Latest Developments On Spacex'S Falcon 1 and Falcon 9 Launch Vehicles and Dragon Spacecraft

You might also like

Download as pdf or txt
Download as pdf or txt
You are on page 1of 15

Latest Developments on SpaceX’s Falcon 1 and Falcon 9

Launch Vehicles and Dragon Spacecraft


Lauren Dreyer
SpaceX
1 Rocket Road
Hawthorne, CA 90250
310-363-6392
lauren@spacex.com

Abstract—SpaceX is committed to revolutionizing access to 9 is a much larger, EELV-class booster capable of lifting
space by providing highly reliable, low cost launch services. 12,500 kg to LEO, or 4,640 kg to Geosynchronous Transfer
To this end, SpaceX has been developing a family of Orbit (GTO). Like the Falcon 1, it is a two-stage launch
orbital transportation solutions comprised of SpaceX- vehicle which uses RP-1 and LOX propellants. Falcon 9
developed proprietary technologies, as well as off-the-shelf will initially launch from SpaceX’s launch complex SLC-40
and minimally modified hardware from leading aerospace on Cape Canaveral. This launch pad will also support the
subcontractors. SpaceX is currently offering launch Falcon 9 Heavy variant starting in late 2010, which will
services on the Falcon 1, Falcon 9, and Falcon 9 Heavy have a payload capacity of over 29,600 kg to LEO and
launch vehicles as well as commercial flights on the Dragon 15,000 kg to GTO.
spacecraft. Founded in mid-2002, SpaceX has been busy.
This paper provides the latest developments and progress, Additionally, SpaceX is developing a reusable spacecraft,
including recent launches and future plans. 12 Dragon, with NASA sponsorship under the Commercial
Orbital Transportation Services (COTS) program. It is
TABLE OF CONTENTS designed to deliver over 2.5 metric tons of cargo to the
International Space Station (ISS) when launched on board
1. INTRODUCTION .................................................................1
SpaceX’s Falcon 9 Launch Vehicle. The inaugural flight of
2. COMPANY BACKGROUND .................................................1
Dragon is scheduled for 2009. Although Dragon is being
3. FALCON 1 LAUNCH VEHICLE ...........................................4
designed to address ISS cargo requirements, its generic
3. FALCON 9 LAUNCH VEHICLE ...........................................7
architecture allows it to accommodate in-space technology
3. DRAGON SPACECRAFT ...................................................10
demonstrations and scientific instrument testing. The
4. CONCLUSION ..................................................................15
spacecraft can effectively serve as a recoverable and
reusable host spacecraft bus with its own propulsion,
1. INTRODUCTION avionics, attitude determination & control, communications,
SpaceX entered the market with a small but scalable thermal control and power subsystems. Dragon offers both
satellite launch vehicle, the Falcon 1. The Falcon 1 is a pressurized and unpressurized payload accommodations,
two-stage launch vehicle, capable of lifting approximately with the former being fully recoverable.
420 kg into low earth orbit (LEO). Both stages burn the
same propellants, namely RP-1 rocket-grade kerosene and
liquid oxygen (LOX), and are propelled by engines entirely 2. COMPANY BACKGROUND
designed and developed in-house by SpaceX. Falcon 1 has
Space Exploration Technologies (SpaceX) was founded in
launched four times from SpaceX’s launch facilities on
2002 for the express purpose of increasing the reliability,
Omelek Island at United States Army Kwajalein Atoll
and reducing the cost, of space access. (In a truly
(USAKA). The enhanced Falcon 1, or Falcon 1e, is
commercial environment these two objectives are
planned as a block upgrade to the Falcon 1 launch vehicle
necessarily inseparable). The first product, the Falcon 1
and offers additional capability enabled by an upgraded
launch vehicle, was designed, built, qualified and static
Merlin engine, elongated first stage tank, and an expanded
fired on a launch pad at Vandenberg Air Force Base in
fairing. With a capability of just over 1000 kg to LEO,
California less than two and a half years after company
Falcon 1e will begin launching mid-2010.
inception, with the inaugural launch occurring less than a
year later. Furthermore, the vehicle was designed from a
SpaceX is also developing multi-engine versions of the
blank sheet, with all major components including the
Falcon that will serve the medium, intermediate and heavy
structure, mechanisms, engines for both stages, avionics,
launch markets: Falcon 9 and Falcon 9 Heavy. The Falcon
flight and guidance software and ground systems all being
1 developed (and largely fabricated) entirely in-house. This
1
978-1-4244-2622-5/09/$25.00 ©2009 IEEE. approach, while highly atypical for the aerospace industry
2
IEEEAC paper#1667, Version 3, Updated 2009:01:09

1
in general, is central to SpaceX’s overall philosophy of footing as we move towards volume commercial launches.
minimizing external dependencies, both to control costs and
to decrease development time. The subsequent Falcon 9 The ultimate objective for SpaceX is not launching rockets
and the Dragon spacecraft developments have used a similar or transporting cargo, but human space transportation and
approach with minimal outsourcing or use of contractors everything SpaceX has undertaken to date is focused on this
and very few single-source suppliers. In 2006, the Falcon 9 goal. The Falcon 1 launch vehicle, although a useful
Launch Vehicle and Dragon spacecraft were selected by product in its own right, is also a test platform for the much
NASA via a Space Act Agreement to demonstrate delivery larger Falcon 9 vehicle. The Falcon 9 has been designed
and return of cargo to the International Space Station (ISS). from the start to comply with NASA human-rating
Three demonstration missions will be conducted, requirements (safety factor of 1.4). The Dragon spacecraft
culminating in Dragon berthing with ISS, delivering is being designed to meet NASA’s ISS cargo resupply
simulated cargo, and returning to Earth. needs after Shuttle retirement, but it is also designed from
the start to be upgraded to full crew capability with
SpaceX currently has twelve launches on its manifest, with relatively minor modifications. This goal of human space
its customer base distributed fairly evenly between US transportation permeates everything SpaceX does and also
government, commercial satellites and foreign entities. In mandates the highest levels of reliability.
2008, NASA awarded SpaceX a NASA Launch Services
contract for the Falcon 1 and Falcon 9 launch vehicles. SpaceX is currently offering commercial launch services on
The contract is an Indefinite Delivery/Indefinite Quantity two different launch vehicles, the Falcon 1 and Falcon 9, as
(IDIQ) contract where NASA may order launch services well as commercial flights on the Dragon spacecraft.
through June 30, 2010, for launches to occur through
December 2012. Under the NASA Launch Services IDIQ
contracts, the potential total contract value is up to $1
billion, depending on the number of missions awarded.
SpaceX also has an IDIQ contract with the US Air Force.

