Design of Rockets and Space Launch Vehicles [2 ed.] 2022012407, 2022012408, 9781624106415, 9781624106422

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Design of Rockets and Space Launch Vehicles Second Edition

Don Edberg and Willie Costa With a Foreword by Homer Hickam

Joseph A. Schetz Editor-In-Chief

Design of Rockets and Space Launch Vehicles Second Edition

Design of Rockets and Space Launch Vehicles

Second Edition

Don Edberg Consultant & Professor of Aerospace Engineering California State Polytechnic University, Pomona

Willie Costa Engineering & Management Consultant

AIAA EDUCATION SERIES Joseph A. Schetz, Editor-in-Chief Virginia Polytechnic Institute and State University Blacksburg, Virginia

Cover image: Starship Super Heavy, courtesy of SpaceX. (CC BY-NC 2.0) https://creativecommons.org/licenses/by-nc/2.0/. American Institute of Aeronautics and Astronautics, Inc., Reston, Virginia 1 2 3 4 5 Library of Congress Cataloging-in-Publication Data Names: Edberg, Donald L., author. | Costa, Guillermo, author. Title: Design of rockets and space launch vehicles / Don Edberg, Consultant & Professor of Aerospace Engineering, California State Polytechnic University, Pomona, Willie Costa, Engineering & Management Consultant. Description: Second edition. | Reston, Virginia : The American Institute of Aeronautics and Astronautics, Inc., [2022] | Series: AIAA education series | Includes bibliographical references and index. Identifiers: LCCN 2022012407 (print) | LCCN 2022012408 (ebook) | ISBN 9781624106415 (print) | ISBN 9781624106422 (ebook) Subjects: LCSH: Rockets (Aeronautics)–Design and construction. | Launch vehicles (Astronautics)–Design and construction. Classification: LCC TL782 .E33 2022 (print) | LCC TL782 (ebook) | DDC 621.43/56–dc23/eng/20220408 LC record available at https://lccn.loc.gov/2022012407 LC ebook record available at https://lccn.loc.gov/2022012408 Cataloging in Publication data on file. Print ISBN: 978-1-62410-641-5 Ebook ISBN: 978-1-62410-642-2

Copyright # 2022 by the Authors. Published by the American Institute of Aeronautics and Astronautics, Inc., with permission. Data and information appearing in this book are for informational purposes only. AIAA is not responsible for any injury or damage resulting from use or reliance, nor does AIAA warrant that use or reliance will be free from privately owned rights.

AIAA EDUCATION SERIES Editor-in-Chief

Joseph A. Schetz Virginia Polytechnic Institute and State University

Editorial Board Joa ˜o Luiz F. Azevedo Comando-Geral De Tecnologia Aeroespacial Marty Bradley University of Southern California James R. DeBonis NASA Glenn Research Center Kajal K. Gupta NASA Dryden Flight Research Center Rakesh K. Kapania Virginia Polytechnic Institute and State University

Michael Mohaghegh The Boeing Company Brett Newman Old Dominion University Hanspeter Schaub University of Colorado Humberto Silva III Sandia National Laboratories David M. Van Wie Johns Hopkins University

CONTENTS Preface to the First Edition

xiii

Preface to the Second Edition

xxi

Foreword

xxv

About the Authors

xxvii

Testimonials

xxviii

Acknowledgements

Chapter 1

Launch Vehicles: Introduction, Operation, and the Design Process

xxxi

1

1.1 Introduction to Launch Vehicles 1.2 Anatomy of a Launch Vehicle 1.3 The Phases of Launch and Ascent 1.4 Typical Launch Vehicle Mission and Mission Elements 1.5 The Typical Launch Vehicle Design Process 1.6 Launch Sites 1.7 Launch Site Selection Criteria 1.8 The Space Industry 1.9 Summary References 1.10 Assignment: Launch Vehicle System Report

1 3 9 17 19 21 23 31 34 34 35

Chapter 2

37

2.1 2.2 2.3 2.4

A Technical History of Space Launch Vehicles

Rockets in the Early 20th Century World War II and the Development of the V-2 The Cold War, ICBMs, and the First Space Launch Vehicles The Moon Race

37 42 45 97 vii

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2.5 The Space Shuttle 2.6 Launch Vehicle Oddities and Dead-Ends 2.7 Other Launch Vehicles from Around the World 2.8 Commercial Launch Vehicles: The Future? 2.9 Small Launch Vehicles References

