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C S U L B C O L L E G E O F E N G I N E E R I N G
S B I R / S T T R W O R K S H O P
AFRL ROCKET LAB:SBIR PROCESS & INSIGHT
D R . S H A W N P H I L L I P S , C H I E F , R O C K E T P R O P U L S I O N D I V I S I O N
D R . R I C H A R D C O H N , C H I E F E N G I N E E R , R O C K E T P R O P U L S I O N D I V I S I O N
A E R O S P A C E S Y S T E M S D I R E C T O R A T E
2 1 F e b 2 0 1 9
Distribution A: Public Release
4
RQ-West
(Edwards AFB CA)
RQ-East
(Wright Patterson AFB OH)
Air Force Research Lab, Aerospace Systems Directorate,Rocket Propulsion Division
Rocket Engines & Motors
Satellite Propulsion
Advanced Propulsion
Fuels and Propellants
Modeling & Simulation
System Analysis
Air Vehicle Structures
Controls
Turbine Engines
Ramjet Engines
Hypersonic Engines
Aircraft Power
Thermal Management
Fuels and Propellants
System Analysis
We are the symbol of revolutionary rocket R&D and the innovation hotspotfor the United States’ weapons, launch and satellite propulsion systems • Distribution A: Public Release
5Distribution Statement C. Distribution authorized to U.S. Government agencies and their contractors only
AFRL Rocket Lab
Replacement of Russian RD-180 engine Prognostic Capability for Strategic Systems
Green Propellant Infusion Mission for
In-Space Propulsion
Adv Tactical Booster Tech for High
Speed Strike Weapon
Distribution Statement C: Distribution authorized to U.S. Government agencies and their
contractors only; Critical Technology; Aug 2016. Other requests for this documents must be
referred to AFRL/RZS, 5 Pollux Drive, Edwards AFB, CA 93524. WARNING - Export Controlled
6
AFRL Rocket LabNational Asset
•65 Square Mile Development Facility
– Air quality limits do not inhibit research activities
– Noise abatement not a problem
– Wind/population corridor does not inhibit research
– Environmental monitor/control systems in place
– Flight Test Center relation/support ongoing
•135 Major Lab/Engineering Facilities & Buildings
•30 Major Active Areas and Stands
– High Thrust Facilities
•19 Liquid Engine stands (up to 2.5M lbs
thrust)
•13 Solid Rocket Motor pads (up to 4.0M lbs
thrust)
– Altitude Facilities (micro-newtons to 50K lbs
thrust)
• Unique geophysical set-up ($2.5B+ investment)
• 515 On-Site Personnel
Distribution A: Approved for Public Release; Distribution Unlimited
7
MM I MM II MM III
RS Sidewinder
AMRAAM
RS Maverick
Titan IV
Space ShuttlePershing II
Trident I
Trident II
SICBM
Peacekeeper
MM III PRP
SRAM-A/SRAM IISM-3
Super Strypi
SRM M&S Programs
Orion 38HP
IHPRPT Missile Propulsion
SLS Boost
1957 Today Operational Systems and Solid Rocket Motors
Liquid Rocket Engine
AFRL Rocket Lab: Timeline
Saturn V
F-1
AFRL IPD
XLR-132
HC Boost
AFRL XLR-129
Centaur Upper Stage
RL10-B2
X-33
Linear Aerospike
SSME
STS
Delta IV Atlas V
Navajo
Atlas I
Delta II AR-1
• Distribution A: Public Release
8
History of “the Rock”
Atlas I-V Delta II-IV
Saturn V (F-1)
Not STINFO Approved: Distribution A: Unlimited
• Minuteman I, II, & III ICBMs 1960-Present
• Peacekeeper ICBM 1970s-1980s
• Titan I & II ICBM
– Test Stand 1-3 in Early 1960s
• Titan IV solid rocket booster
– 1980s – 1990s in Area 1-32 and Test Stand 1-C
• Shuttle & Atlas V strap-on boosters
Peacekeeper STS-ShuttleTitan 1-IV
MM I MM II MM III
• Distribution A: Public Release
9
