Rocketdyne developed the F-1 and the E-1 to meet a 1955 U.S. Air Force requirement for a very large rocket engine. The E-1, although successfully tested in static firing, was quickly seen as a technological dead-end, and was abandoned for the larger, more powerful F-1. The Air Force eventually halted development of the F-1 because of a lack of requirement for such a large engine. However, the recently created National Aeronautics and Space Administration (NASA) appreciated the usefulness of an engine with so much power and contracted Rocketdyne to complete its development. Test firings of F-1 components had been performed as early as 1957. The first static firing of a full-stage developmental F-1 was performed in March 1959. The first F-1 was delivered to NASA MSFC in October 1963. In December 1964, the F-1 completed flight rating tests. Testing continued at least through 1965.[2]
Early development tests revealed serious combustion instability problems which sometimes caused catastrophic failure.[3] Initially, progress on this problem was slow, as it was intermittent and unpredictable. Oscillations of 4kHz with harmonics to 24kHz were observed. Eventually, engineers developed a diagnostic technique of detonating small explosive charges (which they called "bombs") outside the combustion chamber, through a tangential tube (RDX, C-4 or black powder were used) while the engine was firing. This allowed them to determine exactly how the running chamber responded to variations in pressure, and to determine how to nullify these oscillations. The designers could then quickly experiment with different co-axial fuel-injector designs to obtain the one most resistant to instability. These problems were addressed from 1959 through 1961. Eventually, engine combustion was so stable, it would self-damp artificially induced instability within one-tenth of a second.
Design
F-1 rocket engine components
The F-1 engine is the most powerful single-nozzle liquid-fueled rocket engine ever flown. The M-1 rocket engine was designed to have more thrust, but it was only tested at the component level. The later developed RD-170 is much more stable, technologically more advanced, more efficient and produces more thrust, but uses four nozzles fed by a single pump. The F-1 burned RP-1 (rocket grade kerosene) as the fuel and used liquid oxygen (LOX) as the oxidizer. A turbopump was used to inject fuel and oxygen into the combustion chamber.
One notable challenge in the construction of the F-1 was regenerative cooling of the thrust chamber. Chemical engineer Dennis "Dan" Brevik was faced with the task of ensuring the preliminary combustion chamber tube bundle and manifold design produced by Al Bokstellar would run cool. In essence, Brevik's job was to "make sure it doesn’t melt." Through Brevik's calculations of the hydrodynamic and thermodynamic characteristics of the F-1, he and his team were able to fix an issue known as ‘starvation’. This is when an imbalance of static pressure leads to 'hot spots' in the manifolds. The material used for the F-1 thrust chamber tube bundle, reinforcing bands and manifold was Inconel-X750, a refractory nickel based alloy capable of withstanding high temperatures.[4]
The heart of the engine was the thrust chamber, which mixed and burned the fuel and oxidizer to produce thrust. A domed chamber at the top of the engine served as a manifold supplying liquid oxygen to the injectors, and also served as a mount for the gimbal bearing which transmitted the thrust to the body of the rocket. Below this dome were the injectors, which directed fuel and oxidizer into the thrust chamber in a way designed to promote mixing and combustion. Fuel was supplied to the injectors from a separate manifold; some of the fuel first traveled in 178 tubes down the length of the thrust chamber — which formed approximately the upper half of the exhaust nozzle — and back in order to cool the nozzle.
A gas generator was used to drive a turbine which drove separate fuel and oxygen pumps, each feeding the thrust chamber assembly. The turbine was driven at 5,500 RPM, producing 55,000 brake horsepower (41MW). The fuel pump delivered 15,471 US gallons (58,560 litres) of RP-1 per minute while the oxidizer pump delivered 24,811USgal (93,920L) of liquid oxygen per minute. Environmentally, the turbopump was required to withstand temperatures ranging from input gas at 1,500°F (820°C) to liquid oxygen at −300°F (−184°C). Structurally, fuel was used to lubricate and cool the turbine bearings.
