[Research on the 2021 Aerospace Development of the World's Three Major Aerospace Defense Companies (III)]
Boeing 2021 Aerospace Development Research
Article | Zhang Jingnan
This article was published in the 2022 issue of "Satellites and Networks" magazine
2021. Although Boeing's development in the aerospace field has not completely reversed its decline, it has made significant progress in important system engineering projects such as lunar launch vehicles and manned spacecraft , providing important support for the United States' return to the moon and the development of manned space.
, launch vehicle
As the main contractor of NASA's "Artemis" return to the moon program, Boeing has developed the rocket's core stage, upper stage and avionics equipment.
(I) SLS rocket core stage static ignition test
2021, the core stage of the first SLS rocket to perform a launch mission completed 2 static ignition tests. To carry out ignition testing, Boeing has formed a testing team, with experts from skilled avionics, hydraulics, propulsion systems, ground electronics and testing from all over the country, inside and outside the company. Including: Boeing, NASA and Aerojet Rocketdyne, etc., it has technical advantages from rockets, space shuttle , satellite launch to testing.
, the first
In January 2021, NASA, Boeing and Aerojet Rocketdyne conducted the first ignition test of the core stage participating in the first flight of the SLS rocket at the B-2 test bench in , Mississippi. During the fuel filling and supercharge process of the core stage, the RS-25 engine manufactured by Aerojet Rocketdyne completed the 67.2-second ignition test, while collecting important rocket data takes at least about 4 minutes, and it takes 8 minutes to work during actual flight.
Boeing said that in order to ensure the safety of the core level, the test parameters were specially designed to be conservative and only suitable for ground testing to avoid unnecessary risks to the core level, which triggered the engine shutdown earlier, but the core level was in good condition after ignition. The team analyzed the test data, cleaned and repaired the engine, performed minor repairs to the core-level thermal protection system, updated the previously conservative control logic parameters, and repaired the faulty wire harness. The wire harness caused the core-level No. 4 engine failure information, but this was only an instrument problem and did not affect the engine operation.
This core-level ignition test obtains data from the core-level and engine main propulsion system and thrust vector control system over longer working hours. The main tests and operations include: transforming into an automatic launch sequence operated by a core-level flight computer and "green run" test software; completing the final countdown sequence, like a launch countdown; pressurizing the fuel tank, delivering propellant to the engine, demonstrating the performance of the core-level propulsion system; starting the engine with 109% power; and operating the thrust vector control system to rotate the engine.
January 16, 2021, fuel filling and pressurization tests for the core stage used for the Artemis 1 mission, four RS-25 engines were shut down after ignition and working for one minute
January 16, 2021, in a scheduled Heat test conducted by NASA Stanis Space Center near St. Louis Bay, Mississippi, the core stage built by Boeing for NASA's first SLS rocket was seen on the B-2 test bench. During the test, water flows out of the test bench, creating huge steam clouds.
, the second
In March 2021, Boeing completed the second ignition test at NASA's Stanis Space Center. Test data proves that the core level is operating properly and can be used for flight, and the data is used to support flight missions. In this test, the engine ignition worked for 499.6 seconds, that is, 8 minutes and 19 seconds. After testing, the core stage was sent to NASA's Kennedy Space Center in , Florida, and integrated with "Orion" manned spacecraft , temporary cryogenic upper stage and solid rocket booster , to perform Artemis 1 manned moon-orbiting mission, preparing for subsequent manned missions.
On March 18, 2021, NASA conducted the first Heat test of the core stage of the space launch system rocket at the Stennis Space Center in Mississippi. Steam rolled out from under the B-2 test bench
, B-2 test bench
B-2 test bench 106.7 meters high and is fixed on the ground by 43.9 meters of reinforced concrete. It has been used since the "Apollo" project (Apollo) period. After modern modification and reinforcement, it will be used for the ignition test of the SLS rocket core stage in January 2021. Previously used for testing of the US "Saturn" series rockets and the "Delta 4" rockets and space shuttles. Currently, the B-2 test bench bracket and its fire extinguishing and fuel systems have been renovated to handle larger and heavier SLS rocket core stages. Before the start of the test work of the
SLS rocket test work, the steel of the B-2 test bench was rusted and the facilities and equipment were too old. For SLS rocket testing, NASA mainly transformed the B-2 test bench: the high-pressure industrial water plant can deliver 1.26 million liters of water to the B-2 per minute, an increase of 94,635 liters per minute than the original system; in order to hoist the core stage of the SLS rocket, the main boom crane on the B-2 bracket has been extended by 15.2 meters, and the rated load has increased by 177 tons. This core stage is larger and heavier than the early "Saturn 5" rocket stage; the auxiliary mobile lifting system and temporary access platform can enter the entire shell of the core stage.
