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NASA, France Skeptical of SpaceX Reusable Rocket Project

MarkWhittington writes: "The drive by SpaceX to make the first stage of its Falcon 9 launch vehicle reusable has attracted the attention of both the media and the commercial space world. It recently tested a first stage which 'soft landed' successfully in the Atlantic Ocean. However both NASA and the French space agency CNES have cast doubt that this kind of reusability could ever be made practical, according to a Monday story in Aviation Week. SpaceX is basing its plan on the idea that its Merlin 1D engines could be reused 40 times. However, citing their own experience in trying to reuse engines, both NASA and the CNES have suggested that the technical challenges and the economics work against SpaceX being able to reuse all or part of their rockets. NASA found that it was not worth trying to reuse the space shuttle main engines after every flight without extensive refurbishment. The CNES studied reusing its Ariane 5 solid rocket boosters liquid fueled and reusable but soon scrapped the idea."

23 of 333 comments (clear)

  1. Just because... by torkus · · Score: 5, Insightful

    ...we can't do it, you clearly can't either.

    Sorry but big government's approach to things isn't what I usually measure up against. They spent how much on the space shuttle and so it would be reusable and instead after every flight the basically take it apart and rebuild every major and most minor subsystems?

    Let someone else give it a go before you just say it's impossible

    --
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    1. Re:Just because... by jellomizer · · Score: 5, Insightful

      The biggest thing is Space-X is applying modern technology, not 50 year old technology, to their solutions.

      If you think back to the shuttle design... Most of the work was done on paper, with perhaps a few months on computer simulation.

      Space-X with its new design and all computer driven, means they can test fix test and retest in the computer before they build a working system. This allows them engineer to reliability, without a bunch of testing.

      --
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    2. Re:Just because... by Andrio · · Score: 5, Funny

      "Things are only impossible until they are not." -Picard

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    3. Re:Just because... by Registered+Coward+v2 · · Score: 5, Insightful

      ...we can't do it, you clearly can't either.

      Sorry but big government's approach to things isn't what I usually measure up against. They spent how much on the space shuttle and so it would be reusable and instead after every flight the basically take it apart and rebuild every major and most minor subsystems?

      Let someone else give it a go before you just say it's impossible

      They're not saying it is impossible; they're saying they discovered the cost of doing it was much higher than expected. It may have been cheaper to simply build new ones and spread the manufacturing costs over many more engines than try to rebuild them. One challenge they faced was limited engine flight data to identify how to rebuild them cost effectively without compromising safety. Add in the impact of salt water and you have some serious engineering challenges that may not be cost effective to solve. It's great that Space X wants to reuse them but NASA/ESA are saying they need to look carefully at the economics of reusability vs. all new components. One luxury Space X doesn't have that NASA/ESA have is large budgets and the ability to tap into even more public funds if needed so a mistake could spell the end of Space X.

      --
      I'm a consultant - I convert gibberish into cash-flow.
    4. Re:Just because... by torkus · · Score: 4, Informative

      Exactly.

      NASA built redundancy into everything because they didn't know better. Material science was far less developed. Computer simulations basically non-existent. They didn't design a 30% margin into parts, they guessed and fixed whatever part broken with a strong/better one and tried again. If some part was 5000% over-engineered it wouldn't break but would negatively impact the overall system complexity/weight.

      I'm pretty sure NASA (and plenty of others) also said Elon/Space-X was stupid for getting into building launch vehicles too. Yet here we are with their innovation not only a success, but bringing cheaper launches than anyone else. Clearly Space-X is not to be believed. /sarcasm

      --
      You can get rich if you own a politician, but you have to be rich to buy one in the first place.
    5. Re:Just because... by NotDrWho · · Score: 5, Funny

      Exactly, SpaceX thinks *outside the box*. This innovative thinking allows them to toss aside all learned wisdom and knowledge from those old dinosaurs at NASA.

      Innovative thinking, used to build synergy and form a new paradigm, THAT'S what it's all about. The physical reality will follow from that.