Below the thrust chamber was the nozzle extension, roughly half the length of the engine. This extension increased the expansion ratio of the engine from 10:1 to 16:1. The exhaust from the turbine was fed into the nozzle extension by a large, tapered manifold; this relatively cool gas formed a film which protected the nozzle extension from the hot (5,800°F (3,200°C)) exhaust gas.[5]
Each second, a single F-1 burned 5,683 pounds (2,578kg) of oxidizer and fuel: 3,945lb (1,789kg) of liquid oxygen and 1,738lb (788kg) of RP-1, generating 1,500,000lbf (6.7MN; 680tf) of thrust. This equated to a flow rate of 671.4USgal (2,542L) per second; 413.5USgal (1,565L) of LOX and 257.9USgal (976L) of RP-1. During their two and a half minutes of operation, the five F-1s propelled the Saturn V vehicle to a height of 42 miles (222,000ft; 68km) and a speed of 6,164mph (9,920km/h). The combined flow rate of the five F-1s in the Saturn V was 3,357USgal (12,710L)[5] or 28,415lb (12,890kg) per second. Each F-1 engine had more thrust than three Space Shuttle Main Engines combined.[6]
Pre and post ignition procedures
During static test firing, the kerosene-based RP-1 fuel left hydrocarbon deposits and vapors in the engine post test firing. These had to be removed from the engine to avoid problems during engine handling and future firing, and the solvent trichloroethylene (TCE) was used to clean the engine's fuel system immediately before and after each test firing. The cleaning procedure involved pumping TCE through the engine's fuel system and letting the solvent overflow for a period ranging from several seconds to 30–35 minutes, depending upon the engine and the severity of the deposits. Sometimes the engine's gas generator and LOX dome were also flushed with TCE prior to test firing.[7][8] The F-1 rocket engine had its LOX dome, gas generator, and thrust chamber fuel jacket flushed with TCE during launch preparations.[8]
Specifications
Installation of F-1 engines to the Saturn V S-IC Stage. The nozzle extension is absent from the engine being fitted.
F-1 thrust and efficiency were improved between Apollo 8 (SA-503) and Apollo 17 (SA-512), which was necessary to meet the increasing payload capacity demands of later Apollo missions. There were small performance variations between engines on a given mission, and variations in average thrust between missions. For Apollo 15, F-1 performance was:
Thrust (average, per engine, sea level liftoff): 1,553,200lbf (6.909MN)
S-IC total sea level liftoff thrust: 7,766,000lbf (34.54MN)
Measuring and making comparisons of rocket engine thrust is more complicated than it may first appear. Based on actual measurement the liftoff thrust of Apollo 15 was 7,823,000lbf (34.80MN), which equates to an average F-1 thrust of 1,565,000lbf (6.96MN) – slightly more than the specified value.[citation needed]
During the 1960s, Rocketdyne undertook uprating development of the F-1 resulting in the new engine specification F-1A. While outwardly very similar to the F-1, the F-1A produced about 20% greater thrust, 1,800,000lbf (8MN) in tests, and would have been used on future Saturn V vehicles in the post-Apollo era. However, the Saturn V production line was closed prior to the end of Project Apollo and no F-1A engines ever flew.[10]
There were proposals to use eight F-1 engines on the first stage of the Saturn C-8 and Nova rockets. Numerous proposals have been made from the 1970s and on to develop new expendable boosters based around the F-1 engine design. These include the Saturn-Shuttle, and the Pyrios booster (see below) in 2013.[10]As of 2013[update], none have proceeded beyond the initial study phase. The Comet HLLV would have used five F-1A engines on the main core and two on each of the boosters.[11]
The F-1 is the largest, highest-thrust single-chamber, single-nozzle liquid-fuel engine flown. Larger solid-fuel engines exist, such as the Space Shuttle Solid Rocket Booster with a sea-level liftoff thrust of 2,800,000lbf (12.45MN) apiece. The Soviet (now Russian) RD-170 can develop more thrust than the F-1, at 1,630,000lbf (7.25MN) per engine at sea level, however, each engine uses four combustion chambers instead of one, to solve the combustion instability problem.
F-1B booster
The Vulcain for the Ariane 5 rocket uses a similar cycle design to F-1 engine, with the turbine exhaust gases piped directly overboard.