Facilities
Bench-level Labs
High Thrust Facilities
• 19 Liquid Engine stands, up to 8,000,000 lbs thrust
• 13 Solid Rocket Motor pads, up to 10,000,000 lbs thrust
Altitude Facilities
• From micro-newtons to 50,000 lbs thrust
Not STINFO Approved: Distribution A • Distribution A: Public Release
Space Access
Strategic (& Tactical)
Systems
In-Space Propulsion
Experimental Demonstration
Affordable Responsive Modular Rocket (ARMR)
Build Any Rocket, Any Size in <2 Years- Integrated Modular Rocket Engine enables: low cost development & test through AM, scalability from 20K-1,000Kblf thrust
Rapid Reconstitution- Parts for integrated units of any size readily available
- Leverages commercial space push for small sat launches
Multi-Mode Satellite PropulsionSame Fuel for Electric and Chemical Propulsion- Leverages AFRL/RQR Green Ionic Liquid Fuel
- Combines Electrosprays with Green Chem Thrusters
Space Resiliency and Responsiveness
- Common propellant increases operational flexibility to more effectively adapt to handle unplanned maneuvers
Produce On-Demand (POD) Solid Rocket MotorsDevelop, Leverage and Innovate Advanced Methodologies for Mat’ls, Propellants, Processing
- Flexible design and manufacturing methods for changing threats
- Mission-specific weapons available at the right time and place
Physics-based Design Tools- Reduce development cost & time for new strategic and tactical propulsion systems
- Input requirements and output new motor design to avoid test-fail-fix cycle
Modular Engine Component TestSkid-Mounted, Quickly Configurable Engine
Component Testing- Multiple propellants, flows, pressures- Concentrate on most valuable data products- Space and high altitude testing of small
components to 50K thrust engines and motors- Small characterization to large atmospheric test
The AFRL Rocket LabMission: Perform cutting-edge rocket propulsion R&D, while addressing
our customer’s requirements and future needs
Vision: To be the symbol of revolutionary rocket R&D and the innovation hotspotfor the United States’ weapons, launch and satellite propulsion systems
- ENABLE RAPIDLY FIELDED SYSTEMS TO ADJUST TO & COUNTER ADVERSARIES- PREDICTIVE CAPABILITY R&D FOR THE FUTURE OF ROCKET PROPULSION- MULTI-POINT DESIGN FOR ADAPTIVE, AFFORDABLE, LOW-COST NEEDS
• Distribution A: Public Release
SBIR Program and the AFL Rocket Lab
Distribution A: Public Release
SBIR Program goals
• Develop and transition technology to the warfighter
• Cost effectively solve current problems
• Infuse innovative ideas/solutions into existing and new programs to develop new capabilities
• Better utilize Small Businesses to develop creative solutions
• The overall SBIR program has emphasized increasing the number and quality of transitions in recent years
• Recent trends
• Emphasis on transitions
• Commercialization Readiness Program (CRP)
• Seeing less opportunity for “Blue Sky” topics which explore a technology area
• Distribution A: Public Release
SBIR Phases
• Funding: 3.2% of R&D Budget
• Three phase effort (typical AF values and lengths)
• Phase 1: 6 month/$150K – Technical merit, feasibility, commercial potential (plus 3 month reporting)
• Phase 2: 2 years/$750K – Reduce risk of phase 1 effort to enable transition (plus 3 month reporting)
• Phase 3: Develop the technical product – no typical dollar amounts or time frames.
