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Ideas Powering Freedom Eduardo Casillas Manager, Mission Architecture Engineering Rocket Propulsion Chabot College E10 Guest Lecture.

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Presentation on theme: "Ideas Powering Freedom Eduardo Casillas Manager, Mission Architecture Engineering Rocket Propulsion Chabot College E10 Guest Lecture."— Presentation transcript:

1 Ideas Powering Freedom Eduardo Casillas Manager, Mission Architecture Engineering Rocket Propulsion Chabot College E10 Guest Lecture

2 A GenCorp Company 2 Education Community College: San Jose City, Evergreen Valley B.Sc. Mechanical Engineering - San Jose State University, 1979 Graduate Studies in Mechanical Engineering, San Jose State University, Various Professional Courses (AIAA, Launchspace, etc) Work Experience 25+ Years of Experience in Lead, Support, or Managing Capacity of Systems Analysis and Preliminary Propulsion Design and Trade Studies (CSD and Aerojet)  Large Launch Vehicles (Shuttle, Titan IVA-IVB, ASRM, Delta II-III, Atlas II-III)  Orbital Vehicles (Inertial Upper Stage, Various Apogee and Perigee Motors)  Small Launch Vehicles (Athena, Pegasus, Multiple Ground / Air Launched Small Launch Vehicle)  Strategic Missiles (Minuteman III, SICBM, Trident II, LBSD, SLIRBM)  Missile Defense (THAAD, SM3 Boost / DACS, GMD, CorpSAM)  Miscellaneous (Scramjet Booster, Tomahawk Underwater Booster, Hybrid Boosters, Launch Abort) Significant Achievements Numerous Letters of Recognition Two Patent Awards (Dual Action Solid Hybrid Rocket, 1.5 Stage Symbiotic Hybrid Vehicle) Key Technical Member of Numerous Successful Proposals How I Became Interested in Propulsion Local Rocket Company (CSD, San Jose, Ca) Specialized in Solid Rocket and Ramjet Propulsion Design / Development Trials & Tribulations Bow Down When Your Motor Flies Exploring the Universe and Defense of Freedom are Among the Noblest of Professional Endeavors Eduardo Casillas Biographical Information Eduardo Casillas RocketPropulsion ChabotCollege E pptx

3 A GenCorp Company Agenda Rocket Propulsion Emphasis on Solid Propulsion Aerojet Company Overview Videos Aerojet 70 th Anniversary Video Mars EDL 7 Minutes of Terror Video Summary Questions? 3 Eduardo Casillas RocketPropulsion ChabotCollege E pptx

4 A GenCorp Company Agenda Rocket Propulsion Emphasis on Solid Propulsion Aerojet Company Overview Videos Aerojet 70 th Anniversary Video Mars EDL 7 Minutes of Terror Video Summary Questions? 4 Eduardo Casillas RocketPropulsion ChabotCollege E pptx

5 A GenCorp Company Rocket Propulsion TypePropellants SolidCombined solid mix of fuel and oxidizer Liquid Bipropellant Separate liquid fuel and oxidizer Liquid Monopropellant Decomposable fuel HybridSeparate solid fuel and liquid oxidizer (other combinations possible) Gas Blow-downHigh pressure gas SupersonicSolid or liquid fuel and air HypersonicLiquid fuel and air ElectricInert ionized gas Nuclear ThermalLiquid fuel 5 Eduardo Casillas RocketPropulsion ChabotCollege E pptx Accelerate medium to create thrust (mostly gas medium) pages/engines/what-is-a-hybrid.htm Figures provided courtesy of the following web sites:

