Reusable Booster Rockets, Asian Roundup

January 11, 2022 by Chris Lott 28 Comments

The Space Shuttle’s solid rocket boosters were reusable, although ultimately the overall system didn’t prove cheaper than expendable launches. But given the successes of the Falcon 9 program — booster B1051 completed its 11th mission last month — the idea of a rocket stage returning to the launch site and being reused isn’t such a crazy proposition anymore. It’s not surprising that other space agencies around the world are pursuing this technology.

Last year the India Space Research Organization (ISRO) announced plans for a reusable launcher program based on their GSLV Mark III rocket. The Japan Aerospace Exploratory Agency (JAXA) announced last Fall that it is beginning a reusable rocket project, in cooperation with various industries and universities in Japan. The South Korean space agency, Korea Aerospace Research Institute (KARI), was surprised in November when lawmakers announced a reusable rocket program that wasn’t requested in their 2022 budget. Not in Asia, but in December France’s ArianeGroup announced a reusable rocket program called Maïa.

Speaking of South Korea’s rocketry program, we wrote about the Nuri rocket in October which failed to reach orbit because of a problem in the third stage. Kari recently completed a review of all the data, and concluded the problem was with the anchors of the helium tanks which are located inside the oxidizer tank.

Apparently the changing buoyancy of the submerged tanks with altitude wasn’t completely accounted for in the design of the mounting brackets. When they ultimately failed, the resulting broken piping caused a LOX leak and the subsequent 46-second premature engine shutdown. The next scheduled launch in May 2022 will very likely be delayed.

Retrotechtacular: Junior Missile Men Of The 1960s

November 22, 2021 by Dan Maloney 30 Comments

Just like the imaginative kids depicted in “Junior Missile Men in Action,” you’ll have to employ a fair bit of your own imagination to figure out what was going on in the original film, which seems to have suffered a bit — OK, a lot — from multiple rounds of digitization and format conversion. [GarageManCave] tells us he found the film on a newsgroup back in the 1990s, but only recently uploaded it to YouTube. It’s hard to watch, but worth it for anyone who spent hours building an Estes model rocket and had that gut-check moment when sliding it onto the guide rail and getting it ready for launch. Would it go? Would it survive the trip? Or would it end up hanging from a tree branch, or lost in the high grass that always seemed to be ready to eat model rockets, planes, Frisbees, or pretty much anything that was fun?

Model rocketry was most definitely good, clean fun, even with the rotten egg stink of the propellant and the risk of failure. To mitigate those risks, the West Covina Model Rocket Society, the group the film focuses on, was formed in the 1960s. The boys and girls pictured had the distinct advantage of living in an area where many of their parents were employed by the aerospace industry, and the influence of trained engineers shows — weekly build sessions, well-organized range days, and even theodolites to track the rockets and calculate their altitude. They even test-fired rockets from miniature silos, and mimicked a Polaris missile launch by firing a model from a bucket of water. It was far more intensive and organized than the early rocketry exposure most of us got, and has the look and feel of a FIRST robotics group today.

Given the membership numbers the WCMRS boasted of in its heyday, and the fact that model rocketry was often the “gateway drug” into the hacking lifestyle, there’s a good chance that someone in the Hackaday community got their start out in that park in West Covina, or perhaps was even in the film. If you’re out there, let us know in the comments — we’d love to hear a first-hand report on what the club was like, and how it helped you get started.

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Space Shuttle Model In A Hypersonic Wind Tunnel

Mach 20 In A Wind Tunnel: Yes, It’s Rocket Science

November 4, 2021 by Ryan Flowers 5 Comments

Hypersonic speeds are defined by those exceeding Mach 5, and lately there’s been a lot of buzz about unmanned hypersonic vehicles making test flights. Vehicles returning from orbital flight also travel at hypersonic speeds as they do their best to transition back to the terrestrial realm. Before anything leaves ground though, these machines are tested in wind tunnels. [Scott Manley]’s video “How Hypersonic Wind Tunnels Recreate Mach 20” (embedded below) does a wonderful job of explaining the engineering behind wind tunnels for testing hypersonic vehicles.

While the earliest wind tunnels such as that used by the Wright Brothers were powered by simple fans, it is not possible for any propeller to surpass subsonic speeds. This is evidenced by there not being any propeller driven aircraft that can exceed Mach 1. Since an aircraft can’t reach those speeds with a propeller, it follows that a wind tunnel cannot be driven by propellers, fans, or any such device, and exceed Mach 1 wind speed, either. So it begs the question: Just how do they do it?

You might think that the answer lays in Bernoulli’s law – but it does not. You might think it involves compressing the air into smaller and smaller tubes and pipes. It doesn’t. As [Scott Manley] so expertly explains in the video below the break, it has quite a lot in common with actual rocket science.

You may be interested to know that we’ve covered some DIY wind tunnel builds as well as a small desktop wind tunnel in the past. While not hypersonic, they’re exactly what you’d want to have if you’re an aerospace hacker of any kind.

Thanks [Zane Atkins] for the tip!

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Magnesium: Where It Comes From And Why We’re Running Out

November 1, 2021 by Adam Zeloof 94 Comments

Okay, we’re not running out. We actually have tons of the stuff. But there is a global supply chain crisis. Most of the world’s magnesium is processed in China and several months ago, they just… stopped. In an effort to hit energy consumption quotas, the government of the city of Yulin (where most of the country’s magnesium production takes place) ordered 70% of the smelters to shut down entirely, and the remainder to slash their output by 50%. So, while magnesium remains one of the most abundant elements on the planet, we’re readily running out of processed metal that we can use in manufacturing.