As part of the Space Launch System (SLS) program, NASA had been running the Advanced Booster Competition, which was scheduled to end with the selection of a winning booster configuration in 2015. In 2013, engineers at the Marshall Space Flight Center began tests with an original F-1, serial number F-6049, which was removed from Apollo 11 due to a glitch. The engine was never used, and for many years it was at the Smithsonian Institution. The tests are designed to refamiliarize NASA with the design and propellants of the F-1 in anticipation of using an evolved version of the engine in future deep-space flight applications.[12]
In 2012, Pratt & Whitney, Rocketdyne, and Dynetics, Inc. presented a competitor known as Pyrios, a liquid rocket booster, in NASA's Advanced Booster Program, which aims to find a more powerful successor to the five-segment Space Shuttle Solid Rocket Boosters intended for early versions of the Space Launch System. Pyrios uses two increased-thrust and heavily modified F-1B engines per booster.[13][14] Due to the engine's potential advantage in specific impulse, if this F-1B configuration (using four F-1Bs in total) were integrated with the SLS Block 2, the vehicle could deliver 150 tonnes (330,000lb) to low Earth orbit,[15] while 130 tonnes (290,000lb) is what is regarded as achievable with the planned solid boosters combined with a four-engine RS-25 core stage.[16]
The F-1B engine has a design goal to be at least as powerful as the unflown F-1A, while also being more cost effective. The design incorporates a greatly simplified combustion chamber, a reduced number of engine parts, and the removal of the F-1 exhaust recycling system, including the turbine exhaust mid-nozzle and the "curtain" cooling manifold, with the turbine exhaust having a separate outlet passage[17] beside the shortened main nozzle on the F-1B. The reduction in parts costs is aided by using selective laser melting in the production of some metallic parts.[13][18] The resulting F-1B engine is intended to produce 1,800,000lbf (8.0MN) of thrust at sea level, a 15% increase over the approximate 1,550,000lbf (6.9MN) of thrust that the mature Apollo 15 F-1 engines produced.[13][needs update]
Sixty-five F-1 engines were launched aboard thirteen Saturn Vs, and each first stage landed in the Atlantic Ocean. Ten of these followed approximately the same flight azimuth of 72 degrees, but Apollo 15 and Apollo 17 followed significantly more southerly azimuths (80.088 degrees and 91.503 degrees, respectively). The Skylab launch vehicle flew at a more northerly azimuth to reach a higher inclination orbit (50 degrees versus the usual 32.5 degrees).[19]
Ten F-1 engines were installed on two production Saturn Vs that never flew. The first stage from SA-514 is on display at the Johnson Space Center in Houston (although owned by the Smithsonian) and the first stage from SA-515 is on display at the INFINITY Science Center at John C. Stennis Space Center in Mississippi.
Another ten engines were installed on two ground-test Saturn Vs never intended to fly. The S-IC-T "All Systems Test Stage," a ground-test replica, is on display as the first stage of a complete Saturn V at the Kennedy Space Center in Florida. SA-500D, the Dynamic Test Vehicle, is on display at the U.S. Space and Rocket Center in Huntsville, Alabama.[20]
A test engine is on display at the Powerhouse Museum in Sydney, Australia. It was the 25th out of 114 research and development engines built by Rocketdyne and it was fired 35 times. The engine is on loan to the museum from the Smithsonian's National Air and Space Museum. It is the only F-1 on display outside the United States.[21]
An F-1 engine, on loan from the National Air and Space Museum, is on display at the Air Zoo in Portage, Michigan.[22]
An F-1 engine is installed vertically as a memorial to the Rocketdyne builders on De Soto Avenue, across the street from the former Rocketdyne plant in Canoga Park, California. It was installed in 1979, and moved from the parking lot across the street some time after 1980.[23]
An F-1 Engine is on display outside of The New Mexico Museum of Space History in Alamogordo, New Mexico.[citation needed]
A recovered F-1 thrust chamber is on display at the Cosmosphere.[24] An intact engine (without nozzle extension) is displayed outdoors.
On March 28, 2012, a team funded by Jeff Bezos, founder of Amazon.com, reported that they had located the F-1 rocket engines from an Apollo mission using sonar equipment.[25] Bezos stated he planned to raise at least one of the engines, which rest at a depth of 14,000 feet (4,300m), about 400 miles (640km) east of Cape Canaveral, Florida. However, the condition of the engines, which had been submerged for more than 40 years, was unknown.[26] NASA Administrator Charles Bolden released a statement congratulating Bezos and his team for their find and wished them success. He also affirmed NASA's position that any recovered artifacts would remain property of the agency, but that they would likely be offered to the Smithsonian Institution and other museums, depending on the number recovered.[27]
On March 20, 2013, Bezos announced he had succeeded in bringing parts of an F-1 engine to the surface, and released photographs. Bezos noted, "Many of the original serial numbers are missing or partially missing, which is going to make mission identification difficult. We might see more during restoration."[28] The recovery ship was Seabed Worker, and had on board a team of specialists organized by Bezos for the recovery effort.[29] On July 19, 2013, Bezos revealed that the serial number of one of the recovered engines is Rocketdyne serial number 2044 (equating to NASA number 6044), the #5 (center) engine that helped Neil Armstrong, Buzz Aldrin, and Michael Collins to reach the Moon with the Apollo 11 mission.[30] The recovered parts were brought to the Kansas Cosmosphere and Space Center in Hutchinson for the process of conservation.[30][29]
In August 2014, it was revealed that parts of two different F-1 engines were recovered, one from Apollo 11 and one from another Apollo flight, while a photograph of a cleaned-up engine was released. Bezos plans to put the engines on display at various places, including the National Air and Space Museum in Washington, D.C.[29]
On May 20, 2017, the Apollo permanent exhibit opened at the Museum of Flight in Seattle, WA and displays engine artifacts recovered including the thrust chamber and thrust chamber injector of the number 3 engine from the Apollo 12 mission, as well as a gas generator from an engine that powered the Apollo 16 flight.
