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TerraN_EmpirE

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But it's all the way down in Brownsville though, right next to the border along Mexico. I don't know if there are too many people interested in moving down there for a space jobs, but who knows. Why work there when you can work in a superb environment with great schools down in the Clear Lake area of the JSC near the beach of Galveston?:eek: I'm just saying.

True, but Cape Canaveral (NASA launch center) is in Florida, how is Brownsville going to compete with the coastal beaches of Florida (oh and those bikinis)?:eek:
Hay Equation remember when you were asking how SpaceX and the like would end up getting the Engineers and specialist over NASA? perhaps you should check your own news paper.
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Space Flight: Increasingly, Gifted Individuals are Opting for the Private Sector Over NASA
By Susan Du
Published Wed., Aug. 13 2014 at 10:00 AM

Illustration by Ellen Weinstein

Amy Hoffman doesn't realize she's tapping her boots underneath the table at Boondoggles, where she's having a last lunch with Clear Lake friends before skipping town. The boots are baby-blue Cavenders, ankle high and definitely out of season because it's the first week of July and her friends are sweating in T-shirts, cargo shorts and sandals. Hoffman is deep in conversation about her imminent move from her native Texas, the scramble to stake an apartment in a market riddled with scams and listings that don't even include refrigerators.

Hoffman (not her real name) grew up in Austin and spent the past three years working in Houston, where Boondoggles, with its spacious seating and encyclopedic beer selection, became a regular hangout for her engineering clique. She always ran into coworkers there after hours -- astronauts, too, on occasion. Hoffman recounts over pizza chips how those sightings invariably cause her to geek out intensely, yet internally. She's always tempted to corner an astronaut and say hi, but she gets how creepy that would be. A friend who has dropped by to see her off tells her she's going to be missed.

As a NASA engineering co-op student at Johnson Space Center, Hoffman trained in various divisions of the federal space agency to sign on eventually as a civil servant. She graduated from college this year after receiving a generous offer from NASA, doubly prestigious considering the substantial reductions in force hitting Johnson Space Center in recent months. She did have every intention of joining that force -- had actually accepted the offer, in fact -- when she received an invitation to visit a friend at his new job with rising commercial launch company SpaceX.

Hoffman took him up on the offer, flying out to Los Angeles in the spring for a private tour. Driving up to the SpaceX headquarters, she was struck by how unassuming it was, how small compared to NASA, how plain on the outside and rather like a warehouse.

As she walked through the complex, she was also surprised to find open work areas where NASA would have had endless hallways, offices and desks. Hoffman described SpaceX as resembling a giant workshop, a hive of activity in which employees stood working on nitty-gritty mechanical and electrical engineering. Everything in the shop was bound for space or was related to space. No one sat around talking to friends in the morning, "another level from what you see at NASA," she said. "They're very purpose-driven. It looked like every project was getting the attention it deserved."

Seeing SpaceX in production forced Hoffman to acknowledge NASA might not be the best fit for her. The tour reminded her of the many mentors who had gone into the commercial sector of the space industry in search of better pay and more say in the direction their employers take. She thought back to the attrition she saw firsthand at Johnson Space Center and how understaffed divisions struggled to maintain operations.

From 1993 to July of this year, the number of NASA civil servants declined by more than 8,000. In contrast, SpaceX has been on the rise since it was founded in 2002, now numbering upwards of 3,000 employees and rivaling private industry newcomer Sierra Nevada Corporation. Publicly held aerospace manufacturer Boeing claims more than 56,000 in its defense, space and security group. Although NASA remains to date the only American agency to have sent humans to space, those three companies are competing for crew contracts from NASA. SpaceX and Virginia-based Orbital Sciences have previously launched cargo.

Most impressive of all, Hoffman saw SpaceX engineers working on their own projects -- not a novel concept. But it brought her back to her days as a NASA co-op when she had to drop her arduously designed blueprints off at the shop and wait for contractors to slap her baby together. Often shop workers had long lists of orders to fill, leaving her to twiddle her thumbs or work on less urgent projects when she'd rather be at the mill herself.

At NASA, getting orders back from the shop didn't mean she was guaranteed to see her projects fly. Due to funding constraints, NASA projects are constantly shelved or canceled altogether. Hoffman felt this most acutely as a student because the co-op program allowed her only a limited amount of time at various branches. In order to complete a project, she had to abide by a strict timeline.

In Hoffman's three years at NASA, she worked on only one or two projects that would ever see space, which she considers a very poor rate. Most of her efforts were spent on potential prototypes or preliminary research for future projects, leaving her to ask, "Well, I guess I kinda sorta contributed?"


cs-Jehonce560.jpg
Photo by Ashli Hill
Jehon Leonce is a former flight controller at NASA who left the space industry for more leadership roles in oil and gas.
A Johnson Space Center spokeswoman declined to comment on how project cancellation affects workforce morale. NASA headquarters spokeswoman Sonja Alexander said NASA civil servants tend to stay with the agency until retirement, and talent retention is no issue.

"Space exploration is a tri-sector enterprise between government, academia and the commercial sector," she wrote in a statement. "No one sector can do it alone. We encourage flow of people, money and projects between these sectors. Collaboration has been the NASA business model since the agency was created."

SpaceX inspired Hoffman to reimagine a career with opportunities to work on her engineering projects even if the technicians were busy and not have it considered diverting work from contract labor. If she chose to work long hours at a commercial company, she wouldn't be "punished for being an overachiever." If she spent months on a project, she could be assured it would get launched into space.

For Hoffman, having her projects go unfinished at NASA may have been the personal foul that tipped her toward private industry, but she also suspected her own engineering frustrations were only the surface byproduct of more institutionalized problems. NASA's financial insecurity, its lack of administrative direction and its bureaucracy had worn on her confidence in its future.

Because she joined the space industry aiming to realize a personal goal of one day vacationing in space, Hoffman is looking to forward-thinking companies with the same idea of revolutionizing commercial spaceflight. Las Vegas startup Bigelow Aerospace is a company with serious plans to develop "crewed space complexes," essentially orbiting space hotels. Hoffman believes space tourism will eventually become reality after commercial launch companies take over missions from NASA.

So with the academic pedigree and skill set to keep her in indefinite demand, Hoffman gritted her teeth and stepped away from an agency traditionally viewed as the dream destination for the nation's most promising young engineers to take a job with a private company.

She's not alone in her decision. Increasingly, civil servants are leaving for the money in oil and gas. Subcontractors are breaking away to seek job prospects at more entrepreneurial, less bureaucratic companies. And career services reps at top universities are encouraging their engineering students to weigh a complex host of questions while searching for jobs in the space industry -- including whether they should expect to actually practice what they've learned in school.

