April 16, 2020 | International, Aerospace
Irene Klotz
The first Falcon 9 rocket to land successfully after dispatching a payload into orbit stands on permanent display outside SpaceX headquarters in Hawthorne, California, a testament to the perseverance of founder, CEO and chief engineer Elon Musk, who wants a fleet of fully reusable spaceships to reduce the cost of colonizing Mars.
The vision is shared by fellow tech entrepreneur Jeff Bezos, whose Kent, Washington-based Blue Origin space company is developing a series of reusable vehicles, beginning with the New Shepard suborbital passenger transport system. The New Shepard made 12 uncrewed flight tests over the last five years, with more to come before commercial flights begin.
Bezos also has pumped $2.5 billion into developing the New Glenn, a reusable system powered by seven BE-4 methane-fueled engines designed to carry nearly 50 tons to low Earth orbit. “That is the smallest orbital vehicle we are planning to build and launch,” says Clay Mowry, Blue Origin vice president of sales, marketing and customer experience.
But the first BE-4s to power a rocket to orbit may not be aboard the New Glenn. United Launch Alliance (ULA) is buying the engines to power the first stage of its Vulcan rocket, an expendable booster—at least for now—which, like the New Glenn, is slated to debut next year.
At some point, ULA may decide to recover and reuse just the BE-4 engines, a pair of which will fly on each Vulcan. The idea is for the engine compartment to disengage after launch and fall back through the atmosphere protected by an inflatable hypersonic shield. A helicopter would be positioned to snag the engine section midair as it makes a parachute descent. ULA calls the approach its Sensible Modular Autonomous Return Technology, or SMART.
“It does not impact, in any significant way, the overall performance of the launch vehicle because you don't have to save fuel to fly home with,” ULA CEO Tory Bruno tells Aviation Week. “You still get to burn up all your fuel, separate your engine, which is the most expensive piece, and recover it.”
“We have not really changed our assessment over the last couple of years because we have yet to see the other forms of reusability—flyback or propulsive return to Earth—demonstrate economic sustainability on a recurring basis,” Bruno says. “It's pretty darn hard to make that actually save money. . . . We've seen nothing yet that changes our analysis on that.”
SpaceX currently is the only launch company reflying orbital rockets. SpaceX launched its final version of the workhorse Falcon 9 booster, called the Block 5, in May 2018. Within two months, the company was flying Block 5s exclusively. The upgrade includes higher-thrust Merlin engines, stronger landing legs and dozens of upgrades to streamline recovery and reuse.
Block 5s were designed to fly 10 times with minimal maintenance between flights, and up to 100 times with refurbishment. SpaceX President and Chief Operating Officer Gwynne Shotwell says the company no longer expects to need to fly a Falcon 9 more than 10 times.
“We don't have to ramp up our production, at least for boost phases, like we thought we were going to,” Shotwell said on March 10 at the Satellite 2020 conference in Washington.
“From a reliability perspective, we want to know the limits of Falcon 9, so we'll push them, but . . . some government customers want new vehicles—I think over time, they will come to flight-proven vehicles as well,” she added. “But if I have to build a couple of new ones every year, or 10 new ones a year, that adds to the fleet, and I don't know that I'll have to push a rocket more than 10 [flights.]”
With regard to how much the company has been able to cut costs by reflying rockets, Shotwell would only say, “We save a lot of money.”
As a privately held company, those operating expenses are not publicly available, but the Block 5 flight record is. So far, SpaceX has flown 14 Block 5 core boosters over 31 missions, including two Falcon Heavy flights, which use three cores apiece.
Of those 14 boosters with flight history, five remain part of the operational fleet. The rest were expended—several after multiple missions—due to payload performance requirements or unsuccessful landings. One booster was intentionally destroyed as part of a Crew Dragon capsule launch abort flight test.
SpaceX's fleet leader flew five times before failing to land on a drone ship stationed off the Florida coast on March 18. SpaceX has not said if the botched landing was related to a premature engine shutdown during the final phases of ascent. The rocket's remaining eight Merlin engines compensated for the shutdown, and the payload—a batch of 60 SpaceX Starlink broadband satellites—reached its intended orbit.
While it continues to fly the Falcon 9 and Falcon Heavy for NASA, national security and commercial missions, SpaceX is developing a fully reusable, human-class deep-space transportation system called Starship at its own expense.
Another company testing the waters of reusability is Rocket Lab, which builds and flies the Electron small-satellite launcher.
“For a long time, I said we weren't going to do reusability,” Rocket Lab CEO Peter Beck said in August 2019, when he announced the new initiative. “This is one of those occasions where I have to eat my hat.”
Electrons do not have the performance for a propulsive return like SpaceX's Falcons do, so Rocket Lab is pursuing a midair, helicopter recovery system to snare the booster's first stage. The intent is not to reduce costs per se but to increase flight rates without having to boost production. The company currently is producing one Electron rocket about every 30 days. “We need to get that down to one a week,” Beck says.
