Thiokol (variously Thiokol Chemical Corporation(/Company), Morton Thiokol Inc. (MTI), Cordant Technologies Inc., Thiokol Propulsion, AIC (Alcoa Industrial Components) Group, then part of Alliant Techsystems (ATK) Inc., then ATK Thiokol, ATK Launch Systems Group; finally Orbital ATK before becoming part of Northrop Grumman Innovation Systems and Northrop Grumman) was an American corporation concerned initially with rubber and related chemicals, and later with rocket and missile propulsion systems. Its name is a portmanteau of the Greek words for sulfur (θεῖον "theion") and glue (κόλλα "kolla"), an allusion to the company's initial product, Thiokol polymer.
The Thiokol Chemical Company was founded in 1929. Its initial business was a range of synthetic rubber and polymer sealants. Thiokol was a major supplier of liquid polymer sealants during World War II. When scientists at the Jet Propulsion Laboratory discovered that Thiokol's polymers made ideal binders for solid rocket fuels, Thiokol moved into the new field, opening laboratories at Elkton, Maryland, and later production facilities at Elkton and at Redstone Arsenal in Huntsville, Alabama. Huntsville produced the XM33 Pollux, TX-18 Falcon, and TX-135 Nike-Zeus systems. It closed in 1996. In the mid-1950s the company bought extensive lands in Utah for its rocket test range.
During its existence, Thiokol was involved in two notable loss of life incidents. On February 3, 1971, at a Thiokol chemical plant southeast of Woodbine, Georgia, a fire entered a storage facility holding nearly five tons of ignition pellets, flares, and other highly flammable materials. The facility exploded, killing 29 people and severely wounding more than 50 others, including many with severed limbs. Windows were shattered 11 miles (18 km) from the site and the explosion was heard for 50 miles (80 km) around.[1] Georgia law prevented employees from suing their employer because they were covered by workers' compensation insurance.[2]
On January 28, 1986, the Space Shuttle Challengerexploded 73 seconds into its flight, killing all seven crew members aboard. An investigation found the cause was two O-ring seals in the Space Shuttle's right solid rocket booster, which had been manufactured by Morton Thiokol. Test data from as early as 1977 had revealed a potentially catastrophic flaw in the O-rings in low-temperature situations, but neither Morton Thiokol nor NASA addressed or corrected the issue. Shortly before takeoff, several Morton Thiokol engineers recommended calling off the launch until temperatures at Cape Canaveral increased, but they were overruled by company management.[3][4]
Company history
Model 601 U.S.A.F. Thiokol SnowcatThiokol Spryte used for winter service
In 1926, two chemists, Joseph C. Patrick and Nathan Mnookin, were trying to invent an inexpensive antifreeze. In the course of an experiment involving ethylene dichloride and sodium polysulfide, they created a gum whose outstanding characteristic was a terrible odor.[5] The substance clogged a sink in the laboratory, and none of the solvents used to remove it were successful. Then the frustrated chemists realized that the resistance of the material to any kind of solvent was a useful property. They had invented a synthetic rubber, which they christened "Thiokol".[6] In 1929, Bevis Longstreth, an executive at a salt company, founded the Thiokol Corporation in Trenton, New Jersey. He became its president and general manager.[7]
Longstreth died in 1944, leaving the position of president and general manager open. William Crosby became general manager.[7] The next year, in 1945, Charles Bartley, working for the nascent Jet Propulsion Laboratory, discovered the use of thiokol as a stabilizer in solid-fuel rockets.[8] In 1948, a plant in Elkton, Maryland was opened, producing solid rocket motors.[9] In 1949, Thiokol produced the TX-18 Falcon missile, the world's first solid-fueled missile system.[10]
In 1957, anticipating the forthcoming Minuteman contract, the company built its plant at Brigham City, Utah, and Thiokol Huntsville began building XM33 Pollux missiles.
