrust is increased 39,000 pounds force by modifying the turbine nozzles from axis-symmetric to 3 dimensional to reduce turbine blade loading and to Figure 8. View of Ares V with Engine Skirt expand the operational range of both the fuel and oxidizer turbopumps. Specific impulse is improved by increasing the number of the main injector combustion Ares V Summary Schedule elements which improves mixing and combustion Rev 5b efficiency. Other AATS funded improvements to the Ares V

Level I/II Milestones RS-68A engine include a new bearing material that is Altair Milestones (for more resistant to stress corrosion cracking, improved reference only) nd Phase 1 Ares V Project Milestones processing of the 2 stage fuel turbopump blisk to reduce cracking potential, improved oxidizer turbopump

System Engineering and Integration chill sensor and an improved hot gas temperature sensor. An improved gas generator igniter that has less foreign Core Stage object debris potential is also under development and Core Stage Engine (RS-68B)

Booster expected to be included in the RS-68A certification Earth Departure Stage program. Earth Departure Stage Engine Payload Shroud

Instrument Unit NASA has requested three changes for the RS-68B for

Systems Testing Ares V. First is to reduce the amount of free hydrogen at engine start to mitigate the potential for fire around Figure 9. Ares V Schedule the vehicle and need for added thermal protection. The second is to reduce the amount of helium purge gas used by the engine which currently taxes the Cape Canaveral Air Force Station (CCAFS) helium infrastructure from both a flow rate and total usage standpoint for the 3- engine Delta IV Heavy vehicle. The third change is to modify the ablative nozzle to accommodate the duration

4 requirements of the Ares V mission. Figure 11 shows The effect of free hydrogen on the launch pad is also a how the RS-68 engine is modified for both the RS-68A function of the pad design and environment (weather / and RS-68B configurations. The proposed RS-68B wind) the day of launch. The Delta IV pad has an design changes were studied from early 2006 to May enclosed or cover flame trench, while the Space Shuttle 2007, and the results are summarized below. launch pad is open. Computational fluid dynamics (CFD) analyses of an Ares V with the previous 5-engine configuration were performed for the current start RS-68A, AATS & RS-68B Upgrades configuration, one with software start sequence change only, and one with both the software and helium spin RS-68A Rqmts Higher Density start design change. Results are shown in Figure 13. Main Injector 1st Delivery The plumes are 1000F isotherms at when the engine 4th Qtr 2009 OTP & FTP 3D Turbine Nozzles exhaust would start to aspirate the plume out the flame AATS Incorporated based on Risk Bearing Material To trench. As noted by the figure, hydrogen plume size and 3 Address SCC

Alternate GG Igniter A height is significantly reduced with the new start design. 3 1st Delivery Added RS-68B Rqmts th Improve OTP for MPTA 4 3 Temperature Sensor Qtr 2014 Start Change Case 2 3 Improve Hot Gas Sensor to Mitigate Case 1 Case 3 Free Hydrogen Start Mod Only Current Start (no hardware change) Hdwr & Start Mod 2nd Stage FTP Blisk 3 Crack Mitigation Helium Mitigation Time = 2.74 Cavitation Suppression Increased RS-68 PMP Plan & ECU Duration Upgrade Ablative Nozzle 3 Demonstrated on E10009 B

Figure 11. RS-68A and RS-68B Upgrades

The free hydrogen reduction is being accomplished by Figure 13. CFD Analysis Comparison of Current Start, changing the start sequence and helium spin start Sequence Change Only, and Sequence Change with hardware. A software change for valve sequencing to Helium Spin Start Modification. reduce the hydrogen lead time by 1 second will result in approximately a 15 percent reduction in free hydrogen. The reduction in helium consumption by the engine will The helium spin start inlet port is being changed to be accomplished redesigning the oxidizer turbopump provide more helium flow to the oxidizer turbopump to interpropellant seal. The current labyrinth seal will be speed up its start contributing to a total reduction in free replaced with a segmented carbon contact seal similar to hydrogen of approximately 50 percent. With these what is used on the J-2X engine. This seal is expected improvements, the amount of free hydrogen on the to reduce both the maximum flow rate and total helium launch pad will be about equivalent to what is released consumption to the level of three SSME’s. Figure 14 by three Space Shuttle Main Engines (SSME). Figure shows comparison of maximum flow rate of current 12 shows engineering model of test rig and test engine design versus floating carbon seal and segmented hardware that will be used to validate the helium spin carbon contact seal. start analysis and design change.