103 109 119 132 139 143

Chapter 3

147

Missions, Orbits, and Energy Requirements

3.1 Launch Vehicle Requirements Derive from Payload and Mission 3.2 Orbits, Orbital Parameters, and Trajectories 3.3 Spacecraft Mission Orbits and Trajectories 3.4 Required Energy to Be Delivered for Orbit 3.5 Determining the Launch Vehicle Velocity Vector 3.6 Direct Orbit 3.7 Desired Inclination Less than Launch Latitude 3.8 Launch Vehicle Performance Curves 3.9 Launch Windows References 3.10 Example Problems

148 150 155 161 182 187 192 195 197 202 203

Chapter 4

211

Propulsion

4.1 Combustion 4.2 The Thrust Equation and Rocket Equation 4.3 The Rocket Equation 4.4 Solid-Propellant Motors 4.5 Liquid-Propellant Engines 4.6 Examples of Rocket Engine Performance 4.7 Rocket Engine Power Cycles 4.8 Aerospike Engines 4.9 Hybrid Rockets References 4.10 Example Problems

212 215 225 229 235 238 242 256 261 267 267

Chapter 5

271

5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8

Launch Vehicle Performance and Staging

The Three Categories of Launch Vehicle Mass Finding a Rocket’s Speed Change in Free Space Burnout Speed Single-Stage-to-Orbit Staging Calculation of Speed Supplied by a Multistage Rocket Payload Ratio Unrestricted Staging

272 274 277 277 279 282 285 286

Contents

5.9

Gross Mass vs. Staging Speed for Families of TSTO LVs with Differing Propellants 5.10 All-Hydrogen Saturn V? 5.11 Parallel Burns and Staging 5.12 Launch Vehicle Design Sensitivities 5.13 Some Useful Results: Determining Component Mass Values 5.14 Summary References 5.15 Exercises

291 301 305 310 320 322 323 323

Chapter 6

337

Ascent Trajectory Analysis and Optimization

6.1 Vertical Flight in Gravity, No Atmosphere 6.2 Inclined Flight in Gravity, No Atmosphere 6.3 General Flight with Gravity, Atmosphere Effects 6.4 Aerodynamics of Launch Vehicles 6.5 Getting to Orbit 6.6 Launch Vehicle Trajectory Simulation 6.7 Trajectory Optimization 6.8 Some Examples of Launch Profiles and Trajectories 6.9 Some Typical Launch Trajectories 6.10 Conclusion References 6.11 Exercises

338 342 346 357 372 373 380 384 392 398 399 400

Chapter 7

407

Space Launch Vehicle Structures and Layout

7.1 The Thor IRBM 7.2 The Delta II: Evolved from Thor 7.3 Atlas Takes Tank Structure Principle to Extremes 7.4 The Mighty Saturns 7.5 The Saturn V 7.6 Another Way to Save Mass: Tank Dome Shapes 7.7 Spherical vs Cylindrical Tanks: Which Have Less Mass? 7.8 The Space Shuttle 7.9 Delta IV 7.10 Engine Configurations and Other Design Layout Considerations 7.11 Payload Accommodations 7.12 Launch Vehicle Structure Types 7.13 Structural Materials References

407 408 412 415 420 429 429 436 440 441 445 452 457 461

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Chapter 8

Sizing, Inboard Profile, Mass Properties

463

8.1 Inboard Profile 464 8.2 Vehicle or Step Mass Calculations 466 8.3 Liquid Propulsion System Real-Life Additions to Mass and Volume 467 8.4 Other Launch Vehicle Components 477 8.5 Solid Propulsion System Sizing 486 8.6 Comments about Upper Steps and Payload Fairings 490 8.7 Mass Estimation Process 493 8.8 Calculation of Tank or Shell Thicknesses 529 References 537 8.9 Exercises: Sizing, Inboard Profile, and Mass Properties of TSTO LV 539

Chapter 9

Ground and Flight Loads and Analysis

9.1 9.2

545

Launch Vehicle Load Cases Example: Max-q Air Load Calculation for Saturn V/Apollo 11 (SA-506) 9.3 Load Curves Rules of Thumb 9.4 Global vs. Local Loads 9.5 Real Calculation of Vehicle Loads 9.6 Dealing with High-Altitude Winds 9.7 Design Issues for Ascent Phase 9.8 Load Relief During Launch 9.9 Endnote References 9.10 Exercises