In addition, NASA has selected the SpaceX Falcon 9 launch


vehicle and Dragon spacecraft for the International Space
Station (ISS) Cargo Resupply Services (CRS) contract
award. The contract is for a guaranteed minimum of 20,000
kg to be carried to the International Space Station. The firm
contracted value is $1.6 billion and NASA may elect to
order additional missions for a cumulative total contract
value of up to $3.1 billion. SpaceX is on sound financial

Customer Launch Vehicle


Falcon 9 Maiden Q4 2008* Falcon 9
li h
ATSB Malaysia 2009 Falcon 1
Falcon 1 Flight 6 2009 Falcon 1 Figure 1 – SpaceX Vehicles: (top to bottom, left to right)
Falcon 1 Flight 7 2009 Falcon 1 Falcon 1, Falcon 1e, Dragon spacecraft, Falcon 9 w/5.2m
fairing, Falcon 9 Heavy w/5.2m fairing
MDA Corp 2009 Falcon 9
NASA COTS 1 2009 Falcon 9/ Dragon Personnel and Facilities
Avanti HYLAS (GTO) 2009 Falcon 9 SpaceX has grown to nearly 600 employees in six years,
NASA COTS 2 2009 Falcon 9/ Dragon with a projected growth rate of approximately 50% per year.

NASA COTS 3 2010 Falcon 9/ Dragon Headquarters, Hawthorne, CA— The company is
MDA Corp 2010 Falcon 1 headquartered in Hawthorne, California where SpaceX has
a 51,000 m2 (550,000 ft2) facility. Most employees are
Swedish Space Corps. 2010 Falcon 1 stationed in this location and all vehicle design and
DragonLab™ Mission 2010 Falcon 9/ Dragon manufacturing is performed in this facility.
1
Bigelow Aerospace 2011 Falcon 9/ Dragon
DragonLab™ Mission 2011 Falcon 9/ Dragon
2
Table 1. SpaceX Launch Manifest
* Flight hardware at launch site

2
and propellant and gas infrastructure is currently being
installed. An integration facility for the vehicle and
payloads and a Launch Control Center are also being built
at this location. These launch facilities received the first
Falcon 9 at the end of 2008.

SpaceX also has a small Washington DC office and several


permanent personnel at the Falcon 1 launch facility in the
Ronald Reagan Ballistic Missile Defense Test Site (RTS) at
United States Army Kwajalein Atoll (USAKA).

Achievements
In six years, SpaceX has achieved the following:
• Developed, built, tested and successfully launched the
Figure 2 - SpaceX’s Hawthorne Headquarters and Falcon 1 four times, which included “clean sheet”
Production Facility development of all propulsion, structures and avionics,
fully qualifying the vehicle, ground and launch support
Texas Test Facility, McGregor, TX—Approximately 70 systems, and certifying a Flight Termination System
employees are permanently stationed at SpaceX’s 120 ha with a Federal Range. The fourth flight of Falcon 1, on
(300 ac) Propulsion and Structural Test Site, near Waco, September 28, 2008, resulted in Falcon 1 becoming the
Texas, where all vehicle rocket engines and structures are first privately developed, liquid fueled rocket to reach
tested and qualified. This site hosts six different rocket orbit.
engine test stands. These range from a small hypergolic test
facility where the Draco reaction control thrusters for the • Developed, built and activated (with range approval)
Dragon spacecraft are being tested to the 67 m (220 ft) high two launch sites, including all regulatory approvals and
Falcon 9 test stand capable of test firing an entire Falcon 9 coordination, and began development of Space Launch
first stage with over 3.67 MN (825,000 lbf) thrust. Complex 40 at Cape Canaveral in Florida. This site has
Structural test stands are capable of supporting qualification been approved for use by the Department of Defense,
testing of the Falcon 1 and Falcon 9 first and second stages, and a site license for SpaceX use has been granted.
as well as the various composite components of the Design of ground support equipment (GSE) is largely
vehicles. Fairing deployment tests have also been complete and construction has started at the site. All
supported by this facility. ground segment systems are expected to be installed,
tested, and operational for the first launch of the Falcon
9 vehicle. Additional launch sites will be built in the
near future, based on customer needs, to establish
launch site redundancy and ensure all customers launch
without delay.
• Developed and demonstrated a responsive launch
operations campaign. The United States Air Force
“clocked” our operations and determined that SpaceX
could launch the Falcon 1 within 77 hours of arrival of
hardware at the launch site. Additionally, following an
automated abort during Falcon 1’s March 2007 launch
campaign, SpaceX demonstrated the ability to refuel,
recycle and successfully launch in less than one hour.
SpaceX also completed the same procedure in less than
forty minutes in the August 2008 launch campaign for
Falcon 1 Flight 3.
• Established a Mission Integration and Launch Services
Figure 3 - Engine and Structural Tests at SpaceX's
program which has successfully integrated three
Texas Test Site
missions – each in less than one year. Notably, for the
Cape Canaveral Launch Facility, Cape Canaveral, FL— Office of Operationally Responsive Space’s Jumpstart
Another 30 personnel are employed in Florida developing mission (Falcon 1 Flight 3), mission integration was
the Falcon 9 launch pad on Cape Canaveral. SpaceX has completed for three separate candidate payloads, with
been granted a lease by the US Air Force’s 45th Space the actual flight payload determined just four weeks
Wing to launch Falcon 9 vehicles from SLC-40, the former prior to static fire.
Titan IV launch pad. All demolition has been completed,