(II) Core stage development and delivery
. The first SLS rocket core stage development
In 2021, Boeing delivered the SLS rocket core stage to NASA, with a core stage 65 meters high and weighing 85.275 tons. In April, the SLS rocket core class was uninstalled on an barge at the Kennedy Space Center and moved to the Rocket Assembly Building. The 65-meter-long core stage will be composed of a temporary cryogenic superposition, 2 solid rocket boosters, 1 launch vehicle stage adapter and 1 "Orion" spacecraft . Each team will prepare SLS to launch Orion spacecraft and fly around the moon without a manned situation. The temporary low temperature superior was jointly developed by Boeing and the United Launch Alliance. In June, the SLS rocket core stage was sent to the mobile launch pad of the Kennedy Space Center (KSC) launch vehicle assembly building (VAB).
April 21, 2021, SLS rocket core stage ht located in Stanis Space Center ml1
SLS rocket's core first stage arrives at the Kennedy Space Center
. Spray foam protection SLS rocket
In the development process in 2021, Boeing will apply the rocket thermal protection system (TPS) to the SLS rocket core second stage, which operates faster than the core first stage. The yellow to orange coating on the surface of the SLS rocket is TPS, i.e. spray foam. In extreme environments for preparation and launch, it is used to withstand temperatures of 733,000 gallons of liquid hydrogen and liquid oxygen propellant at -423 degrees Fahrenheit and -297 degrees Fahrenheit, respectively. The entire core secondary spraying process took 100 minutes. Automatic spraying was adopted for the dome of the core secondary storage tank. Previously, due to the complex geometry of the dome, it required manual spraying. The core level 1 performance has been stable after ignition test. Some TPS areas of the four engines are ablated by fire when they are ignited and will be renovated later.
Boeing uses 3D projection technology for foam trimming for more precise and higher quality applications. Through process improvements, the thermally protected foam has customized 3D printed molds, which can be sprayed on small parts that cannot be sprayed on the previous core level, such as the engine and box section. The mold is installed around the complex profile and is filled with poured foam, which is removed after the poured foam is cured. There are still areas that require manual spraying, such as flange interface between the core-level parts. Under the 3D printing manufacturing process, more than 300 molds have been manufactured, which can make complex geometric shapes. The foam used by the
SLS rocket is a lightweight polyurethane foam material. It is strong enough to protect the rocket's hardware and flexible enough to maintain its protective seal at extreme temperatures, and will continue to improve in the future. Boeing is using the third generation foam material for the SLS rocket and begins validating the fourth generation.
. The first SLS rocket is docked with the Orion spacecraft
In September 2021, the SLS rocket completed two main tests: the umbilical cord release and recovery test (URRT), and a comprehensive modal test using the Orion mass simulator. The umbilical cord cable connects the electrical and fluid interfaces connecting the rocket core stage and the upper stage to the launch tower, and seamless release and retrieval must be achieved before launch. 4 umbilical cords are connected to the core stage, interstage section, liquid oxygen storage box and liquid hydrogen storage box, and there are 2 stabilizers fixed to the front skirt. The URRT test verifies operation timing and functionality. Boeing supports checks before and after testing, and then helps analyze data. The SLS rocket also conducted comprehensive modal testing to determine the full frequency and vibration range of the rocket so that the flight software and navigation systems can safely guide the rocket during launch and ascend.