      --
      SJW's don't eliminate discrimination. They just expropriate it for themselves.
    6. Re:Just because... by Teancum · · Score: 5, Informative

      Beyond stating the obvious, these quotes from the NASA engineers don't really seem to fly with me.

      I get that building rocket engines is a tough challenge, as can be clearly demonstrated by how few new rocket engine designs ever get completed.n All of the complaints about the RD-180 engine with its manufacturing being done in Russia center around the fact that trying to get even just a rough equivalent would require building a brand new engine from scratch. For large engines that can launch payloads of several metric tones into orbit, typically only one or two ever get designed each decade by anybody around the world. This past decade one of those engines was the Merlin engine designed by SpaceX.

      What makes the Merlin engine so interesting is precisely because it is bland. SpaceX hasn't been trying to push the envelope in a hardcore sense with exotic fuels or pushing the limits of specific impulse (the efficiency rating of a rocket engine). Instead they are using rather mundane fuels (Kerosene and Liquid Oxygen.... stuff used in rockets for decades) and instead are trying to simplify the design of the rocket every chance they get. Also unlike the SSME, the #1 consideration on building the Merlin has been saving money and not trying to improve performance.

      I'll also note that SpaceX does not intend to do sea recovery of these rockets, so doing any consideration of salt water besides general ocean spray into the launch environment (still a problem at KSC) is not really an issue. A problem facing the managers at KSC, or rather the Cape Canaveral Air Station, is trying to find a place for these stages to land. Both the Cape Canaveral Staff and the FAA-AST want to make sure that SpaceX doesn't land their rockets on top of other facilities (like taking out pad 39B), but that is a traffic control problem and not anything to do with the technical capability of getting the rockets to a recoverable location.

      As for the economics argument, a company driven by profits rather than a government agency who gets billions of dollars to extend failed programs is somebody who I expect to understand if something is going to be economically feasible or not. I'm sure SpaceX has done all of the number crunching a long time ago as they don't have the sugar daddies in the U.S. Senate to bail them out if it doesn't work.

    7. Re:Just because... by Teancum · · Score: 4, Informative

      >>I'm pretty sure NASA (and plenty of others) also said Elon/Space-X was stupid...

      Actually, didn't NASA award SpaceX a bunch of money to help get started... That's what I remember anyway. Do they help fund stupid?

      It was DARPA, not NASA, which gave some initial seed money to fly a few experimental payloads. Still, even that money was just a drop in the bucket for what was needed to get the rocket off the ground and certainly wasn't sufficient to pay for the development. All told, the development costs of getting the Falcon 9 ready were under a billion dollars, something a NASA study done a few years ago claimed couldn't be done for less than $10 billion.

      The DARPA money was just a few tens of millions of dollars. NASA has certainly paid for stuff like the ISS resupply missions (one is currently in space as I write this down), and they are also paying for a commercial crew program that also has money going to some other companies as well. Those were also highly competitive contracts that were literally open to any business or even group of investors who cared to put together an idea for a vehicle (including Jeff Bezos with his Blue Origin company who actually submitted a bid for that money too).

      Still, none of that would have been possible without substantial private capital including most of the private fortune of Elon Musk himself who has reportedly invested as much as $200 million of his own money into SpaceX.

    8. Re:Just because... by jythie · · Score: 5, Informative

      The idea that NASA has been poo-pooing SpaceX is mostly a myth. NASA has been urging caution and realism, but NASA has been on SpaceX's side from the early days. However people really get into the narrative of hip young capitalists taking on the stogy old government and shoe horn an adversarial narrative in.

    9. Re:Just because... by FatLittleMonkey · · Score: 5, Insightful

      What makes the Merlin engine so interesting is precisely because it is bland. SpaceX hasn't been trying to push the envelope

      It surprises me how few people get this. Even people within NASA.

      Saturn V was Kero/LOx, and it had a crappy Isp. But it built upon the experience of the previous two decades of rocket (and missile) research.

