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Falcon I was a two stage, reusable, liquid oxygen and kerosene powered launch vehicle. A single engine powered the first stage. It was designed for cost-efficient and reliable transport of satellites to low Earth orbit. First launch of the Falcon I was scheduled for mid-2004 from Vandenberg, carrying a US Defense Department communications satellite. Development delays and problems with USAF clearances for launch from Vandenberg resulted in the first launch attempt being made in 2006 from a private facility at Omelek near Kwajalein atoll in the Pacific. The first stage primary structure was made of a space grade aluminium alloy in a patent pending, graduated monocoque, common bulkhead, flight pressure stabilized architecture developed by SpaceX. The design was a blend between a fully pressure stabilized design, such as Atlas II, and a heavier isogrid design, such as Delta II. As a result, SpaceX claimed to have captured the mass efficiency of pressure stabilization, but avoided the ground handling difficulties of a structure unable to support its own weight. A single SpaceX Merlin engine powered the Falcon I first stage. After engine start, Falcon would be held down until all vehicle systems were verified to be functioning normally before release for lift-off. Helium tank pressurization was provided by composite over-wrapped inconel tanks from Arde Corporation, the same model used in Boeing's Delta IV rocket. Stage separation occurred via dual initiated separation bolts and a pneumatic pusher system. All components were space qualified and had flown before on other launch vehicles. The first stage returned by parachute to a water landing, where it was picked up by ship in a procedure similar to that of the Space Shuttle solid rocket boosters. The parachute recovery system was built for SpaceX by Irvin Parachute Corporation, who also builds the Shuttle booster recovery system. The second stage tank structure was made of aluminium-lithium alloy. SpaceX found this to be the lowest total system mass in this application of any material examined, including liquid oxygen compatible super-alloys and composites. A single SpaceX Kestrel pressure-fed engine powered the Falcon I upper stage. For added reliability of restart, the engine had dual redundant torch igniters. Helium pressurization was again provided by composite over wrapped inconel tanks from Arde. The helium was also used in cold gas thrusters for attitude control and propellant settling when a restart was needed. Manufacturer: SpaceX. Launches: 2. Failures: 2. Success Rate: 0.00%. First Launch Date: 2006-03-24. Last Launch Date: 2007-03-21. Launch data is: continuing. LEO Payload: 670 kg (1,470 lb). to: 200 km Orbit. at: 28.00 degrees. Payload: 430 kg (940 lb). to a: 700 km sun synchronous orbital trajectory. Liftoff Thrust: 318.000 kN (71,489 lbf). Total Mass: 27,200 kg (59,900 lb). Core Diameter: 1.70 m (5.50 ft). Total Length: 21.30 m (69.80 ft). Span: 1.70 m (5.50 ft). Boost Propulsion: Lox/Kerosene. Boost engine: Merlin. Cruise Propulsion: Lox/Kerosene. Cruise engine: Kestrel. Cruise Thrust: 33.300 kN (7,486 lbf). Launch Price $: 6.000 million. in: 2004 price dollars. Cost comments: Initial offering price for contracts signed in 2004.
Falcon 5.
Falcon V was a two stage, reusable, liquid oxygen and kerosene powered launch vehicle. The maiden flight was targeted for mid-2005 as of early 2004. It used of the same engines, structural materials and concepts, and avionics and launch system as the Falcon I, differing in having five first-stage engines instead of 1 and a larger diameter. This meant that all the critical components would have a flight proven history even before first launch. By 2006 first launch of the Falcon I had been unsuccessful, and SpaceX had received a contract for the even larger Falcon 9 from NASA. It seemed the Falcon V would be leapfrogged and perhaps never fly... The five engine, single tank first stage configuration meant that the Falcon V was the first American launch vehicle since the Saturn V to offer true engine out reliability. Depending on the phase of flight, the first stage could lose as many as three engines and still complete its mission. The primary structure was made of a space grade aluminum alloy in a patent pending graduated monocoque, common bulkhead, flight pressure stabilized architecture developed by SpaceX. The design was a blend between a fully pressure stabilized design, such as Atlas II, and a heavier isogrid design, such as Delta II. SpaceX claimed to have captured the mass efficiency of pressure stabilization, but avoided the ground handling difficulties of a structure unable to support its own weight. After engine start, Falcon would be held down until all vehicle systems were verified to be functioning normally before release for liftoff. Helium tank pressurization was provided by composite over-wrapped inconel tanks from Arde Corporation, the same model used in Boeing's Delta IV rocket. Stage separation occured via dual initiated separation bolts and a pneumatic pusher system. All components were space qualified and have flown before on other launch vehicles. The first stage returned by parachute to a water landing, where it would be picked up by ship in