10 In October, at the rocket assembly building at the Kennedy Space Center in Florida, the first SLS rocket core stage carrying the upper stage and avionics equipment, the Orion adapter and the Orion spacecraft were installed on the top. Among them, the "Orion" adapter was hoisted above the temporary low-temperature propulsion stage (ICPS), and the overall height reached 98 meters. Boeing also completed the Design Certification Review (DCR) of the SLS Rocket, checking all test data, reports and verifications during the team's preparation for launch to ensure safe operating conditions and reliability.
is located in NASA Kennedy Space Center in Florida. The Orion spacecraft is hoisted on the top of the SLS rocket
. Other core stage development
2021, Boeing assembled the liquid oxygen storage tank and interstage section of the core stage of the Artemis 2 mission SLS rocket in Michoud, and began to prepare to install the front skirt. Boeing also works in the lower half of the Artemis 2 mission SLS rocket core stage, including the installation of the engine, thermal protection spraying of the liquid hydrogen storage tank, and preparation for the final assembly. The five core stages currently developed by Boeing for SLS rockets will each undertake unique flight missions, and the installation and operation of each corresponding equipment is also different, including the integration of computers, batteries, lines and instruments, propellant pipelines and other systems.
In August, the United Launch Alliance shipped the second temporary cryogenic propulsion stage (ICPS) from the factory in Decatur, Alabama to the Florida facility for integration, and will be delivered to NASA later. The Artemis 2 mission SLS rocket is integrated at the Michoud assembly plant in New Orleans . ULA and Boeing developed the third ICPS at ULA's Decatur plant. At the same time, Boeing is developing the second, third and fourth core stages of the SLS rocket, as well as exploring the replacement of the early ICPs (EUS), thereby developing the SLS Block 1B rocket for subsequent missions. The SLS rocket core stage engine of the
Artemis 2 mission connects the components
Artemis 2 mission temporary low-temperature propulsion stage (ICPS) of the 2 mission arrives at the Space Force Station of the Cape Canaveral
Artemis 2 mission core secondary liquid oxygen storage tank
(III) Follow-up work
Artemis 1 mission, the first manned Artemis 2 mission will be carried out. The Michoud assembly plant in New Orleans manufactures the SLS rocket core stages for the Artemis 2 and Artemis 3 missions, and uses a friction stirring process to make the welded SLS rocket core stage structure for the Artemis 3 mission. The Artemis 3 mission will bring the first female astronaut and the next male astronaut to the surface of the moon. The exploration section (EUS) developed by Boeing has been put into production in Michoud for the long-term launch mission planned by Artemis. Boeing is also designing and developing the exploration of the subsequent SLS rocket use.
In the first SLS rocket launch, in addition to the unmanned Orion spacecraft, ICPS will also deploy 10 secondary payloads. After the Orion is flying around the moon, it will return to the earth and splash to the sea. The SLS rocket will launch probes to Saturn's satellite Enceladus in the future, sample its geysers, and place scientific probes on its surface. SLS rockets can also be used for planetary defense, such as sending massive objects to targets, implementing kinetic energy push, surface explosion or gravity traction, and ultimately redirecting asteroids that threaten Earth.In addition, NASA is demonstrating the use of the SLS rocket with the Exploration (EUS) to complete a Mars flyby mission in 2033, that is, the next Mars opposition year.
2. Manned spacecraft
(I) Install and test spacecraft NASA docking system (NDS) shell
In January 2021, a new NASA docking system (NDS) shell was installed and tested on the assembly plant of the Kennedy Space Center in Florida, CST-100 "Starliner". Designed and developed by Boeing, NDS is a standardized docking system that allows two spacecraft to reliably dock and automatically form a short tunnel so that astronauts can move between the two spacecraft. The new housing will provide additional protection for the automatic docking system during re-entering the atmosphere. During its return to the atmosphere, the capsule will face temperatures of about 1,650 degrees before landing at one of the five landing sites in the western United States. NDS was originally designed for one-time use, however, after adding a shell to the atmosphere, tasks can be performed multiple times. When
is launched, the NDS housing is located under the hemispherical "rise housing" of the crew compartment, and will be exposed during orbital operation after the "rise housing" is discarded. It acts as a hatch on the top of the spacecraft, opens when docking with the international docking adapter made by the Boeing on the International Space Station, and closes after being disconnected. The NDS shell was installed on the CST-100 spacecraft that will conduct its second test flight in the future, namely the "Orbital Flight Test-2" (OFT-2) spacecraft.
