OrbitalHub

Credits: SpaceX

SpaceX recently reached two major milestones towards the goal of servicing the International Space Station (ISS) after the retirement of the Space Shuttle in September 2010.

The milestones are the successful testing of the heat shield material used for the thermal protective system of the Dragon spacecraft, and a mission-length firing of the Merlin Vacuum engine that powers the second stage of the Falcon 9 launch vehicle.

On February 23, 2009, SpaceX announced that the PICA-X high performance heat shield material passed an arc jet testing. During the test that recreates the conditions experienced during an atmospheric reentry, the material was subjected to temperatures as high as 1850 degrees Celsius.

PICA is short for Phenolic Impregnated Carbon Ablator. It is a material used for thermal protection, which was initially developed by NASA. PICA-X is an improved variation of the original PICA and was developed by SpaceX with the assistance of NASA. SpaceX becomes the second commercial source for this high-performance carbon-based material.

“We tested three different variants developed by SpaceX,” said Tom Mueller, VP of Propulsion, SpaceX. “Compared to the PICA heat shield flown successfully on NASA’s Stardust sample return capsule, our SpaceX versions equaled or improved the performance of the heritage material in all cases.”

Credits: SpaceX

The arc jet tests were performed at the Arc Jet Complex at NASA Ames Research Center, as the test center is capable of creating the reentry conditions. The Arc Jet Complex has a long history in the development of thermal protective systems.

PICA-X will protect the Dragon spacecraft and the crew during the reentry in the atmosphere from low Earth orbit (LEO).

One remarkable detail that I discovered when reading the press release is that PICA-X will also be used to coat the second stage of the Falcon 9 launch vehicle, as SpaceX plans to reuse the second stage of the launch vehicle as well.

On March 7, 2009, the Merlin Vacuum engine completed a full mission duration firing at the SpaceX Test Facility in McGregor, Texas. During the test that lasted 6 minutes, the engine consumed more than 100,000 pounds of liquid oxygen and rocket grade kerosene.

The Merlin Vacuum engine is a variation of the Merlin 1C engine that powers the Falcon 1 launch vehicle, and it accommodates changes that make it more efficient to fire in the vacuum of space (most notably the shape of the nozzle).

Credits: SpaceX

“Specific impulse, or Isp, indicates how efficiently a rocket engine converts propellant into thrust,” said Tom Mueller. “With a vacuum Isp of 342 seconds, the new Merlin Vacuum engine has exceeded our requirements, setting a new standard for American hydrocarbon engine performance in space.”

The engine uses a regeneratively cooled combustion chamber, which means that the propellant is injected into the walls of the combustion chamber and prevents them from melting.

The nozzle is radiatively cooled and much larger, and also has a larger exhaust section than the Merlin 1C. This results in an improved performance of the engine. The engine is capable of multiple restarts and can operate at reduced thrust, which will enable the upper stage to deliver payloads matching a broad range of orbital profiles.

“Falcon 9 was designed from the ground up to provide our customers with breakthrough advances in reliability,” said Elon Musk, CEO and CTO of SpaceX. “In successfully adapting our flight tested first stage engine for use on the second stage, this recent test further validates the architecture of Falcon 9, designed to provide customers with high reliability at a fraction of traditional costs.”

The first flight of the Falcon 9 /Dragon launch system is scheduled for late 2009 from Launch Pad SLC-40 at Cape Canaveral, Florida. For more information about SpaceX and the Falcon 9 /Dragon launch system, you can visit the SpaceX website.

Credits: SpaceX

SpaceX has announced that the Falcon 9 launch vehicle was raised to vertical on its launch pad at Space Launch Complex 40 (SLC-40) in Cape Canaveral, Florida.

SpaceX was awarded a Commercial Resupply Service (CRS) contract in December 2008. The Falcon 9 launch vehicle and the Dragon spacecraft will be used as the primary means of transporting cargo to and from the International Space Station (ISS) after the Space Shuttle is retired by NASA.

The Falcon 9 launch vehicle will provide the lowest cost per kilogram to orbit. The 54.9 m long and 3.6 m wide launcher will be able to lift payloads with a mass of 12,500 kg to a low Earth orbit (LEO) for only $36.75 million. For more details on the pricing of the Falcon 9 missions, you can check out the page dedicated to Falcon 9 on SpaceX’s web site.