In 1958, Thiokol merged with Reaction Motors Inc. (RMI), makers of liquid propellant rocket motor systems.[11] Also in 1958, Thiokol received a contract to build the TU-122 rocket motor for the first stage of the LGM-30 MinutemanICBM system. In 1959, Thiokol Huntsville began producing CASTOR strap-on booster rocket, used on the Atlas rocket.
In 1964, the Woodbine, Georgia plant was constructed to build solid propellant motors for NASA, but the agency changed course and used liquid fuel.[12]
In 1980, Thiokol acquired Carlisle Chemical Company of Cincinnati, Ohio. In 1982, Thiokol merged with Morton-Norwich products (owners of the Morton Salt concern, the Simoniz automotive products brand, and various chemical concerns) with the merged company called Morton Thiokol Incorporated (MTI).[13][14]
In 1986, an O-ring fault in an MTI SRB destroyedSpace Shuttle Challenger in flight. The company was found at fault for the destruction of Challenger and deaths of the astronauts, as a direct causality from pressure from NASA to launch, based on inconclusive evidence of O-ring failure, while under freezing temperatures. (See Space Shuttle Challenger disaster).
In 1989, Morton Thiokol split, with most of the chemical concern going with Morton but the propulsion systems division became Thiokol Inc. Then in 1998, Thiokol changed its name to Cordant Technologies. Also in 1998, Thiokol branded polymer products purchased by PolySpec L.P., a Houston-based manufacturer of industrial coatings, marine decking, and subsea insulation products.
In 2000, Thiokol merged with two divisions of Alcoa and with Howmet Castings and Huck Fasteners to become AIC Group (Alcoa Industrial Components). In 2001, Alliant Techsystems (ATK) Inc. (a company formed when Honeywell spun off its defense division) spent $2.9 billion buying Thiokol and related businesses from AIC/Alcoa. ATK built the third stage of the Trident missile and had earlier bought Hercules Aerospace Co., builder of the second stage. With the purchase of Thiokol, makers of the missile's first stage, ATK controlled the lion's share of the US solid rocket-fuel market. In 2005, ATK-Thiokol won the contract to produce the Ares Ilaunch vehicle first stage for NASA's Project Constellation.[15]
In 2006, Alliant Techsystems (ATK) Inc. was renamed ATK-Thiokol to ATK Launch Systems Group. In 2014, Orbital ATK was formed from the merger of Orbital Sciences Corporation and parts of Alliant Techsystems. In 2018, Orbital ATK was purchased by Northrop Grumman.
Products
Thiokol gas generators were used in the airbags on Mars Pathfinder. The top photo shows a complete airbag assembly under test, the bottom shows the three titanium Thiokol gas generators used to inflate the airbags.
In addition to ski lifts, Thiokol produced a range of equipment for ski resorts including snowcats and snow grooming vehicles. These businesses were spun off in 1978 when the company restructured itself to concentrate on its rocket products and related technologies. John Z. DeLorean purchased the Thiokol snowcat operation and renamed it DMC. DMC continued to manufacture snowcats until 1988, when the company was renamed LMC. LMC continued making snowcats for 12 more years but ceased operations in 2000. Thiokol produced snow vehicles with a wide range of capabilities and duties. The company also produced several utility based vehicles based on their snowcat tracked vehicle, in addition to larger snow grooming machines suitable for use on steep ski-slopes. Thiokol machines were used in ski resorts, operated by the USAF in Alaska and other northern regions, and are now popular with private owners as dependable snowcats and for all-terrain transport.
Amphibious Thiokol Swamp Spryte All Terrain Vehicle
Thiokol pioneered the short-burn rocket motors used in aircraft ejection seats. The company also produced a number of the earliest practical airbag systems, building the high-speed sodium azideexothermic gas generators used to inflate the bags. Thiokol bags were first used in U.S. military aircraft, before being adapted to space exploration (Mars Pathfinder bounced down on Mars on Thiokol airbags) and automotive airbags. Thiokol's generators form the core of more than 60% of airbags sold worldwide.