NASA docking system (NDS) shell is functionally tested at the Kennedy Space Center commercial manned and cargo processing facility
(II) Manned landing site
In view of safety considerations, when astronauts land on "Starship", they are required to evacuate astronauts from the spacecraft within about 1 hour when landing in the "Starship". The "Starship" spacecraft is designed for land landing, with 5 landing sites in the western United States, two of which have one in New Mexico , Utah , Arizona and California each. In 2021, the Mission Safety Working Group coordinates the Utah landing site with the University of Utah Health Center, the University of Arizona Affiliated Academic Hospital Banner-Tucson University Medical Center coordinates the Arizona landing site, and Edwards Air Force Base coordinates the California landing site. Most landing sites are very remote and are likely to experience extreme temperature changes and severe damage to people within 24 hours.
(III) System security verification and drill
In January 2021, Boeing completed the re-certification of the "Starship" flight software and conducted a formal review of future mission modifications or upgrades. Through a series of tests, the updated spacecraft software is confirmed to comply with the design specifications and has conducted static and dynamic tests in hundreds of cases in the software integration lab, from single command verification to a comprehensive end-to-end mission scenario using core software.
In May, Boeing and NASA conducted a five-day end-to-end mission simulation exercise for the second test mission of the Starship using the final version of flight hardware and flight software at Boeing’s Avionics Equipment and Software Integration Laboratory (ASIL) in Houston, including complete pre-launch, docking, separation and landing operations. The mission operation team in the flight control room of NASA's Johnson Space Center directed the drill using actual flight procedures. The drill starts 26 hours before launch and continues until the spacecraft docks with the International Space Station, operates on the station, and starts the power supply for 32 hours, then disengages, lands and turns off the power supply. This drill allows software to run in the loop with the highest fidelity hardware and mission controllers, with maximum closeness to real flight.
At present, the "Starship" plans to test flights in the first half of 2022 to dock at two available ports of the International Space Station, but it may be occupied by the "Manned Dragon" spacecraft , "Cargo Dragon" spacecraft, or "Manned Dragon" commercial spacecraft.
At the Kennedy Space Center, Florida, the CST-100 spacecraft crew cabin that performs the "Orbital Flight Test-2" (OFT-2) mission in the future will be tested for weight and center of gravity
NASA Aerospace Barry Wilmore and Mike Fink monitor the launch process within the laboratory through the astronaut display connected to the simulator. Each dynamic
(IV) anthropometric test equipment is ready for the second flight
June 2021, Boeing's anthropometric test equipment "Rosy Rocket Man" was installed in the "Starship" to prepare for the second test flight.
"Rossi Rocket Man" is a test device weighing about 82 kilograms. The entire sign is located at the median of human height and weight. It has provided hundreds of data on the load-bearing data of astronauts during the first test flight of the Starship. The second flight of the "Rossi Rocket Man" is used to keep the spacecraft rising, docking, separation and landing the center of gravity. The spacecraft data capture port previously connected to it will be used to collect data from sensors placed along the seat tray to describe the motion characteristics of all 4 seats.
Before the integration of the Starship and the God of Universe 5 rockets, the Starship consisting of crew cabins and service cabins will be loaded onto the weight and centroids of the Kennedy Space Center commercial crew and cargo handling facilities to ensure that the Rossi Rocket Man on the spacecraft is in balance and cargo.
In the future, the "Starship" will be launched on astronauts for the first time after successfully completing its second test flight.
"Rossi Rocket Man" is tied to the commander's seat
, satellite system
(I) 5G satellite development
February 2021, a total of 16 commercial satellites were in different development stages of the Boeing satellite system factory in El Segundo, California, USA. Among them, it includes the SES-20 satellites and SES-21 satellites designed, tested and manufactured by Boeing for satellite operator SES, both of which use the small platform 702SP. In 2022, these two satellites will be launched into geostationary orbit with the same rocket, clearing 300 MHz C-band communications, and realizing 5G communications throughout the United States.
through SES-20 and SES-21 satellites, US Federal Communications Commission (FCCh will clean up the main operating spectrum and promote the US 5G wireless carrier business. This is also part of the FCC's "5G FAST" program, a comprehensive strategy to promote the leadership of the US 5G industry.
