0603302F Space and Missile Rocket Propulsion

Note: In FY 1996, launch technology efforts in Projects 6340 and 6341 were combined into Project 4373. Also, in FY 1996, Project 0003, Launch Vehicle Technology, was transferred from PE 0603401F into this PE to combine all space launch technologies into a single PE.

(U) A. Mission Description and Budget Item Justification: This Advanced Technology Development program develops and demonstrates advanced rocket propulsion and space launch technologies. This program provides the technological step necessary to transition the most promising rocket propulsion and space launch technologies to applications using full-scale, proof-of-principle demonstrations. The projects within this program are structured to support Air Force Space Command's and Air Combat Command's mission area requirements for space and missile technologies which include the goals established in the Integrated High Payoff Rocket Propulsion Technology Initiative, a multi-agency/industry effort to focus the development of U.S. rocket propulsion technology.

New and improved components will be integrated with the environmentally improved propellants developed in this program to create new propulsion systems for the next generation of launch vehicles and satellites. Anticipated technological advances in this program will improve the performance of expendable systems' payload capabilities by 21% and reduce the launch and operations and support (O&S) costs by 28%. In a reusable launch system, the anticipated improvements are an increase in payload capability of 170% and a reduction in launch and O&S costs of 79%. The advances in propulsion in this program result from the achievement of the 2010 goals of the Integrated High Payoff Rocket Propulsion Technology Initiative. The development of these technologies has been coordinated with NASA to eliminate duplication of efforts. The space launch and missile propulsion industry will leverage the technologies from this program to enhance the country's industrial competitiveness.

Note: Congress added $5 million for Integrated High Payoff Rocket Propulsion Technology (IHPRPT) in FY 1996 and $2 million for Pentaborane Disposal and $3 million for Scorpius in FY 1997 which explains the perceived decrease in FY 1998. In FYs 1999 and out, additional emphasis has been placed on space launch technology.

(U) B. Program Change Summary ($ in Thousands):

	FY 1996	FY 1997	FY 1998	FY 1999	Total Cost
(U) Previous President's Budget	19,246	15,740	15,114	17,069	Cont
(U) Appropriated Value	20,203	23,240
(U) Adjustments to Appropriated Value
a. Congressional/General Reductions	-451	-466
b. SBIR	-305	-399
c. Omnibus/Other Above Threshold Reprogrammings	-460	-22
e. Below Threshold Reprogrammings	-825
(U) Current Budget Submit/FY 1998 PB	18,162	22,353	16,247	22,037	Cont

(U) Change Summary Explanation:

Funding: Changes to this PE since the previous President's Budget are due to budget constraints and priorities within the Science and Technology (S&T) Program.

Schedule: Not Applicable.

Technical: Not Applicable

(U) C. Other Program Funding Summary: Not Applicable.

(U) D. Schedule Profile: Not Applicable.

	COST ($ In Thousands)	FY 1996 Actual	FY 1997 Estimate	FY 1998 Estimate	FY 1999 Estimate	FY 2000 Estimate	FY 2001 Estimate	FY 2002 Estimate	FY 2003 Estimate	Cost to Complete	Total Cost
0003	Launch Vehicle Technology	571	588	663	663	672	682	703	725	Continuing	Continuing

Note: In FY 1996, launch technology efforts in Projects 6340 and 6341 were combined into Project 4373. Also, in FY 1996, Project 0003, Launch Vehicle Technology, was transferred from PE 0603401F into this PE to combine all space launch technologies into a single PE.

(U) A. Mission Description and Budget Item Justification: This project develops advanced and innovative launch vehicle technologies in the areas of structures (i.e., fairings, interstages, struts, thermal protection systems, etc.), tanks, and operations.