      When NASA went to the shuttle, it threw away everything it had learned and started again. A LH/LOx engine (much harder), with the highest Isp of any engine to date (even harder), which was reusable (seriously?), on a 100 tonne space-plane (I mean, seriously!), launched side-mount on an entirely new configuration. There were no stepping stones, no way to learn your "craft", to understand the limits of materials and techniques. It was completely unrelated to either previous rocket programs or X-Plane research. Much of the proposed design was only theoretically possible, such as the heat-shield, but every single piece had to work right on the very first test launch, manned, in 1981. That is an Apollo level challenge and it's stunning that they were able to get anything that flew, let alone flew for over two decades. But it's not how you build practical systems. It's not how you build affordable systems.

      --
      Science is all about firing a drunk pig out of a cannon just to see what happens.
  2. I can tell this article is worthless from the summ by drinkypoo · · Score: 4, Informative

    NASA, France Skeptical of SpaceX Reusable Rocket Project

    Yes, that's a lovely headline. But the original headline ("NASA, CNES Warn SpaceX of Challenges in Flying Reusable Falcon 9 Rocket") tells the same story with 42% less bullshit.

    NASA found that it was not worth trying to reuse the space shuttle main engines after every flight without extensive refurbishment.

    Really? So because the space shuttle couldn't do it, nobody could do it, perhaps by learning lessons from the shuttle program? If this is an example of the kind of thinking in the article, it's a fat waste of time. If it isn't an example, why mention it at all?

    I went ahead and skimmed the article, and indeed, the sole counterexample to the potential of reuse continues to be the space shuttle. The article is crap. Flush.

    --
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  3. Origami Space Station by NReitzel · · Score: 5, Insightful

    Does anyone remember the history of the space station?

    NASA spent billions (with a B) of dollars, and for a decade we had not one bolt flying in orbit. I used to call the project the Origami space station, made out of paper. It wasn't until the Russians went ahead and launched the first module that NASA got around to giving up on Powerpoint and Viewgraphs and meetings, and actually -did- something.

    I just love it when people proudly proclaim that something isn't possible.

    History shows that such pronouncements have a very poor track record.

    --

    Don't take life too seriously; it isn't permanent.

    1. Re:Origami Space Station by NotDrWho · · Score: 5, Insightful

      I just love it when people proudly proclaim that something isn't possible.

      Agreed. I remember back in the 50's when I was a kid and innovative thinkers were planning flying cars. A lot of luddite skeptics rose up and proclaimed that flying cars were impractical, too dangerous, too expensive, etc. But did the forward-thinkers let the skeptics hold them back? HELL NO!

      Never let old-school thinkers hold you back! No idea is crazy as long as you BELIEVE IN IT ENOUGH!

      --
      SJW's don't eliminate discrimination. They just expropriate it for themselves.
    2. Re:Origami Space Station by FatLittleMonkey · · Score: 5, Funny

      No, NASA management is done in Powerpoint.

      (NASA engineering is done in Excel.)

      --
      Science is all about firing a drunk pig out of a cannon just to see what happens.
    3. Re:Origami Space Station by FatLittleMonkey · · Score: 4, Informative

      GP is referring to Freedom Space Station, not Skylab. You know that, why are you lying and pretending you don't?

      Freedom was proposed to Reagan in '86 and accepted in '88 (continuing under Bush I). It was supposed to cost $8 billion all up and take 8 years.

      8 years and $8 billion later, nothing had been launched; hell, nothing had been built. The design had shrunk from a 12 man space station much larger (internally) than Skylab, to a 4 man station much smaller than Skylab. (The in-house joke at the time was that they had to call it "Fred" because they could no longer fit all the letters of "Freedom" on the side.)

      So in '96, Clinton forced an enquiry which required them to take what had been designed up to that point, pick one of the three leading configurations, and just build it. This led to the current design, then nicknamed "Alpha". In '98, a requirement was added to merge the station with Russian modules (and to a lesser degree Europa and Japan). This would reduce NASA's cost in developing some of the core modules, get modules launched earlier, and buy access to Mir technology/experience; it was also thought beneficial to keep Russia's space program intact, to prevent rocket engineers going to work for Iran/Iraq/etc. That became the ISS.