700

600

Nominal He Consumption Reduction

500

GG modified for testing different helium 400 spin start inlet port locations Flow rate range Nominal Flow Rate Requirement 300

200

Test rig includes TCA FUEL PUMP PUMP STRUTS 100 • Shell pumps with turbine nozzles & He SS DUCT GG • Gas Generator LOX PUMP • Thrust Chamber Assembly SPOOL Pc’s – Injector and Main Combustion 0 Chamber Hardware ready and available at SSC Current RS68 Engine Floating Ring with Barrier Variable for Segmented Carbons Variable Barrier Chill (113 SCFM switch to 33 SCFM) (113 SCFM switch to 33 SCFM) • Helium spin start line

Figure 12. Helium Spin Start Test Rig and Test Figure 14. RS-68 Oxidizer Turbopump Interpropellant Hardware Seal Design Comparison

5 The change to the ablative nozzle to permit it to run at Summary the enhanced thrust level for full duration of approximately 330 seconds was expected to result in a The Ares V with its heavy lift capability will be a weight increase of less than 150 pounds. However, national asset not only for NASA’s lunar and future since the 2006 study a material obsolescence issue with Mars missions, but also for other government strategic the ablative material has been encountered and a new and scientific missions. The RS-68B engine is a key material is being implemented on the RS-68A program. element of the Ares V, and its success is dependent upon The impact to the RS-68B nozzle is not expected to be the success of the current RS-68A upgrade program as significant nor require early risk reduction effort. well as other AATS and NASA upgrades.

Another part of the early RS-68B study was to assess the Acknowledgments gaps between the RS-68 design certification and the NASA Constellation Program requirements. Seventeen The authors wish to thank the following for there efforts major Constellation specifications containing 1770 on the Ares V and RS-68 program and their requirements were evaluated. Of these, 76 percent were contributions to this paper. considered applicable to the engine, and of these only 55 percent were compliant. The majority of requirements Phil Sumrall, NASA, MSFC not met deal with NASA specific review boards and Martin Burkey, The Schafer Corporation other oversight provisions. A thorough review and Steve Ebert, Pratt & Whitney Rocketdyne waiver process will need to be conducted to resolve Craig Stoker, Pratt & Whitney Rocketdyne these differences and to maintain a common configuration for the components and engine for the Ares V and Delta IV applications.

Although the Ares V and RS-68B full scale development will not begin in earnest until October 2010, there is benefit in conducting risk reduction tasks to preserve the RS-68B 2014 delivery schedule for the Main Propulsion Test Article. See Figure 15 for the preliminary RS-68B development schedule. These include preliminary effort on the hydrogen and helium mitigation requirements as well as engine-vehicle interface and integration studies as listed below. • Engine-vehicle interface and integration studies • RS-68B performance trades • Engine layout trade studies • Base heating mitigation and turbine exhaust ducting trades • Helium Spin Start (HeSS) DDT&E • OTP interpropellant seal design • Requirements assessment

2009 2010 2011 2012 2013 2014 2015 2016 FY09 FY10 FY11 FY12 FY13 FY14 FY15 FY16 RR PDR CDR RS-68B Milestones

Risk Reduction Studies

E15001 Assy & Test

Long Lead Material

RS-68B DDT&E Design & Analysis

Component Fab

E15002 Assy & Test

E40001 Assy & Test

E40002 Assy & Test

MPTA Engines

Production Flight Engine Sets

Figure 15. RS-68B Preliminary Development Schedule

6 National Aeornautics and Space Administration

JANNAF - Liquid Propulsion Subcommittee SteveSteve CreechCreech NASANASA MSFCMSFC JimJim TaylorTaylor NASANASA MSFCMSFC Lt.Lt. Col.Col. ScottScott BellamyBellamy AFSPCAFSPC FritzFritz KuckKuck PrattPratt && WhitneyWhitney RocketdyneRocketdyne DecemberDecember 8-12,8-12, 20082008

AresAres VV andand RS-68BRS-68B

Pratt & Whitney Rocketdyne ConstellationConstellation ProgramProgram VehiclesVehicles