A rocket engine uses stored rocket propellants as the reaction mass for forming a high-speed propulsive jet of fluid, usually high-temperature gas. Rocket engines are reaction engines, producing thrust by ejecting mass rearward, in accordance with Newton's third law. Most rocket engines use the combustion of reactive chemicals to supply the necessary energy, but non-combusting forms such as cold gas thrusters and nuclear thermal rockets also exist. Vehicles propelled by rocket engines are commonly used by ballistic missiles and rockets. Rocket vehicles carry their own oxidiser, unlike most combustion engines, so rocket engines can be used in a vacuum to propel spacecraft and ballistic missiles.
The expander cycle is a power cycle of a bipropellant rocket engine. In this cycle, the fuel is used to cool the engine's combustion chamber, picking up heat and changing phase. The now heated and gaseous fuel then powers the turbine that drives the engine's fuel and oxidizer pumps before being injected into the combustion chamber and burned.
The Saturn IB(also known as the uprated Saturn I) was an American launch vehicle commissioned by the National Aeronautics and Space Administration (NASA) for the Apollo program. It uprated the Saturn I by replacing the S-IV second stage, with the S-IVB. The S-IB first stage also increased the S-I baseline's thrust from 1,500,000 pounds-force (6,700,000 N) to 1,600,000 pounds-force (7,100,000 N) and propellant load by 3.1%. This increased the Saturn I's low Earth orbit payload capability from 20,000 pounds (9,100 kg) to 46,000 pounds (21,000 kg), enough for early flight tests of a half-fueled Apollo command and service module (CSM) or a fully fueled Apollo Lunar Module (LM), before the larger Saturn V needed for lunar flight was ready.
The RS-25, also known as the Space Shuttle Main Engine (SSME), is a liquid-fuel cryogenic rocket engine that was used on NASA's Space Shuttle and is used on the Space Launch System (SLS).
The J-2, commonly known as Rocketdyne J-2, was a liquid-fuel cryogenic rocket engine used on NASA's Saturn IB and Saturn V launch vehicles. Built in the United States by Rocketdyne, the J-2 burned cryogenic liquid hydrogen (LH2) and liquid oxygen (LOX) propellants, with each engine producing 1,033.1 kN (232,250 lbf) of thrust in vacuum. The engine's preliminary design dates back to recommendations of the 1959 Silverstein Committee. Rocketdyne won approval to develop the J-2 in June 1960 and the first flight, AS-201, occurred on 26 February 1966. The J-2 underwent several minor upgrades over its operational history to improve the engine's performance, with two major upgrade programs, the de Laval nozzle-type J-2S and aerospike-type J-2T, which were cancelled after the conclusion of the Apollo program.
The Rocketdyne H-1 was a 205,000 lbf (910 kN) thrust liquid-propellant rocket engine burning LOX and RP-1. The H-1 was developed for use in the S-I and S-IB first stages of the Saturn I and Saturn IB rockets, respectively, where it was used in clusters of eight engines. After the Apollo program, surplus H-1 engines were rebranded and reworked as the Rocketdyne RS-27 engine with first usage on the Delta 2000 series in 1974. RS-27 engines continued to be used up until 1992 when the first version of the Delta II, Delta 6000, was retired. The RS-27A variant, boasting slightly upgraded performance, was also used on the later Delta II and Delta III rockets, with the former flying until 2018.
The RL10 is a liquid-fuel cryogenic rocket engine built in the United States by Aerojet Rocketdyne that burns cryogenic liquid hydrogen and liquid oxygen propellants. Modern versions produce up to 110 kN (24,729 lbf) of thrust per engine in vacuum. Three RL10 versions are in production for the Centaur upper stage of the Atlas V and the DCSS of the Delta IV. Three more versions are in development for the Exploration Upper Stage of the Space Launch System and the Centaur V of the Vulcan rocket.
Merlin is a family of rocket engines developed by SpaceX. They are currently a part of the Falcon 9 and Falcon Heavy launch vehicles, and were formerly used on the Falcon 1. Merlin engines use RP-1 and liquid oxygen as rocket propellants in a gas-generator power cycle. The Merlin engine was originally designed for sea recovery and reuse, but since 2016 the entire Falcon 9 booster is recovered for reuse by landing vertically on a landing pad using one of its nine Merlin engines.