A solid-propellant rocket or solid rocket is a rocket with a rocket engine that uses solid propellants (fuel/oxidizer). The earliest rockets were solid-fuel rockets powered by gunpowder; The inception of gunpowder rockets in warfare can be credited to ancient Chinese ingenuity, and in the 13th century, the Mongols played a pivotal role in facilitating their westward adoption.
The Rogers Commission Report was written by a Presidential Commission charged with investigating the Space Shuttle Challenger disaster during its 10th mission, STS-51-L. The report, released and submitted to President Ronald Reagan on June 9, 1986, both determined the cause of the disaster that took place 73 seconds after liftoff, and urged NASA to improve and install new safety features on the shuttles and in its organizational handling of future missions.
Alliant Techsystems Inc. (ATK) was an American aerospace, defense, and sporting arms firm headquartered in Arlington County, Virginia, in the United States. The company operated in 22 states, Puerto Rico, and internationally. ATK revenue in fiscal year 2014 was about US$4.78 billion.
The Space Shuttle Solid Rocket Booster (SRB) was the first solid-propellant rocket to be used for primary propulsion on a vehicle used for human spaceflight. A pair of these provided 85% of the Space Shuttle's thrust at liftoff and for the first two minutes of ascent. After burnout, they were jettisoned and parachuted into the Atlantic Ocean where they were recovered, examined, refurbished, and reused.
Pegasus is an air-launched launch vehicle developed by Orbital Sciences Corporation (OSC) and now built and launched by Northrop Grumman. Pegasus is the world's first privately developed orbital launch vehicle. Capable of carrying small payloads of up to 443 kg (977 lb) into low Earth orbit, Pegasus first flew in 1990 and remains active as of 2021. The vehicle consists of three solid propellant stages and an optional monopropellant fourth stage. Pegasus is released from its carrier aircraft at approximately 12,000 m (39,000 ft), and its first stage has a wing and a tail to provide lift and altitude control while in the atmosphere. Notably, the first stage does not have a thrust vector control (TVC) system.
Orbital Sciences Corporation was an American company specializing in the design, manufacture, and launch of small- and medium- class space and launch vehicle systems for commercial, military and other government customers. In 2014, Orbital merged with Alliant Techsystems to create a new company called Orbital ATK, Inc., which in turn was purchased by Northrop Grumman in 2018. The remnants of the former Orbital Sciences Corporation became a subsidiary of Northrop Grumman, known as Northrop Grumman Space Systems.
The Graphite-Epoxy Motor (GEM) is a family of solid rocket boosters developed in the late 1980s and used since 1990. GEM motors are manufactured with carbon-fibre-reinforced polymer casings and a fuel consisting of HTPB-bound ammonium perchlorate composite propellant. GEM is produced by Northrop Grumman Space Systems. GEM boosters are used on the Atlas V and were previously used on the Delta II, Delta III, and Delta IV launch vehicles. A new variant, the GEM 63XL, flew as part of the Vulcan Centaur launch vehicle on 8 January 2024.
Athena was a 1990s Lockheed Martin expendable launch system which underwent several name changes in its lifetime.
The booster separation motors or BSMs on the Space Shuttle were relatively small rocket motors that separated the reusable solid rocket boosters (SRB) from the orbiter after SRB burnout. Eight booster separation motors were attached to each of the shuttle's two reusable solid rocket boosters, four on the forward frustum and four on the aft skirt.
Allegany Ballistics Laboratory (ABL) located in Rocket Center, West Virginia, is a diverse industrial complex employing some 1,000 people across 1,628 acres (6.59 km2). The facility is a member of the Federal Laboratory Consortium and is operated by Northrop Grumman under contract with the Naval Sea Systems Command (NAVSEA).