Earth Departure Stage

Orion Crew Exploration Ares V Vehicle Cargo Launch Vehicle

Altair Lunar Lander

Ares I Crew Launch Vehicle

PrattPratt & & Whitney Whitney Rocketdyne Rocketdyne 74817481..22 NASA’sNASA’s ExplorationExploration RoadmapRoadmap

05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25…

ExplorationExploration andand ScienceScience LunarLunar RoboticsRobotics MissionsMissions LunarLunar OutpostOutpost BuildupBuildup

ResearchResearch andand TechnologyTechnology DevelopmentDevelopment onon ISSISS

Commercial Orbital Transportation Services for ISS

SpaceSpace ShuttleShuttle OperationsOperations

SSPSSP TransitionTransition

AresAres II andand OrionOrion DevelopmentDevelopment

OperationsOperations CapabilityCapability DevelopmentDevelopment (EVA(EVA Systems,Systems, GroundGround Operations,Operations, MissionMission Operations)Operations)

Ares I-X OrionOrion andand AresAres II ProductionProduction andand OperationOperation Test Flight April 2009

AltairAltair DevelopmentDevelopment

AresAres VV && EarthEarth DepartureDeparture StageStage

SurfaceSurface SystemsSystems DevelopmentDevelopment

032408

Pratt & Whitney Rocketdyne 7481.3 Ares V Elements

Altair Lunar Stack Integration Lander • 3.7M kg (8.2M lb) gross liftoff weight First Stage • 116 m (381 ft) in length • Two recoverable 5.5-segment EDS PBAN-fueled boosters (derived J–2X Payload J–2X from current Ares I first stage) Fairing Loiter Skirt Core Stage Interstage • Six Delta IV-derived RS–68 LOX/LH engines (expendable) Earth Departure Stage (EDS) 2 • 10 m (33 ft) diameter stage • One Saturn-derived J–2X LOX/LH 2 • Composite structures engine (expendable) • Aluminum-Lithium (Al-Li) tanks • 10 m (33 ft) diameter stage • Aluminum-Lithium (Al-Li) tanks • Composite structures, instrument unit and interstage • Primary Ares V avionics system

Vehicle 51.0.48 RS–68

Pratt & Whitney Rocketdyne 7481.4 AresAres VV CapabilitiesCapabilities forfor OtherOther MissionsMissions

21.7 m (71.1 ft) 10 m (33 ft) ♦♦ PayloadPayload capabilitiescapabilities •• LEOLEO (130(130 xx 130130 nminmi @ @ 2929 deg)deg) ~150 ~150 mTmT 23.2 m (76.2 ft) •• GTOGTO (130(130 xx 1932319323 nminmi @ @ 2929 deg)deg) ~75 ~75 mTmT • GEO (19323 x 19323 @ 0 deg) ~40 mT 10 m • GEO (19323 x 19323 @ 0 deg) ~40 mT (33 ft) 116.2 m (381.1 ft) ♦♦ PayloadPayload envelopenvelop

71.3 m •• 8.88.8 mm diameterdiameter (233.8 ft) 58.7 m (192.6 ft) •• 9.79.7 mm barrelbarrel lengthlength •• 700700 mm33 approximateapproximate volumevolume

NOTE: These are MEAN numbers

Pratt & Whitney Rocketdyne 7481.5 AresAres VV LCCRLCCR TradeTrade SpaceSpace March-JuneMarch-June 20082008 Core Standard Core Opt. Core Length + Common Design Booster + 5 RS-68B Engines 6 RS-68B Engines Features

51.00.39 +5.0 mT 51.00.46 Spacers: 1 Composite Dry Structures 5 Segment for Core Stage, EDS & PBAN Shroud 63.6 mT 68.6 mT Steel Case 60.2 mT Reusable Metallic Cryo Tanks for Core

+6.1 mT +6.1 mT +6.1 Stage & EDS 51.00.40 +5.0 mT 51.00.47 Spacers: 1 5 Segment RS-68B Performance:

HTPB Isp = 414.2 sec Composite Case 69.7 mT 74.7 mT Thrust = 797k lbf @ vac Expendable 61.5 mT 66.3 mT J-2X Performance: -3.6 mT -3.6 -2.3 mT -2.3