• Uses Program dollars – not funded through SBIR program
Distribution A: Public Release
AF Commercialization Readiness Program
• Strategically driven process to enhance and accelerate transition process
• Recognition that valuable technologies may require more than the $150K phase 1/$750K phase 2
• Links AFRL and Air Force Centers/Commands
• Award additional Phase II efforts, enhance/augment existing programs to accelerate and enable transition
• Total value of SBIR funding allowed on phase 2 normally $1.5M
• Solves an unanticipated problem which occurred during phase 2
• Waivers process recently approved – used successfully
• Compelling argument for transition
• Requirements
• Identified and interested customer (Air Force program office, major contractor, etc.)
• Customer driven defined need
• SBIR/STTR technology that meets the need and shows high potential for providing viable results
Distribution A: Public Release
AFRL Rocket Lab SBIR program
• Our goal is to develop and transition SBIR technologies supporting Launch and In-Space Propulsion activities
• Typically manage 12-15 topics per year
• ~30 phase 1 awards (including SBIRs and STTRs)
• ~20 phase 2 awards (including SBIRs and STTRs)
• ~2-3 enhancements/extensions
• ~2-3 phase 3 efforts
• ~$25M per year
• Topic sponsors Air Force Space Command (Space and Missile Systems Center), Air Force Global Strike
Command (Nuclear Weapons Center)
Distribution A: Public Release
Topics
Distribution A: Public Release
Topic Creation
• Topic idea can be developed by any AF employee
• Works with organizational leadership to hone idea, understand transition potential and customers
• Topic can be generated by nearly any AF employee – Must meet following requirements
• Develops technology to solve an Air Force problem, need, or capability deficiency
• Does not mandate a solution or a specific technology approach
• Clearly defined technology area (sensor, material) and problem to be solved or desired capability
• Solution requires basic research, applied research, or technology development
• Required parameters clearly stated and current state of the art described
• Identifies military and/or civilian uses for technology to be developed
• Required use of government materials/equipment/data/facilities defined
• Phase 1 & Phase 2 task requirements reasonable given time and funding constraints
• Does not duplicate another topic
• Topic submitted to Topic Submission Module
• Topics in the Submission Module are reviewed by Centers/Major Commands for applicability and selection
• Need and transition potential are key criteria
Distribution A: Public Release
Topic Selection
• Each AF command/center is allocated topics based on Research/Engineering/Development budget
• Each command/center has their own topic selection process
• Generally, command/centers look for
• Applicability to current programs
• Program need/criticality
• Potential for transition of technology into fielded systems
• Selected topics released three times per year
• Pre-release: November, April, August
• Open for submission: January, May, September
• Closed: Feb, June, Oct
• Open communication between government and contractor permitted between pre-release and opening for
submission
• Once proposals can be submitted, all communication goes through specified processes and must be made
available to any potential offeror
• Awards typically 6 months after topic closes
Distribution A: Public Release
Key people in SBIR process
• Technical Point of Contact – Responsible for technical portion of the topic,
• Responds to technical questions regarding topic
• Leads topic evaluation team
• Manages/recommends manager for selected proposals
• Contracting Point of Contact
• Contracting officer is only person who can obligate government funds
• SBIR office
• Provides administrative support and ensures compliance with SBIR rules
• SBIR approving advisor
• Confirms topics meet SBIR requirements
• Reviews technical evaluations
• Approves Commercialization readiness Program proposals
Distribution A: Public Release
Evaluation Process
Distribution A: Public Release
Evaluation Process
• Contracting ensures proposals meet BAA requirements
• Technical Point of Contact identifies review team
• Team reviews proposals
• Three criteria
• Technical Merit – 50 points
• Typically, there are multiple proposals with very high technical merit
• Qualifications of PI/Team – 30 points (phase 1), 20 points (phase 2)
• Typically, there are multiple proposals with exceptionally well qualified teams
• Commercialization Potential – 20 points (phase 1), 30 points (phase 2)
• Includes the ability of the offeror to commercialize the technology
• Often becomes the “tie breaker”
• Awards
• Two phase 1 awards
