SpaceX reusable launch system development program: Difference between revisions

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=== Flight test vehicles ===
[[File:SpaceX Grasshopper rocket midflight.png|thumb|upright=1.4|Grasshopper rocket, in 2013, performing a 325 meter flight followed by a soft propulsive landing in an attempt to develop technologies for a reusable launch vehicle]]
 
SpaceX used a set of experimental technology-demonstrator, [[suborbital]] [[Reusable launch system|reusable launch vehicles]] (RLV) to begin [[flight testing]] their reusable booster technologies in 2012. Two versions of the prototype reusable test rockets were built—the {{convert|106|ft|adj=on}} tall ''Grasshopper'' (formerly designated as ''Grasshopper v1.0'') and the {{convert|160|ft|adj=on}} tall ''Falcon 9 Reusable Development Vehicle'', or ''F9R Dev1''—formerly known as ''Grasshopper v1.1''<ref name=nsf20140422/>—as well as a [[space capsule|capsule prototype]] for testing propulsive landings of the [[SpaceX Dragon 2|Dragon]] crew and cargo capsule for the Falcon 9—''DragonFly''.<ref name=nsf20140422/> Grasshopper was built in 2011–2012 for low-altitude, low-velocity hover testing that began in September 2012 and concluded in October 2013 after eight test flights.<ref name="faa20110922" /><ref name="satspot20110926" /><ref name=nsf20140422/> The second prototype vehicle design, F9R Dev1, was built on the much larger [[Falcon 9 v1.1]] booster stage which was used to further extend the low-altitude flight testing [[flight envelope|envelope]] on a vehicle that better matched the actual flight hardware. It made five test flights in 2014.<ref name=nsf20140422/><ref name="msnbc20110927">{{cite news |url=http://www.nbcnews.com/id/44692930/ |title=A rocket that lifts off—and lands—on launch pad |work=NBC News |last=Klotz |first=Irene |date=September 27, 2011 |access-date=November 23, 2011 |archive-date=December 3, 2013 |archive-url=https://web.archive.org/web/20131203023523/http://www.nbcnews.com/id/44692930/ |url-status=live }}</ref><ref name="nsw20121002" /> The low-altitude, low-speed flights of the test vehicle rockets and capsule were conducted at the [[SpaceX Rocket Development and Test Facility|SpaceX Rocket Test Facility]] in [[McGregor, Texas]]<ref name="faa20110922" /><ref name="satspot20110926" /><ref name=nsf20140422/>
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[[DragonFly (rocket)|DragonFly]] was a prototype [[test article (aerospace)|test article]] for a propulsively landed version of the [[SpaceX Dragon]] [[space capsule|capsule]], a [[suborbital spaceflight|suborbital]] [[reusable launch vehicle]] (RLV), intended for low-altitude [[flight test]]ing. {{asof|2014|05}} it was planned to undergo a test program in Texas at the McGregor Rocket Test Facility, during 2014–2015.<ref name=nbc20140521/><ref name=faa201311>{{cite web |last1=James |first1=Michael |last2=Salton |first2=Alexandria |last3=Downing |first3=Micah |title=Draft Environmental Assessment for Issuing an Experimental Permit to SpaceX for Operation of the Dragon Fly Vehicle at the McGregor Test Site, Texas, May 2014 – Appendices |publisher=Blue Ridge Research and Consulting, LCC |pages=12 |date=November 12, 2013 |url=http://www.faa.gov/about/office_org/headquarters_offices/ast/media/20140513_DragonFly_DraftEA_Appendices%28reduced%29.pdf |access-date=May 23, 2014 |archive-date=September 24, 2015 |archive-url=https://web.archive.org/web/20150924005626/http://www.faa.gov/about/office_org/headquarters_offices/ast/media/20140513_DragonFly_DraftEA_Appendices%28reduced%29.pdf |url-status=live }}</ref>{{update after|2014}}
 