+3.7 mT Spacers: 0 Isp = 448.0 sec 5.5 Segment 51.00.41 51.00.48 Thrust = 294k lb @ vac PBAN f Steel Case 71.1 mT Shroud Dimensions: 67.4 mT Reusable 63.0 mT Barrel Dia. = 10 m Usable Dia. = 8.8 m Initial LCCR Study Reference Alternative New POD Barrel Length = 9.7 m Recommend for New POD ♦♦ CurrentCurrent GroundGround RulesRules andand AssumptionsAssumptions 1.5 Launch TLI Capability •• 4-day4-day loiter/29loiter/29 degree,130nmidegree,130nmi insertion/100nmiinsertion/100nmi TLITLI departuredeparture Cargo TLI Capability •• TLITLI PayloadPayload Goal:Goal: 75.175.1 mTmT −− LanderLander (45.0(45.0 mT)mT) ++ OrionOrion (20.2(20.2 mT)mT) ++ MarginMargin ♦♦ Note:Note: PerformancePerformance (light(light blue)blue) isis TLITLI payloadpayload inin conjunctionconjunction withwith AresAres II

Pratt & Whitney Rocketdyne 7481.6 AresAres VV EngineEngine LayoutLayout StudyStudy

6 RS-68 Engine Core Configuration Options ε=30

(Current 21.5 expansion ratio) 12.79 ft Footprint diameter for 6 deg. 33.0 ft Vehicle Engine gimbal diameter 33.0 ft Vehicle 11.07 ft Footprint diameter diameter for 6 deg. Engine gimbal 8.88 ft Nozzle 7.56 ft diameter Nozzle diameter

Fixed Fixed Engine Engine 1.6 ft overlap between SRB aft skirt and core 17.6 ft SRB Aft Skirt diameter base diameter 1.6 ft overlap between SRB aft skirt and core 17.6 ft SRB Aft Skirt diameter base diameter ε=40 -or - 33.0 ft Vehicle 11.07 ft Footprint diameter diameter for 6 deg. 14.52 ft Footprint Engine gimbal diameter for 6 deg. 33.0 ft Vehicle Engine gimbal diameter

7.56 ft 10.22 ft Nozzle Nozzle diameter diameter

1.6 ft overlap between 1.6 ft overlap between SRB aft skirt and core SRB aft skirt and core diameter 17.6 ft SRB Aft Skirt diameter 17.6 ft SRB Aft Skirt base diameter base diameter

Pratt & Whitney Rocketdyne 7481.7 AresAres VV EngineEngine LayoutLayout TradeTrade ExampleExample

♦♦ VehicleVehicle thrustthrust loadsloads favorablyfavorably handledhandled withwith enginesengines onon outerouter stagestage circumferencecircumference

♦♦ EnginesEngines positionedpositioned onon stagestage circumferencecircumference requirerequire protectiveprotective skirtskirt –– adds adds weightweight

♦♦ SkirtSkirt createscreates dragdrag andand impactsimpacts vehiclevehicle performanceperformance

Pratt & Whitney Rocketdyne 7481.8 AresAres VV ScheduleSchedule

Ares V

Level I/II Milestones

Altair Milestones (for reference only)

Phase 1 Ares V Project Milestones

System Engineering and Integration

Core Stage

Core Stage Engine (RS-68B)

Booster

Earth Departure Stage

Earth Departure Stage Engine

Payload Shroud

Instrument Unit

Systems Testing

Pratt & Whitney Rocketdyne 7481.9 RS-68RS-68 toto RS-68BRS-68B

* Redesigned turbine HeliumHelium spin-startspin-start nozzles to increase ductduct redesign,redesign, alongalong maximum power withwith startstart sequencesequence level by approx. 6% modifications,modifications, toto helphelp minimizeminimize pre-pre- ignitionignition freefree Redesigned turbine hydrogenhydrogen seals to significantly reduce helium usage for pre-launch ** HigherHigher elementelement densitydensity mainmain injectorinjector improvingimproving specificspecific Other RS-68A upgrades or changes 6 that may be included: impulseimpulse byby ~~6 • Bearing material change secondsseconds • New Gas Generator igniter design • Improved Oxidizer Turbo Pump temp sensor • Improved hot gas sensor Increased duration • 2nd stage Fuel Turbo Pump blisk capability ablative crack mitigation nozzle • Cavitation suppression • ECU parts upgrade * RS-68A Upgrades