3
• Developed the major Falcon 9 subsystems to a point of designed and developed in-house by SpaceX. All vehicle
significant readiness. In late November 2008, a Falcon structures, most of the avionics and all ground systems were
9 first stage underwent a full mission simulation during also designed (and mostly built) by SpaceX.
a 178 second multi-engine static fire test stand at the
SpaceX Texas Test Facility. This first stage included The first stage is powered by a single Merlin engine which
all the major structural and propulsion elements. The generates 347 kN (78,000 lbf) thrust at lift-off. With a
Merlin engine, used on both the first and second stages vacuum Specific Impulse (Isp) of 304 seconds its
of the vehicle, has completed qualification testing. The performance is equal to the highest performing Gas
Falcon 9 vehicle was fully integrated at Cape Canaveral Generator cycle kerosene engines ever built. Merlin is
one day ahead of schedule on December 30, 2008. turbopump-fed with a regeneratively-cooled thrust chamber
Whether measured by weight or cost, the majority of and nozzle. A pintle injector provides a robust design that
the vehicle was flight hardware. As of the time of final is insensitive to combustion instability. The engine
paper submission, erecting the vehicle to vertical was achieves reliability through simplicity and the use of
imminent. historically-proven design approaches.
• Brought a 550,000 square foot design and The second stage of the Falcon 1 is propelled by a single
manufacturing facility on-line in Hawthorne, CA, Kestrel engine, which generates 31 kN (7,000 lbf) vacuum
which utilizes the latest technology available for thrust. Kestrel is a pressure-fed engine and uses an ablative
machining, quality control, welding, and composite combustion chamber. It burns for approximately 420
production. With the current addition of duplicate seconds during a typical mission and is also re-startable
production capability equipment, bolstering timeline during flight allowing for two or more burn orbit insertions
assurance, SpaceX has the manufacturing infrastructure which significantly increases vehicle payload capability.
and capability to provide the quality and on-time
production to support up to twenty (20) Falcon 9 flights
Flight History
per year.
SpaceX has executed four launches of the Falcon 1 vehicle,
• To further demonstrate SpaceX’s commitment to the last of which was fully successfully, including
Quality and reliable systems, the company passed its demonstrating second stage re-ignition.
ISO 9001:2000 quality certification in April 2006.
This is unprecedented in the aerospace industry, given Demonstration Missions—Prior to declaring Falcon 1 an
that this occurred while in the system demonstration operational launch vehicle, two demonstration missions
phase of the product development cycle. This was were conducted. Demonstration Flight 1 lifted off on
accomplished in large measure because, since its March 25, 2006 and executed 30 seconds of powered flight
inception, SpaceX premised its planning and before a fire caused early termination. Prior to termination,
engineering on a formalized, improvement-driven all vehicle systems, including the main engine, thrust vector
Quality Management System (QMS). As processes control, structures, avionics, software, guidance algorithm,
matured and key positions were filled, this premise were operating nominally. Less than a year later, on March
became a tangible, certifiable reality. 20, 2007, Demonstration Flight 2 launched. Although
SpaceX does not claim this flight was a complete success,
3. FALCON 1 LAUNCH VEHICLE the primary mission objectives for the Demonstration Flight
2 mission, both programmatic and technical, were met. The
Falcon 1, the first privately-developed, liquid-fueled rocket vehicle attained a peak altitude of 289 km, 5.1 km/s
to reach Earth orbit, has launched four times from SpaceX’s maximum velocity and remained in the center of the
launch facilities on the remote island of Omelek, in intended ground track throughout flight. An upper stage
Kwajalein Atoll in the South Pacific Ocean. The Enhanced control anomaly, however, ultimately prevented it from
Falcon 1 (Falcon 1e) is planned in 2010 as a block upgrade reaching orbital velocity, an important – but secondary
to the Falcon 1 and will result in approximately a 50% mission objective. This mission also demonstrated a highly
increase to payload lift capacity. autonomous ground control system and rapid recycle from a
hot-fire abort to launch in only 65 minutes.
Vehicle Description
The SpaceX Falcon 1 is a two-stage small launch vehicle, Had it not been for a second stage control anomaly, all
capable of lifting approximately 420 kg (925 lbm) into low indications are that Falcon 1 would have achieved its
earth orbit (LEO). The vehicle is 21 m (68’) long and has a intended orbit. The full Flight Review is available on
diameter of 1.7 m (5.5’) with a 1.5 m (5’) diameter payload SpaceX.com and includes detailed information on the
fairing. It has a Gross Lift-off Weight (GLOW) of successes and anomalies of Demo Flight 2.
approximately 27.6 t (61,000 lbm). Both stages burn the
same propellants, namely RP-1 rocket-grade kerosene and SpaceX declared the Falcon 1 ready to exit the
liquid oxygen (LOX), and are propelled by engines entirely demonstration program and upgraded the launch vehicle to