      As for "Powerpoint", it's clearly being used as a euphemism for the endless "paper studies" and over-management that infest NASA. You also know that, why are you lying and pretending that you don't?

      --
      Science is all about firing a drunk pig out of a cannon just to see what happens.
    4. Re:Origami Space Station by DerekLyons · · Score: 5, Insightful

      NASA spent billions (with a B) of dollars, and for a decade we had not one bolt flying in orbit.

      They spent billions because Congress kept delaying and rescoping the project. Then they had to start over again practically from scratch when the President and Congress insisted they had to include the Russians.
       

      I used to call the project the Origami space station, made out of paper.

      Announcing "I'm ignorant of reality" is hardly a convincing argument.
       

      It wasn't until the Russians went ahead and launched the first module that NASA got around to giving up on Powerpoint and Viewgraphs and meetings, and actually -did- something.

      That's like saying "my neighbor is stupid because he waited until his window was broken to replace it". By the time Zarya launched, NASA had already been "doing something" (I.E. bending metal and building hardware) for years.
       

      I just love it when people proudly proclaim that something isn't possible.

      I just love it when people misrepresent what was said. Nobody said making an engine re-useable on the scale SpaceX is planning is impossible, they said it would be challenging and there was reasonable doubt as to if it would be possible based on existing engineering knowledge. And quite frankly, if you're actually conversant with the engineering involved (or at least not extremely biased and and proudly ignorant), the argument isn't completely without merit. SpaceX is headed off into virtually completely unknown territory here.

  4. And so what? by bruce_the_loon · · Score: 5, Insightful

    Why not let SpaceX try and find out for themselves. They know their engines and have tested them for reuse long before they started building Grasshopper and the test protocols for Falcon 9.

    The Merlins are designed to stop and start, and have done it successfully on the launch pad with the launch aborts experienced during their test flights. And SpaceX probably has a set that they've run on a static test pad for a full flight profile, then dusted them off, checked the bearings and seals and ran them again. And again. And again.

    The SSMEs are excessively complex systems that have a much greater thrust than the Merlins. They need a full strip and rebuild because of their complexity.

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  5. Denying Reality by Teancum · · Score: 5, Informative

    No doubt that SpaceX has put a whole lot of effort into making this work, but it amazes me that people who are otherwise knowledgeable about this kind of stuff can't stand looking at actual results rather than assuming this is just random musings. One of the ways SpaceX knows how many potential launches they can get out of their engines is because they have put some of these Merlin-1 engines on their test stand in Texas and have fired them for full mission duration burns 40-50 times. SpaceX definitely doesn't make up these numbers out of their hind end but rather from experience and actually using this equipment.

    Again reality sort of bites these guys hard because SpaceX has been able to bring the 1st stage down to a soft landing. With the most recent launch, SpaceX was denied the opportunity to do more because both the FAA and the USAF folks at Cape Canaveral didn't really want that return stage going anywhere near the launch pad until SpaceX has proven they have control of the vehicle. Regardless, SpaceX has done the really hard part of actually getting the spacecraft to return in a recoverable condition.... something these "experts" in this article are denying is even possible in a theoretical sense.

    The 2nd stage recovery is going to be a whole lot harder, and it is something that even SpaceX themselves have said may not be successful. Still, I wouldn't categorically write off SpaceX either and it is just stupid to dismiss something like this as impossible without even making an attempt to see if it could be done.

  6. Re:Space Shuttle Challenger by Teancum · · Score: 5, Insightful

    The Challenger exploded because the spacecraft was flying outside of its design parameters. The engineers themselves asked for, I dare say even begged NASA to not fly that day, but NASA was under a huge amount of political pressure to get the vehicle into orbit or risk an embarrassing trip to congressional meetings to explain why this supposedly reusable spacecraft (meaning the Space Shuttle) wasn't really reusable and couldn't fly in conditions that were not a problem with the Saturn V.

