Author Topic: Lessons Learned: Rockets in the 1980s and 1990s and now  (Read 67334 times)

Offline Danderman

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Now that we have a bunch of new companies planning to fly new rockets, I thought it would be useful to examine the efforts in the past that mostly failed, and why they failed. Sometimes it was just a question of an early failure that killed the company, and knowing failure modes of the past could be useful.

One common screwup was testing rockets horizontally, and then suffering leaks when actual launch was attempted, when the rocket was vertical. The typical leak would be a LOX leak that would freeze valves, resulting in sadness later on. That happened to AMROC.

Another failure was due to control loss from either underperforming or malfunctioning hydraulics. I think we had 3 of those, Conestoga, Athena and SuperStrypi.

Kistler had a nastier problem, a design that didn't close under a billion dollars. They spend hundreds of millions of dollars and got 75 percent done. The last 25 percent apparently was going to cost a billion dollars. They should have hired Elon.

Another failure was under-capitalization, not necessarily to get to launch, but to survive a recession. There were probably half a dozen launch companies killed by the relatively minor recession that followed the dot.com crash.

But yes, there plenty of companies that just couldn't raise the money for first launch. That would include XCOR and Kistler and Pioneer Rocketplane and Rotary Rocket and others that I can't remember.

The first one that was basically killed by IP litigation was Firefly. Perhaps I am wrong on that.

The US government's track record on getting to first launch is far worse, BTW.

Any more?









Offline rocx

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #1 on: 12/14/2016 07:43 am »
OTRAG was mostly killed by politics. They were German, in an era too close to the time German rockets were fired at London. They were a competitor to Ariane, a European collaboration whose third stage engine was German. They chose Zaire and Libya as their test and launch sites.
Any day with a rocket landing is a fantastic day.

Offline high road

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #2 on: 12/14/2016 08:24 am »
Another failure was under-capitalization, not necessarily to get to launch, but to survive a recession. There were probably half a dozen launch companies killed by the relatively minor recession that followed the dot.com crash.

The numbers don't show a drop in launches following the dotcom crash any more severe than the eighties and nineties trend. The thawing and end of the cold war seems to have caused a steady decline in the number of launches, right until commercial demand picked up in 2006.

This teaches us about past failures that the lower demand for commercial launches likely had an important role in their expected profitability, keeping investors away and expediting their demise. And that the most interesting price point was completely different because the only 'realistic' buyers had deeper pockets. So be careful not to draw too many false conclusions.
« Last Edit: 12/14/2016 08:28 am by high road »

Offline Katana

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #3 on: 12/14/2016 10:08 am »
Now that we have a bunch of new companies planning to fly new rockets, I thought it would be useful to examine the efforts in the past that mostly failed, and why they failed. Sometimes it was just a question of an early failure that killed the company, and knowing failure modes of the past could be useful.

One common screwup was testing rockets horizontally, and then suffering leaks when actual launch was attempted, when the rocket was vertical. The typical leak would be a LOX leak that would freeze valves, resulting in sadness later on. That happened to AMROC.

Another failure was due to control loss from either underperforming or malfunctioning hydraulics. I think we had 3 of those, Conestoga, Athena and SuperStrypi.

Kistler had a nastier problem, a design that didn't close under a billion dollars. They spend hundreds of millions of dollars and got 75 percent done. The last 25 percent apparently was going to cost a billion dollars. They should have hired Elon.

Another failure was under-capitalization, not necessarily to get to launch, but to survive a recession. There were probably half a dozen launch companies killed by the relatively minor recession that followed the dot.com crash.

But yes, there plenty of companies that just couldn't raise the money for first launch. That would include XCOR and Kistler and Pioneer Rocketplane and Rotary Rocket and others that I can't remember.

The first one that was basically killed by IP litigation was Firefly. Perhaps I am wrong on that.

The US government's track record on getting to first launch is far worse, BTW.

Any more?
AMROC, Rotary Rocket and Delta X SSTO are designs that can't close at all.

Conestoga and SuperStrypi dies from software and aerodynamic faults.

XCOR is still surviving as suborbital.