4
operational status. Consistent with SpaceX’s corporate Falcon 1 Flight 3 launched on August 2, 2008. Falcon 1
philosophy of rapid and continuous improvement, Falcon 1 executed a picture perfect first stage flight and ultimately
upgrades were instituted based upon experience from the reached an altitude of 217 km, but encountered a problem
demonstration missions. These and future planned just after stage separation that prevented the second stage
upgrades, are described below. from reaching orbit. However, there were still many
successful aspects of the mission. SpaceX accomplished the
Falcon 1 Flight 3—For Falcon 1 Flight 3, the Department ORS mission goal of rapidly integrating one payload
of Defense’s Operationally Responsive Space Office tasked selected from three possible payloads. SpaceX also
SpaceX with demonstrating its ability to perform responsive integrated the rocket stages, rolled out to the pad, and
mission integration for three separate candidate payloads. launched in only seven days. Positive aspects of the flight
The actual flight payload was to be determined by the ORS itself include:
Office at or before the SpaceX Flight Readiness Review,
which typically occurs two weeks before launch.
• Merlin 1C and overall first stage performance was
The primary ORS Office objective for the Launch vehicle excellent
team on this mission was to perform integration tasks for 3 • The stage separation system worked properly, in
possible ORS Office payloads in addition to completing a that all bolts fired and the pneumatic pushers
mission (Kick off to launch) in ~4 months. In addition to delivered the correct impulse
responsiveness being demonstrated by the launch service • Second stage ignited and achieved nominal
provider, responsiveness was also demonstrated by the chamber pressure
payload and ORS Office teams by building and testing each • Fairing separated correctly
of the three payloads being considered, then testing an • Neither of the near miss potential failures of flight
integrated stack. Also, each payload candidate team two, nor any new ones, were present
participated in a Jumpstart pathfinder exercise where they
went to Kwajalein to plan and verify logistical operation In post-flight analysis, SpaceX quickly determined the
and to set up and certify three separate ground stations for cause of the anomaly in Flight 3. The problem arose due to
use in the mission should they be the one selected to fly. a longer than expected thrust decay of the brand new Merlin
Significant breakthroughs in Operational Responsiveness 1C regeneratively cooled engine. Unburned fuel in the
were demonstrated through the integration activities of this cooling channels and manifold combined with residual
mission. The customer kickoff meeting was held in oxygen to produce a small thrust that was just enough to
February 2008 and the launch vehicle with the payload overcome the stage separation pusher impulse. In fact, a
integrated was vertical at the pad ready for launch in June very small increase in the time between commanding main
2008. Approximately four weeks prior to launch, the ORS engine shutdown and stage separation, an issue corrected
Office made its determination on which of the three payload for Flight 4, would have been enough to save the mission.
candidates would fly. The payload chosen was Trailblazer,
built and operated by SpaceDev of Poway, CA. Falcon 1 Flight 4—On September 28, 2008, SpaceX
successfully launched and achieved Earth orbit with the
fourth flight of the Falcon 1 launch vehicle. With this key
In preparation for the payload decision, the SpaceX team
milestone, Falcon 1 became the first privately developed
had demonstrated responsiveness by preparing for the
liquid-fueled rocket to orbit the Earth.
possibility of flying any of the ORS payloads being
considered. Specifically, documentation and analysis were
Flight 4 lifted off at 4:15 p.m. (PDT) / 23:15 (UTC), just
completed in advance so that regardless of which payload
fifteen (15) minutes into the launch window, from the
was ultimately chosen, the final integration and verification
Reagan Test Site (RTS) on Omelek Island at the U.S. Army
activities could be kept to a bare minimum and fit within the
Kwajalein Atoll (USAKA) in the Central Pacific.
final two to four weeks of the launch campaign. Multiple
Preliminary data indicates that Falcon 1 achieved an
payload configuration analysis completed included coupled
elliptical orbit of 500 km by 700 km, 9.2 degrees
loads analysis, collision avoidance maneuver analysis,
inclination—exactly as targeted, and then went on to coast
performance and trajectory analysis, and safety analysis.
and restart the second stage.
Three separate interface control documents were worked
between SpaceX, the primary payload being considered,
Orbit was achieved with the first burn terminating at 330.5
and the Secondary Payload System teams. Additionally, the
km altitude and 8.99 degree inclination. The goal for initial
FAA demonstrated responsiveness by licensing the launch
insertion was a 330 km altitude and a 9.0 degree inclination.
regardless of payload selected. To do this, they took the
The vehicle executed a second burn of the Kestrel engine to
payload safety information from all three candidates and
circularize. The primary purpose of the second burn was to
reviewed them all for acceptance prior to granting a
test the restart capability and then burn as long as possible.
commercial launch license enveloping them all.
The upper stage coasted for 43.5 minutes and then burned
for 6.8 seconds, which is 4 seconds longer than needed to
5
circularize. Most of the burn was actually done sideways to reliability, performance and allow for potential reuse, the
avoid creating a highly elliptical orbit, hence a change in chamber and nozzle have been upgraded to regeneratively
inclination to 9.3 degrees. The final orbit, confirmed by US cooled designs. The sixteen month return to flight from
Space Command, was 621 km by 643 km. Flight 2 to Flight 3 is due primarily to this engine upgrade.

Launched just eight weeks after Falcon 1 Flight 3, Flight 4 Because it is able to operate at higher temperatures and
carried a payload mass simulator of approximately 165 kg pressures, the regeneratively cooled (Merlin 1C) design
(364 lbs), designed and built by SpaceX, specifically for provides a greater level of thrust, upwards of 125,000 lbf of
this mission. Consisting of a hexagonal aluminum alloy sea-level thrust. The full thrust of the Merlin 1C engine
chamber 1.5 meters (5 feet) tall, the payload remains exceeds the structural margins of the existing Falcon 1 first
attached to the second stage as it orbits Earth. A mass stage tank design, which was originally qualified based on
simulator was chosen, in lieu of launching a payload for one the lower thrust of the ablatively cooled engine. In
of several interested parties, to allow for the expedited addition, when operating at full thrust, the Merlin 1C
launch campaign approval and processing. requires an increased propellant flow rate. Therefore, the
first stage tank structure will be redesigned and qualified to
(Author’s note: as of this submission, the Public Post-Flight meet the increased load requirements and propellant needs
Report was pending State Department approval, but is of the Merlin 1C engine. This full block upgrade, called the
expected in early 2009. Information from the report will be Falcon 1e (for enhanced) will be available beginning in the
included in the presentation, and the full report will be second quarter of 2010. However, as an interim upgrade,
available at SpaceX.com or by contacting the author the Merlin 1C engine will be flown at a reduced thrust level
directly.) for operational launches in 2008, 2009, and early 2010.

First Stage Upgrades—As a weight savings measure, the


stage 2 tank material has been changed from aluminum
2219 to a 2014 aluminum alloy. In addition, slosh baffles
have been added to both the Fuel and LOX tanks to prevent
further occurrences of the stage 2 loss of control anomaly
experienced during the Demo 2 mission. An illustration of
the slosh baffle addition is shown in Figure 5.

Figure 4 – Falcon 1 Flight 4 lifting off

Future Flights—The next flight of Falcon 1 is scheduled for


the first part of 2009 and will carry a Malaysian satellite,
Razaksat, for ATSB to near equatorial orbit. Flights 6 and 7
will follow in late 2009. In 2010, the launch cadence for Figure 5 - Stage 2 cross section illustrating internal slosh
Falcon 1 is expected to increase to one mission every two to baffles
three months. These launches will occur from SpaceX’s
Kwajalein launch facility. Reliability improvements have been made to the Kestrel
engine, which also allowed for some mass reductions. For
Upgrades the Falcon 1e, additional mass savings will be achieved by
changing the second stage tank material to a 2195 aluminum
Consistent with SpaceX’s corporate philosophy of rapid and lithium alloy.
continuous improvement, Falcon 1 upgrades were planned
based upon experience from the demonstration missions. Payload Fairing Upgrades—The Falcon 1 employs a bi-
conic aluminum payload fairing with a maximum inner
First Stage Upgrades—The Merlin engine employed for the diameter of 54 in (1.4 m) and an internal height of 110 in
first two demonstration flights of the Falcon 1 utilized an (2.8 m). Minimal changes were made to the fairing
ablatively cooled thrust chamber and nozzle. To increase assembly in preparation for the operational launches

6
following the Demo 2 mission. For mass savings and to stage engines but employs a much larger nozzle to optimize
provide increased payload volume, the payload fairing for performance for vacuum operation. The Falcon 9 stands
the Falcon 1e will be a composite ogive with a maximum 54.9 m (180 ft) tall on the launch pad when using the 5.2 m
inner diameter of 61 in (1.55 m) and an internal height of (17 ft) diameter payload fairing, or 50 m (165 ft) tall when
150 in (3.8 m). A dimensional comparison of the Falcon 1 launching the Dragon spacecraft. The first and second
and Falcon 1e payload fairings is provided in Figure 6. stages are both 3.6 m (12 ft) diameter and the Gross Lift-off
Weight (GLOW) is approximately 333 t (735,000 lbm) in
the LEO configuration.