Former NASA flight controller Jehon Leonce, 29, let oil and gas entice him away with a project manager offer he couldn't refuse. He summarized NASA's struggle to inspire young engineers as "an uphill battle" considering the federal agency's track record of major cancellations, such as the retirement of the space shuttle program in 2011. He said NASA's current focus on Orion, a craft designed to explore deep space, is well intentioned but still risky. Orion was itself scavenged out of the moon exploration program Constellation, which was canceled in 2010.

"There's not much of a short-term vision," Leonce said. "[Private companies] launch missions, and people are attracted to that. With NASA, until the new vehicle they're working on comes online, honestly speaking, it's kind of boring.


cs-DunbarAtlantis560.jpg
Photo courtesy of NASA public domain galleries
Bonnie Dunbar is a former astronaut advocating for mure funding of NASA projects.
As the government encourages commercial space companies to take on responsibilities that were once strictly NASA's, young people entering the workforce are finding that their employment options have broadened.

"Students have certainly in the last few years gotten more interested in companies like SpaceX. SpaceX certainly has some dynamic leadership, so that catches students' attention," said Michael Powell of the University of Texas at Austin's Cockrell School of Engineering. Cockrell is known in the academic world for its consistent co-op program with NASA, the federal agency's main recruiting tool. According to Powell, the school provides three to five co-ops a class, and most have traditionally signed on with NASA as full-time hires. Still others are drawn to commercial companies, start-ups especially, for more responsibility earlier in their careers. "Even students who wind up accepting a job with a private company could still technically live the dream of working with NASA on a NASA project [as contractors]," he said.

Organizations that are speculative and researched-based will consistently attract risk-taking students, Powell added. Commercial companies appeal to those looking for more tangible results. Nicole Van Den Heuvel of Rice University's career development center believes the surge of talent toward private industry is generally telling of how the younger generation thinks.

"It's leaner. There are more opportunities for quicker growth in companies that are more entrepreneurial," Van Den Heuvel said. "[NASA] is a government entity, a fantastic organization, but with that comes a lot of bureaucracy and layers."

Going back to 2009, Van Den Heuvel said, only a handful of Rice engineering students have accepted full-time positions with NASA. That is due in part to the fact that Rice doesn't have a culture of co-op programs, having decided it's too difficult for students to graduate in four years when they're taking time away from school to work for entire semesters. Engineering students who enroll with the specific intention of finding astronautics jobs are determined to do so out of love for the idea of space, Van Den Heuvel said. They're going to find work regardless, typically at commercial companies where they can have more control over their own projects.

NASA projects undergo extensive development from start to finish before they can be delivered to the International Space Station. There are endless design iterations and tests, the building of software and hardware and certification.

Cancellation somewhere along that ladder is common enough that it has earned the moniker "the valiant death," according to University of Houston Cullen College of Engineering's Dr. Bonnie Dunbar, a former NASA contractor turned civil servant and astronaut.

A weight-compressing project particularly dear to Hoffman abruptly ran out of funding in the middle of her co-op program. Another to which she contributed for a short time, the Multi-Mission Space Exploration Vehicle, is a rover astronauts could eventually drive on asteroid missions, provided its budget holds out. Work on MMSEV has repeatedly stalled and resumed throughout the past decade in conjunction with fiscal cycles, Hoffman said.
Dunbar explained the valiant death as not an engineering problem but a funding one. If work on a project stops after a single mishap, she said, that should be a wake-up call to Congress that NASA needs more dollars.

At SpaceX, funding comes from a mix of commercial and government clients, including a $1.6 billion NASA cargo delivery contract and another $440 million in seed money from the agency to develop life-support systems for crew missions. As a private commercial company, "When we sign that contract, that's when we get paid," SpaceX spokesman John Taylor said.

According to a study by consulting firm Dittmar Associates, the average American taxpayer thinks NASA receives nearly a quarter of the federal budget. In reality, the agency gets less than 0.5 percent. During the 1960s, when funding for NASA was about 4.4 percent of federal spending, it delivered the moon landing and kickstarted the international computer industry, raking in ten times the cost of space programs in returns. Yet in the post-space-race new millennium, NASA's budget has become increasingly difficult to defend in Washington. Its public-relations message of hope, discovery and pushing the boundaries of human potential into the final frontier isn't hitting home for politicians.

In 2011, the space shuttle program officially ended under President Barack Obama owing to costs and safety concerns. Instead, Obama urged Congress to task commercial launch companies like SpaceX, Boeing and Sierra Nevada with transporting crew and cargo to the International Space Station. The transition hasn't been without bumps.

In March 2013, former Texas congressman Steve Stockman, whose district included Johnson Space Center, said, "NASA employees became demoralized, and employee retention became a serious problem" after the space shuttle program was canceled. Contractor companies reliant on NASA appropriations continued to experience waves of layoffs this summer, and Houston's United Space Alliance faces probable dissolution with the completion of its final contract in September. It's unlikely that Stockman's dogged skepticism (as an outspoken "birther") of the President's citizenship helped his case.

Contrary to the common misconception that the space industry isn't big enough for both NASA and the commercial sector, NASA has always encouraged competition by funding the development of a number of commercial launch companies. It licenses technology to those competing for its contracts and assumes the high risk of undertaking space research so commercial companies can then apply that research to profitable use. GPS, global communications, meteorological devices and even the Mylar balloons gracing grocery checkouts all emerged from NASA technology.

Better to buttress a robust space industry with competition than to monopolize a nonexistent one, according to Dunbar.

Problems arise when commercial companies entice not only young talent but also public interest and congressional support away from NASA. Partially to blame: the public's science and engineering illiteracy.

Members of Congress are reluctant to fund new satellites when they don't understand the expenditure is necessary so people can continue checking weather forecasts on their smartphones. Policy makers are less likely to heed the National Research Council's 2014 year-in-production report recommending budget increases for NASA when quick searches of private companies' mounting accomplishments cast doubt on the federal agency's continued relevancy.

A common recommendation aimed at NASA's floundering public image is that it should disseminate a clearer message about its mission. That's not so easy when NASA is precluded from advertising, though Dunbar said education is a different matter. She believes fostering space appreciation among the general public should be a grassroots effort. At the very least, she wants a budget for putting posters in classrooms to get children on the STEM (science, technology, engineering and mathematics) track.

Alternatively, when money is available for undertaking grand projects, poor management of funds can undermine success. Dunbar said problems occur when engineering teams are moving fast, projects are understaffed and under-resourced, and areas that require the most focus aren't getting it. Senior software engineer Adam Nieves (not his real name) calls that phenomenon "faster, better, cheaper," a mentality he said was coined under 1990s NASA administrator Dan Goldin. Nieves believes taking shortcuts in engineering to build cheaper products faster has become more entrenched in the face of pressure from SpaceX and other commercial companies where it's common practice.

