United Launch Alliance (ULA) Vulcan Next Generation Launch System (NGLS)

Since the Vulcan stage's tanking and de-tanking tests appear to have been successfully carried out does this mean we'll a green-run static test-fire of the stage?
 
https://twitter.com/x/status/1658084513963192320
View: https://twitter.com/torybruno/status/1658084513963192320


Good #VulcanRocket Flight Tanking Tests last Friday & Saturday. Will need to adjust a handful of parameters and set points for a reliable FRF count. (Which is is the purpose of this run). Rolling back to the VIF today to work on that. FRF in a few days or so.
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You mention tests (plural). Did you run more than one tanking/detanking sequence?
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https://twitter.com/x/status/1658113688040095745
View: https://twitter.com/torybruno/status/1658113688040095745


One sequence, with a recycle. Contains many discrete test events
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ULA President Tory Bruno just told TPS's Mat Kaplan at the Humans to Mars Summit that Vulcan will launch "this summer or later in the year" depending on what if any fixes are needed to upper stage after that leak in the steel pressure vessel. Will know very soon.
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https://twitter.com/x/status/1658551656735203329
View: https://twitter.com/SpcPlcyOnline/status/1658551656735203329

https://twitter.com/x/status/1658805533002825729
View: https://twitter.com/jeff_foust/status/1658805533002825729


Talked with Tory Bruno yesterday to get the latest status on Vulcan.
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spacenews.com

ULA preparing for Vulcan Centaur static fire

ULA expects to conduct a static-fire test of its Vulcan Centaur rocket in several days, but the timing of the vehicle’s first launch remains uncertain.
spacenews.com spacenews.com
 
Well it looks like we'll be seeing the green run of the first Vulcan stage in the near future, from TheSpaceBucket:


For months now we have seen progress ramp up as United Launch Alliance and the Vulcan rocket approach its maiden flight. While there have been a few different delays thanks to explosive tests and various reasons, the company is still on track for a launch very soon. As ULA phases out other rockets, Vulcan is meant to become the new workhorse and has a lot riding on its success.
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In the last few days, we saw the completion of different tanking tests on the full test article. This is in preparation for the final main test before launch, the flight readiness firing. Based on current progress and updates from Tory Bruno, in only days from now, this test should be attempted. This will see the two BE-4 engines fire on the rocket for the first time and ensure Vulcan is ready for flight.
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Depending on the results of this test, Vulcan’s maiden flight could be only weeks away. This being said, other important factors like payload delivery and the investigation of the test tank anomaly will also play a big part in the rocket’s schedule. Here I will go more in-depth into the recent testing completed by ULA, the final steps before Vulcan’s maiden flight, what to expect in the coming days, and more.
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Full article here - https://thespacebucket.com/the-first-...
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Strange how the test did not last long. I thought that engine tests were supposed to last a certain amount of time before being shut down.
 
FighterJock said:
Strange how the test did not last long. I thought that engine tests were supposed to last a certain amount of time before being shut down.
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FRF does not have to be a full-duration burn (Falcon 9 static fires are 3.5 to 7 seconds). ULA say this was successful; why second-guess their test cards?

https://twitter.com/x/status/1666627584589807617
View: https://twitter.com/ulalaunch/status/1666627584589807617?ref_src=twsrc%5Egoogle%7Ctwcamp%5Eserp%7Ctwgr%5Etweet
 
Well TheSpaceBucket has just put out a video about this successful static test:


For years now both the Vulcan launch vehicle and the BE-4 engines have been going through constant development and testing in preparation for an initial launch. Yesterday they both passed the most important milestone yet with the successful completion of Vulcan's Flight Readiness Firing. With this test done, there are only a few final steps before the long-awaited launch.
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Specifically, ULA completed the first static fire of the two BE-4 engines. In total, they fired all the hardware for a few seconds and with very promising results. We have seen countless BE-4 static fires in the past but nothing on an actual launch vehicle only months away from lift-off.
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While both the rocket itself and the BE-4 engines have had varying results in the past few years in the form of delays, this milestone is a good sign for both. Here I will go more in-depth into yesterday's test, what's left before the maiden flight, what to expect in the coming weeks, and more.
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Nice, a second engine test. I don't want to say it, but does this mean that launch day must be close?
 