6 A GenCorp Company 6 SRM TypeMissionExamplesCharacteristics Rocket Munitions Propel small warheads and / or penetrators to a few miles’ range Hellfire, Javelin, Stinger, EFOGM, TOW Weight < 100-lb, 3-7 in diameter, robust / rugged, produced in the hundreds of thousands Tactical Rockets Propel large warheads from tens to hundreds of miles MLRS, ATACMS, Hawk, Mk-111, Mk-104, Mk-72, AMRAAM, Sidewinder, Weight ~ lb, 5-24-in diameter, robust / rugged, produced in the tens of thousands Missile Defense Boost kill vehicles from local to continental defense coverage PAC-3, THAAD, SM-3, GMDWeight ~ lb, in diameter, composite case / TVC, produced from a few thousand to a “handful” Kill vehicle terminal guidance propulsion PAC-3 ACM, SM-3 DACS [THAAD DACS and GMD EKV- are liquid propulsion] Weight ~ lb, in diameter, thrust-managed, responsive, produced from a few thousand to a “handful” Strategic Missiles Boost ballistic re-entry vehicles to intermediate - intercontinental range Trident, Poseidon, MM-III, Peacekeeper, Pershing Weight ~ klb, in diameter, composite case / TVC, produced in the hundreds, fire-ready for decades Re-entry vehicle range extension and precise maneuvering Trident, Poseidon SGG [MM- III, Peacekeeper are liquid, Pershing is aero-controlled) Weight < 1000-lb, SGGs feed exhaust gas into manifold / valve system for steering, produced in the hundreds Space Boosters Boosters / upper stages that part of a space launch vehicle launch satellites / spacecraft Ariane-V, Atlas-V, Shuttle, Titan-IV, Delta, Taurus, Pegasus, H-IIA, Vega Weight ~ klb, in diameter, metal, composite, segmented cases / TVC / thrust shaping, produced from a few to dozens per year Space Motors Orbital transfer, Interplanetary travel propulsion IUS SRM-1 and SRM-2, STAR Motor Series Weight ~ 1-20-klb, in diameter, titanium, composite cases / TVC, spin / space environments, produced 1-2 per year Auxiliary Systems Crew escape, stage separation, attitude and roll control, spin impulse, shroud removal, TVC-GGs GMC ACS / staging motors, Apollo LES, ICBM shroud removal / roll control / TVC gas generator / RV spin Wide variation in design configuration, sizing, and technologies, produced in unit numbers depending on vehicle application Planet Exploration Assist in extra-terrestrial retro, landing, and launch functions MER retro rockets / air bag gas generators / horizontal velocity adjusting rockets Weight ~ 5-35-lb, 3-12-in diameter, titanium cases / space environments, produced 1-2 sets per mission (every 5-10 years) Wide ranging applications require SRMs with many shapes & functions Solid Rocket Propulsion Eduardo Casillas RocketPropulsion ChabotCollege E pptx

7 A GenCorp Company Program Start Preliminary Ballistics Analysis Preliminary Mechanical Design Layout Detailed Analyses Drawing Generation ThermalBallistics Structures Design Reviews Mech. Design Development & Qualification Testing Functional Configuration Audit (Customer Acceptance) Customer Specification Requirements and SOW Interactions between components must be accounted for in the design process – usually by iteration until the design converges Grain design affects the internal insulation (flame exposure) and motor case (pressure) Nozzle design affects the case (aft opening dia), propellant grain (submergence), and thrust vector actuation system (gimbaled configuration) Attach structures affect the case (skirts, thrust structure) and nozzle (blast tubes, hot-fly out) Second-level interactions (ordnance & avionics mounting, etc) Solid Rocket Propulsion – Design Flow Eduardo Casillas RocketPropulsion ChabotCollege E pptx7

8 A GenCorp Company Typical Solid Rocket Design Team Chief Engineer Project Engineers Systems Engineers Ballistic Design Engineers Design Engineers Propellant Chemists Analysts - CFD, Stress, Thermal, Dynamics Controls Engineers Electronic Avionics Engineers Materials & Processes Engineers Configuration Management Manufacturing Engineers Test and Instrumentation Engineers Eduardo Casillas RocketPropulsion ChabotCollege E pptx8

9 A GenCorp Company Agenda Rocket Propulsion Emphasis on Solid Propulsion Aerojet Company Overview Videos Aerojet 70 th Anniversary Video Mars EDL 7 Minutes of Terror Video Summary Questions? 9 Eduardo Casillas RocketPropulsion ChabotCollege E pptx

10 A GenCorp Company Overview Over 3,000 employees across 13 states 2011 Revenues of $918M Key Capabilities Enabling Space and Launch Systems Tactical Systems Missile Defense Systems Advanced Programs Significant Real Estate Holdings 10 Ascent Main Engine THAAD Static Test PAC-3 Tactical Systems Real Estate Advanced Programs Space & Launch Systems Missile Defense and Strategic Systems Eduardo Casillas RocketPropulsion ChabotCollege E pptx