But NASA, Nieves argues, should know better than to deliver subpar product for use on the space station before thorough testing, citing Johnson Space Center's charter to support manned missions -- that is, to sustain actual human lives in space.

"[Faster, better, cheaper] in itself is okay, but if you're just going to be hacking stuff together, don't expect to fly it when you're done," Nieves said. "We're not focused, but we have some money so we're going to do some freaking prototyping. I always thought, well, if more of this stuff blows up, this shit's going to stop...Nothing's changed."

Nieves points to NASA's Active Response Gravity Offload System as a prime example of management mistakes that had real potential for harm. A machine used to simulate microgravity environments, ARGOS accidentally dropped a test subject about 18 inches in January 2013, though the subsequent investigation found that the drop could have occurred from four or five feet above the ground. In March of this year, the Houston Rockets' beloved center Dwight Howard was filmed swinging from ARGOS during a visit to Johnson Space Center, his dominant left arm extended in a Superman pose.

Senior engineers like Nieves believe it's only a matter of time before corner-cutting in engineering results in a serious accident, yet younger engineers liken that attitude to "red tape." Leonce and others believe that NASA's endless bureaucracy can constrain innovation and exploration. Historically, the agency has been committed to strapping proud Americans with freshly signed wills into rockets and launching them into space via a bomb detonated at one end. He thinks that spirit is sacred.

"You can take safety overboard," Leonce said. "I've sat in many meetings where we're just arguing over the simplest things. It just becomes borderline ridiculous. I don't think we could have ever gotten to the moon if the culture that now exists at NASA existed in the '60s."

Leonce said he understands the older generation's anxieties considering they've worked through the deadly Challenger and Columbia disasters. Yet private launch companies will be more attractive for engineers fresh out of school, he said, because that culture of risk aversion is "a death in itself."

Now a project manager in oil and gas, Leonce said he left his glamorous role at NASA as a flight controller in the front room -- the "Houston" in "Houston, we have a problem" -- because he was stagnating in a position with no potential for promotion. At LEAM Drilling Systems, he applies his NASA-cultivated quick thinking to a leadership role. Still, Leonce said he considers energy to be a pit stop in his plans to return to the space industry, and when that happens, he would likely look to a commercial company.

Looking back, Hoffman still considers NASA to be the symbol of her childhood dreams. Private industry offers her more opportunities to do the work she went to school for, but the old job was undeniably more glamorous. She spent her days around astronauts, celebrity figures who were present when history was being made. NASA's human capital was unparalleled, Hoffman said, and she believes, "They really do have the best interests of space travel at heart."

Yet she couldn't overlook NASA's financial culture, the projects getting canceled, the workforce attrition, the dwindling opportunities to be selected for the astronaut corps. She compared the trajectories of NASA and commercial startups, and looked to those with more experience in the industry to establish that the traffic of talent was moving from federal to private.

"Being able to see it, see my project get canceled and see a lot of the older engineers who had many projects canceled, that really informed my decision. That is something that is actually happening and is frustrating engineers," Hoffman said. "I was worried that I was going to get five years into my career [at NASA] and find...that I was unhappy."

Charles Hill, a materials engineering contractor who later became a NASA civil servant, said he can empathize with students' disillusionment when their designs don't result in deliverable goods, though that's a fact of life at NASA. Throughout his career, he mentored university students, co-ops and interns in the structural engineering division and loved it, he said, because of the interest and ambition with which young engineers took to the work he considered routine. With priorities of his own and responsibilities to the space station, Hill occasionally assigned his co-ops side projects to which he couldn't devote much personal time. Sometimes their work is patented, and sometimes funding runs out before designs even leave the blueprinting stage.

"It takes years and years, really, for new, innovative concepts to really be developed," Hill said. "Anything that is new, there's an element of risk there that we don't want to invest tons of money to develop something that we're not sure of yet, that sort of thing."

Hill said he advocates for patenting his co-ops' research through an administrative board, but board members don't always invite him to present the merits of new technology in person. Rather, they make decisions based on reports and pictures he submits. Hill said he understands how the failure to secure an innovation patent could frustrate students.

Contractors keep the rights to their innovations, but civil servants' designs would belong to NASA, according to NASA patent lawyer Kurt Hammerle. Even if civil servants left for commercial companies, they couldn't take their own technology with them for completion without licensing it first. Hoffman, however, never received patents on her stalled NASA projects, so as far as she knows, her innovations are in limbo.

Hoffman declined NASA's job offer after working there as a student, and Dunbar said the young engineer may have acted too soon considering that NASA staffs the brightest minds in spaceflight to contribute scientific research in a way commercial companies do not. Going to space is worth waiting for despite the odds, she added. And part of the reason Hoffman didn't want her real name used for this story is that she says she might want to return to NASA some day.

"I do find that young people don't always take the long view. Companies also go through risk. Each individual has to make decisions with the best available data," Dunbar said. "In this case, knowing that Congress is starting to wake up, the American public is starting to wake up, the fact that you have three other nations announcing publicly that they're going to the moon, I'm optimistic there's some new energy out there."

Hoffman said she had only followed in the footsteps of her peers, many of whom were leaving for the same reasons. Retired NASA contractor and software engineer Del Murphy said the young don't always prioritize safety as much as they should. He said bureaucracy is good when following strict procedures through a system of checks and counterbalances minimizes human casualties. However, it's a lose-lose situation when too much bureaucracy in fact contributes to tragedy, as the Rogers Commission found in its investigation following the Challenger disaster. Dunbar explained that space shuttle Challenger broke up 73 seconds after launch because of a materials malfunction related to human error. The people who knew about the problems weren't heard out, she said.

Murphy said poor engineering standards and administrators' lack of accountability are at the root of NASA's internal wrangling over innovation and risk aversion. He said NASA is more interested in covering up failure than in learning from it. After NASA's first fatal disaster, the 1967 Apollo I fire that trapped three astronauts in a capsule with an inward-opening hatch, the fear of failure became an institutionalized melancholy.

"A healthy environment is an open forum where people discuss back and forth about problems and get it down," Murphy said. "I can't tell you the searing that went through all our minds when those shuttles blew up."

NASA's engineering blunders don't always result in harm to human beings. Valkyrie, a $3 million "superhuman robot" unveiled with great pomp, quietly placed last at the 2013 DARPA Robotics Challenge. Yet its predecessor, Robonaut, a virtually controlled device with an innovative electronic communications system, contributed technologies that were transferred for use in Houston's medical industry. UH Cullen College of Engineering Professor Jose Luis Contreras-Vidal collaborated with NASA to produce thought-controlled exoskeleton robots to help recovering stroke victims walk again. His patients are outfitted with brain-scanning helmets and robotic splints for their legs, which he expects will re-create natural mobility with continued use.

