Russian RD-180 rocket engines were a bone of contention between the two US companies United Launch Alliance (ULA) and rival Orbital Sciences. The first does not allow the second to purchase engines for its Antares missiles.
Clash of the Titans
The fault was the participation of Orbital Sciences in government tender procurement. ULA illegally prevents competitors from purchasing RD-180 engines from two companies. This is the contractor of RD Amross - SPNPO Energomash - and the American intermediary Pratt & Whitney Rocketdyne. The first produces the necessary RD-180 liquid rocket engine. Another supplies components to the United States.
The only RD-180 liquid engine is optimally suited for tenders announced by the US government. According to experts, the characteristics of these components are ideal for heavy rocket launchers and the needs of NASA.
What is the RD-180 rocket engine
RD-180 is a two-chamber derivative of the four-chamber RD-170 used at the Zenith. The RD-180 closed-circuit liquid-propellant rocket engines with afterburning have incorporated the high performance, convenience, and reusability of the RD-170 in dimensions to meet the requirements of engines for the Atlas V Evolved Expendable Launch Vehicle.
RD-180 is a hydraulic motor for actuating a control valve and a deviation draft vector in a gimbal, with pneumatics for actuating a valve and a purge system: the thrust frame for load distribution is self-sufficient as part of the engine. The motor at start uses LOX lead, with afterburning of the generator gas and LOX rich in a gas turbine drive. Thus, it established a 10 percent increase in productivity compared with the operational acceleration of US engines and subject to a clean, reusable operation.
Only in the main assembly did the turbo pump and booster pump require development to a scale of RD-120 and RD-170. All other components were taken directly from RD-170.
RD-180 was developed in 42 months for a small fraction of the cost of a typical design of a new engine for the United States. The motor runs on an intermediate Atlas III and standard Atlas V rocket launcher
RD-180 is equipped with two pairs of combustion chambers and nozzles. The engine was developed and manufactured by the Russian scientific and production association Energomash. Kerosene is used as fuel; liquid oxygen is an oxidizing agent. The cost of the RD-180 rocket engine for 2010 was $ 9 million.
Design description
- LOX / Kerosene rocket fuel.
- Two persistent chambers (cardan +8 degrees).
- One oxygen-rich block in front of the burner.
- TNA high pressure assembly.
- Two-stage fuel pump.
- Single stage oxygen pump.
- Single turbine.
- Self-igniting ignition.
- Autonomous hydraulic systems (valves, TVC) powered by kerosene from the fuel pump.
- Health monitoring and life forecasting system.
- Automated flight preparation (after installation on a vehicle, all operations are automated by launch).
- Minimization of the interface from the launch pad and vehicles (pneumatic and hydraulic systems, autonomous, electric integrated panels, thrust frame to simplify the mechanical interface).
- Environmentally friendly operations with an enriched oxidizing agent that starts the ignition of a preliminary burner, as well as starting an oxidizing agent and shutdown modes that eliminate coking and non-burned potentially contaminated kerosene.
- 50-100% continuous throttling subject to potential real-time verification of the alignment of the trajectory and the engine on the site before starting the fixation.
- 80% RD-170 parts.
- Pressure chamber: 256.6 bar.
- Area coefficient: 36.4.
- Dead weight ratio: 77.26.
- The oxidizer-fuel ratio: 2.72.
Engine RD-180. Specifications
- Specific Gravity: 5480 kg (12080 lbs).
- Height: 3.6 m (11.67 ft).
- Diameter: 3.2 m (10.33 ft).
- Specific Impulse: 337.8 s.
- Specific momentum at sea level: 311.3 s.
- Recording time: 270 s.
- First launch: 2000
History
In November 1996, the Energomash production association conducted the first test of the RD-180. The engine was recognized as the winner in tenders for installation in the Atlas launch vehicle of the American Lockheed Martin Corporation. This was necessary for the withdrawal of promising manned ships. Since then, RD-180 engines have become the most popular.
The engine is reusable. Thoughtful management provided NPO Energomash with almost legendary reliable deals with the United States. In December 2012, a contract was issued that provides the company with a guarantee for the production of engines until 2019. All production is concentrated in Russia.
