Eduardo Casillas Manager, Mission Architecture Engineering Rocket Propulsion

Eduardo Casillas Manager, Mission Architecture Engineering Rocket Propulsion Chabot College E10 Guest Lecture

Eduardo Casillas Biographical Information • Education • Community College: San Jose City, Evergreen Valley • B.Sc. Mechanical Engineering - San Jose State University, 1979 • Graduate Studies in Mechanical Engineering, San Jose State University,1980-1985 • Various Professional Courses (AIAA, Launchspace, etc) • Work Experience • 25+ Years of Experience in Lead, Support, or Managing Capacity of Systems Analysis and Preliminary Propulsion Design and Trade Studies (CSD and Aerojet) • Large Launch Vehicles (Shuttle, Titan IVA-IVB, ASRM, Delta II-III, Atlas II-III) • Orbital Vehicles (Inertial Upper Stage, Various Apogee and Perigee Motors) • Small Launch Vehicles (Athena, Pegasus, Multiple Ground / Air Launched Small Launch Vehicle) • Strategic Missiles (Minuteman III, SICBM, Trident II, LBSD, SLIRBM) • Missile Defense (THAAD, SM3 Boost / DACS, GMD, CorpSAM) • Miscellaneous (Scramjet Booster, Tomahawk Underwater Booster, Hybrid Boosters, Launch Abort) • Significant Achievements • Numerous Letters of Recognition • Two Patent Awards (Dual Action Solid Hybrid Rocket, 1.5 Stage Symbiotic Hybrid Vehicle) • Key Technical Member of Numerous Successful Proposals • How I Became Interested in Propulsion • Local Rocket Company (CSD, San Jose, Ca) Specialized in Solid Rocket and Ramjet Propulsion • Design / Development Trials & Tribulations Bow Down When Your Motor Flies • Exploring the Universe and Defense of Freedom are Among the Noblest of Professional Endeavors Eduardo Casillas RocketPropulsion ChabotCollege E10 110812.pptx

Agenda • Rocket Propulsion • Emphasis on Solid Propulsion • Aerojet Company Overview • Videos • Aerojet 70th Anniversary Video • Mars EDL 7 Minutes of Terror Video • Summary • Questions? Eduardo Casillas RocketPropulsion ChabotCollege E10 110812.pptx

Rocket Propulsion • Accelerate medium to create thrust (mostly gas medium) Figures provided courtesy of the following web sites: http://history.nasa.gov/conghand/propulsn.htm http://www.ricknewlands.webspace.virginmedia.com/pages/engines/what-is-a-hybrid.htm http://www.answers.com/topic/ramjet Eduardo Casillas RocketPropulsion ChabotCollege E10 110812.pptx

Solid Rocket Propulsion Wide ranging applications require SRMs with many shapes & functions Eduardo Casillas RocketPropulsionChabotCollege E10 110812.pptx

Solid Rocket Propulsion – Design Flow • Interactions between components must be accounted for in the design process – usually by iteration until the design converges • Grain design affects the internal insulation (flame exposure) and motor case (pressure) • Nozzle design affects the case (aft opening dia), propellant grain (submergence), and thrust vector actuation system (gimbaled configuration) • Attach structures affect the case (skirts, thrust structure) and nozzle (blast tubes, hot-fly out) • Second-level interactions (ordnance & avionics mounting, etc) Customer Specification Requirements and SOW Detailed Analyses Structures Mech. Design Preliminary Mechanical Design Layout Preliminary Ballistics Analysis Program Start Ballistics Thermal Functional Configuration Audit (Customer Acceptance) Development & Qualification Testing Drawing Generation Design Reviews Eduardo Casillas RocketPropulsionChabotCollege E10 110812.pptx