Pratt & Whitney Rocketdyne 7481.10 RS-68A,RS-68A, AATSAATS && RS-68BRS-68B UpgradesUpgrades

RS-68A Rqmts Higher Density Main Injector 1st Delivery 4th Qtr 2009 OTP & FTP 3D Turbine Nozzles AATS Incorporated based on Risk Bearing Material To 3 Address SCC

Alternate GG Igniter A 3 1st Delivery Added RS-68B Rqmts th Improve OTP for MPTA 4 3 Temperature Sensor Qtr 2014 Start Change 3 Improve Hot Gas Sensor to Mitigate Free Hydrogen 2nd Stage FTP Blisk 3 Crack Mitigation Helium Mitigation Cavitation Suppression Increased RS-68 PMP Plan & ECU Duration Upgrade Ablative Nozzle 3Demonstrated on E10009 B

Pratt & Whitney Rocketdyne 7481.11 RS-68BRS-68B ProjectProject StatusStatus

♦♦ RS-68BRS-68B studystudy performedperformed fromfrom earlyearly 20062006 toto MayMay 20072007 ♦♦ CompletedCompleted upgradesupgrades SystemSystem RequirementsRequirements ReviewReview •• PreliminaryPreliminary requirementsrequirements forfor earlyearly AresAres VV configuredconfigured vehiclevehicle •• IdentifiedIdentified gapsgaps betweenbetween DeltaDelta IVIV leviedlevied requirementsrequirements andand NASANASA ConstellationConstellation ProgramProgram requirementsrequirements •• DraftedDrafted PrimePrime ItemItem DevelopmentDevelopment SpecificationSpecification forfor engineengine ♦♦ CompletedCompleted preliminarypreliminary designdesign reviewsreviews onon upgradedupgraded componentscomponents •• OxidizerOxidizer TurbopumpTurbopump (OTP)(OTP) interpropellantinterpropellant sealseal forfor heliumhelium mitigationmitigation •• HeliumHelium spinspin startstart systemsystem forfor hydrogenhydrogen mitigationmitigation •• AblativeAblative nozzlenozzle redesignredesign forfor 330330 secondsseconds durationduration atat 108%108% powerpower levellevel

Pratt & Whitney Rocketdyne 7481.12 HydrogenHydrogen MitigationMitigation LaunchLaunch PadPad AnalysisAnalysis

Case 2 Case 1 Start Mod Only Case 3 Current Start (no hardware change) Hdwr & Start Mod

Time = 2.74

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Pratt & Whitney Rocketdyne 7481.13 AresAres VV andand RS-68BRS-68B IntegrationIntegration andand RiskRisk ReductionReduction TasksTasks forfor 2008-20102008-2010

♦♦ Engine-vehicleEngine-vehicle interfaceinterface andand integrationintegration studiesstudies ♦♦ RS-68BRS-68B performanceperformance tradestrades ♦♦ EngineEngine layoutlayout tradetrade studiesstudies ♦♦ BaseBase heatingheating mitigationmitigation andand turbineturbine exhaustexhaust ductingducting tradestrades ♦♦ HeliumHelium SpinSpin StartStart (HeSS)(HeSS) DT&EDT&E ♦♦ OTPOTP interpropellantinterpropellant sealseal designdesign ♦♦ EngineEngine handlinghandling methodsmethods ♦♦ RequirementsRequirements assessmentassessment

Pratt & Whitney Rocketdyne 7481.14 RS-68BRS-68B PreliminaryPreliminary ScheduleSchedule

2009 2010 2011 2012 2013 2014 2015 2016 FY09 FY10 FY11 FY12 FY13 FY14 FY15 FY16 RR PDR CDR RS-68B Milestones

Risk Reduction Studies

E15001 Assy & Test

Long Lead Material

RS-68B DDT&E Design & Analysis

Component Fab

E15002 Assy & Test

E40001 Assy & Test

E40002 Assy & Test

MPTA Engines

Production Flight Engine Sets

Pratt & Whitney Rocketdyne 7481.15