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Falcon 9 Full Thrust

Falcon 9 Full Thrust (also known as Falcon 9 v1.2, with variants Block 1 to Block 5) is a partially reusable medium-lift launch vehicle, designed and manufactured by SpaceX. Designed in 2014–2015, Falcon 9 Full Thrust began launch operations in December 2015. As of 26 January 2023, Falcon 9 Full Thrust had performed 179 launches without any failures. Based on the Lewis point estimate of reliability,[definition needed] this rocket is the most reliable orbital launch vehicle currently in operation.[8]

Falcon 9 Full Thrust
Launch of the first Falcon 9 Full Thrust flight, Falcon 9 Flight 20, carrying 11 Orbcomm satellites to orbit. The first stage was recovered at Cape Canaveral Air Force Station LZ-1 following the first successful Falcon 9 landing.
FunctionPartially reusable orbital medium-lift launch vehicle
ManufacturerSpaceX
Country of originUnited States
Cost per launch$62M (2016),[1] $50M (Reusable, 2018)[2]
Size
Height71 m (233 ft) with payload fairing[3]
Diameter3.66 m (12.0 ft)[4]
Mass549,000 kg (1,210,000 lb)[4]
Stages2
Capacity
Payload to LEO (28.5°)
Mass
  • Expendable: 22,800 kg (50,300 lb),[1] 17,400 kg (38,400 lb) when landing
Payload to GTO (27°)
Mass
  • Expendable: 8,300 kg (18,300 lb)[1]
  • Reusable: 5,500 kg (12,100 lb)[1]
Payload to Mars
Mass4,020 kg (8,860 lb)[1]
Associated rockets
FamilyFalcon 9
Derivative workFalcon Heavy
Comparable
Launch history
StatusActive
Launch sites
Total launches179[5]
Success(es)179
Notable outcome(s)1 (destroyed before launch)
Landings156 / 162 attempts
First flight22 December 2015
Last flight2022
Type of passengers/cargo
First stage
Powered by9 Merlin 1D
Maximum thrustSea level: 7,607 kN (1,710,000 lbf)[4]
Vacuum: 8,227 kN (1,850,000 lbf)[4]
Specific impulseSea level: 282 seconds[6][needs update]
Vacuum: 311 seconds[6][needs update]
Burn time162 seconds[4]
PropellantSubcooled LOX / Chilled RP-1[7]
Second stage
Powered by1 Merlin 1D Vacuum
Maximum thrust934 kN (210,000 lbf)[4]
Specific impulse348 seconds[4]
Burn time397 seconds[4]
PropellantLOX / RP-1

On April 8, 2016, the Full Thrust version of the Falcon 9 family was the first launch vehicle on an orbital trajectory to successfully vertically land a first stage. The landing followed a technology development program conducted from 2013 to 2015. Some of the required technology advances, such as landing legs, were pioneered on the Falcon 9 v1.1 version, but that version never landed intact. Starting in 2017, previously flown first-stage boosters were reused to launch new payloads into orbit.[9][10] This quickly became routine, in 2018 and in 2019 more than half of all Falcon 9 flights reused a booster. In 2020 the fraction of reused boosters increased to 81%.

Falcon 9 Full Thrust is a substantial upgrade over the previous Falcon 9 v1.1 rocket, which flew its last mission in January 2016. With uprated first- and second-stage engines, a larger second-stage propellant tank, and propellant densification, the vehicle can carry substantial payloads to geostationary orbit and perform a propulsive landing for recovery.[11]

Design

 
Falcon 9 Full Thrust launch on 4 March 2016. The discarded first stage is in the lower right. The second stage is in the upper left, with the two parts of the jettisoned payload fairing.

A principal objective of the new design was to facilitate booster re-usability for a larger range of missions, including delivery of large commsats to geosynchronous orbit.[12]

Like earlier versions of the Falcon 9, and like the Saturn series from the Apollo program, the presence of multiple first-stage engines can allow for mission completion even if one of the first-stage engines fails mid-flight.[13]

Modifications from Falcon 9 v1.1

The third version of the Falcon 9 was developed in 2014–2015 and made its maiden flight in December 2015. The Falcon 9 Full Thrust is a modified reusable variant of the Falcon 9 family with capabilities that exceed the Falcon 9 v1.1, including the ability to "land the first stage for geostationary transfer orbit (GTO) missions on the drone ship"[14][15] The rocket was designed using systems and software technology that had been developed as part of the SpaceX reusable launch system development program, a private initiative by SpaceX to facilitate rapid reusability of both the first–and in the long term, second—stages of SpaceX launch vehicles.[16] Various technologies were tested on the Grasshopper technology demonstrator, as well as several flights of the Falcon 9 v1.1 on which post-mission booster controlled-descent tests were being conducted.[17]

In 2015, SpaceX made a number of modifications to the existing Falcon 9 v1.1. The new rocket was known internally as Falcon 9 Full Thrust,[18] and is also known as Falcon 9 v1.2, Enhanced Falcon 9, Full-Performance Falcon 9,[14] and Falcon 9 Upgrade.[19]

A principal objective of the new design was to facilitate booster reusability for a larger range of missions, including delivery of large commsats to geosynchronous orbit.[12]

Modifications in the upgraded version include:

  • liquid oxygen subcooled to 66.5 K (−206.7 °C; 119.7 °R; −340.0 °F) and RP-1 cooled to 266.5 K (−6.6 °C; 479.7 °R; 20.0 °F)[20] for density (allowing more fuel and oxidizer to be stored in a given tank volume, as well as increasing the propellant mass flow through the turbopumps increasing thrust)
  • upgraded structure in the first stage[19][21]
  • longer second stage propellant tanks[19]
  • longer and stronger interstage, housing the second stage engine nozzle, grid fins, and attitude thrusters[19][21]
  • center pusher added for stage separation[19]
  • design evolution of the grid fins[19][21]
  • modified Octaweb[19]
  • upgraded landing legs[19][21]
  • Merlin 1D engine thrust increased[19] to the full-thrust variant of the Merlin 1D, taking advantage of the denser propellants achieved by subcooling.
  • Merlin 1D vacuum thrust increased by subcooling the propellants.[19]
  • several small mass-reduction efforts.[22]

The modified design gained an additional 1.2 meters of height, stretching to exactly 70 meters including payload fairing,[13] while gaining an overall performance increase of 33 percent.[19] The new first-stage engine has a much increased thrust-to-weight ratio.