When Dunbar hears the phrase "tech transfer," her main concern is that NASA must continue to receive the resources for creating that tech in the first place.

"NASA has to be funded for new technologies and to continue to be provided for as the engine of exploration," she cautioned. "We're starting to fall behind other companies. Once that dries up, there are no new companies. There's no leadership in academia."

SpaceX announced Aug. 4 that it will establish its new spaceport in Brownsville, Texas. State officials have encourged CEO Elon Musk in those plans from the beginning, finally offering his company $2.3 million in incentives to build the world's first commercial launch complex.

"Texas has been on the forefront of our nation's space exploration efforts for decades, so it is fitting that SpaceX has chosen our state as they expand the frontiers of commercial space flight," Gov. Rick Perry said in a news release. "In addition to growing the aerospace industry in Texas, SpaceX's facility will provide myriad opportunities for STEM education in South Texas and inspire a new generation of Texas engineers and innovators."

Other companies, such as Raytheon and XCOR, relocated their space headquarters from California to Texas in 2013, and Lockheed Martin moved 650 jobs from Georgia to Fort Worth. As Texas aggregates aerospace companies, Hoffman hopes to return eventually to her home state.

Lifelong NASA employees like Nieves and Murphy said they feel NASA's institutionalized problems are no longer their fight. They don't think the space shuttle program will reopen, and in ten years when funding for the International Space Station runs out, that will be the end of another era.

Hoffman is worried about that, too. She doesn't believe Congress will renew space station funding, and the end of NASA's space shuttle program meant American astronauts had to buy exorbitant seats on Russian rockets to go to space. If she stayed at NASA, she would face rapidly decreasing chances of becoming an astronaut herself -- a private dream that did play a role in her decision to leave. SpaceX, Boeing and Sierra Nevada are gunning for manned flight, and one stipulation in NASA's competition for crew contracts is that commercial companies send their own people first. Statistically, there's a much better chance Hoffman would realize her dream of flying to space by leaving NASA.

"There are so many people who want to go to space, but chances are slim that'll work with the traditional model," she said. "If people are willing to spend thousands of dollars on a cruise, they'll be willing to spend the same for a trip to space for a couple days. If [commercial companies] can deliver that, they can eventually bring the price down so that it's just a common occurrence, like taking a plane across the country. It would be amazing."

There are everyday clues tugging her toward private industry as well. Hoffman makes light of how ordinary people -- waiters at restaurants, the guy sitting next to her at the bar -- will tell her they thought NASA had already shut down. But the misconception, which Dunbar said she hears also, points to NASA's constant struggle to keep space exploration relevant to the public.

Hoffman stressed it wasn't easy to turn down NASA. "When you're working for NASA, you're just kind of taught that this is something to be very proud of, that this is more than a job," she said. Individual commercial companies aren't as well known outside the scientific community, and it took some time to deflect the shock and confusion among her family and friends when they heard she wasn't staying in Houston. She does believe she'll be happy in private industry, if only for the chance to dirty her hands in the shop.

But she's still going to miss home, wearing cowboy boots and going country dancing. She planned to commemorate her final night in Houston after lunch at Boondoggles, the astronaut bar named -- according to Merriam-Webster -- for "an expensive and wasteful project usually paid for with public money."
Basically they are frustrated. I mean these are talented driven people with dreams who poor there blood, sweat, tears and then some other bodily secretions into projects only to have them canceled because the politicians changed.

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Space » News
Sierra Nevada’s Space Plane in the Chase with SpaceX and Boeing to Win NASA Nod
The company’s Dream Chaser orbital glider has yet to achieve orbit but still is a contender to ferry Americans to and from the International Space Station
Aug 14, 2014 |By Geoffrey Giller |
Sierra Nevada Dream Chaser


Sierra Nevada Corp.'s Dream Chaser, which the company hopes will soon take astronauts to and from the International Space Station.
Credit: NASA
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NASA ended its space shuttle program in 2011, in part to focus on other goals such as putting humans in deep space and on Mars. But the agency still needs a reliable and cost-effective way to get astronauts to and from the International Space Station (ISS). For the past several years it has been paying Russia to do just that. But soon, it will no longer have to do so.

Since 2010 private companies have been competing for a lucrative opportunity: to provide routine transport of American astronauts and cargo to the ISS as well as deliver other low Earth orbit payloads. Now three companies are closing in on that goal; NASA will be announcing the winner or winners later this year. With only a couple months left in a four-year-long race, two well-known spaceflight heavy hitters—SpaceX and Boeing—have been joined by a seeming underdog: Sierra Nevada Corp., a 51-year-old company with spaceflight cred that includes supplying the Virgin Galactic SpaceShipTwo engine.*

In 2010 NASA announced the Commercial Crew Program, with a goal of developing a “safe, reliable and cost-effective crew transportation to low Earth orbit,” says Stephanie Martin, the program’s spokesperson. This strategy takes advantage of the flexibility, efficiency and adaptiveness of private companies in making competitive technologies that respond to a growing space-related business marketplace while reducing taxpayer expenses. According to the Space Foundation’s 2014 Space Report, the space economy is globally valued at about $314.2 billion, a figure that includes everything from telecommunications to weather forecasting to navigation to launches of military satellites. Other organizations would also benefit from the commercial development of more vehicles capable of reaching space at lower costs. “Researchers might want to have access to low Earth orbit to do experiments,” Martin says. Space tourism is another possibility; one consulting firm estimated that space tourism could be worth over a billion dollars by 2021.

NASA awarded five companies a total of nearly $50 million through the first round of funding in 2010 to develop spacecraft, launch systems and support equipment, including Blue Origin, Paragon Space Development Corp. and United Launch Alliance as well as those involved in manned vehicle development like Boeing and Sierra Nevada. Over the subsequent rounds of funding SpaceX entered the fray whereas other companies dropped out or, in some cases, entered into “unfunded Space Act Agreements,” allowing the firms to continue working with NASA scientists but without receiving more funding.

The latest round of the competition, awarded in 2012, gave $10 million to Sierra Nevada for the recently completed safety testing of its vehicle, called Dream Chaser. In July the company completed another milestone by successfully testing several of Dream Chaser’s major systems, including life-support as well as environmental and thermal controls. Earlier in the month it also tested the vehicle’s main propulsion system.

With the completion of this latest safety-testing milestone of key systems, Mark Sirangelo, corporate vice president of Space Systems at Sierra Nevada, says that this stage of the Dream Chaser program, before NASA announces a winner, is “90 to 95 percent complete,” with at least one more landing flight test and tests of the thrusters remaining. The company has a November 1, 2016, date set for the first unmanned launch of its spacecraft into orbit. If all goes as planned, it would stage a second launch about six months later and would then apply to NASA to certify the Dream Chaser as ready to take a crew to the ISS, Sirangelo says.