“We view [rocket reuse] as sort of a journey,” ULA's Bruno adds. “We're going to start with the engines because we're pretty sure we can save money with that and pass those savings on right away. As we learn more by doing, we'll continue to assess other valuable parts of the rocket, and we may discover that we can do that there as well.”
“There is one funny thing about reusability,” he adds. “As you make your rocket less expensive, and you make parts of your rocket less expensive, it's harder to close a business case on reuse because the thing you're recovering isn't as valuable. There's a balance there.”
https://aviationweek.com/shows-events/space-symposium/economics-rocket-reuse-still-air
January 15, 2024 | International, Aerospace
A pair of US Army surplus Sikorsky UH-60A Black Hawk helicopters were delivered to Albania on 13 January, Albanian Minister of Defence Niko Peleshi disclosed on the same day. A file photo of a UH-60A Black Hawk, of the type that Albania has ...
September 21, 2018 | International, Aerospace
By: Kyle Rempfer As the U.S. military turns its attention to the threats posed by near-peer adversaries, Air Force leadership is shifting its focus to great power approaches to combat, like multi-domain operations and expeditionary warfare. A culture of innovation among airmen will be pivotal in preparing for such a conflict, and the effort to foster that independence and creativity is already underway. In the coming weeks, the Air Force will be rolling out a new initiative to crowdsource solutions from airmen around the service. Across all specialty codes, the service is calling on airmen to design apps, develop algorithms and create new approaches to the problems that plague their career fields or help the Air Force carry out its missions. The program — dubbed the Vice Chief's Challenge — will be spearheaded by Air Force Vice Chief of Staff Gen. Stephen Wilson. “We want to take the ideas our airmen have to see around corners, anticipate what's next and solve these really complex national security challenges,” Wilson told Air Force Times. Those challenges range from fusing open-source social media information into actionable intelligence with new software, to upgrading legacy aircraft with gadgets to help airmen stay in the fight longer. “Navigation apps like Waze change the way we travel across town by giving us an intuitive display that integrates traffic, hazards, and route recommendations in real time. Companies like Uber and Amazon have transformed our view of logistics," according to a copy of the Vice Chief's Challenge provided to Air Force Times. "They are not the only ones leaning forward. I am sure each of you have seen opportunities to enhance [multi-domain operations]. I want to hear your best ideas.” The initiative is designed to deliver capabilities to the Air Force in months, rather than the usual years, Wilson said. And it's going to become routine, always running against the backdrop of the service's other acquisition initiatives. “It's this cultural change and this shift that happens ... and today, I think it's clear in this great power competition, we need this urgently," Wilson said. “I need to remove barriers to innovation." The Vice Chief's Challenge will consist of three phases. First, ideas will be solicited from across the service in a broad announcement. Then, workshops will be set up in which subject matter experts help refine the most promising proposals and draft development plans for the budding ideas. The final phase will involve developing and demonstrating prototypes for the chosen concepts. “We'll start small by gathering ideas from individual airmen, rapidly evolve concepts with national thought leaders, and scale fast by working with industry to build and demonstrate prototypes in the next year,” Wilson said. Each phase will be led by a different organization, but the Air Force Research Lab and the Office of the Vice Chief of Staff will serve as executive agents to ensure smooth transition between phases. The initiative is similar to last year's first-ever Spark Tank innovation proposals. “Each of the [major commands] went out to their different wings and solicited ideas, picked their best ones and came to us," Wilson said. "There were a dozen ideas, of which we picked six of them and presented them at the [Warfighter's Edge] conference.” The idea chosen for development ended up being that of a boom operator on the KC-135 Stratotanker. He proposed a plan to re-engineer the boom operator platform instructor position for the entire KC-135 fleet at a projected cost of $1.5 million. The proposed innovation aims to both reduce back and neck injuries and save the Air Force $132 million each year in this critical aircrew specialty, according to Air Mobility Command. “It was across the fleet, easy to implement, and that's what we're using now,” Wilson said. Other innovative ideas that Wilson has already seen, and clearly wants more of, involve software development that connects sensors, platforms and nodes to share information across the force. “We had an airman and second lieutenant who briefed me on software development they had done that was unbelievable — the capability they were bringing me and the speed at which they were doing it,” Wilson said. The duo took SIPRNet information and found a way to fuse it together using complex computer coding for targeting purposes. The result was a tool dreamed up in-house that directly solved a pressing issue. Much of that is simply owed to the fact that those airmen knew what they needed to do, how to do it and already worked in a position to provide the service. “The CEO of Pivotal [Software Inc.] pulled me aside and said ‘I work with all the Fortune 500 companies across the world, and I would put these two people against any company, anywhere,'” Wilson said. That's the sort of innovation the Vice Chief's Challenge is looking to tap into. Wilson doesn't know yet how many ideas will be taken to completion, but by this time next year, he's hoping that the Vice Chief's Challenge will be handing out some awards. “I can't compensate them like industry can, but I can offer them purpose," he said. https://www.airforcetimes.com/news/your-air-force/2018/09/20/ill-be-their-angel-investor-air-force-vice-chief-wants-to-crowdsource-airmens-ideas