The full-thrust first stage booster could reach low Earth orbit as a single-stage-to-orbit if it is not carrying the upper stage and a heavy satellite.[23]

Versions launched in 2017 have included an experimental recovery system for the payload fairing halves. On 30 March 2017, SpaceX for the first time recovered a fairing from the SES-10 mission, thanks to thrusters and a steerable parachute helping it glide towards a gentle touchdown on water.[24]

On the 25 June 2017 flight (Iridium NEXT 11–20), aluminum grid fins were replaced by titanium versions, to improve control authority and better cope with heat during re-entry.[25] Following post-flight inspections, Elon Musk announced the new grid fins likely will require no service between flights.[26]

Autonomous flight termination system

SpaceX has been developing for some time an alternative autonomous system to replace the traditional ground-based systems that had been in use for all US launches for over six decades. The autonomous system has been in use on some of SpaceX' VTVL suborbital test flights in Texas, and has flown in parallel on a number of orbital launches as part of a system test process to gain approval for use on operational flights.

In February 2017, SpaceX's CRS-10 launch was the first operational launch utilizing the new Autonomous Flight Safety System (AFSS) on "either of Air Force Space Command's Eastern or Western Ranges." The following SpaceX flight, EchoStar 23 in March, was the last SpaceX launch utilizing the historic system of ground radars, tracking computers, and personnel in launch bunkers that had been used for over sixty years for all launches from the Eastern Range. For all future SpaceX launches, AFSS has replaced "the ground-based mission flight control personnel and equipment with on-board Positioning, Navigation and Timing sources and decision logic. The benefits of AFSS include increased public safety, reduced reliance on range infrastructure, reduced range spacelift cost, increased schedule predictability and availability, operational flexibility, and launch slot flexibility."[27][28]

Block 4

In 2017, SpaceX started flying incremental changes to the Falcon 9 Full Thrust version, calling them "Block 4".[29] At first, only the second stage was modified to Block 4 standards, flying on top of a "Block 3" first stage for three missions: NROL-76 and Inmarsat-5 F4 in May 2017, and Intelsat 35e in July.[30] Block 4 was described as a transition between the Full Thrust v1.2 "Block 3" and the following Falcon 9 Block 5. It includes incremental engine thrust upgrades leading to the final thrust for Block 5.[31] The maiden flight of the full Block 4 design (first and second stages) was the NASA CRS-12 mission on 14 August 2017.[32]

Block 5

SpaceX announced in 2017 that another series of incremental improvements were in development, a Falcon 9 Block 5 version, which has succeeded the transitional Block 4. The largest changes between Block 3 and Block 5 are higher thrust on all of the engines and improvements on landing legs. Additionally, numerous small changes will help streamline recovery and re-usability of first-stage boosters. Alterations are focused on increasing the speed of production and efficiency of re-usability. SpaceX aims to fly each Block 5 booster ten times with only inspections in between, and up to 100 times with refurbishment.[33][34]

Rocket specifications

Falcon 9 Full Thrust specifications and characteristics are as follows:[13][30][35]

Characteristic First stage Second stage Payload fairing
Height[35] 42.6 m (140 ft) 12.6 m (41 ft) 13.228 m (43.40 ft)
Diameter[35] 3.66 m (12.0 ft) 3.66 m (12.0 ft) 5.263 m (17.27 ft)
Mass (without propellant)[35] 22,200 kg (48,900 lb) 4,000 kg (8,800 lb) 1,700 kg (3,700 lb)
Mass (with propellant) 433,100 kg (954,800 lb) 111,500 kg (245,800 lb) N/A
Structure type LOX tank: monocoque
Fuel tank: skin and stringer
LOX tank: monocoque
Fuel tank: skin and stringer
Monocoque halves
Structure material Aluminum lithium skin; aluminum domes Aluminum lithium skin; aluminum domes Carbon fiber
Engines 9 × Merlin 1D 1 x Merlin 1D Vacuum N/A
Engine type Liquid, gas generator Liquid, gas generator
Propellant Subcooled liquid oxygen, kerosene (RP-1) Liquid oxygen, kerosene (RP-1)
Liquid oxygen tank capacity[35] 287,400 kg (633,600 lb) 75,200 kg (165,800 lb)
Kerosene tank capacity[35] 123,500 kg (272,300 lb) 32,300 kg (71,200 lb)
Engine nozzle Gimbaled, 16:1 expansion Gimbaled, 165:1 expansion
Engine designer/manufacturer SpaceX SpaceX
Thrust (stage total)[4] 7,607 kN (1,710,000 lbf) (sea level) 934 kN (210,000 lbf) (vacuum)
Propellant feed system Turbopump Turbopump
Throttle capability[13] Yes: 816 kN-419 kN

(190,000 lbf to 108,300 lbf)

(sea level)[36]

Yes: 930–360 kN (210,000–81,000 lbf)
(vacuum)
Restart capability Yes (only 3 engines for boostback/reentry/landing burns) Yes, dual redundant TEA-TEB
pyrophoric igniters
Tank pressurization Heated helium Heated helium
Ascent attitude control
pitch, yaw
Gimbaled engines Gimbaled engine and
nitrogen gas thrusters
Ascent attitude control
roll
Gimbaled engines Nitrogen gas thrusters
Coast/descent attitude control Nitrogen gas thrusters and grid fins Nitrogen gas thrusters Nitrogen gas thrusters
Shutdown process Commanded Commanded N/A
Stage separation system Pneumatic N/A Pneumatic

The Falcon 9 Full Thrust uses a 4.5 meter long[35] interstage which is longer and stronger than the Falcon 9 v1.1 interstage. It is a "composite structure consisting of an aluminum honeycomb core surrounded by a carbon fiber face sheet plies".[13] The overall length of the vehicle at launch is 70 meters, and the total fueled mass is 549,000 kg.[35] The aluminium-lithium alloy used is 2195-T8.[37]

The Falcon 9 Full Thrust upgraded vehicle "includes first-stage recovery systems, to allow SpaceX to return the first stage to the launch site after completion of primary mission requirements. These systems include four deployable landing legs, which are locked against the first-stage tank during ascent. Excess propellant reserved for Falcon 9 first-stage recovery operations will be diverted for use on the primary mission objective, if required, ensuring sufficient performance margins for successful missions".[13] The nominal payload capacity to a geostationary transfer orbit is 5500 kg with the first-stage recovery (the price per launch is US$62 million), versus 8300 kg with an expendable first-stage.[35]