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https://twitter.com/x/status/1672587310423244800
View: https://twitter.com/jeff_foust/status/1672587310423244800


An update this morning from ULA on Vulcan. Some "minor modifications" needed to the Centaur upper stage after the investigation into the March test anomaly that require destacking the Cert-1 vehicle. No new target launch date for that mission.
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(Cape Canaveral Space Force Station, Fla., June 24, 2023) - The team completed the data review following the recent Flight Readiness Firing and all test objectives were successfully achieved. In parallel, we have determined the root cause and corrective action for the Centaur V structural test stand anomaly at Marshall Space Flight Center on March 29. Centaur's thin-walled pressure stabilized tanks require minor reinforcement at the top of the forward dome prior to flight. We plan to de-stack the Vulcan rocket and return the Centaur V to Decatur for modifications. The booster is healthy and ready to support the first launch and will be stored horizontally in the Horizontal Integration Facility until we are ready to resume mission processing. ULA has several Centaur V flight articles in production in Decatur and one will be identified as the test article to complete qualification testing. Tory Bruno, ULA president and CEO, will provide an update at a media telecon in the next few weeks. A media advisory will be sent with information as well as how to RSVP.
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At least they are carrying out the modifications that are needed to get the Vulcan ready for launch, all they need to do is take their time and not to rush the modifications.
 
Some news concerning the Vulcan Centaur's upper-stage being sent back to the factory, from TheSpaceBucket:


Vulcan Centaur is a launch vehicle developed by United Launch Alliance that is expected to become the future workhorse for the company. As they phase out other rockets such as the Delta IV Heavy, the Vulcan is supposed to increase its launch cadence to around a mission every two weeks. This would be a significant step up for the company and its launch vehicle.
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However, before this can happen they need to get it off the ground first. Unfortunately, this has been a lot harder than initially hoped with a few different problems coming up quite frequently. Only days ago in a company statement, they revealed that an explosion with a test Centaur upper stage back in April is now going to delay the maiden flight.
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While they didn't provide a new timeline or estimate on how long this process would take, they did describe exactly what needs to happen between now and the first launch. Here I will go more in-depth into the recent delay, what this means for Vulcan's future, what to expect in the coming months, and more.
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Full article here - https://thespacebucket.com/ulas-vulca...
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So absolutely no chance of a launch anytime this year? That is a shame. Let's see if they can get the rocket launched next year.
 
Latest update on the launch timeline and its knock on consequences.

https://twitter.com/x/status/1674133237160091648
View: https://twitter.com/sciguyspace/status/1674133237160091648


ULA confirms Vulcan debut will launch NET 4Q 2023. It seems almost certain now that some NSSL Phase 2 missions will move from Vulcan to Falcon.
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arstechnica.com

ULA shipping Vulcan upper stage back to factory for more work

ULA's Vulcan rocket is likely at least a year away from becoming operational.
arstechnica.com arstechnica.com
 
https://twitter.com/x/status/1677351364899348486
View: https://twitter.com/free_space/status/1677351364899348486


Despite delays w/ @ulalaunch Vulcan rocket, Space Force SSC reaffirms 2 flights required prior to first nat'l security space mission. “ULA and Space Force developed a detailed certification plan for the Vulcan which ULA is still accountable to meeting. SSC is not planning any additional objectives or combining objectives into a single mission,” SSC tells @AviationWeek
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Next issue with Centaur come this:

according CNBC
on June 30 2023 BO tested in West Texas a BE-4 engine, that after 10 seconds exploded.
lucky no one was injured, but test stand was heavily damaged so eyewitness.
According sources to CNBC was this a BE-4 engine for Second Vulcan rocket.