584 605 606 606 607 608 609 610 611 612

Chapter 10

623

Launch Vehicle Stress Analysis

10.1 Strength and Stress Analysis 10.2 Stress Determination Using External Loads 10.3 Allowable Stresses Based on Stability (Buckling) Criteria 10.4 Effect of Internal Pressure on Stresses 10.5 Determining the Overall Stress State 10.6 Real World Detailed Stress Analysis 10.7 Summary: Simple Rules for LV Structures References 10.8 Exercises

546

624 628 635 641 648 658 662 662 663

Contents

Chapter 11

Launch Vehicle and Payload Environments: Vibration, Shock, Acoustic, and Thermal Issues

11.1 Mechanical Loads 11.2 Acoustic Environment 11.3 Launch Vehicle Thermal Environment 11.4 Payload Environment: The Spacecraft’s Point of View 11.5 Spacecraft Structure Design Verification Process 11.6 Summary References 11.7 Exercise

Chapter 12

Launch Vehicle Stability and Control; LV Vibration and Instabilities

669 669 675 683 690 692 709 709 710

713

12.1 Guidance and Navigation vs Attitude Control 12.2 Stability and Control 12.3 Controlled Vehicle Equations of Motion 12.4 Launch Vehicle Structural Vibrations and Instabilities 12.5 Propulsion Instabilities 12.6 Summary References 12.7 Exercises: Vibration and TVC Analysis

714 725 749 768 782 789 789 790

Chapter 13

795

Launch Vehicle Manufacturing

13.1 Launch Vehicle Fabrication 13.2 Saturn I Second Step (S-IV) Manufacturing Process 13.3 Composite Structure Fabrication 13.4 Manufacturing: The Future 13.5 Vehicle Stacking and Assembly 13.6 Postassembly Activities 13.7 Summary References

Chapter 14 14.1 14.2 14.3 14.4 14.5 14.6 14.7

795 796 808 817 818 822 822 823

Launch Vehicle Systems and Launch Pad Facilities

825

Saturn V S-IC Fuel Systems Launch Vehicle Pressurization Saturn V S-IC Oxidizer Systems Saturn V Mechanical Services Staging and Separation Systems Launch Vehicle Avionics Launch Pad Facilities and Ground Accommodations

826 829 834 836 838 860 872

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14.8 Launch and Liftoff Considerations 14.9 Vehicle Recovery and Reuse 14.10 Summary References 14.11 Exercise

879 892 904 904 906

Chapter 15

907

Testing, Reliability, and Redundancy

15.1 Testing 15.2 Redundancy 15.3 Summary References 15.4 Exercise

Chapter 16

Failures, Lessons Learned, Flight Termination Systems, and Aborts

16.1 Causes of Expendable Launch Vehicle (ELV) Failures 16.2 Failure Rates of Launch Vehicles 16.3 Some Examples of Launch Vehicle Failures 16.4 Additional Ways to Learn from Others’ Mistakes 16.5 Range Safety and Flight Termination Systems 16.6 Best Practices to Avoid Failure 16.7 Summary References

Chapter 17

Launch Vehicle Financial Analysis and Project Management

907 930 939 939 940

941 941 944 948 960 960 971 972 972

975

17.1 Stages of Mission Development 17.2 The Design Cycle 17.3 Design Decision Making 17.4 Cost Engineering 17.5 Cost Considerations 17.6 Cost Modeling Examples 17.7 Reusability Effects on Costs 17.8 The Effects of New Technology on Cost 17.9 Concluding Remarks References 17.10 Exercises: LV Cost Estimation