The Falcon 9 will initially launch from SpaceX’s launch


complex SLC-40 on Cape Canaveral in mid-2009. This
launch pad will also support the Falcon 9 Heavy variant
starting in late 2010, which will have a payload capacity of
over 28,000 kg (62,000 lbm) to LEO.

The Falcon 9 has been designed from its inception to be a


human-rated vehicle. It meets or exceeds all NASA human-
rating requirements, including structural Factors-of-Safety
of 1.4 (vs. 1.25 for EELV), design for minimum risk, and
failure-tolerance criteria. It will be crew-capable when
combined with the Dragon spacecraft and a Launch Escape
System. Furthermore, it is the only vehicle in its class with
engine-out capability from lift-off (and two engine-out
capability during part of the 1st stage burn), thereby
Figure 6 - Falcon 1 and Falcon 1e payload fairing increasing mission reliability. Like the smaller Falcon 1, it
is held down to the launch pad for approximately three
dimensions, m [in]
seconds after first stage ignition to allow engine pressures to
stabilize before committing to flight. If the Flight Computer
detects any key parameters out of specification at T-0.5
3. FALCON 9 LAUNCH VEHICLE seconds, lift-off is aborted, the engines shut down and the
SpaceX’s Falcon 9 launch vehicle is a much larger, EELV- vehicle safed. Launch control personnel can then review
class (Evolved Expendable Launch Vehicle) booster data and decide whether a recycle is possible within the
capable of lifting 12,500 kg (27,500 lbm) to LEO, or 4,640 current launch window. This feature of the Falcon vehicles
kg (10,200 lbm) to Geosynchronous Transfer Orbit (GTO). also greatly enhances reliability by ensuring all critical
Like the Falcon 1, it is a two-stage launch vehicle with both systems are operating nominally prior to lift-off.
stages also burning RP-1 and LOX propellants. The first
stage is powered by nine Merlin engines, virtually identical As part of the Falcon 9 development, SpaceX has been
to those used on the Falcon 1 first stage, which generate a conducting a series of multi-engine hot-fires to ensure a
combined thrust of over 4.9 MN (1,100,000 lbf) at lift-off. thorough understanding of the complexities involved in
making nine engines work together successfully. This was
The second stage is powered by a single Merlin-vacuum one of the most significant challenges of the Apollo
engine which shares over 90% commonality with the first

Figure 7 – Falcon 9 Launch Vehicle, fully integrated at Cape Canaveral Space Launch Complex (SLC) 40

7
Program’s Saturn V booster development.

On November 22, 2008, a nine engine, 178 second full The engine assembly from Texas and other hardware from
mission simulation burn was performed on the Falcon 9 California converged in Florida for integration. The
Test Stand in Texas. This test was the culmination of a following figures chronicle that process:
series of burns on this test stand, starting with a single
engine and progressing through two, three, five then all nine
engines totaling over 95 seconds of testing. No significant
issues were encountered while ramping up to the full
complement of nine, and efficiencies in fueling rate and
countdown procedures were gained throughout.

Figure 8 – Nine Merlin engines prior to hot-fire Figure 10 - The Falcon 9 Payload Fairing half on its
shipping stand
Immediately following the nine-engine, mission duration
test, the engines were shipped to Cape Canaveral, Florida
and integrated with the Falcon 9 vehicle. The Falcon 9
vehicle was fully integrated on December 30, 2008, and (as
of final paper submission) erecting the vehicle to vertical
was imminent. Falcon 9 will have its maiden flight in mid
2009.

Figure 11 - Falcon 9 skirt mated with fuel tank end of


the first stage

Figure 9 - Engine assembly leaving Texas bound for


Florida

8
40.

Figure 15 - Side view of the entire assembly (from left)


engines, skirt, first stage tank, interstage, second stage
and 5.2 meter payload fairing (prior to fairing
integration)

Figure 12 – Falcon 9 first stage tank being loaded onto


the shipping structure

Figure 16 - Fully integrated Falcon 9

Figure 13 - Falcon 9 first stage being lifted off the


shipping truck and lowered it onto the integration
assemblies

Figure 17 - A view of the erector (center) standing


vertical on the launch mount base with the cradle on top

Figure 14 - Falcon 9 second stage (left) and the two 5.2


meter diameter fairing halves (right) arriving at SLC-

9
change required to provide crew transportation services to
and from the ISS.

3. DRAGON SPACECRAFT
The Dragon spacecraft is under development by SpaceX in
collaboration with NASA to provide cargo (and potentially
crew) transportation services to and from the International
Space Station (ISS). In response to NASA’s Commercial
Orbital Transportation Services (COTS) call in 2005,
SpaceX proposed, and has been developing, a flexible,
generic and reusable spacecraft dubbed “Dragon”. Dragon
launches on a standard Falcon 9 booster identical to the
commercial version, and is capable of delivering at least
2550 kg (5600 lbm) of cargo to the ISS. Furthermore,
Dragon is equipped with a heatshield and other recovery
systems to enable a controlled atmospheric reentry and
splashdown in the ocean under parachutes, thereby
providing NASA with cargo down-mass capability.