June 23, 2020 | International, Naval
By: Capt. Walker D. Mills and Lt. Joseph Hanacek The Navy intends to acquire up to 30 new light amphibious warships, or LAW, to support new Marine Corps requirements. The vessels are needed to meet the challenges of “evolving threats in the global maritime environment,” according to the Navy program office, and are tied to the new operational concepts of Expeditionary Advanced Base Operations and Distributed Maritime Operations as well as the Marine Corps' Force Design 2030 effort. Once complete, the acquisition will have almost doubled the number of L-class amphibious ships already in naval service. Rather than accepting a new amphibious design built from the ground up, however, decision-makers should take advantage of the fact that many key requirements of the new vessels are very similar to the capabilities of vessels operated by U.S. Army Transportation Command. The Navy and Marine Corps should delay any new construction and immediately acquire some of these existing vessels to drive experimentation and better inform their requirements for the LAW program. The key requirements of the future LAW include having 8,000 square feet of cargo space, a range of 3,500 miles, a speed of up to 14 knots, accommodation for a crew of up to 40 Navy personnel and 75 embarked Marines, and up to 200 feet in length. The vessel also needs to have a roll-on/roll-off capability, preferably with a stern ramp. U.S. Army Transportation Command has over 100 vessels, and dozens have similar capabilities to those required of the LAW. The Army's LCU-2000s, also called the Runnymede-class large landing crafts, are smaller, with roughly half of the cargo space designed for the LAW and slightly slower, but they boast nearly double the range. The Runnymede-class vessels have nearly 4,000 square feet of cargo space and can travel 6,500 miles when loaded and at 12 knots; and they can unload at the beach with their bow ramp. The Army's General Frank S. Besson-class logistics support vessels are larger than the future LAW, at 273 feet in length but can claim 10,500 square feet of cargo space and a 6,500-mile range loaded to match the LCU-2000. These vessels also have both a bow and stern ramp for roll-on/roll-off capability at the beach or ship-to-ship docking at sea. The version built for the Phillipine military also has a helipad. Army Transportation Command has 32 Runnymede-class and eight General Frank S. Besson-class vessels in service. Mostly built in the 1990s, both classes of vessel have many years left in their life expectancy and more than meet the Navy's 10-year life expectancy for the LAW. These vessels are operable today and could be transferred from the Army to the Navy or Marine Corps tomorrow. In fact, the Army was attempting to divest itself of these watercraft less than a year ago, which underscores the importance of this opportunity even further. Congress is firmly set against the Army getting rid of valuable, seaworthy vessels and has quashed all of the Army's efforts to do so thus far, but transferring this equipment to the Navy is a reasonable course of action that should satisfy all parties involved. While acquiring “surplus” military equipment might lack the allure and promise of designing a new ship class from the ground up, the reality of the situation is that this overlapping of service needs couldn't come at a better time. By acquiring a watercraft that meets most of their requirements from the Army, the Navy and Marine Corps simultaneously fill current capability gaps and obtain an invaluable series of assets they can use to support the evaluation and experimentation of new designs and concepts. This will allow Navy and Marine leaders to give their units the maximum amount of time to evaluate and experiment with new designs to get a better idea of what they need both in future amphibious craft as well as operational and support equipment. The significance of so rapidly acquiring the Army's amphibious craft isn't just limited to developing a better amphibious force either. There is a very real capability gap that exists in the fleet today in the areas of surplus seagoing capacity, and acquiring these Army watercraft would go an extremely long way toward addressing it. Often overlooked, the availability of surplus vessels is absolutely critical to the process of developing new technologies, developing the tactics to employ them, conducting training, and providing decision-makers the requisite capacity to remain flexible in the face of unexpected challenges. The Navy and Marine Corps today are hurtling toward a new future of distributed operations and unprecedented levels of integration in the littorals. The Marine Corps commandant has clearly specified that force design is his No. 1 priority and that significant changes to the Marine Corps are in the works. At the same time, the Navy and Marine Corps continue to serve as the first responders for many of the nation's emerging challenges around the globe. They've long been in need of a boost in their amphibious capabilities so as to be better positioned to meet the demands of today and prepare for the challenges of tomorrow, and taking possession of the Army's Runnymede- and Frank S. Benson-class vessels is a solution on a silver platter. Capt. Walker D. Mills is a U.S. Marine Corps infantry officer serving in Cartagena, Colombia. Lt. Joseph Hanacek is a U.S. Navy surface warfare officer based in Dam Neck, Virginia. The views expressed here are theirs alone and do not necessarily represent the views of these military branches or the Defense Department. https://www.defensenews.com/opinion/commentary/2020/06/22/the-us-navy-and-marine-corps-should-acquire-army-watercraft/