This delay the Vulcan program further

Source:
www.cnbc.com

Jeff Bezos’ Blue Origin rocket engine explodes during testing

It's a destructive setback with potential ramifications for the company's customer United Launch Alliance and Blue Origin's own rocket New Glenn.
www.cnbc.com www.cnbc.com
 
Michel Van said:
on June 30 2023 BO tested in West Texas a BE-4 engine, that after 10 seconds exploded.
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IMO that would appear to be a catastrophic turbo-pump failure likely the result of a manufacturing defect in one or more of its' components.
 
NMaude said:
IMO that would appear to be a catastrophic turbo-pump failure likely the result of a manufacturing defect in one or more of its' components.
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since BE-4 use oxygen-rich staged combustion cycle
my guess
control value malfunction and follow by Turbopump over pressure the combustion chamber.
Mai 13. 2017 they lost the Turbopump /Preburner in explosion
 
FighterJock said:
Not good to see that Blue Origin having a catastrophic explosion with the same engine that Vulcan uses.
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I thought I read that it was an engine going through acceptance testing for the second Vulcan launcher.
 
TheSpaceBucket has just put out a video concerning the destruction of the BE-4 rocket-motor on the test-stand:


For around a decade now Blue Origin has been developing and manufacturing the BE-4 engine. In that time the company has run into quite a few delays but still managed to produce a next-generation engine. Most recently we saw increases in production as the demand for these engines is expected to grow significantly in the coming months.
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Unfortunately, yesterday reports came out that a BE-4 flight engine exploded 10 seconds into its static fire. This happened last month during acceptance testing at one of Blue Origins’ test stands. The explosion destroyed the engine and was responsible for a decent amount of damage to the test stand infrastructure.
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Even more concerning is the problem itself and whether or not this issue could affect Vulcan, which currently has two BE-4 flight engines installed and ready for the maiden flight. Not to mention the production underway and plans with New Glenn. Here I will go more in-depth into the BE-4 explosion, what it means for Vulcan and New Glenn, what to expect in the coming weeks, and more.
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Full article here - https://thespacebucket.com/a-closer-l...
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Get another test organised and see if it was just that one dodgy engine, that is what I am thinking right now, surely lightning can't strike twice?
 
FighterJock said:
Get another test organised and see if it was just that one dodgy engine, that is what I am thinking right now, surely lightning can't strike twice?
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I'd say you're looking at a complete teardown of other BE-4 engines from that production batch followed by a very thorough examination of all of each engine's components (Followed by the replacement of any defective parts) before said engines are rebuilt and retested.
 
So it's more difficult than I first thought NMaude, it will be interesting to see if this causes a delay to the launch of the first Vulcan which will be a pity but it is better to be safe than sorry with a new Vulcan exploding on the launch pad.
 
Update on the Centaur mods:

https://twitter.com/x/status/1679522531886202880
View: https://twitter.com/w_robinsonsmith/status/1679522531886202880


22/22

@joroulette: Does the added 300 pounds on the Centaur V affect any of the missions @ulalaunch currently has lined up?

Bruno: "The 300 pounds doesn't affect us at all. We have margins today against every mission we have."

That's it today from ULA. A very thorough brief.
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https://twitter.com/x/status/1679528504105263110
View: https://twitter.com/spcplcyonline/status/1679528504105263110

Centaur V will be qualified for the Cert-1 trajectory for the flight by the end of this year. Remaining tests will be completed in 1st Q 2024. Cert-2 flight is Sierra Space's Dream Chaser "a few months" after Cert-1. First NSSL launch in 2nd Q 2024.
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The additional stainless steel will add 300 pounds of weight to the Cert-1 vehicle, but they're not close to the mass limit so won't matter. Won't be that much on future vehicles. Vulcan can take 60,000 lbs to LEO so not a significant change.
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