(U) FY 1996 ($ in Thousands):

(U) $571	Develop space launch vehicle technology.
	(U) Defined technological needs for future expendable and reusable military launch vehicles including operations technologies, light-weight airframe structures, durable composite cryogenic tanks, and all-weather thermal protection.
	(U) Designed and fabricated advanced composite sub-scale vehicle stage connectors (interstages) using techniques that promise up to 50% weight reductions and 30-60% cost reductions.
(U) $571	Total

(U) FY 1997 ($ in Thousands):

(U) $588	Develop space launch vehicle technology.
	(U) Continue to define technological needs for future expendable and reusable military launch vehicles including operations technologies, lightweight airframe structures, durable composite cryogenic tanks, and all-weather thermal protection.
	(U) Fabricate full-size advanced composite interstages for future launch vehicles, using and validating techniques that promise up to 50% weight reductions and 30-60% cost reductions.
(U) $588	Total

(U) FY 1998 ($ in Thousands):

(U) $663	Develop space launch vehicle technology.
	(U) Continue to define technological needs for future expendable and reusable military launch vehicles including operations technologies, lightweight airframe structures, durable composite cryogenic tanks, and all-weather thermal protection.
	(U) Continue fabrication of full-size advanced composite interstages for future launch vehicles, using and validating techniques that promise up to 50% weight reductions and 30-60% cost reductions.
(U) $663	Total

(U) FY 1999 ($ in Thousands):

(U) $663	Develop space launch vehicle technology.
	(U) Continue to define technological needs for future expendable and reusable military launch vehicles including operations technologies, lightweight airframe structures, durable composite cryogenic tanks, and all-weather thermal protection.
	(U) Complete fabrication of full-size advanced composite interstages for future launch vehicles, using and validating techniques that promise up to 50% weight reductions and 30-60% cost reductions.
	(U) Begin flight experiment for advanced composite payload shroud.
(U) $663	Total

(U) B. Program Change Summary ($ in Thousands):

	FY 1996	FY 1997	FY 1998	FY 1999	Total Cost
(U) Previous President's Budget	571	612	617	624	Cont
(U) Current Budget Submit/FY 1998 PB	571	588	663	663	Cont

(U) Change Summary Explanation:

Funding: Changes to this project since the previous President's Budget are due to budget constraints and priorities within the Science and Technology (S&T) Program.

Schedule: Not Applicable.

Technical: Not Applicable.

(U) C. Other Program Funding Summary:

(U) Related Activities:

(U) PE 0602102F, Materials.

(U) PE 0602601F, Phillips Laboratory.

(U) PE 0603401F, Advanced Spacecraft Technology.

(U) PE 0603853F, Evolved Expendable Launch Vehicle Program.

(U) This project has been coordinated through the Project Reliance process to harmonize efforts and eliminate duplication.

(U) D. Schedule Profile: Not Applicable.

	COST ($ In Thousands)	FY 1996 Actual	FY 1997 Estimate	FY 1998 Estimate	FY 1999 Estimate	FY 2000 Estimate	FY 2001 Estimate	FY 2002 Estimate	FY 2003 Estimate	Cost to Complete	Total Cost
4373	Launch and Orbit Transfer Propulsion Technology	15,686	19,526	13,707	19,488	20,233	20,216	20,927	21,496	Continuing	Continuing

Note: In FY 1996, launch technology efforts in Projects 6340 and 6341were combined into this project.

(U) A. Mission Description and Budget Item Justification: This project develops advanced and innovative, low-cost rocket turbomachinery and components, low-cost space and missile launch propulsion system manufacturing technologies, and environmentally acceptable propellants. Characteristics such as environmental acceptability, affordability, reliability, reduced weight, reduced operation and launch costs, and increased life and performance of propulsion systems are emphasized in this project. Technological advances developed in this program will improve the performance of expendable systems' payload capabilities by 21% and reduce the launch and operations and support (O&S) costs by 28%. The advances in propulsion in this program result from the achievement of the 2010 goals of the Integrated High Payoff Rocket Propulsion Technology Initiative.