The Dragon spacecraft has both pressurized and


unpressurized cargo volumes. Pressurized cargo is
accommodated in the pressurized section of the “capsule”,
which is recoverable. This allows both up- and down-mass
capability for pressurized cargo. Unpressurized cargo is
carried in the “trunk”: the unpressurized sleeve that joins
Dragon to the Falcon 9 second stage during launch. This
trunk is jettisoned from the Dragon capsule just prior to
reentry and is therefore not recoverable. Figure 18 - Two views of the Dragon spacecraft and
trunk
Cargo mass can be freely traded between capsule and trunk
sections. Pressurized cargo is mounted inside the pressure The Dragon spacecraft will transport at least 2550 kg (5600
vessel using a flexible rack system designed to lbm) of cargo to the ISS (almost 3400 kg (7500 lbm)
accommodate all standard NASA cargo packages, both soft without growth and margin allocations), and is capable of
and hard-mounted. Unpressurized cargo is attached to a returning 2000 kg (4400 lbm) or more to earth depending
cargo carrier inside the trunk using the same standard bolt on other mission parameters. These values are based on the
pattern as the shuttle cargo bay carriers. After orbit Block 1 Falcon 9 which will be available in 2009. By the
insertion and separation from the Falcon 9 second stage, this end of 2010, the Block 2 Falcon 9 will increase up-mass
trunk volume is open to space. If Flight Releasable Attach capacity by approximately 2500 kg (5500 lbm).
Mechanisms (FRAMs) are used to attach the unpressurized
cargo to the cargo carrier, then the Space Station Robotic Table 1. Basic System Parameters
Manipulator System (SSRMS) can unload this cargo while
Dragon is berthed with ISS. Unpressurized trash for Total Pressurized Volume 15 m3
disposal can also be reloaded into the trunk as needed. Total Unpressurized Volume 30 m3
Usable Pressurized Volume 7~10 m3
Since SpaceX intends to perform both cargo and crew
Usable Unpressurized Volume >14 m3
services using Dragon, it was designed from the start to
human-rating requirements and is essentially identical in Array Power Capacity 1.8 kW
either configuration. The inclusion of three windows and Dry Mass 4800 kg1
higher structural Factors-of-Safety speaks to these Propellant load 1230 kg
intentions. The Environmental Control System will need to
Pressurized Cargo 1700 kg
be upgraded to a full Life Support System with carbon
dioxide scrubbers and humidity control, and crew External Cargo 850 kg
accommodations like seats, spacecraft control over-rides Total lift-off mass 8620 kg
etc. would also be required, but otherwise the Dragon Falcon 9 capability to ISS orbit 9290 kg2
spacecraft is crew capable. Up to seven crew members can 1. Includes 15 – 20% growth margin
be accommodated. The addition of a Launch Escape 2. Block 1, no margin
System to the Falcon 9/Dragon stack is the only additional

10
Dragon avionics is architected around four redundant Flight
Computers which are interconnected using a Byzantine
Spacecraft Subsystem Summary redundancy management system, currently being developed
by SpaceX. SpaceX is also designing a generic Remote
The major structural elements of the Dragon spacecraft are Input-Output module (RIO), each of which contains a
shown in Figure 19. The nose cone is jettisoned during complement of up to 14 FPGA-based “Personality
ascent like a payload fairing. A Passive Common Berthing Modules” (PMs). Depending on the specific combination
Mechanism (PCBM) is used to provide the ISS mechanical of PMs, a RIO can serve as an engine controller for the
interface. The pressure vessel is aluminum alloy and the Falcon 9, a value controller in Dragon, a communications
trunk is a composite structure. The “Service Section” is an controller (including command encryption/decryption), or a
unpressurized annulus that wraps around the base of the host of other functions. Consequently these RIO modules
capsule and houses the propulsion and recovery systems. appear throughout the Falcon 9 and Dragon architecture in
Although the total pressurized volume in the capsule is nearly a dozen different roles.
approximately 15 m3, the usable volume is typically 7-10
m3, due to the practicalities of packing this complex shape Electrical power is generated using two single-axis gimbled
with cargo consisting largely of rectangular prisms. solar arrays deployed from the Dragon trunk. Energy
Similarly, although the total unpressurized volume is storage uses batteries of commercial Lithium-Polymer cells
approximately 30 m3, protrusions into this volume make the that SpaceX has been developing and recently qualified for
usable volume closer to 14 m3. use on the Falcon launch vehicles. The Dragon power
system is design with over 200% power margins and is at
least three-fault tolerant.

Nose Cone

Passive Common
Berthing Mechanism

Pressurized Section

Service Section
(Unpressurized)

NTO/MMH
Thrusters
Heat Shield

Figure 20 – Draco Thruster Hot-Fire Testing


Trunk
(Unpressurized) Thermal Control is achieved using dual pumped fluid loops
with a radiator on the skin of the trunk structure. The
Environmental Control System maintains a comfortable
“shirt-sleeve” environment inside the pressure vessel by
providing air circulation, controlling pressure,
pressurization rates and temperature. Humidity is also
Figure 19 - Major Dragon Components monitored. For ISS missions, fire detection, pressure
equalization, air sampling and exchange with ISS is also
Dragon uses 18 “Draco” hypergolic thrusters for both provided.
reaction control and orbital maneuvers including de-orbit.
They are arranged in four cross-strapped modules which are On-orbit communications and commandability is achieved
identical except that two modules have four thrusters and using commercial S-band digital transceivers linking
the others have five (this is mandated by ISS safety directly to ground stations or via TDRSS. Crosslink
requirements). The whole propulsion system is at least two- communications with ISS (both telemetry and command) is
fault (and in most cases three or more fault) tolerant. These through a UHF transceiver that SpaceX is developing,
thrusters and the propellant tanks are being developed and dubbed Commercial UHF Communications Unit (CUCU).
tested in-house at SpaceX. NASA will be launching this hardware on a shuttle flight in
2009 for installation in an Express Rack on ISS prior to the
Demo C2 mission.

