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Space colony art: Don Davis


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The K-1 is dead, long live TSTO RLVs

I've followed the K-1 story since it started back in the mid-1990s. Rob Coppinger in fact today has posted an ancient video showing the very first "throw out the rulebook" Kistler Aerospace design with the unusual "bedpost" style first stage. Subsequently, Kistler brought in a team headed by the famous George "all-up testing" Mueller and including other Apollo era heavyweights like Dale Myers and Aaron Cohen. Even Maxime Faget helped them for a while.

I've never thought the K-1 design that they came up with was anywhere close to an ideal RLV. For example, it doesn't allow for incremental testing to find problems without losing the vehicle as Rutan could do with the SS1. However, it was a proof of principle that even a group of conservative NASA/Apollo/Saturn engineers could sit down and design a two-stage-to-orbit (TSTO) fully reusable vehicle without breaking any laws of physics or requiring even an ounce of unobtainium. Other than the occasional anonymous commenter posting "the K-1 is crap" sort of criticism, I've never seen any credible person point to some particular part of the K-1 design and say this definitely is not going to work.

Kistler got 75% of the hardware built for the first K-1 when their target LEO comsat constellation market disappeared and funding dried up. Kistler had at that point spent about $800M but raised only $600M. The company itself had remained relatively small and had farmed out most of the hardware to various mainstream aerospace companies. (SpaceX decided that building many of its major components in house could save lots of money over this outsourcing approach.) People who were involved with other entrepreneurial launch vehicle companies during that period occasionally express annoyance, to say the least, that Kistler Aerospace soaked up most of the private investment available for such ventures yet still didn't get anything into the air.

Kistler struggled to survive for several years. It got some NASA funding in 2001 with a Space Launch Initiative contract to demonstrate RLV technologies but most of the money wouldn't come until they started flying. In 2004 they won a $227.4M contract for ISS resupply but it was subsequently canceled when SpaceX successfully challenged the single-source manner in which the contract was awarded.

In 2003 the company entered Chapter 11 bankruptcy proceedings, which kept it in business but protected from creditors while it searched for new money. The company was on the verge of being liquidated when Rocketplane bought it in early 2006 and quickly put together a proposal for the COTS program. A major factor apparently in the Rocketplane Kistler (RpK) combo winning a COTS contract was the fact that they had substantial hardware already built and in storage.

Unlike SpaceX, Rocketplane Kistler on its own did not have sufficient internal funding to get the K-1 vehicles built and flying. Instead, they planned to use the credibility provided by the COTS award and the expectation of a long term ISS resupply contract to convince investors to provide the necessary development funding. However, it turned out that without an ironclad guarantee of a such a contract, investors balked at providing the large amount, $500M, that RpK needed.

Unless their is another amazing last second rescue, the COTS contract termination appears to close the final chapter on the K-1 saga. However, this is hardly the end of the TSTO reusable launch vehicle story. SpaceX, in fact, plans to reuse both stages of the Falcon 9 (however, they won't include this in their flight costs estimates until the water recovery technique is proven). Several other companies have viable TSTO designs of various sorts. Unlike single-stage-to-orbit (SSTO) RLV designs such as VentureStar, there are no bleeding edge technologies needed for TSTO RLVs. It's just a question of implementation and systems engineering execution to get them built and operating.

Comments

there were issues in the K-1,

that flyback return burn is seriously challenging
and the CG management of the issues are
hard.

the biggest one was the cost growth was high
and the actual ops cost model was unproven.
the return accuracy of the K-1 LAP required
moving to the outback, which meant
the time to restack was going to be high

Posted by anonymous at 10/19/07 13:43:16

I've heard rumours from people that Kistler spent a lavish money on the business side of thing, having big fancy offices and such, but of course I have no way to confirm it.

SpaceX has spent a lot less money so far, although of course their designs haven't been so ambitious and they haven't even built a Falcon 9 yet.

I think your points about incremental testing make a lot of sense. Let's hope that the next wave of newspace companies like Armadillo, Masten and XCor can make a difference, reach for really cheaper spaceflight.

Posted by mz at 10/19/07 14:00:11

75% huh? Was the last 25% of the DESIGN ever completed?

I believe that in the next twenty years, two thousand "Falcon 9 Heavy's" (or their equivalent) could be used to launch no less than a thousand 10 MW space based solar power sats into LEO in two pieces.

The first launch would be a hydrogen gas inflated Kapton sphere, 2,250 ft in diameter, covered with 40% efficiency multi-juction "sphelar" solar cell film that accepts light from all angles. No pointing and tracking required.

