National Aeronautics and Space Administration NASA’s Reusable Stages and Liquid Oxygen/Hydrocarbon (LOX/HC) Engines Garry Lyles Space Launch System (SLS) Chief Engineer Marshall Space Flight Center February 17, 2012 Space Launch System Launch Space www.nasa.gov Advancing the U.S. Legacy of Exploration National Aeronautics and Space Administration 8032_SLS Overview_E.2 NASA Experience with LOX / RP-1 Propulsion • NASA systems – RP-1 experience spans a significant period of Agency history – Strong heritage of hardware design, development, analysis and test exists within the agency – MSFC has significant capabilities in supporting disciplines such as materials, manufacturing, and test • Industrial base strengthened through NASA programs and technology transfer – History of partnering with industry in various capacities has further advanced the U.S. knowledge base – Transfer of key design codes, test and materials data, analytical results – Recent F-1 disassembly work, both at MSFC and at PWR, ensures the next generation has an understanding of RP-1 propulsion National Aeronautics and Space Administration 8032_SLS Overview_E.3 History of LOX/RP-1 Engine Development MSFC Partnered with Industry F-1 Gas Generator Cycle TR107 Prime: Rocketdyne Ox- Rich Stage Combustion Flew on Saturn V Prime: TRW Engine to CoDR fidelity F-1A In development at the end Subscale (5k) Pintle Test at Purdue of the program 250 k Preburner Built, not Tested Upgraded Turbomachinery Fastrac (MC-1) Gas Generator Cycle Government Design Hardware Prime: Summa Vehicle Prime: Orbital Engine was Fully Developed Engine assembled into the X- 34 vehicle but did not fly RS-84 Ox-rich Stage Combustion Prime: Rocketdyne Engine to IDR (nearly CDR fidelity) Significant subscale testing completed National Aeronautics and Space Administration 8032_SLS Overview_E.4 History of LOX/RP-1 Engine Development Engine Size Comparison LOX/Hydrogen LOX/Kerosene Fastrac TR107 ORSC-RS84 F1 Tsl = 60 Klbf Tsl = 1,000 Klbf Tsl = 1,050 Klbf Tsl = 1,522 Klbf Tvac = 63.9 Klbf Tvac = 1,074 Klbf Tvac = 1,155 Klbf Tvac = 1,748 Klbf Isp (sl) = 300 sec Isp (sl) = 300 sec Isp (sl) = 305 sec Isp (sl) = 265.4 sec Isp (vac) = 314 sec Isp (vac) = 327 sec Isp (vac) = 335 sec Isp (vac) = 304.1 sec Pc = 652 psia Pc = 2500 psia Pc = 2700 psia Pc = 982 psia Wt = lbm e = 25:1 e = 30:1 e = 16:1 T/W (sl/vac) = / L =” Wt = 11,300 lbm Wt = 15,925 lbm Wt = 18,616 lbm Nozzle ID = 45.7” T/W (sl/vac) = 88 / 95 T/W (sl/vac) = 65 / 73 T/W (sl/vac) = 82 / 94 MR = 2.17 L = 180” L = 168” L = 220” Nozzle ID = 92” Nozzle ID = 95.5” Nozzle ID = 140” MR = 2.7 MR = 2.7 MR = 2.27 History of LOX/RP-1 Propulsion Engine System and Component Design and Analysis Engine Systems Turbomachinery PREBURNER PRESSURE (PSIA) HTF Run Box with Ox Pump Nss Limits 2000 WinPlot v4.2 172 Combustion Devices 170 Current HTF Run Box Nss = 20000 1600 Nss = 21000 168 Lines, Valves, Nss = 22000 New Method 166 1200 164 Old Method Actuators Detail 162 800 160 Test Data Design 158 400 2.0 2.5 3.0 3.5 4.0 156 TIME SECONDS TIME IN SECONDS 30 35 40 45 50 55 60 65 70 11:08:28PM 01/26/2004 Stress, Life Assessment, Loads and Dynamics, Thermal, Acoustics, and CFD Analysis History of LOX/RP-1 Propulsion Fastrac Engine and Stage Testing and Integration HTF PTA Alfa 1 ALL Total Tests 35 5 17 57 Total Hot Fires 27 3 12 42 Total Main Stage Tests > 5 sec 15 2 8 25 Total Seconds 428 138 322 888 Main Stage Sec 330 126 276 732 Early Cuts for Engine Causes 9 0 2 11 National Aeronautics and Space Administration 8032_SLS Overview_E.7 History of LOX/RP-1 Propulsion Component Testing Provides Critical Risk Reduction Purdue TR107 5k ORPB Testing MSFC Fastrac Component Testing RS84 Testing at MSFC and SSC History of LOX/RP-1 Propulsion Unique Test Facilities Aid Industry East Test Area Materials Lab North Test Area • Subscale and component level • Failure investigation • Unique, low-cost, quick- high-pressure testing of injectors, • Comprehensive Materials Testing turnaround fluid flow tests nozzles, pumps, thrust chambers • State of the Art Welding, Brazing • Turbine, Inducer, Pump, techniques • TS115, TS116 and Nozzle test facilities • Structured light • Advanced Manufacturing Component Development Area SSC • Unique propulsion system component • LOX/RP1 Engine technology assessment Systems Testing • Focused on valve, regulator, solenoid, and • LOX/RP1 Large seal development component testing • Stage Testing History of LOX/RP-1 Propulsion Recent F-1 Disassembly Prepares Government and Industry Workforce for SLS Advanced Booster NRA Studies & Activities Leading to the SLS Decision 2009 2010 2011 ACTIVITY J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D Review of Human Space Flight (HSF) Plans Committee (Augustine Panel) Heavy Lift Launch Vehicle (HLLV) Study Heavy Lift Propulsion Technologies Study (HLPT) Human Exploration Framework Team (HEFT) and HEFT II Broad Agency Announcements (BAA) NASA/U.S. Air Force (USAF) Common