Author Topic: SpaceX Falcon Heavy Discussion (Thread 6)  (Read 551551 times)

Offline jketch

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1120 on: 07/27/2021 09:44 am »
Are there any larger variants of the Star motor that were manufactured in the current century, are flight rated and not unflown research projects, and thus could reasonably be considered to be "available" to NASA for the EC mission without them having to fund NG to restart a development program that was shut down a generation ago?
Pegasus motors (Orion 50s) were looked at.
They may have been looked at, but ORION motors can be discarded as a possibility for direct-to-Jupiter pretty easily.  From the catalog, ORION 50S XLT (high performance, air start) masses 16221 kg at start, and 1121 kg at burnout.  Assuming an isp of 294 (IUS like) that's a delta V with a 6000 kg payload of 3279 m/s.  So for a final C3 of 80, you need the booster to give a C3 of -2.4 to a 22.2 ton payload.  But FH can only boost 16 tonnes to this C3 (LSP plot only goes to C3 = -1.7, but that's a very minor extrapolation).  So it's not even close.


You also need a new(heavier) payload adapter for over 10,000 Kg.

Elon has said many times the easiest way to boost FH performance is to stretch the S2. He said they hadn't done it due to no previous missions needing it. Is this the one?

Can you close the gap doing this? How much of a stretch would it require?

For non-expendable FH and F9 this would also have a positive "knock-on" performance effect reducing S1 burnout velocity/apogee reducing residual prop required.
I wondered that as I’ve seen a few people state that this mission will be flying with a stretched S2.

I don't have any special insight but I'd be very surprised if NASA allowed this to fly on the first launch of a stretched S2. I also doubt it'd be worth it to do all the design work a stretched stage would entail for a one time $180M contract.

Offline gongora

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1121 on: 07/27/2021 02:01 pm »
A stretched S2 would be a new launch vehicle configuration.

Offline TrevorMonty

Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1122 on: 07/27/2021 03:58 pm »
A stretched S2 would be a new launch vehicle configuration.
Still lot lower risk than adding SRM kick stage which is another point of failure.

If FH can do it in current configuration then that is safest option even if it adds a few extra months to trip time.

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Online Robotbeat

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1123 on: 07/28/2021 09:51 pm »

They may have been looked at, but ORION motors can be discarded as a possibility for direct-to-Jupiter pretty easily.


It never was for direct-to-Jupiter.  There was only one option for that.

And staged solids was looked at.
Was going to point out solids staging as a possibility, too. Glad they were thorough.

Another possibility (depending on the thrust of the spacecraft’s main engine, if it has one) is to stretch the spacecraft’s main propellant tank a bit and use that to assist Earth-departure. That may increase burnout dry mass by less than a solid rocket stage.

Another issue is that the LSP website is actually pretty conservative, although to do better may require more careful analysis by SpaceX.
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Offline woods170

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1124 on: 08/22/2021 01:53 pm »

Offline docmordrid

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1125 on: 08/22/2021 04:37 pm »
Details of the FH extended fairing.
https://twitter.com/spacex360/status/1429380060373524486?s=19

From the new Falcon User Guide,

"SpaceX can also provide an extended fairing as a nonstandard service. The extended fairing has the same diameter as the standard faring (5.2 m, 17.2 ft) and an overall height of 18.7 m (61.25 ft)."

Vehicle height

Standard: 70m
Extended: 75.2m
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Offline alugobi

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1126 on: 08/22/2021 06:42 pm »
Are there any non-military payloads that would require that one?

Offline tbellman

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1127 on: 08/22/2021 06:55 pm »
Are there any non-military payloads that would require that one?

The launch of PPE+HALO (the two first parts of Lunar Gateway) needs the extended fairing.  It was ordered back in February, and launch is tentatively planned for 2024.

Offline yoram

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1128 on: 08/22/2021 06:57 pm »
Are there any non-military payloads that would require that one?

The launch of PPE+HALO (the two first parts of Lunar Gateway) needs the extended fairing.  It was ordered back in February, and launch is tentatively planned for 2024.

Do we know where the extended fairing is produced? Is it in Hawthorn or did they contract it out?


Online niwax

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1129 on: 08/22/2021 08:32 pm »
Are there any non-military payloads that would require that one?

The launch of PPE+HALO (the two first parts of Lunar Gateway) needs the extended fairing.  It was ordered back in February, and launch is tentatively planned for 2024.

Do we know where the extended fairing is produced? Is it in Hawthorn or did they contract it out?

There was news about SpaceX simply buying the fairing from RUAG who also make them for ULA and others, but I don't have any confirmed source for what they actually went for. Contracting it out makes sense as they get to pass on the cost to their government customer and don't really have any commercial advantage from spinning up another fairing line.
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Offline docmordrid

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1130 on: 08/22/2021 10:12 pm »
Are there any non-military payloads that would require that one?

The launch of PPE+HALO (the two first parts of Lunar Gateway) needs the extended fairing.  It was ordered back in February, and launch is tentatively planned for 2024.

Do we know where the extended fairing is produced? Is it in Hawthorn or did they contract it out?

There was news about SpaceX simply buying the fairing from RUAG who also make them for ULA and others, but I don't have any confirmed source for what they actually went for.
>

ULA claimed IP rights.

https://www.reddit.com/r/spacex/comments/cpyq97/comment/ewul0ow/
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Offline gongora

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1131 on: 08/22/2021 10:58 pm »
ULA claimed IP rights.

https://www.reddit.com/r/spacex/comments/cpyq97/comment/ewul0ow/

ULA claimed IP rights to the fairing they had RUAG develop for them.  Other companies can still get RUAG to design and build a fairing.