The RS-68 (Rocket System-68) was a liquid-fuel rocket engine that used liquid hydrogen (LH2) and liquid oxygen (LOX) as propellants in a gas-generator cycle. It was the largest hydrogen-fueled rocket engine ever flown.
A liquid rocket booster (LRB) uses liquid fuel and oxidizer to give a liquid-propellant or hybrid rocket an extra boost at take-off, and/or increase the total payload that can be carried. It is attached to the side of a rocket. Unlike solid rocket boosters, LRBs can be throttled down if the engines are designed to allow it, and can be shut down safely in an emergency for additional escape options in human spaceflight.
The Aerojet M-1 was one of the largest and most powerful liquid-hydrogen-fueled liquid-fuel rocket engines to be designed and component-tested. It was originally developed during the 1950s by the US Air Force. The M-1 offered a baseline thrust of 6.67 MN and an immediate growth target of 8 MN. If built, the M-1 would have been larger and more efficient than the famed F-1 that powered the first stage of the Saturn V rocket to the Moon.
The Saturn V is a retired American super heavy-lift launch vehicle developed by NASA under the Apollo program for human exploration of the Moon. The rocket was human-rated, had three stages, and was powered by liquid fuel. Flown from 1967 to 1973, it was used for nine crewed flights to the Moon, and to launch Skylab, the first American space station.
A cryogenic rocket engine is a rocket engine that uses a cryogenic fuel and oxidizer; that is, both its fuel and oxidizer are gases which have been liquefied and are stored at very low temperatures. These highly efficient engines were first flown on the US Atlas-Centaur and were one of the main factors of NASA's success in reaching the Moon by the Saturn V rocket.
Rocketdyne's E-1 was a liquid propellant rocket engine originally built as a backup design for the Titan I missile. While it was being developed, Heinz-Hermann Koelle at the Army Ballistic Missile Agency (ABMA) selected it as the primary engine for the rocket that would emerge as the Saturn I. In the end, the Titan went ahead with its primary engine, and the Saturn team decided to use the lower-thrust H-1 in order to speed development. The E-1 project was cancelled in 1959, but Rocketdyne's success with the design gave NASA confidence in Rocketdyne's ability to deliver the much larger F-1, which powered the first stage of the Saturn V missions to the Moon.
Fastrac was a turbo pump-fed, liquid rocket engine. The engine was designed by NASA as part of the low cost X-34 Reusable Launch Vehicle (RLV) and as part of the Low Cost Booster Technology project. This engine was later known as the MC-1 engine when it was merged into the X-34 project.
Since the founding of SpaceX in 2002, the company has developed four families of rocket engines — Merlin, Kestrel, Draco and SuperDraco — and since 2016 developed the Raptor methane rocket engine and after 2020, a line of methalox thrusters.
The BE-3 is a liquid hydrogen/liquid oxygen rocket engine developed by Blue Origin.
The RS-27 was a liquid-propellant rocket engine developed in 1974 by Rocketdyne to replace the aging MB-3 in the Delta. Incorporating components of the venerable MB-3 and the H-1 designs, the RS-27 was a modernized version of the basic design used for two decades. It was used to power the first stage of the Delta 2000, 3000, 5000, and the first model of the Delta II, the Delta 6000.
The MARC-60, also known as MB-60, MB-XX, and RS-73, is a liquid-fuel cryogenic rocket engine designed as a collaborative effort by Japan's Mitsubishi Heavy Industries and US' Aerojet Rocketdyne. The engine burns cryogenic liquid oxygen and liquid hydrogen in an open expander cycle, driving the turbopumps with waste heat from the main combustion process.
S-IC-T is a Saturn V first stage, S-IC rocket, of the three stage rocket system. S-IC-T was built by Boeing Company, under contract from National Aeronautics and Space Administration, to be a static test rocket. The main role of the S-IC-T was the testing of the five liquid fuel rocket engines to be used in the Apollo program. S-IC-T static test fired the rockets at NASA Mississippi Test Facility, now known as Stennis Space Center. S-IC-T was assembled at the Marshall Space Flight Center in Huntsville, Alabama. S-IC-T was given the nickname T-Bird. The first burn test was on April 10, 1965. The Saturn V's S-IC-T rocket is a first stage of the super heavy-lift launch vehicle. S-IC-T is now on display at Kennedy Space Center in Florida.
* Different versions of the engine use different propellant combinations
Engines in italics are under development
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