Engine Study Heavy-Lift Vehicle (HLV) Analysis of Figures of Merit (FOM) Requirements Analysis Cycle (RAC) 1 SLS Mission Concept Review (MCR) Exploration Systems Development (ESD) SLS Analysis of Alternatives (AoA) Agency Integrated Architecture Decision SLS Program Planning and Budget Execution for FY13 to Agency SLS Acquisition Strategy Meeting Independent Cost Assessment Report (Booz Allen Hamilton) SLS Rolled out by NASA Administrator Engineering and Business Analyses Validated SLS Architecture Selected by the Agency National Aeronautics and Space Administration 8132_PPandC_Intro.11 NASA Authorization Act of 2010 ♦ The Congress passed and the President signed the National Aeronautics and Space Administration Authorization Act of 2010. • Bipartisan support for human exploration beyond low-Earth orbit (LEO) ♦ The Law authorizes: • Extension of the International Space Station (ISS) until at least 2020 This rocket is key to implementing the plan • Strong support for a commercial space laid out by President Obama and Congress transportation industry in the bipartisan 2010 NASA Authorization Act. — NASA Administrator Charles Bolden • Development of Orion Multi-Purpose Crew September 14, 2011 Vehicle (MPCV) and heavy lift launch capabilities • A “flexible path” approach to space exploration, opening up vast opportunities including near-Earth asteroids and Mars • New space technology investments to increase the capabilities beyond Earth orbit (BEO) Delivering on the Laws of the Land … and Obeying the Laws of Physics National Aeronautics and Space Administration 8032_SLS Overview_E.12 The Future of Exploration My desire is to work more closely with the human spaceflight program so we can take advantage of synergy…We think of the SLS as the human spaceflight program, but it could be hugely enabling for science. — John Grunsfeld, Associate Administrator NASA Science Mission Directorate Nature, Jan 19, 2012 National Aeronautics and Space Administration 8132_PPandC_Intro.13 SLS Driving Objectives ♦ Safe: Human-Rated ♦ Affordable • Constrained budget environment • Maximum use of common elements and existing assets, infrastructure, and workforce • Competitive opportunities for affordability on-ramps ♦ Sustainable • Initial capability: 70 metric tons (t), 2017–2021 ‒ Serves as primary transportation for Orion and exploration missions ‒ Provides back-up capability for crew/cargo to ISS • Evolved capability: 105 t and 130 t, post–2021 ‒ Offers large volume for science missions and payloads ‒ Modular and flexible, right-sized for mission requirements Flexible Architecture Configured for the Mission National Aeronautics and Space Administration 8132_May.14 SLS Evolutionary Block Upgrades 130 t 376 ft. 105 t Orion Multi-Purpose 321 ft. Crew Vehicle (MPCV) 70 t (378.5 ft.) 320.9 ft. Payload Fairings 30 ft. (10 m) Launch Abort System Payload Adapter (PA) Orion Interim Cryogenic Upper Stage Propulsion Stage (ICPS) 27.5 ft. (8.4 m) 27.5 ft. (8.4 m) with Interstage J-2X Core Stage Core Stage Engine Solid Rocket Boosters Advanced Boosters RS-25 Core Stage Engines (Space Shuttle Main Engines) Incremental Capabilities Delivered within the Planned Budget National Aeronautics and Space Administration 8132_PPandC_Intro.15 Assets in Inventory and Testing in Progress First Flight 2017 National Aeronautics and Space Administration 8032_SLS Overview_E.16 Key Milestones FY10 FY11 FY12 FY13 FY14 FY15 FY15 FY17 FY18 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Flight Manifest EFT–1 EM–1 Uncrewed C–SRR C–SDR KDP KDP HEO / ESD C– Milestones SRR C–SDR Checkpoint Checkpoint Checkpoint Checkpoint Checkpoint KDP–A KDP–C KDP–D (TBD) SLS / KDP–B PPBE 13 ASM SRR Rev. 1 PSM Checkpoint Major Milestones MCR SRR/ PDR CDR DCR SDR SLS-SCHED-69 Approved: Nov 17, 2011 LEGEND: ASM Acquisition Strategy Meeting HEO Human Exploration and Operations C-SDR Cross-Program System Definition Review KDP Key Decision Point C-SRR Cross-Program System Requirements Review MCR Mission Concept Review CDR Critical Design Review PDR Preliminary Design Review DCR Design Certification Review PPBE Program Planning & Budget Estimate EFT Exploration Flight Test PSM Procurement Strategy Meeting EM Exploration Mission SDR System Definition Review ESD Exploration Systems Development SRR System Requirements Review FY Fiscal Year TBD To be determined National Aeronautics and Space Administration 8032_SLS Overview_E.17 Early Exploration Missions EM-1 • Un-crewed circumlunar flight – free return trajectory • Mission duration ~7 days • Launch vehicle built around providing the customer-requested 11 km/s re- entry velocity EM-2 • Crewed lunar orbit mission • Vehicle performance and requirement set derived from customer needs and stakeholder NGOs • Vehicle architecture built around customer-required performance with fully capable spacecraft Requirements built around customer values, initial missions, and stakeholder needs, goals, and objectives.