(U) FY 1996 ($ in Thousands):

(U) $6,436	Develop advanced, environmentally acceptable propellants for current and future launch systems.
	(U) Completed large-scale testing of non-toxic, chlorine-free space launch propellant and verified the performance capabilities and cost-benefit analyses for replacement of current propellants.
	(U) Quantified costs and benefits, and performance characteristics of solid motors developed using environmentally acceptable manufacturing techniques.
	(U) Conducted impact analyses of environmentally improved propellants on solid rocket motor components (such as hotter burning temperatures and highly erosive environments) and determined performance needs of replacement components.
	(U) Developed low-cost, carbon/carbon nozzles, quantifying the manufacturing cost savings of a new, rapid densification process.
	(U) Identified and assessed technologies for solid motor components.
(U) $9,250	Develop propulsion technologies for existing and future launch vehicles.
	(U) Completed design and began fabrication of low-cost, highly reliable turbopump, preburner, and thrust chamber components with fluid film bearing technologies to increase liquid booster propulsion capabilities.
(U) $15,686	Total

(U) FY 1997 ($ in Thousands):

(U) $5,294	Develop advanced, environmentally acceptable propellants technology for current and future launch systems.
	(U) Publish final report assessing the increased performance benefits of a new, non-toxic chlorine-free propellant for replacement of current propellants in solid launch systems.
	(U) Continue studying current and proposed environmental regulations for their impact on the manufacturing of large-scale solid rocket booster propellants.
	(U) Begin development of a new solid-fuel motor which maintains motor integrity and performance while drastically increasing safety by creating a method to load the fuel at the launch site. (This eliminates the risk of explosion during transport).
	(U) Design, fabricate, and demonstrate solid motor components.
	(U) Begin disposal of pentaborane.
(U) $14,232	Develop propulsion technologies for existing and future launch vehicles.
	(U) Integrate fluid film bearing technologies into the oxygen and hydrogen rocket turbopumps, increasing liquid-booster propulsion performance.
	(U) Begin development of advanced, lightweight, thrust chamber components to be integrated with rocket turbopumps and preburners.
	(U) Design and fabricate a complete thrust chamber with extended thermal-cycle life, decreased system costs, and increased liquid engine reliability that will be used in boost and orbit transfer missions.
(U) $19,526	Total

(U) FY 1998 ($ in Thousands):

(U) $3,699	Develop advanced, environmentally acceptable propellants technology for current and future launch systems.
	(U) Publish report detailing impacts to solid rocket motor designs by using the environmentally cleaner propellants.
	(U) Publish report detailing environmentally acceptable manufacturing techniques for the development of future cleaner burning large solid booster.
	(U) Begin to scale-up the technology developed in the Process Efficient Motor Technology program to apply innovations to full-scale solid boosters.
(U) $6,806	Develop propulsion technologies for existing and future launch vehicles.
	(U) Continue fabrication of turbopump assemblies and begin testing in relative environment.
	(U) Continue development of advanced lightweight thrust chamber components for integration into advanced liquid booster.
(U) $3,202	Develop propulsion technologies for existing and future upperstage and orbit transfer vehicles.
	(U) Complete design and begin fabrication and assembly of a high pressure liquid oxygen/hydrogen upperstage engine.
	(U) Begin design of high altitude solar thermal Orbital Transfer Vehicle (OTV) balloon experiment.
	(U) Begin design of pulsed plasma thruster for inclusion in the MightlySat Flight demo.
(U) $13,707	Total

(U) FY 1999 ($ in Thousands):

(U) $6,705	Develop advanced, environmentally acceptable propellants technology for current and future launch systems.
	(U) Continue scale-up of the technology developed in the Process Efficient Motor Technology program to apply innovations to full-scale solid boosters.
(U) $6,547	Develop propulsion technologies for existing and future launch vehicles.
	(U) Complete testing of turbopump assembly and preburner components for integration into an advanced liquid booster.
	(U) Complete assembly and engine testing of a 1200 psi liquid oxygen/hydrogen upperstage engine.
(U) $6,236	Develop propulsion technologies for existing and future upperstage and orbit transfer vehicles.
	(U) Complete assembly and engine testing of a high pressure liquid oxygen/hydrogen upperstage engine.
	(U) Complete design and high altitude balloon testing of solar thermal OTV propulsion.
	(U) Continue testing of pulsed plasma thruster for insertion into MightySat flight demo.
(U) $19,488	Total

(U) B. Program Change Summary ($ in Thousands):

	FY 1996	FY 1997	FY 1998	FY 1999	Total Cost
(U) Previous President's Budget	16,770	14,050	13,681	15,606	Cont
(U) Current Budget Submit/FY 1998 PB	15,686	19,526	13,707	19,488	Cont

(U) Change Summary Explanation:

Funding: Changes to this project since the previous President's Budget are due to budget constraints and priorities within the Science and Technology (S&T) Program.