Development history

 
Falcon 9 Full Thrust rocket with the SpaceX CRS-8 Dragon spacecraft on the launch pad in April 2016

Development

As early as March 2014, SpaceX pricing and payload specifications published for the expendable Falcon 9 v1.1 rocket actually included about 30 percent more performance than the published price list indicated. At that time, the additional performance was reserved for SpaceX to conduct reusability testing with the Falcon 9 v1.1 while still achieving the specified payloads for customers. Many engineering changes to support reusability and recovery of the first stage had been made on this earlier v1.1 version. SpaceX indicated they had room to increase the payload performance for the Falcon 9 Full Thrust, or decrease launch price, or both.[38]

In 2015, SpaceX announced a number of modifications to the previous version Falcon 9 v1.1 launch vehicle. The new rocket was known internally for a while as Falcon 9 v1.1 Full Thrust,[18] but was also known under a variety of names including Falcon 9 v1.2,[39] Enhanced Falcon 9, Full-Performance Falcon 9,[14] Upgraded Falcon 9,[40] and Falcon 9 Upgrade.[19][41] Since the first flight of the "full thrust upgrade", SpaceX has been referring to this version as just Falcon 9.[42]

SpaceX President Gwynne Shotwell explained in March 2015 that the new design would result in streamlined production as well as improved performance:[15]

So, we got the higher thrust engines, finished development on that, we're in [qualification testing]. What we're also doing is modifying the structure a little bit. I want to be building only two versions, or two cores in my factory, any more than that would not be great from a customer perspective. It's about a 30% increase in performance, maybe a little more. What it does is it allows us to land the first stage for GTO missions on the drone ship.[14]

According to a SpaceX statement in May 2015, Falcon 9 Full Thrust would likely not require a recertification to launch for United States government contracts. Shotwell stated that "It is an iterative process [with the agencies]" and that "It will become quicker and quicker to certify new versions of the vehicle."[43] The US Air Force certified the upgraded version of the launch vehicle to be used on US military launches in January 2016, based on the one successful launch to date and the demonstrated "capability to design, produce, qualify, and deliver a new launch system and provide the mission assurance support required to deliver NSS (national security space) satellites to orbit".[44]

Testing

The upgraded first stage began acceptance testing at SpaceX's McGregor facility in September 2015. The first of two static fire tests was completed on 21 September 2015 and included the subcooled propellant and the improved Merlin 1D engines.[45] The rocket reached full throttle during the static fire and was scheduled for launch no earlier than 17 November 2015.[46]

Maiden flight

SES S.A., a satellite owner and operator, announced plans in February 2015 to launch its SES-9 satellite on the first flight of the Falcon 9 Full Thrust.[47] In the event, SpaceX elected to launch SES-9 on the second flight of the Falcon 9 Full Thrust and to launch Orbcomm OG2's second constellation on the first flight. As Chris Bergin of NASASpaceFlight explained, SES-9 required a more complicated second-stage burn profile involving one restart of the second-stage engine, while the Orbcomm mission would "allow for the Second Stage to conduct additional testing ahead of the more taxing SES-9 mission."[48]

Falcon 9 Full Thrust completed its maiden flight on 22 December 2015, carrying an Orbcomm 11-satellite payload to orbit and landing the rocket's first stage intact at SpaceX's Landing Zone 1 at Cape Canaveral.[40] The second mission, SES-9, occurred on 4 March 2016.[49]

Launch history

As of 26 January 2023, the Falcon 9 Full Thrust version has flown 179 missions with a success rate of 100%. The first stage was recovered in 156 of them. One rocket was destroyed during pre-launch tests and is not counted as one of the flown missions.

On 1 September 2016, the rocket carrying Spacecom's AMOS-6 exploded on its launchpad (Launch Complex 40) while fueling in preparation for a static fire test. The test was being conducted in preparation for the launch of the 29th Falcon 9 flight on 3 September 2016. The vehicle and $200m payload were destroyed in the explosion.[50] The subsequent investigation showed the root cause to be ignition of solid or liquid oxygen compressed between layers of the immersed helium tanks' carbon-fiber wrappings.[51] To resolve the issue for further flights, SpaceX made design changes to the tanks and changes to their fueling procedure.

Launch and landing sites

Launch sites

SpaceX first used Launch Complex 40 at Cape Canaveral Air Force Station and Space Launch Complex 4E at Vandenberg Air Force Base for Falcon 9 Full Thrust rockets, like its predecessor Falcon 9 v1.1. Following the 2016 accident at LC-40, launches from the East Coast were switched to the refurbished pad LC-39A at Kennedy Space Center, leased from NASA.[52]

Architectural and engineering design work on changes to LC-39A had begun in 2013, the contract to lease the pad from NASA was signed in April 2014, with construction commencing later in 2014,[53] including the building of a large Horizontal Integration Facility (HIF) in order to house both Falcon 9 and Falcon Heavy launch vehicles with associated hardware and payloads during processing.[54] The first launch occurred on 19 February 2017 with the CRS-10 mission. Crew Access Arm and White Room work still need to be completed before crewed launches with the SpaceX Dragon 2 capsule scheduled for 2019.

An additional private launch site, intended solely for commercial launches, was planned at Boca Chica Village near Brownsville, Texas[55] following a multi-state evaluation process in 2012–mid-2014 looking at Florida, Georgia, and Puerto Rico.[56][57] However, the focus of the site has been changed from Falcon 9 and Falcon Heavy launches to VTOL test flights of a subscale Starship Hopper test vehicle. It is very unlikely that it will ever be used for Falcon 9 or Heavy flights, as the current launch pads provide more than enough launch capability.

Landing sites

 
Landing Zone 1 at Cape Canaveral Space Force Station

SpaceX has completed construction of a landing zone at Cape Canaveral Air Force Station, known as LZ-1. The zone, consisting of a pad 282 feet (86 m) in diameter, was first used on 16 December 2015 with a successful landing of Falcon 9 Full Thrust.[58] The landing on LZ-1 was the first overall successful Falcon 9 and the third landing attempt on a hard surface. As of 4 June 2020, only one landing attempt has failed. The booster landed just offshore. In the following few days, it was towed back to Port Canaveral, raised out of the water using two cranes, and brought back to a SpaceX hangar.