The creation of the replacement of the RD-180 in the United States
Ukrainian events entailed sanctions that limited the ability to use Russian rocket engines for the United States. RD-180 must be replaced by an analogue of American production. In December 2014, the Chamber adopted the amendment. She banned the use of Russian RD-180. The engine will continue to be purchased under an existing supply contract until 2019 between Energomash and ULA.
Despite continued cooperation and supplies of RD-180 under existing contracts, the US Secretary of Defense ordered the termination of cooperation with Russia and the transition to American components. America is obliged to get rid of Russian dependence in the military-political spheres.
To this, Frank Kendall (Secretary of Defense for Procurement) replied that the Pentagon has nothing to replace the Russian RD-180 engines with. As an alternative to the current situation, America has announced a tender for the production of its own engines of similar characteristics in its territory.
Russian Deputy Prime Minister Dmitry Rogozin said he was ready to stop the supply of RD-180 and K-33 rocket engines to America.
How much does the RD-180 rocket engine cost for the USA
Talk about pricing. SpaceNews reported that it is necessary to replace the RD-180 engine. The United States will have a whim of $ 1.5 billion. A rather big amount.
How much is the RD-180 engine? The entire project for the implementation of the prototype will last at least six years. According to experts, the United States does not have the opportunity to completely abandon the use of RD-180 engines. It is impossible to solve the arisen problem in a short time, since the motors will be ready only in 2022.
Despite the assurances of the US Air Force that the RD-180 are in stock in the required quantity, a shortage is still present. Therefore, many launches will need to be postponed. Costs in this area may increase to $ 5 billion.
While the United States is competing and applying sanctions, China is already taking the line for the production of the RD-180.
Perspective
The Pentagon has allocated at least $ 162 million to Aerojet Rocketdyne and the United Launch Alliance to work on the development of the AR1 and BE-4 rocket engines, candidates to replace the Russian-made engine on which the Atlas V rocket is currently flying.
The U.S. Air Force is completing its initial investment in new rocket engines as the military seeks to move away from its dependence on the Russian RD-180 engine used on Atlas V, which launches most U.S. government satellites for secure communications, navigation, and intelligence gathering systems.
The Air Force enters into a public-private partnership with Aerojet Rocketdyne and ULA, allocating corporate funds to co-finance engine development.
The President and CEO of ULA continue to meet to achieve the goal of providing the United States with the most reliable launch systems at the most affordable price, while developing a new engine that will introduce completely new opportunities for using outer space.
The agreement with Aerojet Rocketdyne covers the development and testing of the AR1 rocket engine. This is a power unit that burns a kerosene mixture and liquid oxygen. These are the same propellant components as in the RD-180 engine for Atlas V.
Aerojet Rocketdyne seeks to create an engine that has received a certificate of airworthiness by 2019, but the first launch is expected only in 2020.
The Air Force allocates at least $ 115.3 million for the AR1 development program, while Aerojet Rocketdyne and ULA jointly invest $ 57.7 million, the Aerojet Rocketdyne said in a statement.
Prior to testing, the government’s decision to continue supporting the AR1 engine program is at a maximum of $ 804 million — from $ 536 million from the Air Force and $ 236 million from Aerojet Rocketdyne and ULA.
“AR1 will bring the United States back to first position in the production of kerosene nuclear rocket engines,” Drake said in a press release. “We are implementing the latest achievements in the field of modern production, while, speculating on our rich knowledge of the production of a new generation of rocket engines, everything is done to introduce motors that will put an end to our dependence on a foreign supplier to launch our country's national security assets.”
The AR1 engine will include 3D-printed parts and will work with enriched oxygen with afterburning of the generator gas. This is a more efficient engine cycle than currently on other liquid hydrocarbons in US rocket engines.
The BE-4 engine is the focus of the Air Force. For its implementation, monetary injections are allocated. The Air Force is committed to paying at least $ 46.6 million to the United Launch Alliance for the next generation of Vulcan missiles. ULA also agreed to add $ 40.8 million in government award terms.