The DragonFly test vehicle is powered by eight [[SuperDraco]] engines, arranged in a redundant pattern to support [[fault-tolerance]] in the propulsion system design.<ref name=wt20140522/> SuperDracos utilizeuse a [[storable propellant]] mixture of [[monomethyl hydrazine]] (MMH) [[fuel]] and [[nitrogen tetroxide]] [[oxidizer]] (NTO), the same propellants used in the much smaller [[Draco (rocket engine family)|Draco]] thrusters used for [[Spacecraft attitude control|attitude control]] and [[Reaction control system|maneuvering]] on the first-generation [[Dragon spacecraft]].<ref name=faa201311/> While SuperDraco engines are capable of {{convert|16400|lbf|N|order=flip}} of thrust, during use on the DragonFly flight test vehicle, each will be [[Rocket engine throttling|throttled]] to less than {{convert|15325|lbf|N|order=flip}} to maintain vehicle stability.<ref name=faa201311/>
While SuperDraco engines are capable of {{convert|16400|lbf|N|order=flip}} of thrust, during use on DragonFly flight test vehicle each will be [[Rocket engine throttling|throttled]] to less than {{convert|15325|lbf|N|order=flip}} to maintain vehicle stability.<ref name=faa201311/>
 
A test flight program of thirty flights was proposed in 2013–2014, including two ''propulsive assist'' (parachutes plus thrusters) and two ''propulsive landing'' (no parachutes) on flights dropped from a helicopter at an altitude of approximately {{convert|10000|ft|m|sp=us}}. The other 26 test flights were projected to take off from a [[launch pad|pad]]: eight to be ''propulsive assist hops'' (landing with parachutes plus thrusters) and 18 to be ''full propulsive hops'', similar to the [[Grasshopper (rocket)|Grasshopper]] and F9R Dev booster stage test flights.<ref name=faa201311/><ref name="wt20140522">{{cite news |last=Abbott |first=Joseph |date=May 22, 2014 |title=Grasshopper to DragonFly: SpaceX seeks approval for new McGregor testing |url=http://www.wacotrib.com/blogs/joe_science/grasshopper-to-dragonfly-spacex-seeks-approval-for-new-mcgregor-testing/article_11d0c40a-e1f6-11e3-a868-001a4bcf887a.html |accessurl-datestatus=May 23, 2014 |newspaper=Waco Tribune |date=May 22, 2014 |archive-date=June 6, 2020live |archive-url=https://web.archive.org/web/20200606212803/https://www.wacotrib.com/blogs/joe_science/grasshopper-to-dragonfly-spacex-seeks-approval-for-new-mcgregor-testing/article_11d0c40a-e1f6-11e3-a868-001a4bcf887a.html |urlarchive-statusdate=liveJune 6, 2020 |access-date=May 23, 2014 |newspaper=Waco Tribune |___location=Waco, Texas}}</ref> {{asof|2014}}, the DragonFly test program was not expected to start until after the completion of the [[F9R Dev1]] booster testing at the McGregor facility.<ref name=wt20140522/>{{update after|2014}}
{{asof|2014}}, the DragonFly test program was not expected to start until after the completion of the [[F9R Dev1]] booster testing at the McGregor facility.<ref name=wt20140522/>{{update after|2014}}
 
=== Falcon 9 booster post-mission flight tests ===
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{{Main|Falcon 9 first-stage landing tests}}
 