Directly next to LZ-1 SpaceX constructed LZ-2 to allow simultaneous booster landings after Falcon Heavy flights. As of November 2022, four boosters have landed at LZ-2.

SpaceX also created a landing site at the former launch complex SLC-4W at Vandenberg Air Force Base. In 2014, the launch site was demolished for reconstruction as a landing site.[59] On 8 October 2018, a Falcon 9 rocket booster successfully landed at the new ground pad, known as LZ-4, for the first time.[60]

Drone ships

Starting in 2014, SpaceX commissioned the construction of autonomous spaceport drone ships (ASDS) from deck barges, outfitted with station-keeping engines and a large landing platform. The ships, which are stationed hundreds of kilometers downrange, allow for first stage recovery on high-velocity missions which cannot return to the launch site.[61][62]

SpaceX has three operational drone ships, Just Read the Instructions , Of Course I Still Love You and "A Shortfall of Gravitas".[63] Both "A Shortfall of Gravitas" and "Just Read the instructions" are used in the Atlantic for launches from Cape Canaveral, while "Of Course I Still Love You" is being operated in the Pacific from the port of Vandenberg.

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falcon, full, thrust, also, known, falcon, with, variants, block, block, partially, reusable, medium, lift, launch, vehicle, designed, manufactured, spacex, designed, 2014, 2015, began, launch, operations, december, 2015, january, 2023, performed, launches, wi. Falcon 9 Full Thrust also known as Falcon 9 v1 2 with variants Block 1 to Block 5 is a partially reusable medium lift launch vehicle designed and manufactured by SpaceX Designed in 2014 2015 Falcon 9 Full Thrust began launch operations in December 2015 As of 26 January 2023 Falcon 9 Full Thrust had performed 179 launches without any failures Based on the Lewis point estimate of reliability definition needed this rocket is the most reliable orbital launch vehicle currently in operation 8 Falcon 9 Full ThrustLaunch of the first Falcon 9 Full Thrust flight Falcon 9 Flight 20 carrying 11 Orbcomm satellites to orbit The first stage was recovered at Cape Canaveral Air Force Station LZ 1 following the first successful Falcon 9 landing FunctionPartially reusable orbital medium lift launch vehicleManufacturerSpaceXCountry of originUnited StatesCost per launch 62M 2016 1 50M Reusable 2018 2 SizeHeight71 m 233 ft with payload fairing 3 Diameter3 66 m 12 0 ft 4 Mass549 000 kg 1 210 000 lb 4 Stages2CapacityPayload to LEO 28 5 MassExpendable 22 800 kg 50 300 lb 1 17 400 kg 38 400 lb when landingPayload to GTO 27 MassExpendable 8 300 kg 18 300 lb 1 Reusable 5 500 kg 12 100 lb 1 Payload to MarsMass4 020 kg 8 860 lb 1 Associated rocketsFamilyFalcon 9Derivative workFalcon HeavyComparableAtlas V 541 H IIB Long March 3B E Proton M Ariane 5 ESLaunch historyStatusActiveLaunch sitesCape Canaveral SLC 40 Vandenberg SLC 4E Kennedy LC 39ATotal launches179 5 Success es 179Notable outcome s 1 destroyed before launch Landings156 162 attemptsFirst flight22 December 2015Last flight2022Type of passengers cargoDragon capsule Dragon Crew capsule Iridium NEXT fleet Zuma Boeing X 37B Orbital Test Vehicle TESS Beresheet lander Starlink RADARSAT Constellation Sentinel 6 Michael FreilichFirst stagePowered by9 Merlin 1DMaximum thrustSea level 7 607 kN 1 710 000 lbf 4 Vacuum 8 227 kN 1 850 000 lbf 4 Specific impulseSea level 282 seconds 6 needs update Vacuum 311 seconds 6 needs update Burn time162 seconds 4 PropellantSubcooled LOX Chilled RP 1 7 Second stagePowered by1 Merlin 1D VacuumMaximum thrust934 kN 210 000 lbf 4 Specific impulse348 seconds 4 Burn time397 seconds 4 PropellantLOX RP 1 edit on Wikidata On April 8 2016 the Full Thrust version of the Falcon 9 family was the first launch vehicle on an orbital trajectory to successfully vertically land a first stage The landing followed a technology development program conducted from 2013 to 2015 Some of the required technology advances such as landing legs were pioneered on the Falcon 9 v1 1 version but that version never landed intact Starting in 2017 previously flown first stage boosters were reused to launch new payloads into orbit 9 10 This quickly became routine in 2018 and in 2019 more than half of all Falcon 9 flights reused a booster In 2020 the fraction of reused boosters increased to 81 Falcon 9 Full Thrust is a substantial upgrade over the previous Falcon 9 v1 1 rocket which flew its last mission in January 2016 With uprated first and second stage engines a larger second stage propellant tank and propellant densification the vehicle can carry substantial payloads to geostationary orbit and perform a propulsive landing for recovery 11 Contents 1 Design 1 1 Modifications from Falcon 9 v1 1 1 1 1 Autonomous flight termination system 1 1 2 Block 4 1 1 3 Block 5 1 2 Rocket specifications 2 Development history 2 1 Development 2 2 Testing 2 3 Maiden flight 3 Launch history 4 Launch and landing sites 4 1 Launch sites 4 2 Landing sites 4 3 Drone ships 5 ReferencesDesign EditThis section s factual accuracy is disputed Relevant discussion may be found on Talk Falcon 9 Full Thrust Please help to ensure that disputed statements are reliably sourced March 2019 Learn how and when to remove this template message Falcon 9 Full Thrust launch on 4 March 2016 The discarded first stage is in the lower right The second stage is in the upper left with the two parts of the jettisoned payload fairing A principal objective of the new design was to facilitate booster re usability for a larger range of missions including delivery of large commsats to geosynchronous orbit 12 Like earlier versions of the Falcon 9 and like the Saturn series from the Apollo program the presence of multiple first stage engines can allow for mission completion even if one of the first stage engines fails mid flight 13 Modifications from Falcon 9 v1 1 Edit The third version of the Falcon 9 was developed in 2014 2015 and made its maiden flight in December 2015 The Falcon 9 Full Thrust is a modified reusable variant of the Falcon 9 family with capabilities that exceed the Falcon 9 v1 1 including the ability to land the first stage for geostationary transfer orbit GTO missions on the drone ship 14 15 The rocket was designed