11
Dragon Guidance, Navigation and Control (GNC) uses L-2 days and into the capsule until T-9 hours. Two hours
redundant Inertial Measurement Units (IMUs), GPS before launch the vehicle is erected to vertical.
receivers and Star Trackers. Relative navigation with ISS is
being performed using a combination of Relative-GPS and During launch the Dragon spacecraft is typically injected
LIDARs mounted on Dragon. into an elliptical phasing orbit with an apogee at least 10 km
lower than the current ISS altitude. Once the on-orbit and
The shape of the Dragon capsule allows for a lifting reentry ground elements (at both SpaceX and NASA) are ready to
profile with peak quasi-static accelerations around 3.4 g’s. support joint operations, Dragon is given approval to
Two drogue and three main parachutes ensure a safe and approach ISS and begins Proximity Operations, eventually
controlled landing. The entire Entry, Descent and Landing, parking in the predefined “Berthing Box” about 10 m (33 ft)
and Recovery system is at least two-fault tolerant, and is below ISS. The SSRMS then grapples Dragon and
designed for safe passive return even without any guidance maneuvers it into the berthing port (nominally the nadir port
functionality (albeit with higher g-forces). The primary of the Harmony module). Once berthed, the hatches are
heatshield is a PICA-like material, as used on Mars Science opened and the ISS crew unloads pressurized cargo and
Laboratory and Orion. SpaceX is fabricating and qualifying reloads Dragon with down-cargo and/or pressurized trash
this material in-house. for disposal. The SSRMS is used to detach unpressurized
cargo from the trunk and reattach any unpressurized items
COTS for disposal.

Status—SpaceX started work on COTS on September 1, Once cargo and trash transfer is complete, the hatches are
2006, and to-date has completed all 12 scheduled resealed and the SSRMS is used to unberth Dragon and
milestones (of 22 total) on-time. The COTS award is a pay move it to the departure position. Dragon then departs the
by performance award, thus a milestone must be completed vicinity of ISS and begins phasing for return to earth.
to receive the associated payment. These milestones Dragon uses its thrusters to perform a de-orbit burn while
include System Requirement Reviews (SRRs) and still attached to the trunk, but then jettisons it, performs a
Preliminary Design Reviews (PDRs) for each of the three Collision Avoidance Maneuver (CAM) and reorients itself
demonstration missions, plus the Critical Design Review for reentry. The trunk reenters and burns up over the
(CDR) for the first demo mission. Other milestones Pacific Ocean while Dragon, having thermal protection and
completed include the Program Management Review, Initial greater lift than the trunk, lands further downrange under
Hot-Fire of the Draco hypergolic thruster, the 15 second parachutes just off the coast of California. A recovery ship
nine-engine test firing and two Financing Rounds. The next is used to recover Dragon and return it to SpaceX
major milestone is CDR covering both the second and third headquarters for unloading and refurbishment. A typical
demo missions together, which is on-track for completion in cargo mission duration is approximately 2-4 weeks.
December 2008.
Demonstration Missions—Three demonstration missions are
The complete Dragon qualification structure will is planned as part of the SpaceX COTS cargo capability
currently in testing at SpaceX’s Texas Test Facility. Other development. The first mission, known as Demo C1, is
critical qualification articles, such as RIO modules, scheduled to occur in June 2009. This inaugural mission for
batteries, the nose cone and thrusters, are also in testing. Dragon is a very basic “up and back” flight of the
Qualification testing on many items for the first Demo C1 spacecraft. It tests fundamental functionality including
missions is already underway at SpaceX. basic control and maneuvers in orbit. Dragon will be de-
orbited after approximately four hours in orbit and
Concept of Operations—The Dragon spacecraft and the recovered.
Falcon 9 booster will be manufactured at SpaceX
headquarters in California and then shipped to the launch Demo C2, scheduled for November 2009, is a far more
pad at Cape Canaveral, Florida. Cargo manifested for a sophisticated mission nominally lasting approximately five
given missions will be received from NASA and staged in a days. During this time Dragon will approach to about 10
dedicated holding building on SLC-40. Then, in the km below ISS and verify functionality of the radio crosslink
integration facilities currently under construction on SLC- that is required to provide spacecraft telemetry to the ISS
40, the cargo will be loaded into the capsule and the trunk. crew during Proximity Operations and also basic remote
These two sections are then integrated together and mated commandability.
to the launch vehicle horizontally.
The final Demo C3 mission will actually approach and berth
Approximately four days prior to launch, the complete with ISS. Hatches will be opened and cargo transfer will be
integrated vehicle stack is rolled out of the integration demonstrated. After return to earth and recovery, the
hanger to the launch pad and attached to the launch mount. SpaceX COTS system will have been certified and proven
Late-load cargo can be accommodated into the trunk until operational, opening the way for commercial cargo resupply
services.

12
ISS Cargo Accommodations—A typical ISS cargo servicing ISS cargo service missions for NASA. These Dragon
mission will require Dragon to accommodate a manifest missions have been dubbed “DragonLab™” in the tradition
consisting of cargo in a variety of different standard sizes of SkyLab and SpaceLab before it. The first such mission is
and packages. A module rack system allows these packages scheduled for launch in 2010 with at least one flight per
to be stowed according to package type, late-load/early year thereafter.
access and on-orbit access requirements. Power and data
services are provided to cargo items in some locations. DragonLab™ represents a new, emergent capability. Flying
Figure 21 shows Dragon fully loaded with a typical payloads on the shuttle is the closest analogy, but the
complement of pressurized cargo. significant safety requirements inherent to a crewed vehicle
make this path unnecessarily onerous for payloads and
experiments that do not require crew interaction.
Single
-Single CTBCTB Furthermore the 24 month typical timeline for shuttle
-MLEMLEsized locker
sized locker
payloads preclude many classes of experiments, especially
-TripleCTB/CWC for commercial experimenters who frequently require
Triple CTB / CWC
greater flexibility and faster turn-arounds. DragonLab™
-M01
M01
offers the opportunity to get in-space results, acquire flight
-M02 heritage and raise Technology Readiness Levels (TRLs)
M02
much faster and possibly for lower cost than the usual
-M03
M03 ground-test approaches.
-RTA
RTA
For any experiment or payload that does not require crew
-DMLE
DMLEfreezer
freezer interaction, the prospect of being able to fly in space
(GLACIER)
(GLACIER) 8/28
without building a spacecraft bus and without interacting
with any government space agency is extremely appealing.
Figure 21 - Typical Load of Pressurized ISS Cargo The costs and turn-around times for actually flying
experiments are significantly reduced over any comparable
Unpressurized cargo is typically mounted to the cargo avenue, making this ideal for payload with highly
carrier in the trunk using FRAMs so it can be unloaded on- responsive requirements. A nominal payload integration
orbit. Figure 22 shows four large ORUs mounted to the timeline of only five months is anticipated for most
carrier and also unloading by the Special Purpose Dexterous payloads. Furthermore, the Payload Safety requirements for
Manipulator (SPDM) on the SSRMS. DragonLab™ are significantly reduced due to Dragon being
un-crewed (as opposed to other opportunities, such as
DragonLab™ Shuttle), and the approval process is dramatically simpler
and faster. Mission durations from several weeks to over a
Numerous parties have expressed an interest in flying year are anticipated, depending on customer requirements.
payloads on Dragon without any particular need to visit
ISS. Consequently, SpaceX is currently manifesting fully Payloads on these missions can be hosted in any of three
commercial Dragon missions quite apart from any possible sections as follows.