Sierra Nevada’s crew transportation vehicle design differs markedly from that of Boeing or SpaceX. Although all three designs use a traditional vertical launch rocket to get their vehicles into space, Sierra’s competitors are building capsules that are designed to land back on Earth using either parachutes and airbags (in the case of Boeing’s CST-100) or thrusters (SpaceX’s Dragon capsule). But the Dream Chaser uses a lifting-body design—essentially, it is a space plane that resembles a small version of the space shuttle and, like it, can land on a runway. The design is based on a spacecraft, the HL-20, that NASA developed in the 1980s and ’90s but decided not to pursue. Sirangelo says that the lifting-body design is ideal, because it can land with a lower g-force than a capsule; instead of plummeting back to Earth slowed by parachutes or thrusters, it glides. That’s useful in a number of scenarios, according to Sirangelo. A higher g-force, such as what could be experienced in a returning capsule, could cause problems if a delicate experiment was being returned from the ISS or if an astronaut were sick or injured. The space plane design is also more quickly accessible when it returns, as it can land on any commercial runway large enough for a Boeing 737 airplane, Sirangelo says, unlike a capsule landing in a potentially remote area. This past October Sierra Nevada tested the automated landing system by dropping the Dream Chaser from a helicopter; the vehicle’s approach to the runway was spot-on, although a mechanical malfunction prevented one of the wheels from deploying, sending the vehicle skidding off the runway. Nevertheless, both Sierra and NASA deemed the test a success.

NASA hopes to have astronauts flying on the winning vehicle by 2017. Later this summer or early this fall the agency plans to announce the competition winner(s), which will eventually involve transportation of astronauts to the ISS. NASA’s Martin says it is possible that the agency may choose more than one design for crew transportation. “We do look forward to continuing to work with all of our partners,” even those that don’t receive the next contract, she says—down the road NASA may want the option of having multiple transportation vehicles to choose from.

Of course, Sierra Nevada may end up on that also-ran category. Roger Handberg, professor of political science at the University of Central Florida and an expert on space policy, for one, is dubious about the company’s chances. SpaceX, which he thinks is the current favorite, has already completed several successful missions to and from the ISS with an unmanned version of its Dragon capsule whereas the Dream Chaser has not yet been in orbit. “It’s hard to beat something with nothing,” he says. “Until you fly, you’re going to have that problem.” Sierra has also received less funding than its competitors; to date the Commercial Crew Program has awarded the company more than $363 million whereas during the same time period Boeing has received $621 million and SpaceX $545 million. These discrepant figures are due in part to the fact that Sierra Nevada had “the most significant amount of risk reduction and technology development work to do,” according to a statement by NASA when it awarded the latest round of funding in 2012.

Complicating matters, both the Boeing and Sierra designs rely on Atlas 5 rockets to get to orbit, which in turn rely on Russian-made RD-180 engines, Handberg notes. In May Russia announced that the U.S. could no longer use Russian-made engines for military launches; it is not clear whether that includes voyages to the space station. Sierra’s Sirangelo, however, does not think that the recent tensions with Russia will affect future space missions. Martin agrees: “We’ve had great cooperation with Russia,” she says. “We’ll always continue to work with them on the International Space Station.”

*Correction (8/14/14): This sentence was edited after posting to correct the age of Sierra Nevada Corp.
 

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This picture provided by NASA shows the Orbital Sciences Corporation Antares rocket launching with the Cygnus spacecraft onboard on July 13, 2014, at NASA's Wallops Flight Facility in Virginia (AFP Photo/Bill Ingalls)
 

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NASA Closes On Commercial Crew Selection

Aviation Week & Space Technology
Guy Norris
Mon, 2014-08-18 10:47
Commercial Crew bidders hint at future directions as NASA selection looms
A version of this article appears in the August 11/18 double issue of Aviation Week & Space Technology.

Almost five years after beginning its search for a U.S.-developed spacecraft to carry humans into orbit, NASA is poised to award at least one contract to its industry partners in the Commercial Crew Program.

The three contenders—Boeing, Space Exploration Technologies (SpaceX) and Sierra Nevada Corp.—could hear as soon as the end of August which of their proposed vehicles has been selected for a Commercial Crew Transportation Capability contract to fly to the International Space Station.

With NASA widely expected to support multiple solutions, the biggest question is how the awards might be spread over differing vehicle concepts, launch vehicles or both. Assuming two contracts are awarded, NASA must decide whether to support the two capsule designs on offer from Boeing and SpaceX or one of them in combination with the lifting-body concept proposed by Sierra Nevada.

Another factor that may influence the decision is Boeing’s and Sierra Nevada’s selection of the United Launch Alliance (ULA) Atlas V as primary launch vehicle. Although both assert that their designs are “launch-vehicle-agnostic,” concern over the guaranteed supply of the Atlas V’s Russian-made RD-180 main engines could prove a factor. Worries about threats to the engine supply, originally posed by Dmitry Rogozin, Russia’s deputy prime minister, in response to U.S. economic sanctions imposed on Russia after the annexation of Crimea in March, have reemerged following the shootdown of Malaysia Airlines Flight 370 last month.

However, Mark Peller, ULA director of hardware value stream, said at the American Institute of Aeronautics and Astronautics Space 2014 conference here Aug. 4-7 that the company is working to “reduce the perception of the risk,” adding, “at a working level we have seen no changes in the relationship; at our level, it’s been business as usual.” ULA agreed a 29-engine deal with RD Amross, the NPO Energomash and United Technologies Corp. joint venture earlier this year and expects to receive the first two RD-180s from this batch on Aug. 20. Three more engines are scheduled for delivery in October and eight per year in 2015-17.

The three contenders are signaling varied responses should they not be selected. Boeing Commercial Space Vice President John Mulholland says, “it will be difficult to support the business case” without a NASA contract for CST-100. Dragon 2 program manager Garrett Reisman says if Space X’s capsule is not selected, “there would be a lot less resources, and we’d have to bear all the development costs, so things would change. But we are not going to stop.”

Sierra Nevada Space Systems President Mark Sirangelo says the company is committed to the Dream Chaser orbital test flight in November 2016, regardless of a negative decision. “We are now in a place where it is possible to continue,” he says. “We are laying the potential for other things as it goes on, so that the companies that are not chosen have the potential to carry on.”

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Dragon 2 and DreamChaser Time is running out
 

Equation

Lieutenant General
Washington (AFP) - A SpaceX rocket exploded in midair during a test flight, though no one was injured, as the company seeks to develop a spacecraft that can return to Earth and be used again.

The rocket was a three-engine version of the F9R test vehicle that succeeds SpaceX's Grasshopper prototype.

"During the flight, an anomaly was detected in the vehicle and the flight termination system automatically terminated the mission," the company said in a statement, released on Friday.

