AIAA 2017-4796

AIAA Propulsion and Energy Forum

10-12 July 2017, Atlanta, GA
53rd AIAA/SAE/ASEE Joint Propulsion Conference

New developments in Energetic Components and Systems on

The Atlas V Launch Vehicle

John G. Scott
United Launch Alliance, Centennial, Colorado, 80112

Energetic components in aerospace are comprised of explosive transfer lines, destruct

charges such as linear shape charges or conical shape charges and multiple other mechanical
devices that use energy stored in explosive chemicals to perform work such as cutting metal,
Downloaded by University of Michigan - Duderstadt Center on July 10, 2017 | http://arc.aiaa.org | DOI: 10.2514/6.2017-4796

pushing masses, closing pressure lines or many other useful works where quick, light and
reliable energy sources are needed. The modern aerospace world encompasses many
disciplines where modern advances in sensing technology and computing power tend to
dominate major systems advances. Recently a different tack was taken at United Launch
Alliance (ULA) where a complete look at a Payload Fairing (PLF) s separation system, used
essentially unchanged since the 1970s, was forced into a change by impending obsolescence
of multiple avionics components.

Nomenclature
dB = decibel
FMEA = Failure Modes Effects Analysis
LAT = Lot Acceptance Testing
RPN = Risk Priority Number, this is the product of Severity, Occurrence and Detection
SAE = Society of Automotive Engineers
ULA = United Launch Alliance

I. Introduction

E Nergetic components in aerospace are comprised of explosive transfer lines, destruct charges such as linear
shape charges or conical shape charges and multiple other mechanical devices that use energy stored in
explosive chemicals to perform work such as cutting metal, pushing masses, closing pressure lines or many other
useful works where quick, light and reliable energy sources are needed. The modern aerospace world encompasses
many disciplines where modern advances in sensing technology and computing power tend to dominate major
systems advances. Recently a different tack was taken at United Launch Alliance (ULA) where a complete look at a
Payload Fairing (PLF) separation system, used essentially unchanged since the 1970s, was forced into a change by
impending obsolescence of multiple avionics components.
First lets have a little primer on basic launch vehicles. The task of a space rocket booster system is to deliver a
payload either into a suborbital trajectory or into a useful orbit. This has been occurring on a regular basis since
1957 and the launch of Sputnik. The basic system consists of a rocket stage with a payload mounted on top. To
protect the payload a fairing, called a Payload Fairing, encloses the payload protecting it from the effects of
exposure to the earths atmosphere as the rocket accelerates to its intended velocity. Once the mission timing is
correct various systems are used to expose the payload to space or the upper atmosphere by ejecting portions of or
the entre payload fairing.

II. Program Summary

At ULA the Atlas vehicle family has used a 14 diameter PLF on a large portion of missions. The basic design
splits along a vertical split seam from the tip of the PLF to the base and hinges open where momentum imposed by a
spring system thrusts the two halves of the PLF apart. As can be surmised the system holding the vertical split line
together has to be pretty robust mechanically yet splits apart quickly and easily upon command. The basic design
uses explosive bolts that fracture at a predetermined point upon the receipt of an input from a large explosive
cartridge. Imagine a large caliber rifle shell providing pressure to the internal mechanisms in the bolt like moving a
bullet down the barrel of a gun and you will not be far off. As with any complex system timing of each bolt firing
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Copyright 2017 by the American Institute of Aeronautics and Astronautics, Inc. All rights reserved.
 and separating is important to the successful deployment of the PLF. The original system developed in the 1970s
used electrical cables to deliver a short pulse of electricity to multiple explosive squibs mounted on each explosive
bolt to start the cartridge that provide the energy described above. As can be imagined the length of a fairing and the
timing needed requires powerful batteries and complex avionics controllers to provide the precise firing current
correctly. Once the realization came that the controllers and harness components were verging on obsolescence a
full systematic look led to the choice of replacing the harnesses and batteries with explosive transfer lines that
depend on internal chemical energy to transmit a signal to each bolt similar to the previous electrical signal.
A fully comprehensive system upgrade program was started in 2012 to redesign the system to use explosive
transfer lines and limit the amount of electrical signals needed to initiate the system. Special care was taken
throughout to ensure that the explosive lines could not contribute any smoke or particulate that may contaminate the
payload upon initiation of the system. Several new components were developed including a Covered Flexible
Confined Detonating Cord (CFCDCA), a Donorless Thru-Bulkhead Initiator (DTBI), and Specialized Booster to
power the explosive bolts. The final system design finished qualification for all environmental exposure in late 2015
Downloaded by University of Michigan - Duderstadt Center on July 10, 2017 | http://arc.aiaa.org | DOI: 10.2514/6.2017-4796

and first flew successfully on the OA-6 Space Station Resupply mission in March of 2016.

Figure 1 OA-6 Heads for the International Space Station, photo courtesy United Launch Alliance

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 III. Recurring Program
Subsequent flights have all shown successful PLF separation in flight and allowed ULA to remove over one full
day from vehicle processing. As of this publication date ULA has flown a total of seven missions with the upgraded
system. Along with the component changes the total system cost and processing time was reduced significantly
without any reduction in reliability.

Figure 2 - NROL-79 heads to space, photo courtesy of United Launch Alliance

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 Figure 3 Payload Fairing Separation from OSIRIS-Rex, photo courtesy of United Launch Alliance
Downloaded by University of Michigan - Duderstadt Center on July 10, 2017 | http://arc.aiaa.org | DOI: 10.2514/6.2017-4796

The development of new components in the entire system have now become available for use on other unique
programs at ULA such as the human launch programs and new launch vehicle systems. The basics of design all
through the design process never lost sight of uses in other places, with an emphasis on making each component a
building block for other system upgrades as the rocket fleet has evolved.

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 Figure 4 Payload Fairing Separation from OA-7, photo courtesy United Launch Alliance
Downloaded by University of Michigan - Duderstadt Center on July 10, 2017 | http://arc.aiaa.org | DOI: 10.2514/6.2017-4796

IV. Conclusion

This type of program highlights using an innovative view of total system integration looking at all possible
solutions to maintain high reliability, reduce costs and processing times using heritage ordnance components
modified for special installations in launch vehicle systems. The ULA team worked closely with multiple subtier
suppliers throughout the industry, and while we did not invent any new groundbreaking technologies in this system,
we did revert to very basic engineering principles of simplicity to enhance the chances for first flight success.
.

Acknowledgments
The Author wishes to thank the support of United Launch Alliance providing resources to prepare and present
this paper. Thanks are also due to Ms. Kathryn Kostecka and Mr. Derek Gates of United Launch Alliance for
reviews of the paper and content.

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