Figure 22 - Dragon Trunk Cargo accommodations and unloading

13
Pressure Vessel—Payloads mounted inside the pressurized pressure vessel. Thermal control can also be provided via
section are completely recoverable and benefit from a shirt- Multilayer Insulation (MLI) and, if necessary, actively
sleeve laboratory-type thermal and pressure environment. cooled cold plates. Figure 23 shows trunk dimensions and
Convection cooling can be used for electronic modules usable volume.
since air pressure and temperature is maintained within
reasonable limits. Cold plates can also be provided if As with the Pressure Vessel, the trunk could accommodate
necessary for greater heat loads or tighter thermal the entire 6000 kg (13,000 lbm) of payload mass capacity,
requirements. A Shuttle Middeck Locker configuration is but in practice most payloads will be volume limited. Note
the simplest mechanical interface, though any standard that the trunk is jettisoned just prior to re-entry and is not
NASA cargo package is easily accommodated. Custom recoverable.
mechanical mounting configurations can also be arranged.
There is a strong preference for soft packaging (like Crew Sensor Bay—There is also a small recoverable
Transfer Bags) wherever possible since this simplifies unpressurized volume available for payloads on these non-
dynamic interactions, but SpaceX routinely performs ISS missions. The Sensor Bay is part of the Service
Coupled Load Analyses for hard-mounted payloads so these Section, the unpressurized annulus around the base of the
are not an obstacle. capsule that also houses the propulsion and recovery
systems. On ISS missions, this Sensor Bay is filled with
Electrical power (28 V DC) can be provided to payloads if LIDAR equipment required for relative navigation in
needed, with 120 V DC also offered as a non-standard proximity with ISS and hosts the Grapple Fixture required
service. Up to 1000 W continuous (2000 W peak) power is for berthing with ISS. For free-flying missions these
available for all payloads combined, though allocations for LIDARs and Grapple Fixture are not required thereby
individual payloads over the course of a mission will be freeing up this 0.1 m3 (4 ft3) volume. The Sensor Bay hatch
negotiated as part of a launch contract. Payload data is opened after the spacecraft is deployed into orbit and
services including RS-422 serial connections and Ethernet closed again prior to reentry. Hatch dimensions are shown
ports will also be available. Payload telemetry outputs of in Figure 23.
up to 400 kbps (across all payloads) will be available, with
data being either down-linked to the ground during ground
passes, or stored locally on Dragon for download after
landing. Similarly, uplink connectivity can be provided (up
to 8 kbps across all payloads) for basic command and
control of payloads. Note neither the uplink nor the
downlink will necessarily be real-time or continuous.

Nominal cargo integration occurs at L-14 days, though late-


load can be accommodated until T-9 hours. Nominal return
of payloads to customers is at End-of-Mission EOM+7
days, though again, non-standard arrangements can be
accommodated with return as early as EOM+2 hours.
Hatch and vessel dimensions are shown in Figure 23.
Actual pressurized volume is approximately 15 m3 (530 ft3),
though a usable volume of 7-10 m3 (247-353 ft3) is more
realistic. Although the pressurized section can
accommodate up to the full 6000 kg (13,000 lbm) capacity,
in practice most manifests will be volume-limited.

Trunk—The trunk is ideal for hosting unpressurized


payloads and experiments, including those that require large
apertures (up to 3.5 m (11.5’) diameter) or exposure to the
space environment. Furthermore, spacecraft of significant
size and mass can be deployed into orbit from this location.
There is no standard mechanical mounting configuration in
this section, though the cargo carrier uses the same bolt
pattern as the Shuttle cargo carriers. The standard payload
power supplied in the trunk is 120 V DC, though 28 V DC
can also be provided. Payload data services similar to those
in the Pressure Vessel are also provided. An electrical
umbilical and feed-throughs provide connectivity between
trunk payloads and supporting electronics inside the

14
Figure 23 – Dimensions of Dragon Payload Sections DragonLab™ in particular represents an Emergent
Capability unlike anything currently available. SpaceX is
The Sensor Bay is an ideal location for small sensors, actively soliciting expressions of interest from prospective
apertures, collectors and witness plates that require users and working to establish manifests for missions
exposure to space, but also need to be recovered after the starting in 2010.
mission. Electrical feed-throughs allow connectivity
between sensors hosted in the Sensor Bay and supporting Video tours of SpaceX’s California, Florida and Texas
electronics hosted inside the Pressure Vessel. facilities are available online.

Applications—Potential uses for this new DragonLab™


payload capability include:

• Instrument & sensor testing – raise TRLs and gain


Flight Heritage
• Spacecraft deployment from the trunk
• Science observations in support of:
o Earth science, geophysics and aeronomy
o Astronomy, astrophysics and relativity
• Radiation effects research
• Materials and space environments research and
observations
• Microgravity research
• Life sciences research
• Biotech and pharmaceutical research
There has been a groundswell of interest from researchers in
the above communities, many of whom have seen
significant cuts in both funding and flight opportunities in
recent years. Other interested parties include researchers
from the sounding rocket community, and those with shuttle
and ISS experiments in the queue but with little chance of
being manifested on the few remaining flights.

4. CONCLUSION
In six short years, SpaceX has made tremendous progress.
With the pathfinder Falcon 1 launch vehicle, which
successfully reached orbit and became the first privately-
developed, liquid-fueled rocket to reach Earth orbit, critical
systems of the larger Falcon 9 vehicle were proven. With a
robust manifest in 2009, SpaceX is rapidly marking towards
completing development and launching the Falcon 9 launch
vehicle and Dragon spacecraft. Additionally, with at least
three flights in 2009, SpaceX will continue to retire system
risk on the Falcon 1 vehicle.

By changing the price points of launch by a factor of five,


increasing reliability and flight rates, and introducing new
capabilities such as fully commercial DragonLab™
missions for payloads, SpaceX stands on the threshold of a
paradigm shift in the way space is accessed, used and
experienced by people everywhere.

15

You might also like