using systems and software technology that had been developed as part of the SpaceX reusable launch system development program a private initiative by SpaceX to facilitate rapid reusability of both the first and in the long term second stages of SpaceX launch vehicles 16 Various technologies were tested on the Grasshopper technology demonstrator as well as several flights of the Falcon 9 v1 1 on which post mission booster controlled descent tests were being conducted 17 In 2015 SpaceX made a number of modifications to the existing Falcon 9 v1 1 The new rocket was known internally as Falcon 9 Full Thrust 18 and is also known as Falcon 9 v1 2 Enhanced Falcon 9 Full Performance Falcon 9 14 and Falcon 9 Upgrade 19 A principal objective of the new design was to facilitate booster reusability for a larger range of missions including delivery of large commsats to geosynchronous orbit 12 Modifications in the upgraded version include liquid oxygen subcooled to 66 5 K 206 7 C 119 7 R 340 0 F and RP 1 cooled to 266 5 K 6 6 C 479 7 R 20 0 F 20 for density allowing more fuel and oxidizer to be stored in a given tank volume as well as increasing the propellant mass flow through the turbopumps increasing thrust upgraded structure in the first stage 19 21 longer second stage propellant tanks 19 longer and stronger interstage housing the second stage engine nozzle grid fins and attitude thrusters 19 21 center pusher added for stage separation 19 design evolution of the grid fins 19 21 modified Octaweb 19 upgraded landing legs 19 21 Merlin 1D engine thrust increased 19 to the full thrust variant of the Merlin 1D taking advantage of the denser propellants achieved by subcooling Merlin 1D vacuum thrust increased by subcooling the propellants 19 several small mass reduction efforts 22 The modified design gained an additional 1 2 meters of height stretching to exactly 70 meters including payload fairing 13 while gaining an overall performance increase of 33 percent 19 The new first stage engine has a much increased thrust to weight ratio The full thrust first stage booster could reach low Earth orbit as a single stage to orbit if it is not carrying the upper stage and a heavy satellite 23 Versions launched in 2017 have included an experimental recovery system for the payload fairing halves On 30 March 2017 SpaceX for the first time recovered a fairing from the SES 10 mission thanks to thrusters and a steerable parachute helping it glide towards a gentle touchdown on water 24 On the 25 June 2017 flight Iridium NEXT 11 20 aluminum grid fins were replaced by titanium versions to improve control authority and better cope with heat during re entry 25 Following post flight inspections Elon Musk announced the new grid fins likely will require no service between flights 26 Autonomous flight termination system Edit SpaceX has been developing for some time an alternative autonomous system to replace the traditional ground based systems that had been in use for all US launches for over six decades The autonomous system has been in use on some of SpaceX VTVL suborbital test flights in Texas and has flown in parallel on a number of orbital launches as part of a system test process to gain approval for use on operational flights In February 2017 SpaceX s CRS 10 launch was the first operational launch utilizing the new Autonomous Flight Safety System AFSS on either of Air Force Space Command s Eastern or Western Ranges The following SpaceX flight EchoStar 23 in March was the last SpaceX launch utilizing the historic system of ground radars tracking computers and personnel in launch bunkers that had been used for over sixty years for all launches from the Eastern Range For all future SpaceX launches AFSS has replaced the ground based mission flight control personnel and equipment with on board Positioning Navigation and Timing sources and decision logic The benefits of AFSS include increased public safety reduced reliance on range infrastructure reduced range spacelift cost increased schedule predictability and availability operational flexibility and launch slot flexibility 27 28 Block 4 Edit In 2017 SpaceX started flying incremental changes to the Falcon 9 Full Thrust version calling them Block 4 29 At first only the second stage was modified to Block 4 standards flying on top of a Block 3 first stage for three missions NROL 76 and Inmarsat 5 F4 in May 2017 and Intelsat 35e in July 30 Block 4 was described as a transition between the Full Thrust v1 2 Block 3 and the following Falcon 9 Block 5 It includes incremental engine thrust upgrades leading to the final thrust for Block 5 31 The maiden flight of the full Block 4 design first and second stages was the NASA CRS 12 mission on 14 August 2017 32 Block 5 Edit Main article Falcon 9 Block 5 SpaceX announced in 2017 that another series of incremental improvements were in development a Falcon 9 Block 5 version which has succeeded the transitional Block 4 The largest changes between Block 3 and Block 5 are higher thrust on all of the engines and improvements on landing legs Additionally numerous small changes will help streamline recovery and re usability of first stage boosters Alterations are focused on increasing the speed of production and efficiency of re usability SpaceX aims to fly each Block 5 booster ten times with only inspections in between and up to 100 times with refurbishment 33 34 Rocket specifications Edit Falcon 9 Full Thrust specifications and characteristics are as follows 13 30 35 Characteristic First stage Second stage Payload fairingHeight 35 42 6 m 140 ft 12 6 m 41 ft 13 228 m 43 40 ft Diameter 35 3 66 m 12 0 ft 3 66 m 12 0 ft 5 263 m 17 27 ft Mass without propellant 35 22 200 kg 48 900 lb 4 000 kg 8 800 lb 1 700 kg 3 700 lb Mass with propellant 433 100 kg 954 800 lb 111 500 kg 245 800 lb N AStructure type LOX tank monocoque Fuel tank skin and stringer LOX tank monocoque Fuel tank skin and stringer Monocoque halvesStructure material Aluminum lithium skin aluminum domes Aluminum lithium skin aluminum domes Carbon fiberEngines 9 Merlin 1D 1 x Merlin 1D Vacuum N AEngine type Liquid gas generator Liquid gas generatorPropellant Subcooled liquid oxygen kerosene RP 1 Liquid oxygen kerosene RP 1 Liquid oxygen tank capacity 35 287 400 kg 633 600 lb 75 