"Throughout the test and subsequent flight termination, the vehicle remained in the designated flight area."

SpaceX noted that a Federal Aviation Administration representative was present during the test.

It stressed that the test was "particularly complex, pushing the limits of the vehicle further than any previous test."

The company plans to review flight record details to understand what caused the problem before conducting another test.

SpaceX is competing with other companies -- including Boeing, Sierra Nevada and Blue Origin -- to be the first commercial outfit to take astronauts to space, possibly as early as 2017.

Until then, the world's astronauts must rely on Russian Soyuz spacecraft at a cost of $70 million per seat.


[video]http://news.yahoo.com/spacex-rocket-explodes-during-test-flight-012912596.html[/video]

I'm sure the SpaceX program will learn from this and continue on.
 

TerraN_EmpirE

Tyrant King
[video]http://news.yahoo.com/spacex-rocket-explodes-during-test-flight-012912596.html[/video]

I'm sure the SpaceX program will learn from this and continue on.
They do those test just to make sure it happens then and not on the actual mission... like this.
European navigation craft launched into wrong orbit
BY STEPHEN CLARK
SPACEFLIGHT NOW
Posted: August 22, 2014


8
Arianespace confirmed late Friday that two satellites for Europe's Galileo navigation network were released into the wrong orbit after launching aboard a Soyuz rocket from French Guiana.

It was not immediately clear whether the two satellites have enough fuel to make up for the orbit injection error.


Carrying two satellites for Europe's Galileo navigation system, a Soyuz rocket blasted off from French Guiana at 1227 GMT (8:27 a.m. EDT; 9:27 a.m. French Guiana time). Photo credit: ESA/CNES/Arianespace - Optique video du CSG - JM Guillon

Arianespace and European Space Agency officials initially heralded Friday morning's launch as a success, declaring the satellites healthy and claiming they were deployed into their targeted orbit approximately 23,500 kilometers, or 14,600 miles, above Earth.

The Russian-built Soyuz ST-B rocket carrying the Galileo navigation payloads blasted off at 1227 GMT (8:27 a.m. EDT) from the French-run Guiana Space Center in South America. The Soyuz launcher's three booster stages gave way to a Russian Fregat-MT upper stage less than 10 minutes after liftoff.

The Fregat was programmed to fire two times to propel the Galileo satellites into a circular medium Earth orbit tilted at an angle of 55 degrees to the equator.

But U.S. military orbital tracking data indicated the satellites were flying in a lower orbit than planned. Officials confirmed a launch anomaly in a statement late Friday.

"Complementary observations gathered after separation of the Galileo FOC M1 satellites on Soyuz Flight VS09 have highlighted a discrepancy between targeted and reached orbit," Arianespace, the French launch services company, said in a statement.

Arianespace said investigations into the launch anomaly are underway and more information will be provided after a flight data analysis to be completed Saturday.

Orbital data from the U.S. Air Force showed three objects in an orbit with a low point around 13,700 kilometers -- about 8,500 miles -- above Earth. The objects are in an orbit with an inclination of 49.7 degrees, according to Jonathan McDowell, an astrophysicist at Harvard-Smithsonian Center for Astrophysics who tracks global satellite and launch activity.

Russian ground crews manage hands-on Soyuz launch preparations and the final countdown from a control center near the launch pad on the northwestern frontier of the Guiana Space Center, which is also home to Europe's Ariane 5 and Vega rockets.

But Arianespace has final authority for Soyuz missions taking off from French Guiana. Friday's liftoff was the ninth time a Soyuz rocket has launched from the tropical spaceport since beginning operations there in 2011.

It was also the first flight of fully operational Galileo navigation satellites, beginning a rapid-fire series of launches by Soyuz and Ariane 5 rockets to build out Europe's civilian-run counterpart to the U.S. Air Force's Global Positioning System.

The $7.2 billion Galileo network will consist of 30 satellites when complete. At least 24 satellites are needed for independent global navigation coverage, plus spares.

Before Friday's launch, ESA officials said two more Galileo satellites were being prepared for liftoff on another Soyuz launcher in December. Another eight spacecraft were on track for launches on Soyuz or Ariane 5 rockets next year.


Artist's concept of a Galileo navigation satellite in orbit. Photo credit: OHB System

Didier Faivre, ESA's director of navigation programs, announced ground controllers received signals from the Galileo satellites after the launch, verifying they were alive after the ride into orbit.

The satellites were programmed to automatically deploy their solar panels and begin charging their batteries later Friday.

ESA acts as a technical agent for the Galileo system on behalf of the European Commission, the executive body of the 28-nation European Union.

Before Friday's launch anomaly, officials expected the satellites to be operational by mid-November, joining four other Galileo demonstration satellites launched in 2011 and 2012 to expand the constellation to six spacecraft.

The satellites launched Friday were the first of 22 spacecraft built by OHB System of Bremen, Germany, to reach space.

The European Commission and ESA ordered the 22 satellites in two batches. The satellites on Friday's Soyuz launch were purchased in 2010 as part of a 566 million euro contract. Each spacecraft is worth about 40 million euros, or $53 million, under the deal.

At the same time as its selection of OHB to build the first set of operational Galileo satellites, the European Commission finalized a contract with Arianespace for five Soyuz launches to send up two spacecraft at a time.

The launch contract was worth 397 million euros -- about $525 million, or $105 million per flight.

European officials and Arianespace signed another launch contract Wednesday to deploy the other 12 OHB-built Galileo satellites on three Ariane 5 rockets, beginning as soon as next year.

The European Commission and ESA have launched or contracted for 26 Galileo satellites. With Friday's launch, 20 more satellites are on the ground in various states of assembly and testing for launches over the next three years.

In a conference call with journalists earlier this week, Faivre said the European Commission and ESA decided not to purchase insurance for the Galileo satellites.

"This is basically due to the fact that we have 22 satellites on the production floor," Faivre said. "Also, we have many launches. We are, in a way, self-insured due to our procurement process. We prefer to invest in hardware or launch services than to go into the insurance market. If something goes wrong, we use spares.

"We need 24 satellites to get the full performance," Faivre said. "We intend to procure 30 and to launch 30."

The satellites launched Friday were supposed to inaugurate the operational phase of the Galileo program. Called "Full Operational Capability" satellites, they carry navigation payloads supplied by Surrey Satellite Technology Ltd. of the United Kingdom.

The satellites were designed to broadcast signals on three L-band frequency bands. The 10 signals are tailored for the global public, European law enforcement and security services, commercial users and search-and-rescue applications.
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TerraN_EmpirE

Tyrant King
The Rocket that Senate resurrected from one president to the next despite the fact that the next guy never wanted it, And who's engines were have already retired has just had it's first launch pushed back... Again. SLS projected first launch now in 2018.
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Equation

Lieutenant General
The Rocket that Senate resurrected from one president to the next despite the fact that the next guy never wanted it, And who's engines were have already retired has just had it's first launch pushed back... Again. SLS projected first launch now in 2018.
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Delay by a year or two it will not hurt the entire program as long as the SLS is well funded.
 