976 977 979 983 988 996 1014 1016 1017 1018 1019

Glossary and Abbreviations

1023

Index

1053

Supporting Materials

1071

PREFACE TO THE FIRST EDITION This book is based on a course on space launch vehicle design that has been presented as an undergraduate class at California State Polytechnic University, Pomona (Cal Poly Pomona or CPP) in the Aerospace Engineering department, and as a graduate class for the Astronautics Department at the University of Southern California. The material has also been presented as a short course. The authors created this textbook, Design of Rockets and Space Launch Vehicles (“DoRSLaVe”) as a new text to fill the gap between aircraft and spacecraft design textbooks. Until its introduction, there was no comprehensive work covering the breadth of launch vehicle design. When the authors sought a means to teach the subject of launch vehicle (LV) design, they quickly found that there was nothing comprehensive enough—other books covered part of the subject, but none of them was satisfactory for an introductory course. Some of the possibilities had chapters on rocket engines, others on vehicle performance, others had chapters on trajectories & aerodynamics, a few had stability and control. There was little history included, and most were silent about important but “non-engineering” topics such as manufacturing, launch pad and range facilities, testing and reliability, and cost estimation. This text, which we shall refer to as DoRSLaVe, is our attempt to “put it all together” in one comprehensive volume. DoRSLaVe is intended for seniorlevel capstone engineering design classes at colleges and universities, but will work equally well for graduate classes. In particular, it may be used by readers that do not have a degree in aerospace engineering. However, based on the content—which not only includes the theoretical bases for many design principles but also includes many illustrated examples of these bases—it is also recommended for practicing engineers as well as engineering management who are interested in how things work in either the “big picture” sense, or in areas other than one’s specialty. This book will serve to answer many questions people have as far as “why things are done this way” or “what do I need to know about the subject of ___?” A lot of background information is presented in the book’s extensive technical

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history chapter (Ch. 2), as well as the chapters on testing and reliability (Ch. 15) and on failures and lessons learned (Ch. 16). There are many worked numerical examples of all the aspects of the process of engineering and producing LVs, which clearly serve to introduce principles of these aspects and provide a “feel” for what the answer should look like. The authors believe that part of engineering and design is to have a feel for “approximately what” answer should be expected for a given problem. Materials in this book are a combination of original materials generated by the authors, along with material extracted from publicly-available sources: books, papers, symposium presentations, corporate sources, and the Internet. All non-original material is credited to its owner and is printed with permission. No classified or controlled materials have been incorporated. The copy of DoRSLaVe that you hold in your hands has a wide scope, all the way from requirements to performance to analysis, production, testing, and cost estimation. That being said, to save space, this book does not include many comprehensive derivations of theoretical formulae and related material. Such material is available in dedicated texts—and, as Oliver Heaviside (the developer of the Heaviside Step Function) said, “Am I to refuse to eat because I do not fully understand the mechanism of digestion?” Instead of derivations, we provide the pertinent results along with external references at chapter ends providing more in-depth information. This book concentrates on the application of well-known engineering knowledge to the design and simulation of these fascinating vehicles. Therefore, we provide the caveat that this is an introductory text and as the experts will tell you, “the devil is in the details.” This text will introduce the reader to the basic concepts associated with almost all aspects of the design and engineering processes of a launch vehicle, but it will only provide a snapshot of the details or knowledge that would be available to an experienced practitioner in some aspect of the art. There is no substitute for experience; however, this book will guide the reader in the necessary direction to find further information if it is needed. Launch vehicle and rocket design is a continuously-evolving field, and topics that seemed far-fetched at the time we began collecting information for the text have become common-place, such as the recovery and reuse of first steps of rockets to reduce costs and production rates, a now commonplace event by SpaceX. So, this book should be considered a “snapshot” of the current state of LV affairs at the time of its publishing, and will hopefully remain pertinent as time goes on. If it gets horribly out of date – unlikely because the physics of rocketry will remain constant—well, there’s always the possibility of a Second Edition! The materials inside this book not attributed to others are the authors’ own work. The authors would appreciate readers’ inputs including potential