The Star 48 is the largest of a family of solid rocket motors used by many space propulsion and launch vehicle stages. It is used almost exclusively as an upper stage. It was developed primarily by Thiokol Propulsion and is now, after several mergers, manufactured by Northrop Grumman’s Space Systems division. A Star 48B stage is also one of the few man-made items sent on escape trajectories out of the Solar System, although it is derelict since its use. The Star 48B variant was the PAM-D upper stage used on the now-retired Delta II rocket.
Castor is a family of solid-fuel rocket stages and boosters built by Thiokol and used on a variety of launch vehicles. They were initially developed as the second-stage motor of the Scout rocket. The design was based on the MGM-29 Sergeant, a surface-to-surface missile developed for the United States Army at the Jet Propulsion Laboratory.
Antares, known during early development as Taurus II, is an expendable launch system developed by Orbital Sciences Corporation and the Pivdenne Design Bureau to launch the Cygnus spacecraft to the International Space Station as part of NASA's COTS and CRS programs. Able to launch payloads heavier than 8,000 kg (18,000 lb) into low Earth orbit, Antares is the largest rocket operated by Northrop Grumman. Antares launches from the Mid-Atlantic Regional Spaceport and made its inaugural flight on April 21, 2013. Antares 100 was retired in 2014 and series 200 was retired in 2023 due to component unavailability. As of January 2024 Antares 300 is under development.
The NASA Railroad is a Class III industrial short-line railroad at the Kennedy Space Center in Cape Canaveral, Florida. The railroad consists of 38 miles (61 km) of track connecting the mainline of the Florida East Coast Railway and trackage at the Cape Canaveral Space Force Station. NASA uses the railroad to deliver large or bulk materials to support its operations, particularly solid rocket boosters and chemicals such as helium and oxygen for rocket fuel.
Liberty was a 2011 launch vehicle concept proposed by Northrop Grumman Space Systems and Airbus Defence and Space for phase 2 of the NASA Commercial Crew Development (CCDev) program intended to stimulate development of privately operated crew vehicles to low Earth orbit.
The Star is a family of US solid-propellant rocket motors originally developed by Thiokol and used by many space propulsion and launch vehicle stages. They are used almost exclusively as an upper stage, often as an apogee kick motor.
Pegasus II, also known as Thunderbolt, was an air-launched orbital rocket under development in 2012–2015 by Orbital Sciences Corporation for use by Stratolaunch Systems.
Northrop Grumman Innovation Systems (NGIS) was a sector of Northrop Grumman from 2018 through 2019. It was formed from Orbital ATK Inc. a company which resulted from the merger of Orbital Sciences Corporation and parts of Alliant Techsystems in 2015. Orbital ATK was purchased by Northrop Grumman in 2018. Northrop Grumman Innovation Systems designed, built, and delivered space, defense, and aviation-related systems to customers around the world both as a prime contractor and as a merchant supplier. It had a workforce of approximately 12,000 employees dedicated to aerospace and defense including about 4,000 engineers and scientists; 7,000 manufacturing and operations specialists; and 1,000 management and administration personnel. With Northrop Grumman's reorganization of its divisions effective January 1, 2020, NGIS was split, with most of the sector merging with other Northrop Grumman businesses into a new Space Systems sector.
OmegA was a medium-lift to heavy-lift launch vehicle concept that spent several years in development by Northrop Grumman during 2016–2020, with that development substantially funded by the U.S. government. OmegA was intended for launching U.S. national security satellites, as part of the U.S. Department of the Air Force National Security Space Launch (NSSL) replacement program.
Tekoi Rocket Test Range, or Tekoi, is a former solid fuel rocket motor test and calibration site operated by Hercules Aerospace near the Utah Test and Training Range in Utah's West Desert, approximately 80 miles (130 km) west of Salt Lake City, Utah. It is located on the Goshute's Skull Valley Indian Reservation.
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