Schedule: Not Applicable.

Technical: Not Applicable.

(U) C. Other Program Funding Summary:

(U) Related Activities:

(U) PE 0602601F, Phillips Laboratory.

(U) PE 0603853F, Evolved Expendable Launch Vehicle Program.

(U) This project has been coordinated through the Project Reliance process to harmonize efforts and eliminate duplication.

(U) D. Schedule Profile: Not Applicable.

	COST ($ In Thousands)	FY 1996 Actual	FY 1997 Estimate	FY 1998 Estimate	FY 1999 Estimate	FY 2000 Estimate	FY 2001 Estimate	FY 2002 Estimate	FY 2003 Estimate	Cost to Complete	Total Cost
6339	Tactical Propulsion Technology	286	298	336	340	349	358	366	376	Continuing	Continuing

(U) A. Mission Description and Budget Item Justification: This project develops highly energetic propellants and propulsion systems. Improved case, insulation, and propellant interfaces as well as better performing nozzles will be developed. Technology such as thrust vector control, thrust modulation, signature characterization, and signature reduction will be developed in this project. The emphasis in this project is on rocket propulsion system affordability, weight reduction. Anticipated payoffs from these developments, identified through the Integrated High Payoff Rocket Propulsion Technology Initiative (IHPRPT), include a 49% range increase, 50% size reduction, 100% payload increase, and 21% reduction in time-to-target.

(U) FY 1996 ($ in Thousands):

(U) $136	Develop and characterized, in lab-size quantities, propellants and components that can be incorporated into the design and manufacturing of missile systems that will result in higher performance, lower environmental impacts, and reduced missile signatures.
	(U) Completed analysis of environmentally acceptable, reduced smoke, and low-erosion propellants, insulators, and nozzle coatings, as well as solvent-less manufacturing processes, designed to improve missile thrust and reduced signature.
(U) $150	Conduct system payoff analyses which validate program objectives and approaches in pursuit of the IHPRPT goals for tactical missiles.
	(U) Conducted payoff analyses to identify rocket component technologies and determine their benefit to aircraft survivability and kill ratio.
(U) $286	Total

(U) FY 1997 ($ in Thousands):

(U) $298	Develop and characterize, in lab-size quantities, propellants and components that can be incorporated into the design and manufacturing of missile systems that will result in higher performance, lower environmental impacts, and reduced signature characteristics.
	(U) Demonstrate environmentally acceptable, reduced smoke, low-erosion tactical missile propellants and components that improve missile thrust and reduce plume signatures.
(U) $298	Total

(U) FY 1998 ($ in Thousands):

(U) $336	Develop and characterize, in lab-size quantities, propellants and components that can be incorporated into the design and manufacturing of missile systems that will result in higher performance, lower environmental impacts, and reduced signature characteristics.
	(U) Integrate component technologies and hardware for environmentally acceptable, reduced smoke, low-erosion tactical missile propellants and components that improve missile thrust and reduce plume signatures.
(U) $336	Total

(U) FY 1999 ($ in Thousands):

(U) $340	Develop and characterize, in lab-size quantities, propellants and components that can be incorporated into the design and manufacturing of missile systems that will result in higher performance, lower environmental impacts, and reduced signature characteristics.
	(U) Scale-up development for environmentally acceptable, reduced smoke, low-erosion tactical missile propellants and components that improve missile thrust and reduce plume signatures.
(U) $340	Total

(U) B. Program Change Summary ($ in Thousands):

	FY 1996	FY 1997	FY 1998	FY 1999	Total Cost
(U) Previous President's Budget	286	309	313	321	Cont
(U) Current Budget Submit/FY 1998 PB	286	298	336	340	Cont

(U) Change Summary Explanation:

Funding: Changes to this project since the previous President's Budget are due to budget constraints and priorities within the Science and Technology (S&T) Program.

Schedule: Not Applicable.

Technical: Not Applicable.

(U) C. Other Program Funding Summary:

(U) Related Activities:

(U) PE 0602601F, Phillips Laboratory.