• One phase 2 award
• Opportunities exist for additional awards – we have been very successful getting an additional award
Distribution A: Public Release
Common “Concerns” in Proposals
• Technical Merit
• Generic description of solution
• No solution presented to problem – the government is seeking contractor proposals
• Little description of how the contractor is going perform the task
• Personnel qualifications
• Required skill set missing
• Not bringing in system-level expertise
• Commercialization
• No commercialization plan
• No description of how the company plans on commercializing the product
• Discussion of partnerships in the text, but no letter of support from partner
• Do not assume the evaluators will “know” an important detail about your organization
Distribution A: Public Release
Data Rights
• Confusing issue with SBIRs
• Governed by DFARS 252.227-7018(b)(4), Rights in Noncommercial Technical Data and Computer Software –
Small Business Innovation Research (SBIR) Program
• Limited rights for technical data, restricted rights on software
• In effect for five years from completion of SBIR contract, followed by Unlimited Rights
• Clock resets if firm awarded another SBIR contract and data rights properly asserted
• SBIR contract does not have to be from same topic – data rights must be properly asserted
• May not be continuous – gaps can sometimes be present in data rights
• Negotiation of other than SBIR data rights on SBIR contracts prohibited
• Government retains royalty-free license for Government use of technical data delivered under SBIR contract,
whether patented or not
Distribution A: Public Release
SBIR Successes
Distribution A: Public Release
Transition of Innovative CT Imaging Techniques for Solid Rocket Motors
Distribution A: Public Release
Benefit• Sustainment of critical ICBM surveillance capability in
support of Nuclear Deterrence Operations
• Direct impact on ICBM reliability and service life estimations; necessary to support aging fleet
Customer Implementation Actions• Hardware upgrades coordinated with software development
• Validation data during and after software development
FY16 FY17 FY18 FY19 FY20
Algorithm Translation
Cross-scan Comparison
3D Model Development
Integration
Documentation
End User validation
Program Schedule
TRL 6
Scanned Object
Sensor Array
X-ray Source
Facility for Solid
Rocket Motors
Warfighter Need:
Software Development
for ICBM Sustainment
Computed Tomography
New AFRL Technology• Computed tomography (CT) advancements improve
surveillance of the ICBM fleet in quality and quantity
• Algorithms to improve scanning precision
• 3D superresolution for detailed analysis
• Computational recoding to leverage GPUs for faster scans
TRL 7
Distribution A: Public Release
Benefit• Non-destructive inspection of enclosed components
with millimeter-level resolution
• Wide applicability, from airframes to electric motors to missiles to electronic components
• Direct inspection for metal fatigue in three dimensions without removing components from an airframe
• Enables in-situ inspections for condition-based maintenance programs
• Software analysis capabilities to include component color-coding, 3D slice cut-aways, component isolation
FY18 FY19 FY20
Cone Beam Algorithm
Inspection toolkit
Cross-platform integration
Integration
Software Kit
Documentation
Program Schedule
Microfocus
Cone Beam CT
Transition technology for better inspection• Cone Beam Computed tomography (CBCT) was developed for
medical imaging, specifically dentistry for 3D X-rays
• Lickenbrock, through SBIR phase I and II and CRP agreement, are developing commercial software to apply CBCT for non-destructive evaluation (NDE) of equipment
• Image improvements linked to inspection tools for a single analysis package for wide range of cone beam x-ray machines
Technology Product• Commercial-grade software for NDE inspection for all parts of
USAF, direct support integrated to AFNWC inspections at HAFB
TRL 7
Fan Beam CT Cone Beam CT
Transition of Non-Destructive Evaluation Software (CRP)
The RL-10CX will support multiple future government launch needs as it is integrated into new launch systems. (e.g. ULA’s Vulcan, NGIS Omega)
Multiple exciter circuits and complete igniter systems have been built, tested and ultimately transitioned for
integration into launch systems by United Launch Alliance (ULA), Roush, and Aerojet Rocketdyne
CRP 2nd Phase II: Integrated Igniter System for Hydrogen/Oxygen Engines
RL-10CX Igniter Design
RL-10
ULA Vulcan launch vehicle
BENEFITS
• Simplified, lower cost ignition systems for a variety of combustion systems (e.g. rocket engines, reciprocating engines, and gas turbines)
• Insertion of small business innovative technology to Aerojet Rocketdyne and ULA.