“This entire process has helped us validate key interfaces and operations prior to executing our launch campaign with the vehicle in its final flight configuration,” said Elon Musk, CEO and CTO of SpaceX. “We encountered no show-stoppers or significant delays. I am highly confident that we will achieve our goal of being able to go from hangar to liftoff in under 60 minutes, which would be a big leap forward in capability compared with the days to weeks required of other launch vehicles.”

Credits: NASA

Orbital will employ its Taurus II medium-lift launch vehicle and the Cygnus spacecraft in order to service the International Space Station (ISS) under the Commercial Resupply Services (CRS) contract.

Orbital is one of the two companies awarded CRS contracts under the Commercial Orbital Transportation Services Project (COTS).

NASA announced the COTS project on January 18, 2006. The purpose of the program is to stimulate the development of access to low Earth orbit (LEO) in the private sector. At the time, with the imminent retirement of the Space Shuttle fleet, NASA was faced with the option of buying orbital transportation services on foreign launch systems: the Russian Soyuz / Progress, the European Ariane 5 / ATV, or the Japanese H-II / HTV.

Another factor taken into consideration by NASA was that competition in the free market could lead to the development of more efficient and affordable launch systems compared to launch systems that a government agency could build and operate.

Credits: Orbital

Orbital relies on proven experience in launch vehicle technology. Taurus II is designed to provide low-cost and reliable access to space, and it uses systems from other members of Orbital’s family of successful launchers: Pegasus, Taurus, and Minotaur.

Taurus II is a two-stage launch vehicle that can use an additional third stage for achieving higher orbits. The payloads handled by Taurus II can have a mass of up to 5,400 kg.

Orbital is responsible for overall development and integration of the first stage. The two AJ26-62, designed and produced by Aerojet and Orbital, are powered by liquid oxygen and kerosene. The core design is driven by NPO Yuzhnoye, the designer of the Zenit launchers.

The AJ26-62 engines are basically the NK-33 engines designed by the Kuznetsov Design Bureau for the Russian N-1 launch vehicle, and remarketed by Aerojet under a new designation.

The second stage uses an ATK Castor-30 solid motor with thrust vectoring. This stage evolved from the Castor-120 solid stage.

The optional third stage is developed by Orbital. The stage was dubbed the Orbit Raising Kit (ORK) and it uses a helium pressure regulated bi-propellant propulsion system powered by nitrogen tetroxide and hydrazine. ORK evolved from the Orbital STAR Bus. Because it is a hypergolic stage, it allows several burns to be performed in orbit, and can be used for high-precision injections using various orbital profiles.

Credits: Orbital

Cygnus will only have cargo capability and will be able to deliver up to 2,300 kg of pressurized or un-pressurized cargo to the ISS. The spacecraft will also be able to return up to 1,200 kg of cargo from ISS to Earth.

The two components of the Cygnus spacecraft will be the service module and the cargo module.

The service module is based on the Orbital STAR bus (like the ORK stage), and will use two solar arrays for producing electrical power for the navigation systems onboard.

The pressurized cargo module is based on the Italian-built Multi-Purpose Logistics Module (MPLM). The un-pressurized cargo module is based on NASA’s ExPRESS Logistics Carrier.

Cygnus will not dock to the ISS in the same manner as the European ATV, but it will be able to maneuver close to the ISS where the Canadarm 2 robotic arm will be used to capture it and berth it to the Node 2 module, similar to the Japanese HTV or SpaceX’s Dragon spacecraft.

The Mid-Atlantic Regional Spaceport (MARS), located at NASA’s Wallops Island Flight Facility on Virginia’s Eastern shore, was chosen by Orbital to serve as the base of operations for the Taurus II launch vehicle.

MARS has two FAA licensed launch pads for LEO access. MARS also offers access to suborbital launchers, vehicle and payload storage, and processing and launch facilities.

Credits: NASA

Due to the location of the spaceport, latitude 37.8 degrees N, longitude 75.5 degrees W, optimal orbital inclinations for the launches performed at MARS are between 38 and 60 degrees. Polar and retrograde orbits can also be serviced with additional in-flight maneuvering.

The first flight of Orbital’s new Taurus II / Cygnus launch system under COTS is scheduled for late 2010.