TerraN_EmpirE

Tyrant King
I think this is the third delay by a year.
The Program originally was started under the Bush administration as part of Project Constellation which stated the delay process with three year delays and ended with a launch date in the 2020's. With a first launch of the SLS in 2018 this means that the first launch has to be the same launch intended to Send a uncrewed Orion/MPCV on trip around the Moon or bumping the rocket's test launch in that place and bumping the MPCV launch into 2019 or 2020.
And even then who knows. Constellation was killed by Obama, SLS could be killed by his successor just as easily.
 

TerraN_EmpirE

Tyrant King
Boeing takes the money, Space X for the win, Dream Chaser, still dreaming
Boeing, SpaceX To Get $6.8 Billion For Commercial Crew Flights
Sep 16, 2014 Frank Morring Jr. | AWIN First

Boeing has won the lion’s share of the $6.8 billion NASA wants to spend on its next two human spaceflight vehicles over the next five years, drawing a $4.2 billion share for its CST-100 capsule versus the $2.6 billion SpaceX will get to finish developing and fly the crew version of its Dragon cargo vehicle.

Both will work to the same requirements, and both award amounts were based on what the companies said they would need to do the work of getting their vehicles certified to fly four-member crews to the International Space Station, according to Kathy Lueders, NASA’s commercial crew program manager.

Losing out in the competition to return human space launch to U.S. soil was Sierra Nevada Corp., the third company that had received NASA seed money under the agency’s commercial crew-vehicle development program. In picking Boeing and SpaceX, NASA went with traditional capsule designs over the reusable lifting-body approach Sierra Nevada advanced with its Dream Chaser vehicle.

Boeing’s CST-100 is an aluminum capsule with an ablative heat shield, designed to return to Earth on dry land under parachutes, with airbags deploying to soften the final touchdown. It is intended to lift off on the United Launch Alliance Atlas V.

The crew-version Dragon is an upgrade of the Dragon already delivering cargo to the space station under NASA’s Commercial Resupply Services contract, which includes returns after reentry with scientific samples and other "down-mass" cargo under parachute to a splashdown in the Pacific Ocean off the coast of California. Both Dragon variants are designed to be launched on the company’s Falcon 9 rocket.

Lueders declined to specify factors leading to the downselect, saying the agency has yet to brief the companies who bid for the work. Under their contracts, Boeing and SpaceX each must meet five milestones, including a demonstration flight to the ISS with at least one NASA astronaut on board, to qualify for between two and six operational missions.

"Our specialist teams have watched the development of these new spacecraft during earlier development phases, and are confident they will meet the demands of these important missions," said NASA Administrator Charles Bolden, who announced the selections at a Kennedy Space Center press conference Tuesday afternoon. "We are also confident they will be safe for NASA astronauts. To achieve NASA certification in 2017, they must meet the same rigorous safety standards we had for the space shuttle program."

NASA said the two companies will work with the agency to complete the Certification Baseline Review within 90 days of the contracts’ start dates. The agency has a goal of completing certification, including the test flights, by the end of 2017, and will award task orders for "post-certification missions" for as long as five years after the effective date of the contract. Lueders said the two contracts also have extension provisions, and the agency will continue to work with Sierra Nevada, Blue Origin and other commercial crew Space Act Agreement partners should they desire to continue their developments for possible future missions.

Bolden and other NASA human spaceflight officials have repeatedly argued for a two-vehicle approach, both for redundancy and to hold down costs through competition. However, Congress has proved skeptical of that approach, largely because it would cost more. The agency has requested $848.3 million in fiscal 2015 for commercial spaceflight, although it is more likely to receive funding at the $646 million fiscal 2014 level under the continuing resolution lawmakers are expected to approve before recessing for the November elections.

"As we have said, in order for us to get to 2017 what we really need is for the Congress to support the president’s request," Bolden said. " We are confident that given where we are right now with the 2014 budget and its out-run, we can make the 2017 launch date. But that again depends on Congress fully funding the budget as requested by the president."
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This is a blow to Serra Nevada but though Down I am betting not out. There partnerships with the Japanese Space Program and European Space agency's as well as other partnerships may allow them to keep chasing the dream right to the launch pad. As was they were already getting the pocket change not going to boeing and Space X.
[video=youtube_share;b1g6rzqvU1I]http://youtu.be/b1g6rzqvU1I[/video]
Engine Makers Pushing AM, Other Technologies For RD-180 Replacement
RD-180 prototype replacement could be ready to test in 2.5 years
Sep 15, 2014 Frank Morring, Jr. and Amy Butler | Aviation Week & Space Technology
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Risk Reduction

RELATED MEDIA
Podcast: U.S. Scrambles To Develop New Rocket Engine In Wake Of Disagreements With Russia
A version of this article appears in the September 15 issue of Aviation Week & Space Technology.

Rocket-engine developments that evolved from preparations for an advanced strap-on booster to lift the largest version of the planned Space Launch System (SLS) could push a prototype 500,000-lb.-thrust U.S. replacement for Russia’s RD-180 to the test stand in 2.5 years, contractors say.


The single-bell AR-1 kerosene-fueled engine would generate 500,000 lb. thrust and could be twinned for twice the capacity. Credit: Aerojet Rocketdyne Concept
Dynetics and Aerojet Rocketdyne (AJR) have joined forces on risk-reduction work growing out of NASA’s SLS advanced booster program and the Air Force Research Laboratory (AFRL) Hydrocarbon Boost effort. The goal is to hasten the AR-1 hydrocarbon-fueled rocket engine being proposed by AJR in hopes that Congress and the Pentagon will decide to go all-out on a U.S. powerplant for national security space launch in place of the RD-180.

Congressional defense committees have indicated a willingness to begin funding development of a large hydrocarbon rocket, given uncertainty over long-term availability of the RD-180 in the sanctions war over Russian ambitions in Ukraine. The Air Force is polling industry on options for a replacement engine, and the Dynetics/AJR work—so far only with NASA funding—is providing some of the answers.

“We think a risk-reduction program preceding full-scale development is the way to go to get you the fastest route to a real engine for the lowest cost,” says Steve Cook, a former top-level NASA rocket propulsion engineering manager at Marshall Space Flight Center who has been director of corporate development at Dynetics for the past five years.

To that end, Dynetics and AJR have merged their work for NASA and the Air Force in hydrocarbon rocket technology. The new technologies could remove some of the uncertainty that would go into replacing the 860,000-lb.-thrust RD-180 manufactured in Russia by NPO Energomash with the proposed AR-1 (see artist’s concept), a 500,000-lb.-thrust oxidizer-rich, staged-combustion engine that could be twinned for vehicles requiring more thrust.