Suborbital projects have better surviveability of under-capitalization.  Up aerospace lives happily on the basis of CSXT 100km amateur sounding rocket. With launch service frequency  higher than suborbital test frequency of many "orbital" launcher projects.
« Last Edit: 12/14/2016 10:15 am by Katana »

Offline notsorandom

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #4 on: 12/14/2016 01:33 pm »
Many of these startups failed due to economic, political, or business reasons before even getting the hardware to the launch pad. Many had interesting or unique technological approaches to space launch that would supposedly give them an edge or at least be able to compete in the already established market. They never got to test those technologies. Its easy to look back and say if only they had been able to survive long enough we'd have cheap launch! However I'd bet that many of those technological solutions were either unworkable or not doable on their budgets. In contrast SpaceX was very conservative with the Falcon 1. It was a two stage conventional rocket, powered by conventional propellants, and boosted by an evolution of an already well tested engine. Though relatively conservative they still had plenty of difficulty with the rocket and lost the first three. They wouldn't be around today if they had bit off a bigger technological challenge. One of the lesions that could be learned is that getting into space is hard, don't make it harder by reinventing the wheel.

Offline edkyle99

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #5 on: 12/14/2016 01:40 pm »
One common screwup was testing rockets horizontally, and then suffering leaks when actual launch was attempted, when the rocket was vertical. The typical leak would be a LOX leak that would freeze valves, resulting in sadness later on. That happened to AMROC.
A March 16, 1987 Aviation Week & Space Technology article included a photo of an Amroc vertical test in "an old Thor test stand at the Air Force Rocket Propulsion Laboratory" that took place in December, 1986. 

I've always believed that Amroc's rocket demise was mostly due to George Koopman's fatal auto accident.  If his accident hadn't happened, the company might well have marched onward after its rocket failure.   He was a force of nature.

 - Ed Kyle
« Last Edit: 12/14/2016 01:40 pm by edkyle99 »

Offline Jim

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #6 on: 12/14/2016 01:44 pm »

The US government's track record on getting to first launch is far worse, BTW.


Not a relevant point.  They were still learning rocket science

Offline Jim

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #7 on: 12/14/2016 01:47 pm »
Delta III - ignoring a roll frequency mode.  Vehicle development was done on the cheap, just enough to get by.

Offline R7

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #8 on: 12/14/2016 03:27 pm »
Then there was Beal Aerospace which seemed to fold prematurely due to CEO's tantrum against SLI.
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Offline bad_astra

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #9 on: 12/14/2016 05:13 pm »
I don't know that anyone knows for sure what occured with Beal. Considering how close Beal was, and how SpaceX pretty much followed a similar path to success, I sometimes wonder if it wasn't just a lack of conviction. (and a lack of scaling up to their EELV class rocket)


Kelly Space, and Pioneer: business plans requiring the small leo fleets that never really occurred. Maybe they were a couple of decades early.

PlanetSpace: too ambitious.
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Offline John-H

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #10 on: 12/14/2016 11:37 pm »
I don't know that anyone knows for sure what occured with Beal. Considering how close Beal was, and how SpaceX pretty much followed a similar path to success, I sometimes wonder if it wasn't just a lack of conviction. (and a lack of scaling up to their EELV class rocket)


Kelly Space, and Pioneer: business plans requiring the small leo fleets that never really occurred. Maybe they were a couple of decades early.

PlanetSpace: too ambitious.

If Beal had counted on several billion dollars from NASA, and Musk had not, the stories would  be reversed.

John

Offline Lar

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #11 on: 12/15/2016 12:14 am »
If Beal had counted on several billion dollars from NASA, and Musk had not, the stories would  be reversed.

Without getting too far into SpaceX stuff, can you elaborate? I didn't think Musk counted on several billion from NASA.

From the WP article https://en.wikipedia.org/wiki/Beal_Aerospace

Quote
Following NASA's announcement that they would fund research and development of competing launch vehicles under the Space Launch Initiative (SLI), Andrew Beal announced on October 23, 2000 that Beal Aerospace would cease operations. Beal cited NASA's commercial practices as the primary reason for closing.

That sounds rather odd... the whole press release is oddish to me.. http://www.spaceprojects.com/Beal/
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Offline John-H

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #12 on: 12/15/2016 02:05 am »
If Beal had counted on several billion dollars from NASA, and Musk had not, the stories would  be reversed.

Without getting too far into SpaceX stuff, can you elaborate? I didn't think Musk counted on several billion from NASA.

From the WP article https://en.wikipedia.org/wiki/Beal_Aerospace

Quote
Following NASA's announcement that they would fund research and development of competing launch vehicles under the Space Launch Initiative (SLI), Andrew Beal announced on October 23, 2000 that Beal Aerospace would cease operations. Beal cited NASA's commercial practices as the primary reason for closing.

