EXPORT-CONTROLLED/FOR OFFICIAL USE ONLY

ATK Advances In Solid

Propulsion

Presented to: SPST

POC: David McGrath

Email: david.mcgrath@atk.com

Phone: (410) 392 - 1716 October 9, 2014

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Outline

• Orion Launch Abort Attitude Control Motor and Abort Motor

• LDSD

• STAR 48GXV

• SLS

• Stratolauncher

• Summary

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ATK Has Developed the First Human Rated Solid Control System – The Orion LAS ACM

Accomplishments

• Program start to first full scale test in

29 months, flight in 34 months

• Human-rated, single fault tolerant valve

control system and software

• Eight, fully proportional valves using

new high temperature materials

• Greater than 7,000 lbf omni-axis thrust

capability with 100 msec response time

Successful Component Development Testing

Successful Full Scale Development Testing

Successful Flight Testing – PA-1

DM-1

DM-2

Software

Controller

Igniter

Battery

HT-8A

HT-6 Actuators

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ACM Design Overview

Valve Assemblies

• Eight proportionally controlled pintle

valves, redundant motors in actuators

Lithium-Ion Battery Assembly

• Two, redundant command/control and valve power

batteries

Controller Assembly

• Single-fault-tolerant controller

circuits with arbiter

Gas Generator Assembly

• Valve compatible propellant

• Steel case and closure

• Aluminum skirts and controller/battery stand

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DM-1 and DM-2 Test Parameters

DM-1 Key Parameters

• Conditioning Temperature: 60°F

• Valves: 8

• Burn time: ~30 sec

• Maximum thrust: ~7000 lbf

DM-2 Key Parameters

• Conditioning Temperature: 40°F

• Valves: 8

• Burn time: ~30 sec

• Maximum thrust: ~7000 lbf

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6Al-4V Titanium Housing and Nozzle Ring

C/C-SiC Pintle, Guide, and Throat

Carbon/Phenolic Exit Cone Redundant Actuator

Proportional Valve Description

Valve Thrust:Weight ~250:1

PA-1 Valve Assembly Shown

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DM-2 Test Video

Top View

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DM-2 Top View Video

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PA-1 Flight Test – May 6, 2010

ACM Ignition

Pitchover

Controlled Ascent

Controlled Re-orient

LAS Jettison

The ACM performed flawlessly

during the PA-1 flight – meeting all

objectives

Ref: NASA Orion

website information

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High Thrust Valve Tests – HT-9 and HT-10

• Test single valve at full open

conditions

• Determine valve material

response to full loading

conditions during hot gas

testing

• Measure pressure and thrust

• HT-9 successfully tested on

Feb. 12, 2014

• HT-10 test is intended to be a

margin type test with a goal of

achieving 1.4 x MEOP pressure

conditions at full open

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Path Forward and Summary

• The qualification program is getting underway

– Three motors are planned for the qualification program

– CDR is expected to occur in 2015

– Flight deliveries to begin in 2018

• The ACM is the first single-fault tolerant proportionally controlled

solid propellant system to be developed and flown

• The ACM incorporates C/C –SiC materials for the pintle, pintle guide

and throat

• ATK Missile Defense and Controls is honored to be part of the next

steps in human spaceflight away from planet Earth on the Orion

project

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Orion LAS Abort Motor

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Abort Motor Hardware Manufacturing

Abort Motor 1800

Gallon Mix

Abort Motor Igniter

Tooling & Winding Abort Motor

Manifold

Abort Motor Case

Tooling & Winding

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Abort Motor ST-1 Test Firing - ~500,000 lbf thrust

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Pad Abort 1 Abort Motor

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PA-1 LAV During Ascent and Post Mission. Recovered Igniter Slag

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EFT-1 Inert Abort Motor

EFT-1 Rework for Flight

• Manifold Replaced

• Case Line Loads Test

Completed

• Midcase Installed

• TPS Installed

• Raceway Installed

• Build Paperwork Review

• Verification for Flight

ATK Inert Pathfinder

Used in LAS Structural Test Article

Used in Orion

Ground Test Article

Refurbished and Certified

for EFT-1

EFT-1 Inert Abort Motor Reused Multiple Times in Support of Program Affordability

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AM Qualification Path Forward

High Thrust Turn-Flow Abort Motor w/ Head End Nozzles

– Fabrication of 3 Full-Scale (QM series) qualification Abort Motors and

static test firing under representative load conditions

– Test stand mods required to get accurate motor induced acoustics

– Fabrication of demonstration Abort Motors for LAS high altitude

operational flight tests (AA-2 High Altitude)

High Burn Rate Class Propellant

• Mix/Cast/Cure, Acceptance Testing (subscale motors and expanded lot-

to-lot variability mechanical testing. Firing in full scale tests.

High Mass Flow Pyrogen Igniter

• Fabrication of 2 qual Igniters and bench test firings

• Fabrication and test in full-scale Abort Motor test firings listed above

Direct Strike Lightning Protection (Integrated w/ TPS)

• Conducted preliminary TPS Aero and Plume heating and ablation tests

• Complete integrated Lightning and TPS process development trials

• Conduct coupon level and joint E3 qualification testing

• Integrated TPS/DSL design environmental characterization/qualification

testing

Structural Qualification

• Material allowables testing

• Pressurized and unpressurized structural case and manifold ultimate

loads testing

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Low Density Supersonic Decelerator (LDSD)

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LDSD - Issues for Large Payloads at Mars

• Very large payloads being

considered for manned flights

– Tens of thousand of kilograms

• Payload fairings of launchers

from Earth are fixed in size

– (5-10m for SLS)

• Inflatable systems being studied

• Low Density Supersonic

Decelerator (LDSD) program

being funded by JPL to perform

risk reduction testing to gather

data for future designs

• ATK Elkton under contract to

JPL for STAR motors for testing

– Also being considered for future

mission applications

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LDSD Mission

Rev: 0

20 Dec 12

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LDSD Pictures

• One successful flight

conducted to-date

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STAR 48GXV

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STAR 48GXV

• Development began as a risk

reduction for the Solar Probe

mission

– Vehicle change negates the need

for the motor

• High performance, graphite

epoxy case, TVC, carbon-carbon

exit cone

• Expected vacuum delivered Isp

of >308 lbf-sec/lbm

• First development motor

successfully fired in December

2013

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SLS Booster

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SLS Booster

• ATK is developing the 5 segment

booster for SLS

• Builds on Shuttle heritage

• Three development motors

successfully tested

• Program has passed CDR

• Qual motor 1 is being processed

for a test in 2015

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Stratolaunch

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Stratolaunch

• Stratolaunch Systems is owned

by Paul Allen

• The carrier aircraft is being built

by Scale Composites

• The launcher effort is being led

by Orbital

– Launcher has solid lower stages

and liquid upper stage

– ATK is supporting Orbital on the

solid stages

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Summary

• ATK is actively developing new propulsion systems for future

space mission applications

• Controllable solid propulsion offers capability for a variety of

control applications

• ATK has provided propulsion for every manned US space mission

and many spacecraft boost, retro, and landing applications