The Vulcan Rocket Has Been Shipped To The Launch Pad
For almost a decade now United Launch Alliance has been working to develop, manufacture, and test Vulcan. This next generation launch vehicle has a lot riding on its success as the company works to retire its other rockets and replace them with Vulcan. In the last couple of months, progress has been ramping up as the first launch of this rocket closes in.
Just yesterday ULA CEO Tory Bruno gave a bunch of new updates regarding this first test article and its progress related to launch. As we speak, both the first and second stages of Vulcan are on their way to ULA’s launch pad at the Cape. Once here, the rocket will complete some final testing, have its payloads integrated, and attempt its maiden launch in the first quarter of this year.
While this recent shipment confirmation is a big deal, it also confirms that ULA is a bit behind schedule as of now. Months ago in October, the plan was to ship the rocket in November and complete its testing by December, this couple of month delay could push the launch back a few months. Here I will go more in-depth into yesterday’s shipment, the updated schedule of Vulcan, what to expect in the future, and more.
Vulcan Has Shipped
Prior to yesterday, one of the last updates we got on Vulcan and its first launch was in early November. Between then and now, we were in the dark regarding Vulcan’s expected shipment and pre launch testing. Thankfully, yesterday Tory Bruno provided a host of updates on this process. Starting on January 9th, he tweeted saying, “Hmm… Is that a #VulcanRocket getting packaged for its shipment on #ULARocketShip to Florida?” This included an image of teams preparing the first stage. The next day on the 10th, he tweeted again mentioning, “Last one. #VulcanRocket Booster has boarded the ULA Cruise Line’s URS #RocketShip for his trip to the Cape. I’ll admit that our buffet line is not quite 5 star, but the staterooms are first class all the way (if you’re a rocket, that is)”
Based on these updates, both stages are officially on their way to the launch site. Traveling from Decatur, along the Tennessee River to the open ocean, ULA points out that it takes approximately 8 days to transport hardware to Cape Canaveral Space Force Station. This means in just over a week from now we can expect the first and second stages to be delivered. Not only was the first stage prepped for transport yesterday but the upper stage was as well.
With this timeframe in mind, we can determine how behind schedule the launch is at this point. Months ago in October, ULA estimated that the rocket would be shipped to the Cape in November and finish testing in December. Based on current updates, it seems like they are two months behind the ideal timeframe for this launch. Because Vulcan is on its way now and will be delivered later this month, we can expect pre launch testing to be completed in February. Specifically, once at the Cape, Vulcan will undergo a final series of tests to verify its readiness for flight, consisting of multiple tanking tests and a wet dress rehearsal, culminating in flight readiness firing, which will be the final step prior to launch. Following the successful final testing, Astrobotic and the other payloads will be installed on the launch vehicle. Astrobotic is responsible for the primary payload which is the Perigrine Lunar Lander. This payload and company were the original reason for multiple delays to this launch. Most recently they requested it be delayed from late 2022 to early 2023. However, recent updates from the company suggest that they are ahead of schedule and should be capable of a launch within this first quarter.
As for ULA and Vulcan, if they work fast and all the initial test results are perfect, we can expect a launch in March. This being said, it’s important to point out that this will be the first ever launch of this specific rocket, which often comes with various issues. Different major components like the BE-4 engines for example have never actually launched. If ULA runs into some complications it will no doubt push the maiden flight back multiple months. Something we will have to keep an eye on in the coming weeks.
Vulcan’s Maiden Flight
Now that we know more about Vulcan’s recent shipment and some of its delays, we can take a closer look at the rocket itself and what to expect on its upcoming launch day. Vulcan Centaur is a two-stage-to-orbit, heavy-lift launch vehicle with a payload capacity to LEO ranging from 10,800 kilograms to 27,200 kilograms, depending on the number of solid rocket boosters. One of the most unique and long awaited components is the two BE-4 engines on the first stage providing the majority of thrust. Using an oxygen-rich staged combustion cycle, BE-4 is capable of producing 2,400 kN (550,000 lbf) thrust with deep throttle capability.