That sounds rather odd... the whole press release is oddish to me.. http://www.spaceprojects.com/Beal/

I believe Beal interpreted that to mean that his competitors would get piles of NASA money and he would get nothing.  The US government is by far the biggest market for US launchers.

John

Offline Lar

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #13 on: 12/15/2016 02:07 am »
I believe Beal interpreted that to mean that his competitors would get piles of NASA money and he would get nothing. 

Pretty clear on that part. What I'm missing is the several billion you refer to. The numbers bandied about were in the hundreds of millions, and were before SpaceX's time.
"I think it would be great to be born on Earth and to die on Mars. Just hopefully not at the point of impact." -Elon Musk
"We're a little bit like the dog who caught the bus" - Musk after CRS-8 S1 successfully landed on ASDS OCISLY

Offline Kabloona

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #14 on: 12/15/2016 03:31 am »
Now that we have a bunch of new companies planning to fly new rockets, I thought it would be useful to examine the efforts in the past that mostly failed, and why they failed. Sometimes it was just a question of an early failure that killed the company, and knowing failure modes of the past could be useful.

One common screwup was testing rockets horizontally, and then suffering leaks when actual launch was attempted, when the rocket was vertical. The typical leak would be a LOX leak that would freeze valves, resulting in sadness later on. That happened to AMROC.

One of the commonest failure modes is failure of separation events (stage sep, fairing sep), which is why SpaceX smartly tried to minimize the number of sep events (2 stage vs. 3 stage) and decided to use (pre-flight testable) pneumatic pushers instead of (non-preflight testable) pyros. Fairing sep failures killed Taurus, though fortunately not Orbital.

The second Pegasus also suffered multiple separation anomalies. The S1/S2 pyros didn't cut the composite interstage cleanly, so S1 hung on by a thread and yawed the vehicle around so far that when S2 ignited it was almost flying backward. Thanks to a robust GN&C design (kudos to Dan Rovner) the vehicle righted itself and got back on track. Then it had a fairing separation anomaly but still managed to deploy its payloads.

Then Orbital had a lesser known separation anomaly on the TOS/ACTS Shuttle mission. A miswiring of the separation ring pyros caused both the primary and backup detonating cords to fire, instead of just the primary as was intended. Fortunately the stack separated from the Shuttle safely, but the det cords ruptured their containment tube and sprayed the cargo bay with shrapnel. Fortunately the orbiter wasn't badly damaged and everyone made it home safely.

Obviously these didn't kill Orbital, but they did kill one of its vehicles, ie Taurus, and the "lessons learned" for other companies are (1) minimize the number of separation events, and (2) avoid use of separation systems that can't be fully tested before launch, ie pyros, wherever possible. Looks like SpaceX took those lessons to heart.
« Last Edit: 12/15/2016 04:01 am by Kabloona »

Offline Katana

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #15 on: 12/15/2016 12:27 pm »
Many of these startups failed due to economic, political, or business reasons before even getting the hardware to the launch pad. Many had interesting or unique technological approaches to space launch that would supposedly give them an edge or at least be able to compete in the already established market. They never got to test those technologies. Its easy to look back and say if only they had been able to survive long enough we'd have cheap launch! However I'd bet that many of those technological solutions were either unworkable or not doable on their budgets. In contrast SpaceX was very conservative with the Falcon 1. It was a two stage conventional rocket, powered by conventional propellants, and boosted by an evolution of an already well tested engine. Though relatively conservative they still had plenty of difficulty with the rocket and lost the first three. They wouldn't be around today if they had bit off a bigger technological challenge. One of the lesions that could be learned is that getting into space is hard, don't make it harder by reinventing the wheel.
Are pressure feds feasible? harder? Easier? Compared to normal liquid ones? Many instances(OTRAG, Microcorsm, Firefly, Vector, and many) but none success yet. 

Projects with turbopumps are relatively rare but more healthy (SPACEX, BO, Rlabs) with only one dead (in 1980s).

Maybe pressure feds are indications of weakness and turbopumps are indications of strength?

Other types:
Near all solids are based on spare missiles, successful or not. Except UP Aerospace makes propellant in house (CSXT amateur legacy).

Hybrids have inferior performance and scability, AMROC dies too early to prove, SpaceShip1 is successful but SpaceShip 2 suffers.