At the same time, Boeing is developing 11 Medium Earth Orbit (MEO) satellites for SES, building the next generation MEO orbit constellation with a height of 8,000 kilometers. After the launch of the O3b mPOWER system, it can provide 50 Mbps to several gigabits per second connection services to telecommunications, maritime, aviation and energy, as well as governments and agencies around the world. The first batch of O3b mPOWER satellite has been postponed to launch in 2022.
(II) Boeing is approved to carry out the next step of the development of protected tactical satellites (PTS)
In April 2021, the protected tactical satellites (PTS) communications project undertaken by Boeing and Norg were approved to enter the next stage of development, completing the design, construction and testing, and in 2024, two payloads will be loaded on military satellites or commercial satellites for on-orbit demonstration and operation. The subsequent development of
PTS project will continue to be comprehensive and public bidding. PTS prototype As a solution option for the next generation of secure communication satellites, existing advanced extreme high frequency (AEHF) satellites for high-density communications can be supplemented or replaced in the next decade.
The Space Force Space and Missile Systems Center awarded Boeing, Lockheed Martin and Norg in February and March 2020 to design payload prototypes for the PTS project. After
After receiving the contract, the project design of the three contractors underwent a comprehensive assessment, including payload performance, scalability, modularity, stability, cost, progress and risk, and completed the assessment in March 2021.
(III) FCC approved Boeing's 147 satellites V-band constellations
In November 2021, the U.S. Federal Communications Commission (FCC) approved Boeing's application for V-band constellations submitted in March 2017, allowing Boeing to develop and operate 147 non-geostationary orbit (NGSO) broadband satellites. In 2017, companies such as SpaceX, OneWeb, etc., also submitted NGSO applications at the same time as Boeing. Boeing is the last company to obtain the FCC conclusion in this batch.
According to regulatory regulations, each company needs to launch half of its planned satellites into orbit within 6 years, and the remaining satellites of the constellation can be deployed within 9 years. Boeing's constellation includes 132 low-Earth orbit satellites with orbital height of 1,056 kilometers, and the remaining satellites are located between 27,355 and 44,221 kilometers, which will provide services to residential, commercial, institutional, government and corporate customers around the world.
Boeing specializes in the development of large satellites of geostationary orbit (GEO). In order to strengthen the development capabilities of NGSO satellites, Boeing acquired Millennium Space Systems, a small satellite specialist company, in 2018, to strengthen its competitiveness in this field.
Compared with the Ka band and Ku bands of the SpaceX "Starlink" satellite, Boeing uses a higher frequency V-band broadband network speed faster, but rainfall may reduce interference with V-band signal transmission. In addition to allowing Boeing to provide satellite services in the V-band, FCC approved Boeing to establish inter-satellite links in some V-bands. However, the FCC rejected Boeing's request to establish inter-star links in the Ka band and other parts of the V band to avoid potential on-orbit communication problems.
(IV) Obtained the GPS satellite in orbit operation guarantee contract for the next 10 years
In December 2021, US Space Force awarded Boeing a contract worth US$329.3 million to provide support for the in-orbit operation of the GPS-2F satellite in the next 10 years. Of the 31 GPS satellites currently in service in the United States, 12 are GPS-2F satellites. The GPS-2F satellite was launched between 2010 and 2016, replacing the GPS-2A satellite launched between 1990 and 1997. In 2010, the US Air Force chose Lockheed Martin to develop the next generation of GPS-3 satellites. The GPS-2F satellite has a design service life of 12 years. Judging from the experience of US military and commercial satellites in orbit, the service life of the GPS-2F satellite is expected to exceed the design service life of several years.
4. International Space Station
2021, the solar panel developed by Boeing was installed on the International Space Station.
In June, two new solar panels developed by Boeing were launched into orbit and entered the International Space Station, and the installation was completed through three space walks by astronauts on the station. Old solar panels will not be removed and will continue to be used.