Nikon camera body — The magnesium-alloy body of a Nikon d850. Courtesy of Nikon

But, how do we actually use magnesium in manufacturing anyway? Well, some things are just made from it. It can be mixed with other elements to be made into strong, lightweight alloys that are readily machined and cast. These alloys make up all manner of stuff from race car wheels to camera bodies (and the chassis of the laptop I’m typing this article on). These more direct uses aside, there’s another, larger draw for magnesium that isn’t immediately apparent: aluminum production.

But wait, aluminum, like magnesium is an element. So why would we need magnesium to make it? Rest assured, there’s no alchemy involved- just alloying. Much like magnesium, aluminum is rarely used in its raw form — it’s mixed with other elements to give it desirable properties such as high strength, ductility, toughness, etc. And, as you may have already guessed, most of these alloys require magnesium. Now we’re beginning to paint a larger, scarier picture (and we just missed Halloween!) — a disruption to the world’s aluminum supply.

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The Longest Ever Flight Was Over 64 Days In A Cessna 172

October 25, 2021 by Lewin Day 69 Comments

Often, when we think of long-endurance flights, our first thoughts jump to military operations. Big planes with highly-trained crew will fly for long periods, using air-to-air refuelling to stay aloft for extended periods.

However, many of the longest duration flights have been undertaken as entirely civilian operations. The longest of all happened to be undertaken by that most humble of aircraft, the Cessna 172. From December 1958 to February 1959, Bob Timm and John Cook set out to make history. The duo remained aloft for a full 64 days, 22 hours and 19 minutes, setting a record that stands to this day.

A Test of Endurance

One might expect that such an effort was undertaken to push the envelope or to strike new ground in the world of aerospace engineering. However, the real truth is that Bob Timm was a slot machine mechanic and former bomber pilot who worked at the Hacienda casino in Las Vegas. Proprietor Doc Bailey was always on the hunt for promotional ideas, and Timm pitched his boss that a record attempt in a plane bearing the casino’s branding would be a good way to go. Bailey agreed, and committed $100,000 to the effort.

Modifications to prepare the aircraft for the stunt took the best part of a year. The pint-sized Cessna was fitted with a 95-gallon belly tank, paired with a electric pump that could transfer fuel to the main wing tanks as needed. Special plumbing was also added that would allow the engine oil and filters to be changed while the engine was still running.

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Space Age Road Rage: Right Of Way Above The Karman Line

October 13, 2021 by Ryan Flowers 35 Comments

On a dark night in 2006 I was bicycle commuting to my office, oblivious to the countless man made objects orbiting in the sky above me at thousands of miles per hour. My attention was instead focused on a northbound car speeding through a freeway underpass at dozens of miles per hour, oblivious to my southbound headlamp. The car swerved into the left turn lane to get to the freeway on-ramp. The problem? I was only a few feet from crossing the entrance to that very on-ramp! As the car rushed through their left turn I was presented with a split second decision: slow, and possibly stop in the middle of the on-ramp, or just go for it and hope for the best.

A graphic depicting a dawdling bicycle rider about to be in the way of a speeding car driver — In Blue: Terrified cyclist. In Red: A speeding car careening around a corner without slowing down.

By law I had the right of way. But this was no time to start discussing right of way with the driver of the vehicle that threatened to turn me into a dark spot on the road. I followed my gut instinct, and my legs burned in compliance as I sped across that on-ramp entrance with all my might. The oncoming car missed my rear wheel by mere feet! What could have ended in disaster and possibly even death had resulted in a near miss.

Terrestrial vehicles generally have laws and regulations that specify and enforce proper behavior. I had every right to expect the oncoming car be observant of their surroundings or to at least slow to a normal speed before making that turn. In contrast, traffic control in Earth orbit conjures up thoughts of bargain-crazed shoppers packed into a big box store on Black Friday.

So is spacecraft traffic in orbit really a free-for-all? If there were stringent rules, how can they be enforced? Before we explore the answers to those questions, let’s examine the problem we’re here to discuss: stuff in space running into other stuff in space.

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Counting Down To The Final Atlas Rocket

October 4, 2021 by Tom Nardi 32 Comments

The Atlas family of rockets have been a mainstay of America’s space program since the dawn of the Space Age, when unused SM-65 Atlas intercontinental ballistic missiles (ICBMs) were refurbished and assigned more peaceful pursuits. Rather than lobbing thermonuclear warheads towards the Soviets, these former weapons of war carried the first American astronauts into orbit, helped build the satellite constellations that our modern way of life depends on, and expanded our knowledge of the solar system and beyond.

Naturally, the Atlas V that’s flying today looks nothing like the squat stainless steel rocket that carried John Glenn to orbit in 1962. Aerospace technology has evolved by leaps and bounds over the last 60 years, but by carrying over the lessons learned from each generation, the modern Atlas has become one of the most reliable orbital boosters ever flown. Since its introduction in 2002, the Atlas V has maintained an impeccable 100% success rate over 85 missions.

But as they say, all good things must come to an end. After more than 600 launches, United Launch Alliance (ULA) has announced that the final mission to fly on an Atlas has been booked. Between now and the end of the decade, ULA will fly 28 more missions on this legendary booster. By the time the last one leaves the pad the company plans to have fully transitioned to their new Vulcan booster, with the first flights of this next-generation vehicle currently scheduled for 2022.

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