a procedure similar to that of the Space Shuttle solid rocket boosters. The parachute recovery system was built for SpaceX by Irvin Parachute Corporation, who also built the Shuttle booster recovery system. After refurbishment, the stage would be reused. The second stage tank structure was made of aluminum-lithium alloy. SpaceX found this to be the lowest total system mass in this application of any material examined, including liquid oxygen compatible super-alloys and composites. A single SpaceX Kestrel pressure-fed engine powered the Falcon I upper stage. For added reliability of restart, the engine had dual redundant torch igniters. Helium pressurization was again provided by composite over wrapped inconel tanks from Arde. The helium was also used in cold gas thrusters for attitude control and propellant settling when a restart was needed. Provided that there was sufficient mission mass margin to accommodate increased gravity losses, the Falcon V upper stage can complete its mission even if only one engine is operative. In that case, helium cold gas thrusters would provide roll control. The original narrower-tank design was updated by 2006. The Falcon V was now simply a Falcon 9 with four of the engines pulled and a partial propellant load. LEO Payload: 4,200 kg (9,200 lb). to: 200 km Orbit. at: 28.00 degrees. Payload: 1,250 kg (2,750 lb). to a: geosynchronous transfer orbit, 9 deg inclination trajectory. Liftoff Thrust: 1,590.000 kN (357,440 lbf). Total Mass: 129,700 kg (285,900 lb). Core Diameter: 3.40 m (11.10 ft). Total Length: 29.00 m (95.00 ft). Span: 3.40 m (11.10 ft). Boost Propulsion: Lox/Kerosene. Boost engine: Merlin. Cruise Propulsion: Lox/Kerosene. Cruise engine: Kestrel. Cruise Thrust: 66.600 kN (14,972 lbf). Launch Price $: 12.000 million. in: 2004 price dollars. Cost comments: Initial offering price for contracts signed in 2004.
Version: Falcon 9.
In September 2006 SpaceX was named as one of two winners of the NASA Commercial Orbital Transportation Services competition. The SpaceX award was $278 million for three flight demonstrations of the Falcon 9 booster carrying the Dragon space capsule. These were to occur in 2009. Reliability of the Falcon 9 was assured by a hold-before-release system – the Falcon was held down and could not be released for flight until all propulsion and vehicle systems were confirmed to be operating normally. An automatic safe shut-down and unloading of propellant occurred if any off nominal conditions are detected. A Kevlar shield protects each engine from debris in the event of its neighbor failing. All Falcon designs had only two stages and only one stage separation event – the minimum practical. All stage separation bolts were all dual initiated, fully space qualified, and had a zero failure track record in prior launch vehicles. Guidance was by triple redundant flight computers and inertial navigation, with a GPS overlay for additional orbit insertion accuracy. The engines, structural materials and design principles, avionics and launch system were all to have been proven on earlier Falcon 1 flights before the first Falcon 9 was ever launched. The Falcon 9 first and second stage tank walls and domes were made from aluminum 2219, using all friction stir welding. The interstage was made of a carbon fiber honeycomb structure. The separation system consisted of pyrotechnic release bolts and pneumatic separation pushers. Although in-flight failures are very rarely explosive, a Kevlar shield protects each engine from debris in the event of its neighbor failing. LEO Payload: 8,000 kg (17,600 lb). to: 350 km Orbit. at: 52.00 degrees. Liftoff Thrust: 3,400.000 kN (764,300 lbf). Total Mass: 290,000 kg (630,000 lb). Core Diameter: 3.60 m (11.80 ft). Total Length: 53.00 m (173.00 ft). Span: 3.60 m (11.80 ft). Boost Propulsion: Lox/Kerosene. Boost engine: Merlin. Cruise Propulsion: Lox/Kerosene. Cruise engine: Kestrel. Cruise Thrust: 66.600 kN (14,972 lbf). Development Cost $: 378.000 million. in: 2008 average dollars. Launch Price $: 25.000 million. in: 2006 price dollars. Cost comments: Development cost includes both the Falcon 9 and the Dragon spacecraft, and three test flights. Falcon Chronology 2006 March 24 - Kwajalein OM. LV Model: Falcon I . Falcon 1 1 FAILURE: Fuel leak at T+25 seconds caused a fire in the first stage engine area. Falconsat-2 Mass: 20 kg (44 lb). Agency: USAFA. The satellite fell through the roof of SpaceX's machine shop on the atoll. 2007 March 21 - 01:10 GMT - Kwajalein OM. LV Model: Falcon I . Falcon 1 2 FAILURE: Liquid oxygen slosh in the second stage created an oscillation, putting the stage in an uncontrollable roll, starving the engine from propellant. DemoFlight 2 Agency: DARPA. An oscillation appeared in the upper stage control system 90 seconds into the burn. This instability grew and after 30 seconds induced a roll torque that exceeded the control capability of the second stage roll control thrusters. The propellants were centrifuged away from the outlets, causing flame-out of the Kestrel engine. LOX slosh was believed to be the primary contributor to this instability. Second stage slosh baffles would be included in future boosters to prevent reoccurence of the problem. Bibliography:
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