In an arrangement highly unusual for launch vehicles, SpaceX began in 2013 using some first stages of the Falcon 9 v1.1 rockets for propulsive-return controlled-descent [[flight test]]s after they completed the boost phase of an orbital flight. Since the advent of [[orbital spaceflight|spaceflight]] in [[Sputnik 1|1957]], launch vehicle boosters would ordinarily just be discarded after setting their payloads on their way. The over-water tests started by SpaceX took place in the Pacific and Atlantic oceans south of [[Vandenberg Air Force Base]] (California) and east of [[Cape Canaveral Air Force Station]] (Florida). The first flight test occurred on September 29, 2013, after the second stage with the [[CASSIOPE]] and [[nanosat]] payloads separated from the booster. These descent and simulated landing tests continued over the next two years, with the second flight test taking place on April 18, 2014,<ref name="bbc20130930" /><ref name="ut20140419" /><ref name=dn20140224/> two more testtests in [[List of Falcon 9 and Falcon Heavy launches (2010–2019)#2014|2014]], and four subsequent tests conducted in 2015.<ref name=nsf20151231>{{cite news |last1=Gebhardt |first1=Chris |title=Year In Review, Part 4: SpaceX and Orbital ATK recover and succeed in 2015 |url=http://www.nasaspaceflight.com/2015/12/yir4-spacex-orbital-atk-recover-succeed-2015/ |access-date=January 1, 2016 |work=NASASpaceFlight.com |date=December 31, 2015 |archive-date=January 2, 2016 |archive-url=https://web.archive.org/web/20160102175706/http://www.nasaspaceflight.com/2015/12/yir4-spacex-orbital-atk-recover-succeed-2015/ |url-status=live }}</ref> SpaceX continued to make [[Iterative and incremental development|iterative and incremental]] changes to the booster design, as well as the specific reusable technologies, descent profile and propellant margins, on some 2016-20182016–2018 Falcon 9 and Falcon Heavy flights to tweak the design and operational parameters. Many of these descent and landing tests were tested on active orbital spaceflight missions for SpaceX customers as the booster reentered the atmosphere and attempted recoverable landings.
 
==== Re-entry and controlled descent ====
Following analysis of the flight test data from the first booster-controlled descent in September 2013, SpaceX announced it had successfully tested a large amount of new technology on the flight, and that coupled with the technology advancements made on the Grasshopper low-altitude landing demonstrator, they were ready to test a full recovery of the booster stage. The first flight test was successful; SpaceX said it was "able to successfully transition from vacuum through [[hypersonic]], through [[supersonic]], through [[transonic]] speeds, and light the engines all the way and control the stage all the way through [the atmosphere]".<ref name=pm20130930>{{cite news |url=http://www.popularmechanics.com/science/space/rockets/musk-spacex-now-has-all-the-pieces-for-reusable-rockets-15985616 |title=Musk: SpaceX Now Has "All the Pieces" For Truly Reusable Rockets |work=Popular Mechanics |last=Belfiore |first=Michael |date=September 30, 2013 |access-date=October 17, 2013 |archive-date=October 12, 2013 |archive-url=https://web.archive.org/web/20131012044151/http://www.popularmechanics.com/science/space/rockets/musk-spacex-now-has-all-the-pieces-for-reusable-rockets-15985616 |url-status=live }}</ref> Musk said, "the next attempt to recovery [sic] the Falcon 9 first stage will be on the fourth flight of the upgraded rocket. This would be [the] third commercial Dragon cargo flight to ISS. [International Space Station]"<ref name="pa20130930">{{cite news |url=http://www.parabolicarc.com/2013/09/29/falcon-9-launch-payloads-orbit-vandenberg/ |title=Falcon 9 Launches Payloads into Orbit From Vandenberg |work=Parabolic Arc |last=Messier |first=Doug |date=September 29, 2013 |access-date=September 30, 2013 |archive-date=September 30, 2013 |archive-url=https://web.archive.org/web/20130930094429/http://www.parabolicarc.com/2013/09/29/falcon-9-launch-payloads-orbit-vandenberg/ |url-status=live }}</ref>
 
This second flight test took place during the April 2014 Dragon flight to the ISS. SpaceX attached [[Launch vehicle landing gear|landing legs]] to the first stage, decelerated it over the ocean and attempted a simulated landing over the water, following the ignition of the second stage on the [[SpaceX CRS-3|third cargo resupply mission]] contracted to NASA. The first stage was successfully slowed down enough for a soft landing over the Atlantic Ocean.<ref name="ut20140419" /> SpaceX announced in February 2014 the intent to continue the tests to land the first-stage booster in the ocean until precision control from hypersonic all the way through subsonic regimes hashad been proven.<ref name=dn20140224>{{cite news |last=Klotz |first=Irene |title=SpaceX Falcon Rocket to Test Landing Legs |url=http://news.discovery.com/space/private-spaceflight/spacex-falcon-rocket-to-test-precision-landing-legs-140224.htm |access-date=February 25, 2014 |newspaper=Discovery News |date=February 24, 2014 |archive-date=March 2, 2014 |archive-url=https://web.archive.org/web/20140302123926/http://news.discovery.com/space/private-spaceflight/spacex-falcon-rocket-to-test-precision-landing-legs-140224.htm |url-status=live }}</ref> Five additional controlled-descent tests were conducted in the remainder of 2014 through April 2015, including two attempts to land on a [[floating landing platform]]—a SpaceX-built [[Autonomous Spaceport Drone Ship]]—on the [[Atlantic Ocean]] east of the launch site, both of which brought the vehicle to the landing platform, but neither of which resulted in a successful landing.
Five additional controlled-descent tests were conducted in the remainder of 2014 through April 2015, including two attempts to land on a [[floating landing platform]]—a SpaceX-built [[Autonomous Spaceport Drone Ship]]—on the [[Atlantic Ocean]] east of the launch site, both of which brought the vehicle to the landing platform, but neither of which resulted in a successful landing.
 