Months ago we saw the delivery of these engines and only days after they were installed on Vulcan. Blue Origin chose LNG because it is highly efficient, low cost, and widely available. Unlike kerosene, LNG can be used to self-pressurize its tank. Known as autogenous repressurization, this eliminates the need for costly and complex systems that draw on Earth’s helium reserves. LNG also possesses clean combustion characteristics even at low throttle, simplifying engine reuse compared to kerosene fuels. BE-4 was designed from the beginning to be a medium-performing version of a high-performance architecture. It’s a conscious design choice made to lower development risk while attempting to meet performance, schedule, and reusability requirements. Even though Vulcan is an expendable rocket and these engines will be lost during initial flights, ULA has a plan for reuse.
The Sensible Modular Autonomous Return Technology (SMART) reuse concept was also announced during the initial April 2015 unveiling of Vulcan. The booster engines, avionics, and thrust structure would be detached as a module from the propellant tanks after booster engine cutoff. The module would descend through the atmosphere behind a heat shield. Finally, it would slow its descent and float in the ocean on an inflatable aeroshell. ULA estimated this technology would reduce the cost of the first stage propulsion by 90%, and 65% of the total first-stage cost. However, for the first launch and launches in the near future, this will not be attempted.
In addition to the two BE-4 engines on the first stage, Vulcan integrates up to six Northrop Grumman Graphite Epoxy Motor (GEM) 63XL Solid Rocket Boosters (SRBs). They are constructed out of a graphite-epoxy composite with the throttle profile designed into the propellant grain. GEM solids supported the Delta II and Delta IV rockets, and the GEM 63 variant will fly on ULA’s Atlas V rocket prior to the first Vulcan launch. Moving up, Vulcan will rely on two RL10C engines to power its second stage. Logging an impressive record of nearly 400 successful flights and nearly 700 firings in space, RL10 engines, manufactured by Aerojet Rocketdyne, harness the power of high-energy liquid hydrogen. The RL10 boasts a precision control system and restart capability to accurately place payloads into orbit.
This first commercial mission is part of ULA’s requirement to meet the U.S. Space Force certification of its new launch vehicle. Mark Peller, vice president of Major Development, stated “We are committed to ensuring we fly the first certification mission and stay on schedule to achieve U.S. Space Force certification of Vulcan in advance of our first national security space mission in 4th quarter 2023.” Tory Bruno also commented, “We could not be more excited to be this close to seeing Vulcan lift off on its inaugural flight. Vulcan’s high energy design coupled with innovative technology provides one scalable system for all missions and will transform the future of space launch. This has been an incredible journey to get to this point and I am so proud of the development team. We look forward to the first flight as Vulcan offers all customers higher performance and greater affordability while continuing to deliver our unmatched reliability.”
Leveraging a legacy of 100 percent mission success launching more than 150 missions to explore, protect and enhance our world, ULA is trying to withhold the reputation as one of the nation’s most experienced and reliable launch service providers with world-leading reliability, schedule confidence, and mission optimization. In order to keep up this reputation, they will need to work fast and ensure everything is perfect for this maiden flight. In the future, quite a few important launches are already scheduled to utilize Vulcan. If this initial launch gets pushed back or delayed further, it could start impacting other missions as well. For example, the second launch of Vulcan is scheduled for the third quarter of this year with the very important payload of Dream Chaser Tenacity. Not to mention, Blue Origin is in the process of ramping up production of BE-4 in order to keep up with the demand. With Vulcan getting ready to launch somewhat frequently, ULA will need a stream of BE-4 engines over time.
Conclusion
United Launch Alliance is closer than ever to the first launch of the Vulcan Centaur. Just yesterday we learned that both the first and second stages are on their way to the launch site in the Cape. In just over a week from now, we can expect them to arrive and begin preparing for launch. This includes multiple tests and the integration of Astrobotic’s lunar lander, along with a few other payloads. We will have to wait and see how it progresses and the impact it has on the space industry.