The awarded contracts are fixed-price indefinite delivery, indefinite quantity contracts. They will begin January 1, 2009, and are effective through December 31, 2016. SpaceX and Orbital each will have to deliver a minimum of twenty metric tons of cargo to the space station, and they will also have to deliver non-standard services in support of the cargo resupply, including analysis and special tasks as the government deems necessary.

SpaceX will service the ISS with its Falcon9/Dragon system.

“The SpaceX team is honored to have been selected by NASA as the winner of the Cargo Resupply Services contract,” said Elon Musk, CEO and CTO, SpaceX. “This is a tremendous responsibility, given the swiftly approaching retirement of the Space Shuttle and the significant future needs of the Space Station. This also demonstrates the success of the NASA COTS program, which has opened a new era for NASA in US Commercial spaceflight.”

Orbital will employ the Taurus II^TM medium-lift launch vehicle and the Cygnus^TM maneuvering space vehicle.

“We are very appreciative of the trust NASA has placed with us to provide commercial cargo transportation services to and from the International Space Station, beginning with our demonstration flight scheduled in late 2010,” said Mr. David W. Thompson, Orbital’s Chairman and Chief Executive Officer. “The CRS program will serve as a showcase for the types of commercial services U.S. space companies can offer NASA, allowing the space agency to devote a greater proportion of its resources for the challenges of human spaceflight, deep space exploration and scientific investigations of our planet and the universe in which we live.”

Both Orbital and SpaceX have issued press releases with more details about the CRS contracts.

Credits: SpaceX

Another critical milestone has been reached by SpaceX with the arrival of Falcon 9 hardware at Cape Canaveral.

After the full mission-length firing test of the Falcon 9 first stage engines and the firing test of the Dragon maneuvering thruster, the arrival of the Falcon 9 first stage fuel tank fulfills SpaceX’s commitment to having Falcon 9 hardware at Cape Canaveral by year-end.

“Christmas has arrived a few days early for our team at the Cape,” said Brian Mosdell, Director of Florida Launch Operations for SpaceX. “The packages measure extra large this year, and they will keep everyone busy in the coming weeks.”

All of the Falcon 9 elements and the ground support hardware have already left the SpaceX manufacturing facility in Hawthorne, California. The hardware will make its way to the launch site at Cape Canaveral over the next two weeks. The Falcon 9 will then be assembled on horizontal and raised to vertical on the custom built erector.

Credits: SpaceX

There are four Falcon 9 launches scheduled for 2009. Two of these launches are demonstration flights with the Dragon spacecraft as part of the NASA Commercial Orbital Transportation Services (COTS) competition. A total of three flights of the Falcon 9/Dragon launch system will be conducted under the agreement, in order to demonstrate cargo delivery capability to the International Space Station (ISS).

NASA’s agreement with SpaceX can be extended to include demonstrating transport of crew to and from the ISS.

“2008 has been a year of rapid progress for SpaceX,” said Elon Musk, CEO and CTO of SpaceX. “The delivery of the Falcon 9 to the Cape is a major milestone in designing and deploying the most reliable, cost-efficient fleet of launch vehicles in the world. I applaud our SpaceX team who has worked 24/7 to make this happen.”

SpaceX has made available a video of Elon Musk giving a tour of the SpaceX Falcon 9 launch site at Space Launch Complex 40, Cape Canaveral AFS, Florida.

Credits: XCOR Aerospace

XCOR completed the first test fire of the rocket engine that will power the Lynx suborbital launch vehicle. The test was performed on Monday, December 15, 2008, at XCOR’s rocket test facility located at the Mojave Air and Space Port.

The rocket engine is designated as 5K18. The engine is powered by liquid oxygen and kerosene and can produce up to 2900 lbf of thrust.

The 5K18 is the eleventh in a series of rocket engines that XCOR has designed and fired during its nine years of existence.

“Today’s successful hot fire marks an important step forward in building the Lynx,” said XCOR CEO Jeff Greason. “The 5K18 builds on our previous experience in designing and building reliable, durable and fully reusable rocket engines from 15 lbf thrust up to 7500 lbf, that will make it possible to provide affordable access to space.”

The Lynx will use four 5K18 engines and it will be able to perform suborbital flights. Space tourists can buy tickets to fly on the Lynx for $95,000 through RocketShip Tours. The full press release is available on the XCOR Aerospace web site.