==== First landing on ground pad ====
[[File:ORBCOMM-2_First-Stage_Landing_(23271687254).jpg|thumb|Falcon 9 Flight 20's first stage landing viewed from a helicopter, December 22, 2015.]]
During the [[SpaceX CRS-7|2015 launch hiatus]], SpaceX requested regulatory approval from the [[FAA]] to attempt returning their [[Falcon 9 Flight 20|next flight]] to [[CCAFS|Cape Canaveral]] instead of targeting a floating platform in the ocean. The goal was to [[VTVL|land the booster vertically]] at the leased ''[[Landing Zone 1]]'' facility—the former [[Launch Complex 13]] where SpaceX had recently built a large rocket landing pad.<ref name=ft201511201>{{cite news |last1=Dean |first1=James |title=SpacexSpaceX wants to land next booster at Cape Canaveral |url=http://www.floridatoday.com/story/tech/science/space/spacex/2015/12/01/spacex-wants-land-next-booster-cape-canaveral/76576142/ |access-date=December 2, 2015 |work=Florida Today |date=December 1, 2015 |archive-date=December 10, 2015 |archive-url=https://web.archive.org/web/20151210054303/http://www.floridatoday.com/story/tech/science/space/spacex/2015/12/01/spacex-wants-land-next-booster-cape-canaveral/76576142/ |url-status=live }}</ref> The FAA approved the safety plan for the ground landing on December 18, 2015.<ref name="os20151220">{{cite news |date=December 20, 2015 |title=SpaceX aims for Sunday launch and ground landing |url=http://www.orlandosentinel.com/news/space/go-for-launch/os-spacex-engine-testing-sunday-launch-20151218-post.html |url-status=live |archive-url=https://web.archive.org/web/20151221215241/http://www.orlandosentinel.com/news/space/go-for-launch/os-spacex-engine-testing-sunday-launch-20151218-post.html |archive-date=December 21, 2015 |access-date=December 20, 2015 |work=Orlando Sentinel |___location=Orlando, Florida}}</ref> The first stage landed successfully on target at 20:38 local time on December 21 (01:38 UTC on December 22).<ref>{{cite news |url=https://www.theverge.com/2015/12/21/10640306/spacex-elon-musk-rocket-landing-success |title=SpaceX successfully landed its Falcon 9 rocket after launching it to space |work=[[The Verge]] |first=Loren |last=Grush |date=December 21, 2015 |access-date=April 9, 2016 |archive-date=June 28, 2017 |archive-url=https://web.archive.org/web/20170628014841/https://www.theverge.com/2015/12/21/10640306/spacex-elon-musk-rocket-landing-success |url-status=live }}</ref><ref name=nsf20151231/>
The FAA approved the safety plan for the ground landing on December 18, 2015.<ref name=os20151220>{{cite news |title=SpaceX aims for Sunday launch and ground landing |url=http://www.orlandosentinel.com/news/space/go-for-launch/os-spacex-engine-testing-sunday-launch-20151218-post.html |work=Orlando Sentinel |date=December 20, 2015 |access-date=December 20, 2015 |archive-date=December 21, 2015 |archive-url=https://web.archive.org/web/20151221215241/http://www.orlandosentinel.com/news/space/go-for-launch/os-spacex-engine-testing-sunday-launch-20151218-post.html |url-status=live }}</ref> The first stage landed successfully on target at 20:38 local time on December 21 (01:38 UTC on December 22).<ref>{{cite news |url=https://www.theverge.com/2015/12/21/10640306/spacex-elon-musk-rocket-landing-success |title=SpaceX successfully landed its Falcon 9 rocket after launching it to space |work=[[The Verge]] |first=Loren |last=Grush |date=December 21, 2015 |access-date=April 9, 2016 |archive-date=June 28, 2017 |archive-url=https://web.archive.org/web/20170628014841/https://www.theverge.com/2015/12/21/10640306/spacex-elon-musk-rocket-landing-success |url-status=live }}</ref><ref name=nsf20151231/>
 