TECHNOLOGY TRANSITIONS
• IES has designed an igniter system for AerojetRocketdyne (AR) to integrate into new AR RL-10CX engine IES is delivering 1 igniter system to AR in support of RL-10CX
developmental testing
• Designed and fabricated flight-like igniter systems for use in the ULA Centaur. Centaur is the Atlas V and Vulcan launch vehicle upper stage 3 igniter systems will be delivered to ULA for system testing
NGIS OmegAlaunch vehicle
• Distribution A: Public Release
ORBITEC’s Vortex-cooled liquid engine technology Developed under various AFRL SBIRs Uses simple swirl LOX injector located at the rear of the combustion chamber Confines combustion to the center core region Protects the chamber surfaces from hot gases and thermal loads Core configuration appropriate for various propellants
Cost Benefits Short, lightweight chamber with no cooling channels and simple injectors Stable combustion – reliable, robust Low manufacturing and material costs
Phase III: Maturation of SNC VR35K Upper Stage Liquid Rocket Engine –Sierra Nevada Corporation
IMMEDIATE OPPORTUNITIES EXIST FOR VR-35K TO LOWER LAUNCH COSTS
DARPA / BoeingXSP
NGIS OmegA
ULAVulcan
NASA
SLS
RFI for NASA to replace 4x RL10 with 3x
VR35K-A Next Gen Upper Stage
Engine on Vulcan
replace 4x RL10 with
3x VR35K-A
Upper Stage Engine Teaming on Boeing XSP
Upper Stage
Engine for OmegA
30,000 lbf LOX/RP Test
30 lbf O2/CH4 Vacuum Test
EXEC OVERVIEW:
• Unique VORTEX combustion promotes efficient combustion while maintaining cool combustion chamber walls ,
simplifying the engine while sustaining high-performance
• Proactive mixing generates high-performance, while simplicity enables low-cost, reusable, light-weight, robust &
scalable rocket engines & systems in a wide range of sizes
OBJECTIVES:1.Mature full-scale integrated engine on test stand to inform detailed flight
designs
2.Produce and test 2 Protoflight engines for rapid “plug and play” replacement
of existing options
3.On-Ramp to multiple USAF launch service providers and give NASA low-cost
SLS option
MILESTONES:
• Significant SNC IRAD investment including Thrust Chamber,
TurboPump, Preburner, Ignitor, Valves, Systems
−Vortex Thrust Chamber Assembly testing currently- 100% Predicted Performance
matrix to date
−Turbopump competed, designed, fabricated and integrated; testing starts on new
Test Cell Summer 2019
−Full Breadboard integration early 2020; integrated testing to start Q2 2020
• Maturation of Flight Design into Protoflight Engines (2) for Test
Flight
VR35K prototype chamber testing
TPA to be tested under PHASE iii
CONTRACT• Distribution A: Public Release
• AFRL Rocket Lab
• Trisha Spears
RQ-W SBIR/STTR Program Manager
trisha.spears@us.af.mil
661-275-5321
• Aerospace Systems Directorate
• Barb Scenters
RQ SBIR/STTR Program Manager
barbara.scenters@us.af.mil
937-938-4708
• AFRL
• Anissa Lumpkin
AFRL SBIR/STTR Program Manager
anissa.lumpkin.1@us.af.mil
937-269-3481
• AFRL Rocket Lab – Technical POC
• Dr. Richard Cohn
Chief Engineer
Richard.Cohn@us.af.mil
661-275-6177
SBIR POCs
Distribution A: Public Release
Questions?
Distribution A: Public Release
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