After inflation in LEO, solar UV light would rigidize the sphere so the H gas would no longer be required.

The second launch would be a "Bigelow Module" with twenty half megawatt solid state lasers in lab racks inside it, these were originally designed for the medical and automotive industry. These fiber-optic lasers would feed optics mounted on the nadir of the module to beam ten megawatts to a 600 ft diameter reciever on the ground.

This gravity gradient stabilized sphere, with a Bigelow Module attached to the nadir, can self-boost itself, with the laser, to a diquotidian orbit that hovers over industrialized countries that can AFFORD to pay for ultraclean power peaks at twelve hour intervals.

Is this reason enough for Andrews Space and Technology to buy the K-1 patents and finish the damn thing?

We shall see.

Posted by Tony Rusi at 10/19/07 14:05:23

Air drag and sunlight pressure on your sphere?
What's the laser spot size on earth?

What do you mean laser boost? From leo to a high orbit? Impossible, the thrust would be tiny. You need reaction mass.

Posted by mz at 10/19/07 15:28:10

mz,

Air drag and sunlight pressure on your sphere?

I am not sure what it would be on the sphere, but the space station sees only 3lbs of drag total. If sunlight pressure can move the sphere why wouldn't a ten megawatt laser? In LEO you have a density around three billionths of earth's surface atmosphere.

What's the laser spot size on earth?

Read it again. It says 600 ft.

What do you mean laser boost? From leo to a high orbit?

Look up Diqoutidian orbits. It is nowhere near as high as GEO.

Impossible, the thrust would be tiny.

You admitted sunlight pressure would have an effect. So would a laser.

In any case a circular electrodynamic conducting tether (a copper wire) can be embedded in the sphere in every direction to move it around.

You need reaction mass.

Dr. Forward used ice as the reaction mass for his laser driven spacecraft. If reaction mass is needed, and I am not conviced that it is yet, it would be ice. The space station jettisons quite a bit of "dirty ice" from time to time.

Posted by Tony Rusi at 10/19/07 17:11:59

Thanks Clark for the retrospective on RpK. Hopefully in the future, a vibrant space industry will make these sort of bankruptcies a thing of the past and RpK will be the last one that folds after spending so much money. Unfortunately, even a great idea will fail if the timing is wrong.

Posted by Andrew Platzer at 10/19/07 18:40:19

"there were issues in the K-1"

I would be pretty amazed if a brand new vehicle did not have issues before it was launched. The Delta IV heavy, Pegasus XL, etc. all had issues to be worked out during their initial flights.

The SS1 was a much simpler system but they still found a new serious problem almost every time they expanded the envelope. As I mentioned, the incremental testing kept them from losing the vehicle. I could easily see a K-1 on an early flight losing, say, a first or second stage during the landings.

My basic point dealt with the general question of the feasibility of 2-stage RLVs. The issues you mention look serious but they don't seem to be fundamental flaws that can't be fixed.

- Clark

Posted by TopSpacer at 10/19/07 22:14:12

Re: tony rusi

E=m*c^2 => P=dm/dt*c^2
F=(dm/dt)*v

P=Power
F=Force
c=speed of light
v=exhaust velocity (c in the case of photons)

A 10MW light beam will produce a force of F=P/c=1e7/3e8=0.033N. It will take centuries to move a 50t space structure that way.

Posted by anonymous at 10/20/07 04:48:31

anonymous,

Then I will use electrodynamic tethers. Have you got the equations for that one handy?

Posted by Tony Rusi at 10/20/07 09:53:36

I see nothing really seriously wrong with the K1's design other then the CG management and another minor problem I found performing a ullage maneuver using the RCS to settle the propellant before reigniting the main engines.
As for testing the stages both could easily be tested separately if needed.
The First stage could fly first with a dummy stage and ballast and the second stage could be tested partly fueled on an EELV.
The K1 OM replaces the EELV's second stage and fairing.

As for laser as propulsion wouldn't ion engines be a better bet as they are well tested and understood.
The latest engines are so efficient that a large enough cluster of them can power a tug that could move 100tons from LEO to lunar orbit using just 10 tons of xenon propellant.
Also since these new engines are 10x more efficient and the latest solar cells are more efficient the tug could make it's trip in half the time smart one took.

Posted by Ruri at 10/21/07 00:00:51

Aha! So, having successfully challenged it's competitor's single source bid situation, SPACE-X until Orbital was given a contract, was single sourced themselves! Space-X: effing hypocrites!

Posted by Kris Ringwood at 06/26/09 22:09:36
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