    No doubt that the Space Shuttle was an incredibly complicated machine that could break with a series of bad events, but there is far more to the destruction of the Challenger (or the loss of the Columbia a few years later) than simply hand waving and saying "it is so complicated that it was simply going to have problems."

    Besides, the Space Shuttle is a really horrible demonstration vehicle for reusable spacecraft. So many design compromises were done with that spacecraft it is a wonder it flew at all in the first place. It certainly was never going to live up to the hype that surrounded the spacecraft in the late 1970's and early 1980's.

  7. Re:governement approach can waste money trying by clarkkent09 · · Score: 5, Insightful

    the least "big government"
     
    I don't know but from all I read about NASA I get the impression that, as good as the engineers are at the one end, the bureaucracy and politics on the other end are just as bad as in the rest of the government. Space X doesn't have to build their components in 40 different states and in order to please 40 congressmen and get the funding etc.

    Also, don't underestimate the power of competition. NASA only had to meet some arbitrarily set deadline and in the worst case get chewed up in a congressional committee after the 10th delay or cost overrun. Space X has to beat its competitors on price and service or else it goes out of business.

    --
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  8. Except Elon Musk is a genius by Andover+Chick · · Score: 4, Interesting

    Between NASA/CNES being correct and Elon Musk being correct, I'll side with Elon. He's already created the first practical electric car which besides having 200+ mile range is freaking awesome and sporty. Behemoth GM failed to do the same over the course of decades. So proving NASA/CNES wrong, the smart money is on Elon.

  9. Beware bad journalism. by DerekLyons · · Score: 4, Informative

    NASA found that it was not worth trying to reuse the space shuttle main engines after every flight without extensive refurbishment.

    *sigh* This myth again. Folks, this claim is a complete and utter fabrication. (And if you read TFA, it's not actually attributed to NASA.) By the mid-90's, while NASA was still removing the engines after each flight, this was solely for inspection - they no longer disassembled or refurbished them between every flight. By the late 90's/early 00's, they'd stopped routinely removing them after every flight, instead inspecting them with fiber optics and only removing them after every three-to-five flights or if inspection showed them to require removal. As is the case with so much science and technology journalism, the author is... not entirely aware of the facts or in possession of a clue. (Sadly, 90%+ of the Slashdot readers replying to this doesn't know these facts, and will attack the article anyhow because it disagrees with their biases.)
     
    That being said, I tend to agree somewhat with NASA on this one. SpaceX has reduced launch costs mostly by applying known engineering and production techniques that had not previously been applied to launch vehicles. (And with the limited number of launches to date, it's far too early to be reasonably analyze if they've truly been successful.) But when you're talking about flying an engine 40+ times... there aren't really any such previously known but unused techniques. They're headed off into largely unexplored regions of engineering and technology.
     
    Slashdot really needs to stop taking Musk's pronouncements as gospel at face value and look at the engineering and the facts.

  10. Re:governement approach can waste money trying by phayes · · Score: 4, Insightful

    The traditional launcher companies (Boeing Lockmart ATK etc) have all considered the Nasa budget to be a captive market with Nasa having no choice but to use one of them. Their MO was to raise prices as high as possible to maximize profits & then subcontract most of the fabrication out so that it could be farmed out widely in order to play the pork game.

    SpaceX doesn't play by the same rules. They are very heavily vertically integrated & prefer fabricating in-house to farming it out. Yes there will be less support from the porcine section of Congress, but SpaceX is now pretty much the only short term game in town, they are cheaper than the traditional launchers and if recovery keeps going as well as it has so far, will be much cheaper within 2-3 years. Nasa is much more than just a govt subsidy for launchers and congress isn't going to defund Nasa.

    SpaceX would be hurt by a nasa slowdown but they are on the cusp of being able to go on even without them.

    --
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