New solar panels are 18.6 meters long and 6.1 meters wide, and are half the size of the old board, but the electricity generated is twice that of the old board. By 2023, the International Space Station will add four new solar panels, all developed by Boeing's Spectrolab. During each 6.5-hour spacewalk, the Mission Control Center's NASA flight control personnel collaborated directly with the astronauts and were assisted by a 16.8-meter-long robotic arm and mobile transport device on the International Space Station. The device is able to move along the trusses of the International Space Station and is specifically designed to place the device.
New solar panels can be tightly rolled up during launch, supported by a structure that can be unfolded by itself without a heavy motor. They can be unfolded with their own energy and are small in size. After entering orbit, they can be placed by the robot arm of the International Space Station. Astronauts can take it to the far end of the International Space Station trusses through space walk for installation.
These panels will be impacted by micrometeorite fragments and cosmic rays, and can withstand 500-degree temperature changes 16 times a day. When all six new solar panels are installed, the total power generation of the International Space Station will increase to 215 kilowatts, and the total power supply will increase by 20% to 30%, which can support more scientific experiments, technical research, more astronaut survival and commercial needs in low-Earth orbit.
Early in 2021, NASA installed an installation structure on the International Space Station to prepare for Boeing's new solar panels
new solar panels installed on the International Space Station
"Cargo Dragon" spacecraft has two new solar panels loaded before launching
5. Summary and analysis
(I) The development of SLS launch vehicle has made significant progress and has the ability to fly for the first time to support the United States' return to the moon.
SLS launch vehicle development project is the largest aerospace system engineering project currently undertaken by Boeing, and is the focus of Boeing's aerospace system capacity building and development. In 2021, the SLS launch vehicle completed two core-stage static ignition tests on the renovated B-2 test bench, fully verified the system's working performance, achieved the expected goals, and completed docking with the "Orion" spacecraft, and further system-wide testing will be carried out in the future. Before 2021, Boeing's progress in developing the SLS rocket was relatively slow, and NASA's investment was huge, exceeding US$10 billion. However, due to the slow progress of the engineering development, the first flight time was postponed many times.
As the time node for the United States to return to the moon approaches, Boeing and NASA have increased their research and development efforts and jointly promoted the project progress. As of 2021, the SLS launch vehicle itself has basically reached its launch readiness state and has the ability to perform its first unmanned test flight in the first half of 2022.
(II) After continuous testing and optimization, the manned spacecraft has the ability to test flight again to support the US manned spacecraft
"Starship" failed to connect to the International Space Station due to a flight control system failure during its unmanned flight in 2019. Until the end of 2021, NASA and Boeing were continuously testing and troubleshooting, while partially upgrading the spacecraft system.
"Starship" full-system software simulation exercise, spacecraft landing site placement, spacecraft docking system, etc. are all progressing smoothly. It is expected that the second unmanned test flight after 2019 will be completed in 2022. If the test flight is smooth, it can quickly transfer to the manned flight docking International Space Station.
"Starship" is Boeing's second largest aerospace system engineering project that will only be on the SLS launch vehicle. With the progress lagging behind SpaceX's "Manned Dragon" spacecraft, whether it can successfully complete the second unmanned test flight will determine Boeing's position and prospects in the aerospace field.
(III) Small and medium-sized satellite development and constellation deployment projects have become the focus of development in the satellite system field
At present, the global large satellite system development business has generally decreased, and the small and medium-sized satellite business has increased. Boeing has adopted a similar strategy to Lockheed Martin, that is, to acquire companies that develop small satellite platforms while having small and medium-sized satellite platforms.
Boeing is developing SES-20 satellites and SES-21 satellites through the existing 702SP small satellite platform, and developing O3b mPOWER satellites through the 702X medium satellite platform. Millennium Space Systems, a small satellite professional company acquired in 2018, will further support Boeing in this field to develop more types of micro satellites , and develop the newly applied 147 V-band low-orbit broadband satellites.
As the system integrator of traditional large satellites, Boeing is changing its development ideas under the global trend of microsatellites and low-orbit satellites, and is expected to produce more small and medium-sized satellites or microsatellites in the future.