200 kg 165 800 lb Kerosene tank capacity 35 123 500 kg 272 300 lb 32 300 kg 71 200 lb Engine nozzle Gimbaled 16 1 expansion Gimbaled 165 1 expansionEngine designer manufacturer SpaceX SpaceXThrust stage total 4 7 607 kN 1 710 000 lbf sea level 934 kN 210 000 lbf vacuum Propellant feed system Turbopump TurbopumpThrottle capability 13 Yes 816 kN 419 kN 190 000 lbf to 108 300 lbf sea level 36 Yes 930 360 kN 210 000 81 000 lbf vacuum Restart capability Yes only 3 engines for boostback reentry landing burns Yes dual redundant TEA TEB pyrophoric ignitersTank pressurization Heated helium Heated heliumAscent attitude control pitch yaw Gimbaled engines Gimbaled engine and nitrogen gas thrustersAscent attitude control roll Gimbaled engines Nitrogen gas thrustersCoast descent attitude control Nitrogen gas thrusters and grid fins Nitrogen gas thrusters Nitrogen gas thrustersShutdown process Commanded Commanded N AStage separation system Pneumatic N A PneumaticThe Falcon 9 Full Thrust uses a 4 5 meter long 35 interstage which is longer and stronger than the Falcon 9 v1 1 interstage It is a composite structure consisting of an aluminum honeycomb core surrounded by a carbon fiber face sheet plies 13 The overall length of the vehicle at launch is 70 meters and the total fueled mass is 549 000 kg 35 The aluminium lithium alloy used is 2195 T8 37 The Falcon 9 Full Thrust upgraded vehicle includes first stage recovery systems to allow SpaceX to return the first stage to the launch site after completion of primary mission requirements These systems include four deployable landing legs which are locked against the first stage tank during ascent Excess propellant reserved for Falcon 9 first stage recovery operations will be diverted for use on the primary mission objective if required ensuring sufficient performance margins for successful missions 13 The nominal payload capacity to a geostationary transfer orbit is 5500 kg with the first stage recovery the price per launch is US 62 million versus 8300 kg with an expendable first stage 35 Development history Edit Falcon 9 Full Thrust rocket with the SpaceX CRS 8 Dragon spacecraft on the launch pad in April 2016 Development Edit As early as March 2014 SpaceX pricing and payload specifications published for the expendable Falcon 9 v1 1 rocket actually included about 30 percent more performance than the published price list indicated At that time the additional performance was reserved for SpaceX to conduct reusability testing with the Falcon 9 v1 1 while still achieving the specified payloads for customers Many engineering changes to support reusability and recovery of the first stage had been made on this earlier v1 1 version SpaceX indicated they had room to increase the payload performance for the Falcon 9 Full Thrust or decrease launch price or both 38 In 2015 SpaceX announced a number of modifications to the previous version Falcon 9 v1 1 launch vehicle The new rocket was known internally for a while as Falcon 9 v1 1 Full Thrust 18 but was also known under a variety of names including Falcon 9 v1 2 39 Enhanced Falcon 9 Full Performance Falcon 9 14 Upgraded Falcon 9 40 and Falcon 9 Upgrade 19 41 Since the first flight of the full thrust upgrade SpaceX has been referring to this version as just Falcon 9 42 SpaceX President Gwynne Shotwell explained in March 2015 that the new design would result in streamlined production as well as improved performance 15 So we got the higher thrust engines finished development on that we re in qualification testing What we re also doing is modifying the structure a little bit I want to be building only two versions or two cores in my factory any more than that would not be great from a customer perspective It s about a 30 increase in performance maybe a little more What it does is it allows us to land the first stage for GTO missions on the drone ship 14 According to a SpaceX statement in May 2015 Falcon 9 Full Thrust would likely not require a recertification to launch for United States government contracts Shotwell stated that It is an iterative process with the agencies and that It will become quicker and quicker to certify new versions of the vehicle 43 The US Air Force certified the upgraded version of the launch vehicle to be used on US military launches in January 2016 based on the one successful launch to date and the demonstrated capability to design produce qualify and deliver a new launch system and provide the mission assurance support required to deliver NSS national security space satellites to orbit 44 Testing Edit The upgraded first stage began acceptance testing at SpaceX s McGregor facility in September 2015 The first of two static fire tests was completed on 21 September 2015 and included the subcooled propellant and the improved Merlin 1D engines 45 The rocket reached full throttle during the static fire and was scheduled for launch no earlier than 17 November 2015 46 Maiden flight Edit SES S A a satellite owner and operator announced plans in February 2015 to launch its SES 9 satellite on the first flight of the Falcon 9 Full Thrust 47 In the event SpaceX elected to launch SES 9 on the second flight of the Falcon 9 Full Thrust and to launch Orbcomm OG2 s second constellation on the first flight As Chris Bergin of NASASpaceFlight explained SES 9 required a more complicated second stage burn profile involving one restart of the second stage engine while the Orbcomm mission would allow for the Second Stage to conduct additional testing ahead of the more taxing SES 9 mission 48 Falcon 9 Full Thrust completed its maiden flight on 22 December 2015 carrying an Orbcomm 11 satellite payload to orbit and landing the rocket s first stage intact at SpaceX s Landing Zone 1 at Cape Canaveral 40 The second mission SES 9 occurred on 4 March 2016 49 Launch history EditMain article List of Falcon 9 and Falcon Heavy launches As of 26 January 2023 the Falcon 9 Full Thrust version has flown 179 missions with a success rate of 100 The first stage was recovered in 156 of them One rocket was destroyed during pre launch tests and is not counted as one of the flown missions On 1 September 2016 the rocket carrying Spacecom s AMOS 6 exploded on its launchpad Launch Complex 40 while fueling in preparation for a static fire