Offline woods170

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1132 on: 08/24/2021 02:46 pm »
ULA claimed IP rights.

https://www.reddit.com/r/spacex/comments/cpyq97/comment/ewul0ow/

ULA claimed IP rights to the fairing they had RUAG develop for them.  Other companies can still get RUAG to design and build a fairing.

Yes. But that would make an extended fairing more expensive for SpaceX than simply developing and building it in-house. SpaceX was looking at RUAG for an existing long fairing design. Unfortunately, the only two long fairings available had IP rights from ULA and Arianespace written all over them.

There are three give-aways that the long fairing will be produced by SpaceX in-house:

- shape of the fairing at the bottom is identical to that of the standard fairing (same tooling)
- Curvature ratio of the top section of the fairing is identical to that of the standard fairing (same tooling)
- The "dents" in the payload envelope in the curved section are the same (both size and location) for standard and long fairings. Those "dents" house the pneumatic separation pushers. So, same design feature for standard and long fairings.

The only major difference between both fairings is how the seam between the fairing halves is separated. Pneumatic mechanical latches on standard fairing. Bolted frangible seam on long fairing. Those are direct indications for NO recovery and NO reuse of long fairings. Which in turn tells us that SpaceX expects the long fairings to be rarely used and thus those fairings will be expendable.
The long fairing will likely be used on just a handful of specific NSS missions and one-off missions such as the PPE-HALO launch. Thus, not worth the effort to recover them intact and reuse them.


EDIT: Jim just confirmed that the long fairing is indeed a SpaceX in-house product. See post immediately below.
« Last Edit: 09/13/2021 08:18 am by woods170 »

Offline Jim

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1133 on: 08/24/2021 03:19 pm »
did they contract it out?


They didn't

Offline woods170

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1134 on: 08/24/2021 03:30 pm »
did they contract it out?


They didn't

Thank you for confirming what I expected.

Offline markbike528cbx

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1135 on: 10/04/2021 06:40 pm »

...snip...

There are three give-aways that the long fairing will be produced by SpaceX in-house:

- shape of the fairing at the bottom is identical to that of the standard fairing (same tooling)
- Curvature ratio of the top section of the fairing is identical to that of the standard fairing (same tooling)
- The "dents" in the payload envelope in the curved section are the same (both size and location) for standard and long fairings. Those "dents" house the pneumatic separation pushers. So, same design feature for standard and long fairings.

The only major difference between both fairings is how the seam between the fairing halves is separated. Pneumatic mechanical latches on standard fairing. Bolted frangible seam on long fairing. Those are direct indications for NO recovery and NO reuse of long fairings. Which in turn tells us that SpaceX expects the long fairings to be rarely used and thus those fairings will be expendable.
The long fairing will likely be used on just a handful of specific NSS missions and one-off missions such as the PPE-HALO launch. Thus, not worth the effort to recover them intact and reuse them.


EDIT: Jim just confirmed that the long fairing is indeed a SpaceX in-house product. See post immediately below.
How are the seam separation features different? 
Source?   I didn't see any different features in the User's Guide. 
As I recall, the mechanical latches were a big SpaceX differentiator , as frangible bolts can't be tested. 
I fail to see how a major reliability feature would be abandoned.

I've read somewhere that Starlink is volume limited, not mass limited, so this might be able to help there also.

Offline gongora

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1136 on: 10/04/2021 06:43 pm »
I've read somewhere that Starlink is volume limited, not mass limited, so this might be able to help there also.

Starlink is mass limited

Offline Jim

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1137 on: 10/04/2021 07:06 pm »
[
I fail to see how a major reliability feature would be abandoned.

Mass.  The standard fairing and its latches is very heavy compared to other equivalents.

Also, other than the Taurus fairing issues, what other fairings had reliability uses?   
« Last Edit: 10/04/2021 07:22 pm by Jim »

Offline joek

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1138 on: 10/04/2021 07:08 pm »
How are the seam separation features different? 
Source?   I didn't see any different features in the User's Guide. 
As I recall, the mechanical latches were a big SpaceX differentiator , as frangible bolts can't be tested. 
I fail to see how a major reliability feature would be abandoned.
...

Read it again. And @woods170's and @Jim's posts above; emphasis added...
Quote from: SpaceX Falcon User's Guide, Section 2.4, Sep 2021
The two halves of the standard fairing are fastened by mechanical latches along the fairing vertical seam. To deploy the fairing, a high-pressure helium circuit releases the latches, and four pneumatic pushers facilitate positive-force deployment of the two halves. The use of all-pneumatic separation systems provides a benign shock environment, allows acceptance and preflight testing of the actual separation system hardware, and minimizes debris created during separation.

The two halves of the extended fairing are fastened by a bolted frangible seam joint. To deploy the fairing, redundant detonators initiate a detonation cord contained inside an expanding tube assembly. The detonation causes the expanding tube to expand outwards and break the structural seam between the two fairings in a controlled and contained manner. Four pneumatic pushers facilitate positive-force deployment of the two halves. The use of a nonbolted clamshell interface between the payload fairing and the rest of the vehicle provides significant shock attenuation of the separation event, maintaining environments for the payload well within nominal payload requirements.
« Last Edit: 10/04/2021 07:12 pm by joek »

Online envy887

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Re: SpaceX Falcon Heavy Discussion (Thread 6)
« Reply #1139 on: 10/04/2021 07:38 pm »
[
I fail to see how a major reliability feature would be abandoned.

Mass.  The standard fairing and its latches is very heavy compared to other equivalents.

Also, other than the Taurus fairing issues, what other fairings had reliability uses?

It's not exactly common, but Atlas/ATDA, Athena II, Naro-1, and PSLV have all failed missions due to fairing failures. Including Taurus XL, that's roughly once a decade across a variety of providers.

Ariane 5 also recently had a fairing issue on a successful mission that grounded it for a while.

 

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