Real exotics are rare: Roton , XCOR, Skylon.
« Last Edit: 12/15/2016 01:00 pm by Katana »

Offline notsorandom

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #16 on: 12/15/2016 02:51 pm »
Are pressure feds feasible? harder? Easier? Compared to normal liquid ones? Many instances(OTRAG, Microcorsm, Firefly, Vector, and many) but none success yet. 

Projects with turbopumps are relatively rare but more healthy (SPACEX, BO, Rlabs) with only one dead (in 1980s).

Maybe pressure feds are indications of weakness and turbopumps are indications of strength?

Other types:
Near all solids are based on spare missiles, successful or not. Except UP Aerospace makes propellant in house (CSXT amateur legacy).

Hybrids have inferior performance and scability, AMROC dies too early to prove, SpaceShip1 is successful but SpaceShip 2 suffers.

Real exotics are rare: Roton , XCOR, Skylon.
Falcon 1 was both turbopump and pressure fed. Same with the Delta II, ignoring the solids. Turbopumps used to be really difficult and expensive to develop. They still kind of are. SpaceX, Blue and the others have benefited from better computer modeling and the work done by NASA. For example the original Merlin had a lot of heritage from the Fastrac engine. SpaceX even originally used the same contractor that built the turbopump for the Fastrac.

As for pressure fed booster stages, I think its hard to tell if it is a good idea based on past experiences. Many of the companies that have tried them have failed for other reasons before getting to the point where the booster propulsion choices would have mattered. I'd suspect that for rockets beyond a certain size turbo pumps end up with a better cost benefit ratio than a pressure fed design.

Offline orulz

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #17 on: 12/15/2016 03:51 pm »
I think Katana is onto something: The main lesson is, if you're not willing to design a turbopump for at least the booster stage, stick to suborbital rockets and don't waste your time or money on any efforts to go orbital. If you are under-capitalized to the point that you have to simplify your engine on so much, that lack of resources is bound to rear its ugly head elsewhere in your development program as well.

I suppose there have been successes with all-solid designs so that may be a second potential pathway to success - albeit fraught with its own pitfalls and hazards, but pressure fed and hybrid designs seem to be mostly a dead end for companies with orbital ambitions, don't they?

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Offline Katana

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #18 on: 12/16/2016 03:04 pm »
All solids got to success earlier, OSC Pegasus is almost too early to be concerned as "commercial".

For liquids, it's worth thinking why Von Brown choose turbopump for V2 so early.

Besides, solids may overperform pressure feds by high density.
« Last Edit: 12/16/2016 03:32 pm by Katana »

Offline HMXHMX

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Re: Lessons Learned: Rockets in the 1980s and 1990s and now
« Reply #19 on: 12/16/2016 04:28 pm »
Many of these startups failed due to economic, political, or business reasons before even getting the hardware to the launch pad. Many had interesting or unique technological approaches to space launch that would supposedly give them an edge or at least be able to compete in the already established market. They never got to test those technologies. Its easy to look back and say if only they had been able to survive long enough we'd have cheap launch! However I'd bet that many of those technological solutions were either unworkable or not doable on their budgets. In contrast SpaceX was very conservative with the Falcon 1. It was a two stage conventional rocket, powered by conventional propellants, and boosted by an evolution of an already well tested engine. Though relatively conservative they still had plenty of difficulty with the rocket and lost the first three. They wouldn't be around today if they had bit off a bigger technological challenge. One of the lesions that could be learned is that getting into space is hard, don't make it harder by reinventing the wheel.
Are pressure feds feasible? harder? Easier? Compared to normal liquid ones? Many instances(OTRAG, Microcorsm, Firefly, Vector, and many) but none success yet. 

Projects with turbopumps are relatively rare but more healthy (SPACEX, BO, Rlabs) with only one dead (in 1980s).

Maybe pressure feds are indications of weakness and turbopumps are indications of strength?

Other types:
Near all solids are based on spare missiles, successful or not. Except UP Aerospace makes propellant in house (CSXT amateur legacy).

Hybrids have inferior performance and scability, AMROC dies too early to prove, SpaceShip1 is successful but SpaceShip 2 suffers.

Real exotics are rare: Roton , XCOR, Skylon.

Pressure-fed doesn't mean easy.  I tell people that if you aren't spending $2 on your pressurization system for every $1 spent on the engine itself, you are probably doing something wrong.  (This is one reason AirLaunch LLC went to VaPak self-pressurization, but even then, we followed my ratio...)

Today, turbopumps are getting ridiculously cheap, so there is little reason to go pressure-fed.  If I was to embark upon another LV project, it'd be pump-fed.

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