11 A GenCorp Company 11 Broad Portfolio of Programs Across Diverse Mission Areas THAAD HAWK SM3 TDACS EKV Minuteman Missile Defense and Strategic Systems Tactical Systems Space and Launch Systems Advanced Programs F-22 Standard Missile Tactical Tomahawk GMLRS PAC-3 Fragmentation Devices Kinetic Energy Penetrators Warhead Liners M829A3Cartridge, 120mm, APFSDS-T AOT Specialty Metals Atlas Space Thruster AJ26 Orion Eduardo Casillas RocketPropulsion ChabotCollege E pptx

12 A GenCorp Company 12 Northern Virginia Operations Tactical & Technology 325 Employees Washington, D.C. Gainesville, VA Orange, VA Field Offices Operating Locations Engineering Center Product-Focused Manufacturing Centers and Customer- Focused Support Over 3,000 Employees Across 13 States Vernon, CA Socorro, NM Huntsville, AL Hill AFB, UT Denver, CO Eglin AFB, FL Orlando, FL Picatinny Arsenal, NJ Tucson, AZ Dallas, TX Headquarters Sacramento, CA High Value Propulsion 1,650 Employees Headquarters Sacramento, CA High Value Propulsion 1,650 Employees Moscow Tokyo London Edwards AFB, CA Jonesborough, TN Unique Specialty Materials 110 Employees Redmond, WA Precision Liquid Engines 350 Employees Camden, AR Tactical Low Cost High Volume Production 550 Employees Woodland Hills, CA Eduardo Casillas RocketPropulsion ChabotCollege E pptx

13 A GenCorp Company 13 Broad Spectrum of New Opportunities Hydrocarbon Boost Standard Missile Phased Adaptive Approach Axial and Divert Launch Standard Missile Commercial E- Space Taurus II / Bigelow JAGM Advanced Materials Standard Missile Shielding Warhead Liners HyFly Tactical Propulsion for today’s war fighter PAC-3 MSE SM3 TDACS Aeronautical Components Eduardo Casillas RocketPropulsion ChabotCollege E pptx

14 A GenCorp Company Agenda Rocket Propulsion Emphasis on Solid Propulsion Aerojet Company Overview Videos Aerojet 70 th Anniversary Video Mars EDL 7 Minutes of Terror Video Summary Questions? 14 Eduardo Casillas RocketPropulsion ChabotCollege E pptx

15 A GenCorp Company Example – Mars Science Laboratory NASA’s Mars Science Laboratory (MSL) Aerojet engines assisted with entry, descent, and landing. Aerojet thrusters also provided attitude control and trajectory correction maneuvers during the MSL’s transit to Mars. MSL carried eight Aerojet MR-111C 1.0 lbf thrusters, eight Aerojet MR- 107U 68 lbf thrusters, and eight Aerojet MR-80B 800 lbf thrusters with a throttleable thrust range of > 100:1. 68 lbf and 800 lbf thrusters supported the actual landing. 15 Eduardo Casillas RocketPropulsion ChabotCollege E pptx

16 A GenCorp Company Agenda Rocket Propulsion Emphasis on Solid Propulsion Aerojet Company Overview Videos Aerojet 70 th Anniversary Video Mars EDL 7 Minutes of Terror Video Summary Questions? 16 Eduardo Casillas RocketPropulsion ChabotCollege E pptx

17 A GenCorp Company Rocket Propulsion - Summary Rocket propulsion is an exciting, challenging, and rewarding engineering field Tough challenges for high energy propellants, high temperature / lightweight materials, fast acting / high precision control actuation, and systems integration All challenges and tribulations bow-down when your rocket is developed to perform successfully and reliably Rocket propulsion enables some of our most noble endeavors Study of our planet – protect our island Space exploration – expand human presence to other islands Defense of human freedom – protect our way of life now and for future generations Eduardo Casillas RocketPropulsion ChabotCollege E pptx17

18 A GenCorp Company Agenda Rocket Propulsion Emphasis on Solid Propulsion Aerojet Company Overview Videos Aerojet 70 th Anniversary Video Mars EDL 7 Minutes of Terror Video Summary Questions? 18 Eduardo Casillas RocketPropulsion ChabotCollege E pptx


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