Preface to the First Edition

topics or subjects; corrections or typographical errors, or other pertinent information. So now: “Launch is served!” Catherine Edberg, September 8, 2013. About the book: DoRSLaVe is laid out in a sequence that mimics the particular sequence of events that might be used to develop the initial or conceptual design of a LV from scratch; exceptions are pointed in the summary of contents of each chapter immediately below. The majority of chapters have exercises or problems that are intended to highlight the major parts of the chapters’ contents. Chapter 1 provides a broad overview of the “world” of launch vehicles. It provides basic information on what they are used for and the space industry in general, basic launch vehicle layouts, and typical launch trajectories. We then describe the design process with a flowchart which indicates the sequence of events beginning with a set of mission requirements, then carrying out initial vehicle sizing, aerodynamics, performance analysis, ground and launch environment, structure, stability, and control analyses, design iterations, and ending with a cost analysis. Finally, we present a list of the world’s launch sites. Chapter 2 is a background chapter providing the technical history of launch vehicles. Knowing this history provides background for current design practices and also gives knowledge of the vast design space possible for LVs. The chapter spans early history to the pre-WWII period, where the Nazis developed the first ballistic missile, to the development of the ICBM, its evolution into launch vehicles, the moon race, and the development of more modern LVs. It ends with a survey of current LVs and some future developments, including small LVs. Chapter 3 begins the LV design process by considering how the LV’s payload mass and orbital requirements will flow down to specify the performance of the LV. We include a brief explanation of common orbits and their required orbital mechanics. With a specified orbit, we show how to calculate the required LV shutdown performance in terms of shutdown speed and direction. Then, the gravity, drag, and steering losses associated with the trajectory must be vectorially added to the shutdown conditions to determine the LV’s design speed. Finally, we discuss launch azimuth directions, orbit injection strategies, and launch windows for both direct and indirect orbits. Chapter 4 discusses rocket propulsion: how thrust is generated, how the rocket’s performance is calculated, and different types and propellants used. We provide details, advantages, and disadvantages of solid and liquid propulsive methods, and some insights on the liquid propulsion ‘cycles’. We also discuss hybrid rockets and aerospikes. This information is useful 

By “background chapter,” we mean a chapter that is provided for background and historical purposes. Typically these background chapters do not provide assignments at the end and are strictly for educational purposes.

xv

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for understanding available propulsion options, and for selecting the propulsion system for a particular mission or requirement. Chapter 5 is an important chapter on LV performance. We show that there are just three parts of a rocket for performance calculations: payload, propellant, and inert mass. The rocket equation is introduced, and we discuss the need for multi-stage vehicles to achieve needed speeds. We discuss theoretical optimization processes (where optimization here means minimum mass to fly a specified payload) and “brute force” methods to optimize. We consider the effect of different propellants to accomplish a specific mission, and consider what an all-hydrolox Saturn V would have looked like (compared to the existing version which used kerolox in its first stage). We discuss and show how to analyze both serial and parallel staging methods, and look at design sensitivities, which indicate the best places to add propellant, reduce mass, and improve rocket performance. Finally, we provide a set of useful formulas that will be used to calculate useful rocket parameters such as propellant mass, structure mass, etc. for sizing purposes. Once we have some idea of performance and staging requirements, we look at trajectory analysis in Chapter 6. This chapter looks at vertical and inclined flight near bodies with and without an atmosphere. We introduce LV aerodynamics and their effect on ascent. We show a simple way to do trajectory simulations using a simple spreadsheet or numerical integration approach. The elegant mathematics of trajectory optimization are introduced, and various methods and techniques of optimization are demonstrated by providing a number of examples of actual launch vehicle trajectories. Chapter 7 is a background chapter intended to provide a comprehensive introduction to the structures and possible layouts that might be used on various LVs with different propulsion systems. We present a number of ICBMs that evolved into space launchers, as well as dedicated launchers such as the Saturn family, the Space Shuttle and SLS, Atlas V, and Delta IV. We discuss the geometry of tanks, domes, feedlines, and layouts and their ramifications on layout. Finally, we present a survey of structure types and commonly-used structural materials. With structure and layout knowledge available, Chapter 8 begins the physical layout process of the inboard profile of a LV and finishes with an estimate of the LV’s mass, center of mass location, and mass moments of inertia. First, the required speeds along with the rocket equation are used to determine the ideal amounts of solid or liquid propellants needed to accomplish the mission. Then, “real life” additions are made for factors such as engine startup, unusable propellant, tank shrinkage, and so on. The tanks or casings are sized to incorporate these factors, and guidelines are given for interconnecting structure such as intertanks, interstages, payload fairings, and thrust structures. Then, we illustrate the process of mass estimation, and show how to calculate the LV’s center of mass (CM).