First stage booster ''[[B1019]]'' never flew again after the flight.<ref>{{cite news |url=https://www.theverge.com/2015/12/21/10642028/spacex-falcon-9-landing-elon-musk-wont-fly |title=SpaceX's 'reusable' Falcon 9 rocket won't fly again, Elon Musk says |work=[[The Verge]] |first=Sean |last=O'Kane |date=December 21, 2015 |access-date=December 23, 2015 |archive-date=December 23, 2015 |archive-url=https://web.archive.org/web/20151223012030/http://www.theverge.com/2015/12/21/10642028/spacex-falcon-9-landing-elon-musk-wont-fly |url-status=live }}</ref> Rather, the rocket was moved a few miles north to the SpaceX hangar facilities at [[Launch pad 39A]], recentlywas refurbished by SpaceX at the adjacent [[Kennedy Space Center]], where it was inspected before being used on January 15, 2016, to conduct a [[static fire]] test on its original launchpad, [[Launch Complex 40]].<ref>{{Cite news |date=January 16, 2016 |title=SpaceX Test Fires Recovered Falcon 9 Booster in Major Step To Reusable Rockets |url=http://www.universetoday.com/126837/spacex-test-fires-recovered-falcon-9-booster-major-step-reusable-rockets/ |title=SpaceX Test Fires Recovered Falcon 9 Booster in Major Step To Reusable Rockets url- Universe Today |datestatus=January 16, 2016 |newspaper=Universe Today |language=en-US |access-date=January 28, 2017 |archive-date=December 2, 2016live |archive-url=https://web.archive.org/web/20161202083025/http://www.universetoday.com/126837/spacex-test-fires-recovered-falcon-9-booster-major-step-reusable-rockets/ |urlarchive-statusdate=liveDecember 2, 2016 |access-date=January 28, 2017 |newspaper=Universe Today |language=en-US}}</ref> This test aimed to assess the health of the recovered booster and the capability of this rocket design to fly repeatedly in the future.<ref name=f20-static-fire>{{cite web |url=http://spaceflight101.com/returned-falcon-9-booster-fires-up-for-static-fire-test/ |work=Spaceflight 101 |title=Returned falcon 9 booster fires up for static fire test |date=January 15, 2016 |access-date=January 18, 2016 |archive-date=April 22, 2016 |archive-url=https://web.archive.org/web/20160422191153/http://spaceflight101.com/returned-falcon-9-booster-fires-up-for-static-fire-test/ |url-status=live }}</ref><ref name=nsf20151231/> The tests delivered good overall results except for one of the outer engines experiencing thrust fluctuations.<ref name=f20-static-fire /> Elon Musk reported that this may have been due to debris ingestion.<ref>{{cite news |title=SpaceX Tests Recovered Falcon 9 Stage and Prepares for Next Launch |url=http://spacenews.com/spacex-tests-recovered-falcon-9-stage-and-prepares-for-next-launch/ |date=January 15, 2016 |access-date=January 15, 2016}}</ref> The booster was then retired to the SpaceX facility in Hawthorne, California.
The booster was then retired to the SpaceX facility in Hawthorne, California.
 
[[File:First stage of Jason-3 rocket (24423604506).jpg|thumb|First stage of [[Falcon 9 Flight 21]] descending over the floating landing platform, January 17, 2016, immediately prior to a soft touchdown followed by [[deflagration]] of the rocket after a landing leg failed to latch, causing the rocket to tip over.]]