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March 22nd, 2011

United Lauch Alliance + XCOR Aerospace... Rockin' Rocket Revolution (Launch)

XCOR test fires its Lynx 5K18 engine with lightweight aluminum nozzle; United Launch Alliance (ULA) and XCOR to apply the nozzle and XCOR's liquid hydrogen (LH2) pump technology to new LH2 engine development. (Photo Credit: Mike Massee / XCOR)
[SatNews] Demo'd is a revolutionary rocket engine nozzle and a new engine development partnership...

United Launch Alliance (ULA) and XCOR Aerospace have announced their successful hot-fire demonstrations of a lighter-weight, lower-cost approach to liquid-fueled rocket-engine vacuum nozzles. The new nozzle technology, which uses aluminum alloys and innovative manufacturing techniques, is projected to be less costly and save hundreds of pounds of mass compared to nozzles in use today in typical large upper-stage rocket engine systems. Under a 2010 joint risk-reduction program by XCOR and ULA, ULA facilitated an accelerated demonstration of the nozzle technology, which was developed in XCOR's Lynx reusable, suborbital-vehicle technology program. ULA sought to determine the nozzle technology's applicability to future expendable launch vehicle programs. Earlier in the same risk-reduction program, XCOR demonstrated the ability to pump liquid hydrogen (LH2) using cryogenic piston-pump technology it developed for the Lynx suborbital vehicle. Based on the results of these successful technology demonstrations, ULA has now announced a larger follow-on program with XCOR to develop a liquid oxygen (LOX)/LH2 engine.

XCOR Lynx 5K18 main engine being prepped for a test series. Photo courtesy of XCOR.
Conceived as a lower-cost, risk-managed program compared to traditional engine development efforts, the multi-year project's main objective is to produce a flight-ready LOX/LH2 upper-stage engine in the 25,000 to 30,000 lbf thrust class that costs significantly less to produce and is easier to operate and integrate than competing engine technologies. If successful, the effort will lead to significantly lower-cost and more-capable commercial and US government space flights delivered by ULA. The companies structured their LOX/LH2 engine development program with multiple "go / no-go" decision points and performance milestones to ensure a cost-effective and risk-managed approach to this challenging effort. As demonstrated during prior ULA and XCOR joint engagements, XCOR's small-company environment facilitates rapid turnaround for build and test cycles that drive innovative learning, while ULA's small company project management approach ensures their needs are met but does not stifle the creative process or saddle XCOR with excessive paperwork burdens typical of large government contracts. In addition, ULA is helping to bolster the Tier 2 and Tier 3 aerospace-industrial supply chain in the United States, which is critical to ensuring the United States aerospace sector remains competitive in the global marketplace.

The demonstrations just announced are from integrated engine/nozzle test firings with XCOR's Lynx 5K18 LOX/kerosene engine. The engine/nozzle combination demonstrates the ability of the aluminum nozzle to withstand the high temperatures of rocket-engine exhaust over numerous tests, with no discernable degradation of the material properties of the alloys. The tests validated the design, materials and manufacturing processes used in the nozzle, and laid a foundation for scaling the design to EELV-sized engines. The results also demonstrate the reusability of the engine and nozzle combination which is essential for low-cost, daily suborbital flights by the Lynx and other vehicles. ULA homepage. XCOR homepage.