test The test was being conducted in preparation for the launch of the 29th Falcon 9 flight on 3 September 2016 The vehicle and 200m payload were destroyed in the explosion 50 The subsequent investigation showed the root cause to be ignition of solid or liquid oxygen compressed between layers of the immersed helium tanks carbon fiber wrappings 51 To resolve the issue for further flights SpaceX made design changes to the tanks and changes to their fueling procedure Launch and landing sites EditMain article SpaceX launch facilities Launch sites Edit SpaceX first used Launch Complex 40 at Cape Canaveral Air Force Station and Space Launch Complex 4E at Vandenberg Air Force Base for Falcon 9 Full Thrust rockets like its predecessor Falcon 9 v1 1 Following the 2016 accident at LC 40 launches from the East Coast were switched to the refurbished pad LC 39A at Kennedy Space Center leased from NASA 52 Architectural and engineering design work on changes to LC 39A had begun in 2013 the contract to lease the pad from NASA was signed in April 2014 with construction commencing later in 2014 53 including the building of a large Horizontal Integration Facility HIF in order to house both Falcon 9 and Falcon Heavy launch vehicles with associated hardware and payloads during processing 54 The first launch occurred on 19 February 2017 with the CRS 10 mission Crew Access Arm and White Room work still need to be completed before crewed launches with the SpaceX Dragon 2 capsule scheduled for 2019 An additional private launch site intended solely for commercial launches was planned at Boca Chica Village near Brownsville Texas 55 following a multi state evaluation process in 2012 mid 2014 looking at Florida Georgia and Puerto Rico 56 57 However the focus of the site has been changed from Falcon 9 and Falcon Heavy launches to VTOL test flights of a subscale Starship Hopper test vehicle It is very unlikely that it will ever be used for Falcon 9 or Heavy flights as the current launch pads provide more than enough launch capability Landing sites Edit Landing Zone 1 at Cape Canaveral Space Force Station SpaceX has completed construction of a landing zone at Cape Canaveral Air Force Station known as LZ 1 The zone consisting of a pad 282 feet 86 m in diameter was first used on 16 December 2015 with a successful landing of Falcon 9 Full Thrust 58 The landing on LZ 1 was the first overall successful Falcon 9 and the third landing attempt on a hard surface As of 4 June 2020 update only one landing attempt has failed The booster landed just offshore In the following few days it was towed back to Port Canaveral raised out of the water using two cranes and brought back to a SpaceX hangar Directly next to LZ 1 SpaceX constructed LZ 2 to allow simultaneous booster landings after Falcon Heavy flights As of November 2022 update four boosters have landed at LZ 2 SpaceX also created a landing site at the former launch complex SLC 4W at Vandenberg Air Force Base In 2014 the launch site was demolished for reconstruction as a landing site 59 On 8 October 2018 a Falcon 9 rocket booster successfully landed at the new ground pad known as LZ 4 for the first time 60 Drone ships Edit Main article Autonomous spaceport drone ship Starting in 2014 SpaceX commissioned the construction of autonomous spaceport drone ships ASDS from deck barges outfitted with station keeping engines and a large landing platform The ships which are stationed hundreds of kilometers downrange allow for first stage recovery on high velocity missions which cannot return to the launch site 61 62 SpaceX has three operational drone ships Just Read the Instructions Of Course I Still Love You and A Shortfall of Gravitas 63 Both A Shortfall of Gravitas and Just Read the instructions are used in the Atlantic for launches from Cape Canaveral while Of Course I Still Love You is being operated in the Pacific from the port of Vandenberg References Edit a b c d e Capabilities amp Services 2016 SpaceX 28 November 2012 Archived from the original on 15 January 2017 Retrieved 3 May 2016 Baylor Michael 17 May 2018 With Block 5 SpaceX to increase launch cadence and lower prices NASASpaceFlight com Retrieved 24 May 2018 Falcon 9 Launch Vehicle Payload User s Guide PDF 21 October 2015 Archived from the original PDF on 14 March 2017 Retrieved 29 November 2015 a b c d e f g h i Falcon 9 SpaceX 16 November 2012 Archived from the original on 15 July 2013 Retrieved 30 April 2016 Krebs Gunter Falcon 9 Gunter s Space Page Retrieved 7 November 2018 a b Falcon 9 SpaceX 16 November 2012 Archived from the original on 1 May 2013 Retrieved 29 September 2013 elonmusk 17 December 2015 340 F in this case Deep cryo increases density and amplifies rocket performance First time anyone has gone this low for O2 RP 1 chilled from 70F to 20 F Tweet Retrieved 19 December 2015 via Twitter ACTIVE LAUNCH VEHICLE RELIABILITY STATISTICS SPACE LAUNCH REPORT Archived from the original on 29 April 2022 Retrieved 4 February 2022 SpaceX launches retrieves its first recycled rocket Washington Post Associated Press 30 March 2017 Retrieved 2 April 2018 Chang Kenneth 30 March 2017 SpaceX Launches a Satellite With a Partly Used Rocket The New York Times Retrieved 2 April 2018 via NYTimes com B de Selding Peter 16 October 2015 SpaceX Changes its Falcon 9 Return to flight Plans SpaceNews Retrieved 27 January 2016 a b de Selding Peter B 20 March 2015 SpaceX Aims To Debut New Version of Falcon 9 this Summer Space News Retrieved 23 March 2015 a b c d e f Falcon 9 Launch Vehicle Payload User s Guide Rev 2 PDF SpaceX 21 October 2015 Archived from the original PDF on 14 March 2017 Retrieved 27 January 2016 a b c d Svitak Amy 17 March 2015 SpaceX s New Spin on Falcon 9 Aviation Week Aviation Week Network Retrieved 24 October 2015 a b Svitak Amy 21 March 2015 SpaceX s Gwynne Shotwell Talks Raptor Falcon 9 CRS 2 Satellite Internet and More Aviation Week and Space Technology Penton Retrieved 8 May 2015 Abbott Joseph 8 May 2013 SpaceX s Grasshopper leaping to NM spaceport Waco Tribune Retrieved 2 April 2018 Bergin Chris 3 April 2015 SpaceX preparing for a busy season of missions and test milestones NASASpaceflight Retrieved 2 April 2018 a b Bergin Chris 9 September 2015 Full Thrust Falcon 9 stage undergoing testing at McGregor