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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

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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

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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


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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


SBIR Program and the AFL Rocket Lab


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


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


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


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)


Topics


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


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


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


Evaluation Process


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


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


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


SBIR Successes


Transition of Innovative CT Imaging Techniques for Solid Rocket Motors


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


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


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

[email protected]

661-275-5321

• Aerospace Systems Directorate

• Barb Scenters

RQ SBIR/STTR Program Manager

[email protected]

937-938-4708

• AFRL

• Anissa Lumpkin

AFRL SBIR/STTR Program Manager

[email protected]

937-269-3481

• AFRL Rocket Lab – Technical POC

• Dr. Richard Cohn

Chief Engineer

[email protected]

661-275-6177

SBIR POCs


mailto:[email protected]

mailto:[email protected]

Questions?


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