Preface to the First Edition

This is used to find the LV’s mass moments of inertia, which are critical to the maneuvering and stability of a LV. Chapter 9 introduces the calculation of aerodynamic loads on the LV’s structure caused by ground winds on the pad, as well as crosswind “wind shears” that strike the LV during ascent. We show how to estimate the magnitude of the wind loads, their point of application, and how to “march” from top to bottom of the launch vehicle to assess the shear and bending moment distribution along the LV’s length, and the axial load distribution. As an example, these processes are used to calculate the wind loads on a Saturn V in flight during the max-q condition. We finish by discussing some “load relief” techniques. Chapter 10 continues with the calculation of stresses that are induced by the aerodynamic loads from Ch. 9. After providing the terminology and definitions, we show how to calculate axial, shear, and bending stresses using the simple cylinder analysis. We then consider structural stability or “buckling” and show seven ways to improve stability. Pressurization has a strong stabilizing and unloading quality that makes it ideal for LVs in flight. We then show how to size the walls of the propellant containers and their interconnecting structures. Chapter 11 deals with the transient environments on board a LV which include vibration and shock, acoustic, and thermal loading. We discuss each of these environments and show where and when they are most critical. Finally, we discuss the process of “coupled-loads analysis” and the environment that the payload, the LV’s paying customer, will be exposed to. Chapter 12 is fairly involved exposition of LV stability and control, and also a discussion of many interesting dynamical and stability problems that can occur. We show how the LV knows at any given time where it is, what direction it’s pointing, and how fast its direction is changing. With this knowledge and the LV’s aerodynamic loading, we can predict the motion of the LV. By gimbaling the engine(s) or using other control effectors, we can “close the loop” and write the equations of motion to assess the LV’s stability and controllability. After this controls assessment, we consider several instabilities that can occur, such as structure flexibility, “tail wags dog” instability, propellant sloshing, and propulsion instabilities such as pogo and resonant burn phenomena. Chapter 13 is a background chapter providing information on the process of LV manufacturing. We show examples of basic machining needed to assemble LVs, and provide a detailed description of the fabrication of the Saturn I’s S-IV second step, whose structure is primarily aluminum alloys. We then consider composite materials such as fiberglass-epoxy and graphite-epoxy structures and the techniques used to manufacture them. Next, we consider advanced techniques such as filament winding, fiber placement, and additive manufacturing (AKA “3D printing”). Once the parts

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are manufactured, we discuss how the LV is assembled, also known as vehicle “stacking”. Launch vehicle systems and launch pad facilities are discussed in Chapter 14, another background chapter. Here the Saturn V first step is used to demonstrate many of the systems needed for a successful LV; as the expression goes, “the devil is in the details.” Propellant management, power, environmental controls, data management, telemetry, and many other aspects of LVs are presented. We also provide ground accommodation information, including pad services (holddowns, technician access, umbilicals, propellant storage, acoustic suppression, lightning protection, engine startup sequence, and more). Chapter 15 is a collection of information related to LV testing. We show many of the types of testing that is done to best try to verify that the vehicle will operate successfully, including mechanical, shock, vibration, and acoustics; thermal; RF and electrical; wind tunnel testing on the ground and in flight; and software testing procedures. We look at scale model testing for launch pad acoustics and exhaust noise assessment. Then we move on to discuss design procedures to improve reliability. Redundancy is one method used; we show how to calculate reliability with series and parallel connections, and we show reliability for ‘k-out-of-n’ systems, applicable to multiple-engine LVs. Finally, we show the reliability of a LV range-safety system with multiple failure probabilities. Chapter 16 is background chapter which provides a number of examples of LV failures in many disciplines, such as structures, separation systems, propulsion systems, GN&C, and software. The text provides some lessons learned and a number of suggestions on questions evaluators can ask to try to prevent failures in future vehicles. We show how range safety is enhanced by flight termination systems, and how those systems operate. We close with a list of best practices to avoid failure. Chapter 17 is the least “engineering” of the chapters in the book, and also the last, but it’s certainly NOT the least! Economics of engineering and systems is critically important in today’s world, and this chapter introduces the principal aspects of launch vehicle economics. We begin by describing the design cycle and how decision-making early in the cycle can be a “makeor-break” contribution to the system’s overall costs. We discuss cost engineering and considerations that can affect it, and discuss cost estimation methods through statistical fits and modelling. Finally, we provide some actual cost modeling examples. Several exercises challenge the reader to estimate costs on developing their own launch systems, and we provide access to an older graphical but still useful cost estimating model. A comprehensive Glossary provides a list of abbreviations and definitions, followed by an Index which completes the book. Corrections and supplemental materials such as syllabi and curricula will be available from AIAA’s electronic library, Aerospace Research Central

