ULA Vulcan

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MartG

Original Poster:

21,224 posts

211 months

Friday 5th April 2019
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In common with other launch vehicles, I thought that as this one is nearing the hardware stage, perhaps a new thread for it was needed...

Intended to replace both Delta IV and Atlas V in ULA's lineup, Vulcan will use a pair of Blue Origin BE-4 methane fuelled engines in its first stage, while the second stage is initially the tried & tested Centaur



Development path



Performance - note 'single core' ( albeit with solid boosters ) performance of the 'Heavy' version exceeds that of the triple core Delta IV Heavy



ULA CEO says that he sees no market for a triple core version at present, but is keeping it in mind

Beati Dogu

9,187 posts

146 months

Friday 5th April 2019
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Good idea. ULA boss Tory Bruno said last week they’ve started “bump forming” the first side panels for operational Vulcan rockets. This is at the factory in Decatur.


https://arstechnica.com/science/2019/03/ula-has-st...

Edited by Beati Dogu on Saturday 6th April 17:58

Beati Dogu

9,187 posts

146 months

Saturday 13th April 2019
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I’ve been having a play with ULA’s AR (Augmented Reality) app on my iPad & now I’ve got a scale Vulcan rocket in the back garden:



That’s only 3% of its eventual size. You need to be at least 25 feet away to get it life size & my garden isn’t that big. wink

It’s a free app & available for Android too I believe. You can change rockets to an Atlas V or even a Delta 4 Heavy, so you better have understanding neighbours. biggrin

Beati Dogu

9,187 posts

146 months

Wednesday 15th May 2019
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Installing welders for the upgraded Centaur upper stage of Vulcan:

https://www.youtube.com/watch?v=kgso477yXB0&fe...


This is how they mill out the body panels for rockets:

https://www.youtube.com/watch?v=dJr3PMFEPRw

They'll be bent into curved sections in a press like this (also mentioned above):



Then joined into tubular sections with clever use of circumferential stir welding.

MartG

Original Poster:

21,224 posts

211 months

Tuesday 21st May 2019
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Beati Dogu

9,187 posts

146 months

Saturday 29th June 2019
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Here's some more CNC engineering porn:



It's an equipment shelf for Vulcan, made by AMRO in California.

They also make the main body panels for SLS, Vulcan, Atlas V, Mars Lander etc.

Beati Dogu

9,187 posts

146 months

Thursday 1st August 2019
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The first Vulcan booster is ready for structural test qualification. Seen here in the middle, with the smaller Atlas V boosters to the side.



This one will be pushed and pulled all over the place to take it beyond what's expected in flight.

Vulcan's first actual launch in 2021 will carry a commercial payload. No boiler plate test shot for this baby.






MartG

Original Poster:

21,224 posts

211 months

Thursday 15th August 2019
quotequote all
It's been announced that the SNC Dreamchaser will launch on the Vulcan

http://www.collectspace.com/news/news-081419a-drea...

Beati Dogu

9,187 posts

146 months

Saturday 29th February 2020
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Here's a tour of ULA's rocket factory in Decatur, Alabama with ULA boss Tory Bruno.

https://www.youtube.com/watch?v=o0fG_lnVhHw&fe...

This is where they make the Atlas V and Delta 4 rockets and they're working on the Vulcan now. Vulcan will replace both ultimately.


Incidentally, they were doing a test fit of a Vulcan at Cape Canaveral using a mass simulator the other day



This weird looking apparatus is made to the same dimensions as a Vulcan. At least when it comes to the mounting points.

After being brought in from the factory by ship, they hoist it upright like this into the Vertical Assembly Building for payload and booster fitting.

This is at Space Launch Complex 41, which is where they launch Atlas Vs from currently. They're busy adapting it for Vulcan as well.

Beati Dogu

9,187 posts

146 months

Tuesday 9th June 2020
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ULA are aiming to have the maiden launch of Vulcan in early 2021.

It'll be an operational flight and will take Astrobotic Technology's Peregrine lander towards the Moon.

https://www.astrobotic.com/peregrine


Depending on how SpaceX's Starship program gets on, Vulcan may be the first of the new methane powered rockets to achieve orbit.

Blue Origin are quite secretive about their New Glenn rocket, but I think their big problem will be learning how to land it without sinking the landing ship.

It took SpaceX several attempts to get within 10 Km of the landing zone initially.

Beati Dogu

9,187 posts

146 months

Thursday 2nd July 2020
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They've just had the first main BE4 engine delivered to the factory:



This is a pathfinder model, so will probably never fly, but it gives them something to play with.

Beati Dogu

9,187 posts

146 months

Friday 5th February 2021
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The first operational Vulcan rocket booster has left the factory in Alabama, complete with BE-4 engines.



It'll be transported by ship to Cape Canaveral, for pathfinder fit testing.

They've been upgrading pad SLC-41 to accept the new rocket as well as the current, smaller, Atlas V. They installed a new transporter / erector recently, among other updates to the ground support equipment.

They plan to launch it by the end of the year, although it'll likely have to go back to the factory before that.






Beati Dogu

9,187 posts

146 months

Saturday 13th February 2021
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The first operational Vulcan rocket booster has now arrived at Cape Canaveral. It'll be raised up at the Vertical Integration Facility at SLC-41 tomorrow in preparation for a wet dress rehearsal.



Sporting 2 Blue Origin BE-4 engines on the booster. Blue Origin's New Glenn will use 7 of these on the first stage.



Back in Alabama, these are some of the 5.4 meter (17.7 ft) diameter fairings it will use:



With a couple of interstages in the background.

Beati Dogu

9,187 posts

146 months

Tuesday 16th February 2021
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Vulcan booster now raised vertical



It should get production engines fitted by the summer and will launch the Peregrine lunar lander on its maiden flight.

MartG

Original Poster:

21,224 posts

211 months

Saturday 5th June 2021
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It seems there may be an issue with the new version of the RL-10 intended for the Vulcan's second stage - the new engine was flown on the Atlas 5 recently and the nozzle extension was observed to be vibrating

https://www.youtube.com/watch?v=RjOjR1e6GC4

Beati Dogu

9,187 posts

146 months

Saturday 5th June 2021
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Looks like a harmonics issue. They can probably balance that out.

They’re trying to fly a lot of the gear meant for Vulcan on Atlas V first. Upper stage engine, solid boosters, avionics etc. On its maiden flight, only really the main engines should be unflown before.

Beati Dogu

9,187 posts

146 months

Wednesday 27th April 2022
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ULA boss Tory Bruno posted a photo of the first BE-4 flight engines under construction.



After full assembly and testing, they'll be delivered to ULA in the middle of the year sometime.

Beati Dogu

9,187 posts

146 months

Sunday 3rd July 2022
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Tory Bruno posted some more pics of the two BE-4 engines being assembled for Vulcan's first flight:





Beati Dogu

9,187 posts

146 months

Saturday 30th July 2022
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First completed flight engine:


Beati Dogu

9,187 posts

146 months

Friday 21st October 2022
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The first flight ready BE-4 engine for the Vulcan rocket is being fitted:



They should get the other one soon.