That would include the United Launch Alliance Atlas V, currently the launch vehicle of choice for high-value U.S. national security payloads and potentially the next U.S. human launch vehicle as well. As the U.S. and its allies spar with Russia over the ongoing conflict in Ukraine, support for a long-discussed but never-funded U.S. alternative to the RD-180 has been growing (AW&ST May 26, p. 22).

Cook says advance risk-reduction work enabled a tenfold reduction in the time it took for the J-2X engine to reach 100% power in hot-fire testing compared to the RS-68. The J-2X reached full power 29 days after testing started, he says. In the late 1990s, it took the RS-68 320 days to reach the milestone.

“Risk reduction has real, tangible benefits and will save us years in schedule,” says Cook, who was project manager on the Ares launch-vehicle development that was paced by the J-2X upper-stage engine development. “Our estimate is 2-3 years off schedule and several hundred million dollars in cost, because if you get those key risk areas knocked down to a reasonable level, and you understand the affordability equation, when you make your full-scale development decision, you’ve got a lot more data, so you’re a lot smarter. And when you get going on full-scale acquisition, you’re not trying to understand the technology challenges.”

Scott Seymour, president and CEO of AJR parent GenCorp, says the rocket-engine company is targeting a full-production cost of $20-25 million for each two-engine shipset of AR-1s, with a development cost of $800 million to $1 billion over four years after a contract award (AW&ST June 12, p. 33). Technologies developed in the risk-reduction work by Dynetics and AJR include additive manufacturing (AM) of injectors and other engine elements, new alloys and new nozzle technology.

Materials engineers at AJR have developed a set of alloys they have trademarked as “Mondaloy” that combines high strength with resistance to burning, making them particularly useful in the oxygen-rich, high-pressure environments that would be found inside the AR-1 and other oxidizer-rich, staged-combustion rockets. The alloys offer cost and reliability advantages over the coatings used to protect components inside the RD-180, also an oxidizer-rich, staged-combustion engine, according to Paul Meyer, senior vice president for advanced programs and business development at AJR.

“We’ve been characterizing the application of Mondaloy inside that thrust chamber itself,” Meyer says. “We don’t have the normal erosion associated with that oxygen-rich environment. It gives us some reliability. It gives us endurance capability, and it also allows us to reduce some weight. It also helps us from a manufacturing perspective.”


A gas generator test was conducted at Marshall Space Flight Center as part of risk-reduction work underway for the advanced hydrocarbon rocket engine that could replace Russia’s RD-180. Credit: NASA
AM is also playing into the risk-reduction work by the two companies. Dynetics and AJR predecessor Pratt & Whitney Rocketdyne used NASA funding under the $37 million Advanced Booster Engineering Demonstration and Risk Reduction (Abedrr) project to study what it would take to resurrect the F-1 Saturn V main engine for the strap-on boosters intended to bring the SLS to the 130-metric-ton capacity mandated by Congress (AW&ST Jan. 21, 2013, p. 20).

While NASA shelved that effort—at least temporarily—in favor of developing a new upper stage for a 105-ton version of the heavy-lift rocket, Dynetics conducted gas-generator hot-fire tests (see photo) and worked with AJR to build engine components, including an F-1 injector, using AM.

“We built and we’re getting ready to test an additive-manufactured rocket engine injector at the 30,000-lb. class,” says Cook. “The injector itself is the 30,000-lb.-thrust class. Typically, that would have taken 15 months to build. We did it in 15 days.”

The work is continuing at AJR under a separate Air Force cost-sharing contract that the company is using to build and test engine parts made from various materials with large-scale laser-melting AM (AW&ST Aug. 25, p. 12).

“The role model we have is the RL-10, and the RL-10 [program] is actually building space-qualified hardware right now and delivering that hardware for the fundamental testing that will go into hot-fire tests in the first quarter of 2017,” says AJR’s Meyer. “So it’s the pathfinder for what we want to do on AR-1. We’ve already qualified Inconel 65; we’re finishing qualification in titanium, and we’re expanding our capacity—although not necessarily for AR-1—into copper.”

Use of designs from the RL-10—a hydrogen-fueled, upper-stage engine that dates to the early 1960s but is still in use today—as well as the F-1 and the Saturn V J-2 upper-stage engine that formed the basis for the J-2X illustrates how the two companies are taking advantage of heritage technology to hasten development of the AR-1. So far, the saber-rattling along the Ukrainian-Russian border has not had an appreciable effect on the supply of RD-180 engines for the Atlas V, but the Air Force is moving to position itself to begin a new-engine development as early as fiscal 2016.

Based on its request for information issued Aug. 20, which includes a question about a “shared-investment path” that would require industry to help foot the development bill, the Air Force has scheduled an “initial industry day” at its Space and Missile Systems Center in Los Angeles Sept. 25-26. There, company representatives can meet one-on-one with government contracting specialists to present their ideas. Top-level briefings to Defense Department civilians are tentatively scheduled for late next month, and the House Armed Services Committee has authorized the transfer of $26.8 million to keep the process moving despite concern over “the lack of clarity in an acquisition strategy moving forward.”

Dynetics and AJR, which combined their NASA and Air Force risk-reduction contracts last year with Dynetics as the prime contractor under the NASA-funded effort, will present the resulting findings as a team, Meyer says.

“We have looked at taking the combination of the two [risk-reduction efforts] and using the testing that will occur in the Abedrr program and lining that up with our Hydrocarbon Boost [Air Force Research Laboratory] contract,” he says. “So we’ve offered the Air Force, as a team, how we could maximize that government investment to date, that industry investment to date, into a plan that would provide the least amount of risk to a 2019 engine.”

The two companies believe a prototype AR-1 could be a fast-track route to replacing the RD-180, given a decision to begin development. With the work they have already done, Cook says, the engineering path ahead is clear.

“If you look at the major risks that we’ve got to go knock down in order to bring a new RD-180 engine replacement into play, the biggest risk is main combustion stability,” he says. The plan would build on component level work in moving up to the subsystem level, focusing on ensuring combustion stability in the concept, building a full-scale main injector and testing it to “make sure it works like we want it to,” Cook says.

With an injector in hand, the next step would be the turbomachinery. “We’ve got to have high-performance turbomachinery,” he says. “It’s staged-combustion, oxygen-rich, so we have to deal with the oxygen compatibility issues. We have to deal with integrating that turbomachinery in the right-sized package, and then putting that together in a powerpack demonstration where you bring those key pieces together and do a demonstration. We believe we can get to that prototype state in about 2.5 years if a decision is made to go full out, and get a prototype engine as soon as possible.”
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