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Propulsion for the 21st Century

Propulsion for the 21st Century. - Cost Driven - Design/Development/Delivery. Rocketdyne. CP2-12_5028- 1 B1-043sh. Main LOX Inlet. Main Fuel Inlet. Helium Spin Line. GG Oxid Valve. GG Fuel Valve. Fuel Turbopump. Oxid Turbopump. LOX Tank Pressurization. Fuel Tank Repress.

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Propulsion for the 21st Century

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  1. Propulsion for the 21st Century - Cost Driven - Design/Development/Delivery Rocketdyne CP2-12_5028-1 B1-043sh

  2. Main LOX Inlet Main Fuel Inlet Helium Spin Line GG Oxid Valve GG Fuel Valve Fuel Turbopump Oxid Turbopump LOX Tank Pressurization Fuel Tank Repress Gas Generator (GG) Main Fuel Valve Main Oxid Valve Heat Exchanger Regen Cooled Chamber Roll Control Nozzle Ablative Lined Nozzle RS-68 Operating Schematic

  3. Minimum Power Full Power Thrust, vac (KN) 3,341 1,922 (K kg-f/Klb-f) 341/751 197/432 Thrust, s/l (KN) 2,918 1,499 (K kg-f/Klb-f) 299/656 153/337 Chamber pressure (MPa) 9.79 5.62 1,420 815 (psia) Engine mixture ratio 6.0 Isp, vacuum (sec) 409 Isp, sea level (sec) 357 RS-68 Operating Characteristics

  4. 5.2M Heat Exchanger LO2 Turbopump Main Chamber 2.4M Nozzle Thrust Frame LH2 Turbopump Roll Control RS-68 Engine

  5. RS-68 Components Gas Generator Fuel Turbopump Oxidizer Turbopump Injector Heat Exchanger Fuel Exhaust Gimbal Bearing Ducts CombustionChamber Propellant Valves Nozzle

  6. CAIV Key Elements • Design to fabricate (unit cost) • Single 3D design/analysis/fab model • Minimize parts, welding & new mat’ls • Fab process capability built in • Won’t Fail Approach • Electronic work instructions Costs as the Independent Variable (CAIV) Integrated Product Team Driven and • Design to avoid failures (development cost) • Simple - minimize pressure/cooling • Mature technology • Margin to experience • Component/subsystem risk mitigation

  7. Vir tual Des ign Virtual Design Digital Driven Design Environment Suppliers Customers Data Links Single Product Definition Database Interactive Workstations Associative 3-D Master Model

  8. RS-68 Desktop 3D Engine Design Model Rocketdyne

  9. Static Dynamic Thermal RS-68 Virtual Design Thermal FEM Design Solid Model • Associative & Interactive • IPT Concurrence Total

  10. RS-68 Main Chamber Fabrication • Hot Isostatic Pressure bonding reduces cycle time from 24 to 12 months RS-68 SSME Furnace

  11. Turbomachinery Design Simplification 7 6 5 4 3 2 1 0 Block II SSME Fuel Block II SSME LOX Blisks SSME RS-68 Castings Cost ($M) RS-68 vs SSME RS-68 LOX RS-68 Fuel 0 50 100 150 200 250 Number of Unique Parts (1 unique part = 1 drawing number)

  12. Risk Quantification Unknown- Unknowns $3.0 300 $2.5 250 200 $2.0 Known- Unknowns Rocketdyne Historical Data Cost of Corrective Actions, $B Corrective Actions $1.5 150 100 $1.0 Close to Experience RS-68 Assessment $0.5 50 0 $0 0 0.5 0.8 Average Risk Factor

  13. Mitigating “Identified” Risks Gas Generator Tests(SSFL) Electrochemical Machining Hot Isostatic Pressure Bonding Injector stability Tests(MSFC) Environments CP1-6-D021-19 RS-68 Technical Lessons Learned

  14. Incremental Test Approach Combustion Devices Turbopump Assembly Gas Generator Add Add Powerpack Testing • Turbopump Testing • Cold Gas Turbine Drive Prototype Engine Testing

  15. RS-68 Test Facilities SSC B-1 AFRL 1-A B-1B B-1A Development/Cert Development/Cert Production Development / Limits Testing

  16. SSME Development ended Certification started Accumulative Pre-mature Cuts due to engine anomaly RS-68 post certification Accumulative Number of Tests Engine Test Program 200 180 160 First Flight615 Tests 12 Major Failures 140 120 100 80 60 No Major Failures 40 183 Tests 20 0 0 100 200 300 400 500 600 700 800

  17. High Nozzle Ablation Rate Test max Test avg Erosion (in) 6 8 10 18 20 12 14 16 Area Ratio Model Prediction RS-68 Development Issues Resolved Oxidizer Turbopump Turbine Disc/Blade Cracks Fuel Tubopump Turbine Disc Crack Resolved Resolved Oxidizer Turbine Drive Duct Crack Resolved Resolved

  18. Full Mission Power Minimum Mission Power RS-68 Operational Margin Demonstrated Range Engine Thrust Mixture Ratio Fuel Turbopump Speed, rpm LOX Turbopump Speed, rpm Gas Generator Temp (K) 101 51% 105% 58 5.3 6.0 8.5 22472 13650 9686 5090 567 989

  19. RS-68 Endurance Margin 35 30 E10206 E10107(CERT) 25 E10204 20 E10108 Endurance Requirement Total Starts 15 E20001(CERT) Certification Requirement 10 Maximum Flight 5 0 0 500 1000 1500 2000 2500 3000 3500 4000 4500 Total Time, sec.

  20. RS-68 Anchored Reliability Methodology Overview Comparative Design Assessment SSME Historical Data RS-68 Predicted Data Prediction Result .0016 RS-68 vs. SSME SSME .0014 .0012 SSME (Block II) Demonstrated Reliability = .9983 Based on 970,000 secs. RS-68 reliability Predicted =.9987 Failure probability .0010 RS-68 .0008 .0006 .0004 .0002 .0000 Propellant Main Control GG Assembly Exhaust Ancillary Gimbal Feed Combustion (Preburners for SSME)

  21. Non-Recurring Development Cost(2001 Dollars) $B Fail Fix $2.15B Fail Fix $1.52B Fail Fix $2.18B Fail Fix $156M Basic Prog. $688M Basic Prog. $490M Basic Prog. $734M Basic Prog. $344M Reusable 1970-1981 1997-2001 Saturn/Apollo 1960s

  22. Test What You Fly Rocketdyne CP2-12_5086-22 B1-043sh

  23. RS-68 Engine Assembly Facility 0012228.ppt mm

  24. RS-68: Ready to Fly!

  25. RS-68 Summary • First rocket engine designed specifically for Low Cost • Affordable space lift • World-wide commercial competitiveness • U.S. Designed Using State-of-the-Art Tools • Fully tested & certified to fly • U.S. Producibility cost unmatched • A new generation: “Rocket Scientists”

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