NASASpaceFlight Retrieved 18 September 2015 a b c d e f g h i j k l de Selding Peter B 15 September 2015 Falcon 9 Upgrades F9 v1 1 current vehicle to F9 Upgrade SpaceNews journalist twitter feed SpaceX slide republished on Twitter Retrieved 20 January 2016 Elon Musk on Twitter elonmusk 17 December 2015 340 F in this case Deep cryo increases density and amplifies rocket performance First time anyone has gone this low for O2 RP 1 chilled from 70F to 20 F Tweet Retrieved 19 December 2015 via Twitter a b c d Foust Jeff 15 September 2015 SES Betting on SpaceX Falcon 9 Upgrade as Debut Approaches Space News Retrieved 19 September 2015 Svitak Amy 5 March 2013 Falcon 9 Performance Mid size GEO Aviation Week Archived from the original on 11 January 2018 Retrieved 2 April 2018 Elon Musk on Twitter Twitter Retrieved 2 April 2018 Lopatto Elizabeth 30 March 2017 SpaceX even landed the nose cone from its historic used Falcon 9 rocket launch The Verge Retrieved 2 April 2018 elonmusk 25 June 2017 Flying with larger amp significantly upgraded hypersonic grid fins Single piece cast amp cut titanium Can take reentry heat with no shielding Tweet Retrieved 2 April 2018 via Twitter elonmusk 25 June 2017 New titanium grid fins worked even better than expected Should be capable of an indefinite number of flights with no service Tweet Retrieved 2 April 2018 via Twitter 45th SW supports successful Falcon 9 Echostar XXIII launch 45th Space Wing Public Affairs 16 March 2016 Retrieved 7 January 2018 Gebhardt Chris 20 March 2017 Air Force reveals plan for up to 48 launches per year from Cape Canaveral NASASpaceFlight com Retrieved 2 April 2018 Henry Caleb 29 June 2017 SpaceX s Final Falcon 9 Design Coming This Year 2 Falcon Heavy Launches in 2018 Space com Retrieved 2 April 2018 a b SpaceX Falcon 9 v1 2 Data Sheet Space Launch Report 14 August 2017 Retrieved 2 April 2018 Gebhardt Chris 16 August 2017 Home Forums L2 Sign Up ISS Commercial Shuttle SLS Orion Russian European Chinese Unmanned Other Falcon 9 Block 4 debut a success Dragon arrives for Station berthing NASASpaceFlight Retrieved 2 April 2018 SpaceX Falcon 9 launches CRS 12 Dragon mission to the ISS NASA Spaceflight com 14 August 2017 Clark Stephen 4 April 2017 Musk previews busy year ahead for SpaceX Spaceflight Now Retrieved 7 April 2018 NASA 17 February 2017 NASA Holds Pre launch Briefing at Historic Pad 39A at Kennedy Space Center Youtube a b c d e f g h i Fiche Technique Falcon 9 Technical data sheet Falcon 9 Espace amp Exploration in French No 39 May 2017 pp 36 37 Retrieved 27 June 2017 Falcon Users Guide PDF Archived from the original PDF on 20 February 2019 Retrieved 22 February 2019 How Light Metals Help SpaceX Land Falcon 9 Rockets April 2019 Gwynne Shotwell 21 March 2014 Broadcast 2212 Special Edition interview with Gwynne Shotwell audio file The Space Show Event occurs at 08 15 11 20 2212 Archived from the original mp3 on 22 March 2014 Retrieved 30 January 2015 License Order No LLS 14 090A Rev 2 PDF FAA Archived from the original PDF on 26 August 2016 Retrieved 21 August 2016 a b Graham William 21 December 2015 SpaceX returns to flight with OG2 nails historic core return NASASpaceFlight Retrieved 22 December 2015 Gruss Mike 25 January 2016 Falcon 9 Upgrade gets Air Force OK to launch military satellites SpaceNews Retrieved 27 January 2016 Shotwell Gwynne 3 February 2016 Gwynne Shotwell comments at Commercial Space Transportation Conference Commercial Spaceflight Event occurs at 2 43 15 3 10 05 Retrieved 4 February 2016 de Selding Peter B 16 March 2015 SpaceX Says Falcon 9 Upgrade Won t Require New Certification Space News Retrieved 8 May 2015 Clark Stephen 25 January 2016 Falcon 9 upgrade receives blessing from U S Air Force SpaceflightNow Retrieved 26 January 2016 Upgraded Falcon 9 First Stage Static Fire 9 21 15 Youtube 24 September 2015 Retrieved 25 September 2015 Clark Stephen 25 September 2015 First static fire completed on upgraded Falcon 9 Spaceflight Now Retrieved 25 September 2015 Clark Stephen 20 February 2015 SES signs up for launch with more powerful Falcon 9 engines Spaceflight Now Retrieved 8 May 2015 Bergin Chris 16 October 2015 SpaceX selects ORBCOMM 2 mission for Falcon 9 s Return To Flight NASASpaceFlight Retrieved 23 October 2015 Spaceflight Now Launch schedule Spaceflight Now Retrieved 26 January 2016 Malik Tariq 1 September 2016 Launchpad Explosion Destroys SpaceX Falcon 9 Rocket Satellite in Florida Space com Archived from the original on 2 September 2016 Retrieved 14 December 2020 SpaceX 1 September 2016 Anomaly Updates Archived from the original on 16 February 2017 Retrieved 2 June 2017 SpaceX seeks to accelerate Falcon 9 production and launch rates this year SpaceNews com spacenews com 4 February 2016 Retrieved 2 April 2018 NASA signs over historic Launch Pad 39A to SpaceX collectSpace 14 April 2014 Retrieved 2 April 2018 Bergin Chris 1 July 2015 Pad 39A SpaceX laying the groundwork for Falcon Heavy debut NASA Spaceflight Retrieved 2 April 2018 SpaceX breaks ground at Boca Chica beach Brownsville Herald 22 September 2014 Archived from the original on 12 June 2017 Retrieved 21 January 2016 Texas Florida Battle for SpaceX Spaceport Parabolic Arc Retrieved 6 November 2012 Dean James 7 May 2013 3 states vie for SpaceX s commercial rocket launches USA Today Retrieved 2 April 2018 Davenport Christian 21 December 2015 Elon Musk s SpaceX returns to flight and pulls off dramatic historic landing The Washington Post Retrieved 2 April 2018 SpaceX Demolishes SLC 4W Titan Pad YouTube 18 September 2014 Retrieved 3 September 2015 SAOCOM 1A Mission SpaceX 7 October 2018 Retrieved 8 October 2018 elonmusk 12 January 2016 Aiming to launch this weekend and hopefully land on our droneship Ship landings needed for high velocity missions Tweet via Twitter elonmusk 17 January 2016 If speed at stage separation gt 6000 km hr With a ship no need to zero out lateral velocity so can stage at up to 9000 km h Tweet via Twitter SpaceX Elon Musk shares photo of drone ship that enables more missions Wikimedia Commons has media related to Falcon 9 Full Thrust Retrieved from https en wikipedia org w index php title Falcon 9 Full Thrust amp oldid 1135789846, wikipedia, wiki, book, books, library,

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