Preface to the First Edition

(ARC), at arc.aiaa.org: use the menu bar at the top to navigate to Books. AIAA Education Series; then, navigate alphanumerically to this book title’s “landing page.” Suggested curricula for courses of different student level and duration: The material in this book has been presented for two different types of classes: a one-year long undergraduate senior capstone design class, and a one-quarter-long or one-semester-long survey class. It has worked well for both, but the scope of the class may be limited for the survey classes. For the year-long course, we recommend going through the chapters in numerical order, however the presenter may wish to cover Chapter 17 (cost analysis) before presenting Chapters 13–16 (which are primarily “background” chapters) so as to allow time for any Ch. 17 homework assignment to be completed before the course ends. The assignments in Chapters 6, 9, and 10 are significantly time-consuming, so allotting extra completion time is recommended. For a survey course, the presenter should follow a similar schedule, except the following chapters or sections may be omitted without too much loss of content: 3.8, 4.8, 4.9, 5.8, 5.12, 10.6 (or its homework), 12.4, 12.5, Ch. 13, Ch. 14, 15.2, 16.5. Much of the omitted material is interesting in its own right, and it should be suggested that the reader examine it on their own time. Suggested curricula for one- and two-semester versions of this course, as well as class syllabi, may be found at the AIAA’s electronic library, listed above. Disclaimer: The material presented in this book has been carefully selected to describe ideas and principles of rocket design and operation. However, please note that none of the materials provided—engineering formulae, data, material, results, or conclusions—can be absolutely guaranteed, even though every effort has been made to insure accuracy and reliability. This book may include technical inaccuracies as well as typographical errors. The authors assume no responsibility for errors or omissions in this book, or other documents which are referenced by or linked to this book. In no event shall the authors be liable for any special, incidental, indirect, or consequential damages whatsoever, including but not limited to, those resulting from loss of use, data, or profits, and on any theory of liability, arising out of or in connection with the use or reliance on this information. THE FINAL RESPONSIBILITY OF VERIFYING ACCURACY AND CORRECTNESS OF ANY AND ALL RESULTS REMAINS WITH THE USER OF THE BOOK, and not with the authors. Changes made to the information contained herein will be incorporated in new editions of this book. The authors reserve the right to make improvements and/or changes in the book at any time without notice.

xix

PREFACE TO THE SECOND EDITION Why publish a second edition of Design of Rockets and Space Launch Vehicles? The first edition of “DoRSLaVe,” (in aerospace, we have to use acronyms; this one comes from an abbreviation of the first letters of the book’s title) has received acclaim from many readers from many locations all over the world. Some have mentioned that it is their “bible” and have adopted it for themselves or for use of employees in their institutions, while others have commented on its breadth and depth. The publishing of the book has certainly filled a need for a comprehensive “manual” for the design of rockets and has been adopted for capstone design classes at several universities. As an added bonus, in 2021 the book was chosen to receive AIAA’s Summerfield Award for the best book recently published by AIAA. In our 1st edition preface, we wrote that “this book should be considered a “snapshot” of the current state of LV affairs at the time of its publishing, and will hopefully remain pertinent as time goes on. If it gets horribly out of date—unlikely because the physics of rocketry will remain constant—well, there’s always the possibility of a Second Edition!” Well, the physics haven’t changed, but due to the fact that there were some radical changes in launch vehicle design and operation occurring as the 1st edition was being published, that the authors have noticed that some important content had been omitted, and that there were typographical errors that needed correction, the decision was made to release of the 2nd edition that you are now holding in your hands. We have added a wealth of new material as listed below (numbers in parenthesis refer to chapter numbers):

• New material on current launch vehicle developments including SLS, Starship-Superheavy, Electron, Neutron, LauncherOne, Astra, Alpha, Vulcan, Ariane 6 (Ch. 2) • Historical information on Proton, Zenit, Angara, Centaur, Vega, Falcon 1, Falcon 9 (Ch. 2) • Detailed listing and discussion launch vehicle requirements, along with the losses and gains associated with design of the performance of a launch vehicle (Ch. 3).