(U) PE 0602303A, Missile Technology.

(U) PE 0603313A, Missile and Rocket Advanced Technology.

(U) PE 0603792N, Advanced Technology Transition.

(U) This project has been coordinated through the Project Reliance Process to harmonize efforts and eliminate duplication.

(U) D. Schedule Profile: Not Applicable.

	COST ($ In Thousands)	FY 1996 Actual	FY 1997 Estimate	FY 1998 Estimate	FY 1999 Estimate	FY 2000 Estimate	FY 2001 Estimate	FY 2002 Estimate	FY 2003 Estimate	Cost to Complete	Total Cost
6340	Satellite Control and Maneuvering Propulsion Technology	1,619	1,941	1,541	1,546	1,551	1,560	1,576	1,595	Continuing	Continuing

(U) A. Mission Description and Budget Item Justification: Chemical, electric, and solar rocket propulsion system technologies for station keeping and on-orbit maneuvering applications are developed in this project. Technology areas investigated include ground demonstrations of compact, lightweight, advanced propulsion systems, higher efficiency energy conversion systems (derived from an improved understanding of combustion fundamentals), and high-energy chemical propellants. The payoffs for the Integrated High Payoff Rocket Propulsion Technology Initiative (IHPRPT) include a seven-year increase in satellite on-orbit time, a 50% increase in satellite maneuvering capability, a 25% reduction in orbit transfer operational costs, and a 15% increase in satellite payload.

(U) FY 1996 ($ in Thousands):

(U) $1,619	Demonstrate orbit transfer and maneuvering propulsion technology.
	(U) Integrated and demonstrated the 30 kilowatts (kW) ammonia arcjet thruster on the space test and transportation satellite. The satellite was measured for its performance and successful integration with an electric propulsion system. Electromagnetic impulse, contamination, solar array degradation, etc. were scrutinized.
(U) $1,619	Total

(U) FY 1997 ($ in Thousands):

(U) $1,941	Demonstrate solar electric propulsion technologies for orbit transfer and maneuvering propulsion technology.
	(U) Support launch and space demonstration of the 30kW ammonia arcjet thruster, analyze data, and draft final report.
	(U) Design the ground demonstration hardware for a high-powered Hall Thruster.
(U) $1,941	Total

(U) FY 1998 ($ in Thousands):

(U) $541	Demonstrate solar electric propulsion technologies for orbit transfer and maneuvering propulsion technology.
	(U) Continue support launch and space demonstration of the 30kW ammonia arcjet thruster, data analysis, and final report creation.
	(U) Develop and fabricate the ground demonstration hardware for a high-powered Hall Thruster (power processing unit, thruster materials).
(U) $1,000	Demonstrate post boost vehicle strategic sustainment technologies.
	(U) Begin development of post boost vehicle component technologies.
	(U) Begin development of post boost vehicle propellant technologies.
(U) $1,541	Total

(U) FY 1999 ($ in Thousands):

(U) $546	Demonstrate solar electric propulsion technologies for orbit transfer and maneuvering propulsion technology
	(U) Begin testing and analyze performance, life, and integration improvements for a high-powered Hall Thruster.
(U) $1,000	Demonstrate post boost vehicle strategic sustainment technologies.
	(U) Continue development of post boost vehicle component technologies.
	(U) Continue development of post boost vehicle propellant technologies.
(U) $1,546	Total

(U) B. Program Change Summary ($ in Thousands):

	FY 1996	FY 1997	FY 1998	FY 1999	Total Cost
(U) Previous President's Budget	1,619	769	503	518	Cont
(U) Current Budget Submit/FY 1998 PB	1,619	1,941	1,541	1,546	Cont

(U) Change Summary Explanation:

Funding: Changes to this project since the previous President's Budget are due to budget constraints and priorities within the Science and Technology (S&T) Program.

Schedule: Not Applicable.

Technical: Not Applicable.

(U) C. Other Program Funding Summary:

(U) Related Activities:

(U) PE 0602601F, Phillips Laboratory.

(U) This project has been coordinated through the Project Reliance process to harmonize efforts and eliminate duplication.

(U) D. Schedule Profile: Not Applicable.