The lion's share of the initial funding - $ 45.8 million - will go to the development of the BE-4 engine project, which will generate 550,000 pounds of thrust and consume a cryogenic combination of liquefied natural gas and liquid oxygen.
Two BE-4 engines will boost the first stage of the Vulcan rocket. Officials say the BE-4 is fully funded by the company through the United Launch Alliance. Air Force funding will drive the company's progress in integrating the BE-4 engine with the Vulcan launcher.
Aerojet Rocketdyne touts the AR1 as the easiest replacement for the RD-180 due to its powder mix and size. Two AR1 engines are needed to meet the performance of one twin nozzle RD-180 engine on Atlas V.
ULA executives say the BE-4 engine from Blue Origin, an entrepreneurial space firm founded by Amazon.com, will be ready faster and will ultimately be easier to recover for reuse.
While the RD-180 engine had the advantage of more than 60 successful launches, it was time for US investment in the domestic production of similar engines.
The BE-4 is due to complete its certification in 2017, and the ULA is aiming for the first flight of a Vulcan rocket before the end of 2019.
The Air Force also finances the construction of outer space for the habitation of astronauts in deep space exploration and satellite services.
ULA continues to work with both Blue Origin and Aerojet Rocketdyne. It accompanies two options for the next generation of American engines, which is why the company is teaming up with two of the world's leading space achievements firms.
ULA holds the Aerojet Rocketdyne AR1 engine as a backup option. The final selection is expected at the end of 2016.
The Air Force’s financial obligations to Aerojet Rocketdyne and ULA are open after February 29, 2016 after similar agreements with SpaceX and Orbital ATK came.
The new Orbital ATK solid fuel rocket boosters project for ULA's Vulcan rocket and for its own launcher will also receive Orbital ATK funding.
Shadow in space from terrestrial "clouds"
Russian RD-180 engines in the United States have no alternative. Aerojet Rocketdyne vice president Jim Meyzer believes that the United States does not pay enough attention to the development of its own oxygen-kerosene prototypes.
He said that America is definitely lagging behind the Russians and Chinese in creating such propulsion systems. He also mentioned that the US has already developed an oxygen-kerosene engine, which is in operation by Merlin 1D. It is produced by SpaceX. Only here, in terms of its characteristics, it really does not reach the RD-180.
Of course, this is complete nonsense, because earthly clouds can not cast any shadow into space. But in the political sense - alas, they are rejected.
USA: industrialists calm, politicians alarmed
A senior U.S. Air Force official said he would stop launching national security satellites aboard the Atlas V of the United Launch Alliance rocket if the Treasury Department believes that importing a Russian engine does not violate US sanctions.
Earlier, Senator John McCain asked the Air Force to prove that the recent reorganization of its rocket and space industry in Russia does not put the purchase of RD-180 engines in violation of U.S. sanctions imposed against Russian officials in 2014.
US government agencies, led by the Treasury Department, are taking a fresh look at the supply of the RD-180. And they are ready not to stick to sanctions. Grounding Atlas V will create a more serious obstacle to the Pentagon than the conduct of hostilities.
McCain held a hearing at the military spaceport, where he called on the Air Force to obtain a fresh legal opinion that the import of RD-18O violates US sanctions imposed on Russian officials following the annexation of the Crimean peninsula of Ukraine.
McCain singled out two senior Russian officials: Russian Deputy Prime Minister Dmitry Rogozin and Sergey Chemezov, Advisor to Russian President Vladimir Putin. Until recently, they were observers in the space sector. Although they do not have the financial benefit of selling the RD-180, they were sanctioned.
On December 28, by order of Putin, the space sector of Russia will be reorganized. This perestroika makes adjustments to the Russian space industry and the Roscosmos space agency as part of the new state corporation, also called Roscosmos.
McCain noted that this organization is currently led by Rogozin; Chemezov also has a bearing on this. Rogozin and Chemezov were among the first Russian officials to receive sanctions during the Ukrainian crisis. Neither one nor the other can enter the United States. The assets they own have been frozen.