case studies: 2 launch vehicle mishaps titan iv, pegasus xl
TRANSCRIPT
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AIAA OC ASAT, May 2014
Returning the Pegasus XL
Winged Launch Vehicle to
Flight
Pete Young, Col., USAF (Ret.)
May 4, 2014
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AIAA OC ASAT, May 2014
Overview
• Provide background on Return-to-Flight
– Pegasus XL
• Emphasis on
– Determination of mishap root cause
– **Other significant factors**
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AIAA OC ASAT, May 2014
Pegasus “Standard”
Winged, aircraft-launched small satellite
launcher – DARPA initiated program
Prime contractor: Orbital Sciences
Corporation, Dulles VA
Payload: 635 lbs to LEO
First flight April 1990, 8 missions total 3
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AIAA OC ASAT, May 2014
Pegasus XL heritage
• Pegasus XL “stretch” proposed to provide
increased payload performance (635# to
840# to LEO)
- Larger solid motors, minor planform
changes
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AIAA OC ASAT, May 2014
“Stretched” Pegasus XL
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AIAA OC ASAT, May 2014
First P-XL flight, June 28, 1994 – Space Test Program STEP 1
Satellite – SDI/BMDO payload
- P-XL “departed from controlled flight” during first stage burn,
transonic flight regime
- Vehicle destroyed by VAFB Range –
- Root cause: sub-marginal flight stability coefficients derived by
CFD-based extrapolation of Pegasus-Standard aero data
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AIAA OC ASAT, May 2014
2nd Pegasus XL mission: Space Test Program STEP-3 satellite
- Another SDI/BMDO payload
- VAFB launch scheduled for June 22, 1995
My personal situation:
- Newly promoted, named as incoming STP SPO Director
effective July 1, 1995
- Invited to VAFB as a “guest VIP observer”
Show STEP-3 videotapes --
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AIAA OC ASAT, May 2014
Aftermath of STEP-3 Launch Failure
• “Root cause” readily identified: technician error epoxying
foam guideblock to Stage II nozzle
• “Fix and fly” feasible strategy -- ?
• But – two successive XL failures! And for different
reasons!
• Successful 2nd and 3rd stage flight yet to be
demonstrated…
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AIAA OC ASAT, May 2014
1994-1995 -Small Launch Vehicle
Programmatic Situation
• A ‘very bad year’ for small launch vehicles
– Lockheed Martin LMLV and EER Conestoga
• Launch failures on first flights!
– Two successive Pegasus XL failures!
• Pentagon guidance – “Terminate Pegasus XL program ASAP!”
– Extreme DoD reluctance to sponsor a third P-XL flight – and possible third successive failure
• However…substantial P-XL payload backlog
– 14 Air Force, NASA, & commercial smallsats
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AIAA OC ASAT, May 2014
P-XL Payloaders’ Dilemma
• Fundamental problem: NO practical launch alternatives for
backlogged payloads
– Shuttle, Delta, Taurus, Ariane, Proton, Titan, others
• Payload SPOs unwilling to “fix and fly” and risk another
launch failure – total lack of customer confidence
• But…STP obligated to provide orbital flight for customers!
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AIAA OC ASAT, May 2014
Pegasus XL Return-to-Flight Program
July 1995 – requested and received permission from Gen Lester
Lyles to create a P-XL RTF initiative
My ground rules:
- personally selected technical and management support
- fly again when ready (and not before!)
- involvement of Orbital Sciences and all payload customers
- thorough review of ALL areas of concern, not just latest
root cause/flight anomaly
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AIAA OC ASAT, May 2014
Return-to-Flight Methodology
• Investigation to determine 2nd mission “root cause(s)” and corrective action(s)
• Review of P-XL development pedigrees and qualification processes
• OSC-requested review of company procedures and practices
– Dulles,Virginia; Phoenix, Arizona; and VAFB California facilities
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AIAA OC ASAT, May 2014
Major P-XL return-to-flight issues
• Redesign and retest of the Stage I/II separation
mechanisms
• Re-analysis of control surface flutter margins
• Thorough review of Stage II solid rocket motor
nozzle thermal margins
• Comprehensive review, and changes, of company
practices in Virginia, Arizona, California
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AIAA OC ASAT, May 2014
REX II Mission Planning
• Drop zone: approx. 50 miles west of
Monterey Peninsula
• Launch date/time: March 8, 1996, 1745
PST
• Chase support: Edwards AFB F-16, F-18
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AIAA OC ASAT, May 2014
Week of Launch
• Launch readiness briefings to AF senior
management and REX II customer
• Late breaking issues: failure of Parker-Hannifin
master servo controller; satellite ring antenna
damage; overflights by MIR, satellites, space
debris
• “Skeptical” media coverage!
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AIAA OC ASAT, May 2014
Week of launch
• L-1011 “Stargazer” arrived VAFB 3 days
prior; very smooth integration of P-XL and
payload
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AIAA OC ASAT, May 2014
REX II Postscript
• Flawless launch and orbit insertion
• Vehicle deployed solar panels on first rev
• REX II mission totally successful
– Orbital operations turned over to US Naval
Academy Astronautics Department, operated
for several years by USNA students!
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AIAA OC ASAT, May 2014
Pegasus XL postscript
• REX II was the 10th Pegasus mission
attempted (1996)
• OSC launched the 42th Pegasus mission
last June
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AIAA OC ASAT, May 2014
The L-1011 rolls!
Show REX-II
Video
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AIAA OC ASAT, May 2014
Questions?
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BACKUPS
AIAA OC ASAT, May 2014 21
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AIAA OC ASAT, May 2014
My Background
• Multiple AF, NRO and MDA system
program office (SPO) assignments, 1977-
2013
1. Satellite development and launch
integration
- Peacekeeper (MX), Space Shuttle, Titan
ELVs(T-II, T-III, T-IV), Taurus
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AIAA OC ASAT, May 2014
Pegasus XL Return-To-Flight –
“Changing the Culture”
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AIAA OC ASAT, May 2014
Next P-XL Mission/Payload
• Space Test Program empowered to set payload
launch priorities (!)
• REX II - two AF Rome Laboratory experimental
payloads
- 250 lb payload, 30” diameter, 22” high
– 450 nm circular polar orbit
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AIAA OC ASAT, May 2014
P-XL and Kavli Center for Astrophysics’
(ex-MIT-CSR) HETE satellite
• SACB/HETE mission failed April 1996
– Root cause: separation battery internal shorting
• HETE II reflight successful – September
2000!
– L-1011 staged from Kwajalein, satellite
inserted into circular, equatorial orbit
– Satellite has made phenomenal astrophysics
measurements on transient Gamma Ray Bursts
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