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• Discussion of hybrid and quasi-hybrid rockets, including new combustion cycles (Ch. 4)

• Comprehensive table of loaded and inert masses for multiple launch vehicles (Ch. 5)

• English translation of Russian Angara propellant crosslinking system (Ch. 5) • Determination of minimum mass designs for three-stage launch vehicles • • • • • • • • • • • • • • • • • • • •

(Ch. 5) Complete set of equations to allow the calculation of payload mass, propellant mass, structure mass, inert mass, liftoff mass knowing specific impulse and structural ratio (Ch. 5) Attachment methods for strap-ons such as SRMs, external tanks (Ch. 7) Information on carrying multiple payloads: ridesharing, piggybacking (Ch. 7) Discussion of sandwich panel mass and stiffness (Ch. 7) Tables of advantages, disadvantages, and applications of metals and composite materials (Ch. 7) Potential mass reductions possible via use of composite materials (Ch. 7) Information on propellant densification used by SpaceX on its Falcon 9 to increase payload (Ch. 8) Comprehensive discussion of tank arrangements, including tandem, parallel, concentric, toroidal, and common bulkheads (Ch. 8) Discussion of different bulkhead geometries: hemispherical, elliptical hemispheroidal, non-tangent hemispherical segment (Ch. 8) Updated mass estimating relationship equations for composites, solid rocket motors, avionics, and wiring based on 21st-century rocket designs (Ch. 8) Current payload fairing dimensions informational diagram (Ch. 8) Improved discussion of calculation of normal forces on nose cones and reverse tapers (Ch. 9) Table of actual wall thicknesses for selected LVs (Ch. 9) Minimum gauge suggestions for skins, face sheets, stringers, corrugations (Ch. 10) Structural stability guidelines for tapered skirts—do you use larger or smaller radius? (Ch. 10) Material properties at room temperature; 2014 Aluminum down to cryogenic temperatures (Ch. 10) Information on vehicle recovery and reuse, including energy requirements, design issues, and a table of advantages and disadvantages of different ways of recovering rocket steps and payload fairings (Ch. 14) Discussion of Titan IVB failure in 1999 and failure of Astra0007 in 2021 (Ch. 16) Discussion of trajectory shaping for abort of crewed vehicles, including Atlas/Starliner (Ch. 16) New sections on recovery and reuse, including the physics, energy, and mass required to recover payload fairings, 1st steps, and upper steps. We’ve

Preface to the Second Edition

added a table of recovery options including advantages and disadvantages and a simple cost analysis of vehicle reuse (Ch. 17). • An updated index, much more comprehensive and detailed than the one provided in the first edition of the book. With all of these changes, we hope that you, the reader and user, enjoy this new edition and as we stated before, the authors would apprecwiate inputs from readers as to content or other materials. Don Edberg & Willie Costa, Authors

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FOREWORD Homer Hickam, Author of Rocket Boys: A Memoir (aka October Sky) A surprising and positive result of the 1957 launch of Sputnik, the world’s first artificial earth satellite, was the leagues of students who were suddenly energized to learn as much as possible about rockets. For some teenagers of that era, which included me and some friends of mine, that meant enthusiastically slapping together explosives and tubes and aiming the results skyward in hopeful anticipation of seeing them fly. For the most part, however, what we saw besides oily smoke and flying shrapnel was a demonstration that enthusiasm cannot make up for a lack of knowledge After blowing up a few things and generally stinking up our home town of Coalwood, West Virginia, it gradually dawned on the members of our little group that maybe we didn’t know enough. Accordingly, we recruited a rather unpopular fellow student with the reputation of being a boy genius named Quentin Wilson who assured us he knew very well how to build a rocket. As it turned out, he knew enough for us to manage a few successful lift-offs that thrilled me and the other boys but left Quentin wanting to increase the depth of our knowledge. There had to be a book somewhere, he maintained, that would teach us not only how to build a rocket but allow us, through careful design, to predict its capabilities and behavior. Unfortunately, our subsequent search through the school and county libraries turned up no such book. We named our club after our high school and so we became the Big Creek Missile Agency. Before long, we were noticed by Miss Frieda Riley, a young science teacher, who believed that the school’s trophy cases should hold more than sports trophies but also awards for students engaged in intellectual pursuits. After hearing about our need for a book on rockets, she used her meager bank account to purchase for us