Typical Solid Rocket Design Team • Chief Engineer • Project Engineers • Systems Engineers • Ballistic Design Engineers • Design Engineers • Propellant Chemists • Analysts - CFD, Stress, Thermal, Dynamics • Controls Engineers • Electronic Avionics Engineers • Materials & Processes Engineers • Configuration Management • Manufacturing Engineers • Test and Instrumentation Engineers Eduardo Casillas RocketPropulsion ChabotCollege E10 110812.pptx

Ascent Main Engine PAC-3 Space & Launch Systems Tactical Systems THAAD Static Test Missile Defense and Strategic Systems Advanced Programs Real Estate Overview • Over 3,000 employees across 13 states • 2011 Revenues of $918M • Key Capabilities Enabling • Space and Launch Systems • Tactical Systems • Missile Defense Systems • Advanced Programs • Significant Real Estate Holdings Eduardo Casillas RocketPropulsion ChabotCollege E10 110812.pptx

Broad Portfolio of Programs Across Diverse Mission Areas Space and Launch Systems Tactical Systems Standard Missile AOT Specialty Metals Kinetic Energy Penetrators Tactical Tomahawk GMLRS Orion PAC-3 Warhead Liners AJ26 M829A3Cartridge, 120mm, APFSDS-T Atlas Space Thruster Fragmentation Devices Missile Defense and Strategic Systems F-22 SM3 TDACS Advanced Programs HAWK THAAD EKV Minuteman Eduardo Casillas RocketPropulsion ChabotCollege E10 110812.pptx

Operating Locations Field Offices Engineering Center Over 3,000 Employees Across13 States Redmond, WA Precision Liquid Engines 350 Employees Moscow Tokyo London Headquarters Sacramento, CA High Value Propulsion 1,650 Employees Picatinny Arsenal, NJ Northern Virginia Operations Tactical & Technology 325 Employees Washington, D.C. Gainesville, VA Orange, VA Jonesborough, TN Unique Specialty Materials 110 Employees Hill AFB, UT Denver, CO Edwards AFB, CA Tucson, AZ Woodland Hills, CA Socorro, NM Huntsville, AL Vernon, CA Dallas, TX Eglin AFB, FL Camden, AR Tactical Low Cost High Volume Production 550 Employees Orlando, FL Product-Focused Manufacturing Centers and Customer-Focused Support Eduardo Casillas RocketPropulsion ChabotCollege E10 110812.pptx

Broad Spectrum of New Opportunities JAGM Hydrocarbon Boost PAC-3 MSE Tactical Propulsion for today’s war fighter Shielding Warhead Liners HyFly Advanced Materials Aeronautical Components Commercial E-Space Taurus II / Bigelow SM3 TDACS Standard Missile Standard Missile Phased Adaptive Approach Axial and Divert Launch Standard Missile Eduardo Casillas RocketPropulsion ChabotCollege E10 110812.pptx

Example – Mars Science Laboratory • NASA’s Mars Science Laboratory (MSL) • Aerojet engines assisted with entry, descent, and landing. Aerojet thrusters also provided attitude control and trajectory correction maneuvers during the MSL’s transit to Mars. • MSL carried eight Aerojet MR-111C 1.0 lbf thrusters, eight Aerojet MR-107U 68 lbf thrusters, and eight Aerojet MR-80B 800 lbf thrusters with a throttleable thrust range of > 100:1. • 68 lbf and 800 lbf thrusters supported the actual landing. Eduardo Casillas RocketPropulsion ChabotCollege E10 110812.pptx

Rocket Propulsion - Summary • Rocket propulsion is an exciting, challenging, and rewarding engineering field • Tough challenges for high energy propellants, high temperature / lightweight materials, fast acting / high precision control actuation, and systems integration • All challenges and tribulations bow-down when your rocket is developed to perform successfully and reliably • Rocket propulsion enables some of our most noble endeavors • Study of our planet – protect our island • Space exploration – expand human presence to other islands • Defense of human freedom – protect our way of life now and for future generations Eduardo Casillas RocketPropulsion ChabotCollege E10 110812.pptx

Eduardo Casillas Manager, Mission Architecture Engineering Rocket Propulsion