Falcon PDF
Falcon PDF
Falcon PDF
The Falcon 9 v1.0 first stage was powered by nine SpaceX Merlin 1C rocket engines arranged in a
3×3 pattern. Each of these engines had a sea-level thrust of 556 kN (125,000 pounds-force) for a
total thrust on liftoff of about 5,000 kN (1,100,000 pounds-force).
Rocket function: Two-stage-to-orbit
Manufacturer: SpaceX
Design:
The Falcon 9 is a two-stage, LOX/RP-1-powered heavy-lift launch vehicle. Both stages are
equipped with Merlin 1D rocket engines; nine sea-level adapted versions on the first stage and one
vacuum adapted version on the second stage. Every engine uses a pyrophoric mixture of
triethylaluminum-triethylborane (TEA-TEB) as an engine igniter.[58] The first stage engines are
arranged in a structural form SpaceX calls "Octaweb".[59] Many cores include four extensible
landing legs attached around the base of the Octaweb.[60] To control the descent of the boosters and
center core through the atmosphere, SpaceX often uses grid fins which deploy from the vehicle after
separation.[61] The legs will then deploy as the boosters return to Earth, landing each softly on the
ground.[62]
The propellant tank walls and domes are made from aluminum-lithium alloy. SpaceX uses an all
friction-stir welded tank, the highest strength and most reliable welding technique available.[5] The
second stage tank of a Falcon 9 is simply a shorter version of the first stage tank and uses most of
the same tooling, material, and manufacturing techniques, reducing production costs.[5] The Falcon
9 interstage, which connects the upper and lower stage, is a carbon-fiber aluminum-core composite
structure. Reusable separation collets and a pneumatic pusher system separates the stages. The
original design stage separation system had twelve attachment points, which was reduced to just
three in the v1.1 launcher.[63]
The Falcon 9 uses a payload fairing to protect (non-Dragon) satellites during launch. The fairing is
13 m (43 ft) long, 5.2 m (17 ft) in diameter, weighs approximately 1,900 kg, and is constructed of
carbon fiber skin overlaid on an aluminum honeycomb core.[64] SpaceX designed and fabricates
fairings at their headquarters in Hawthorne, California. Testing of the design was completed at
NASA's Plum Brook Station facility in spring 2013 where the acoustic shock and mechanical
vibration of launch, plus electromagnetic static discharge conditions, were simulated on a full-size
test article in a very large vacuum chamber.[65]
SpaceX uses multiple redundant flight computers in a fault-tolerant design. Each Merlin rocket
engine is controlled by three voting computers, each of which has two physical processors that
constantly check each other. The software runs on Linux and is written in C++.[66] For flexibility,
commercial off-the-shelf parts and system-wide radiation-tolerant design are used instead of rad-
hardened parts.[66] Each stage has stage-level flight computers, in addition to the Merlin-specific
engine controllers, of the same fault-tolerant triad design to handle stage control functions.
The Falcon 9 rocket can lose up to two of the engines and still complete the mission. The Merlin 1D
engines can vector thrust for greater control to the rocket. Each Merlin engine produces 854 kN
(192,000 lbf) of thrust.[citation needed]
Basic:
Falcon 9 is a partially reusable two-stage-to-orbit medium lift launch vehicle designed and
manufactured by SpaceX in the United States. It is powered by Merlin engines, also developed by
SpaceX, burning cryogenic liquid oxygen and rocket-grade kerosene (RP-1) as propellants. Its name
is derived from the Millennium Falcon and the nine engines of the rocket's first stage.[15][16] The
rocket evolved with versions v1.0 (2010–2013), v1.1 (2013–2016), v1.2 "Full Thrust" (2015–
present), including the Block 5 Full Thrust variant, flying since May 2018. Unlike most rockets,
which are expendable launch systems, since the introduction of the Full Thrust version, Falcon 9 is
partially reusable, with the first stage capable of re-entering the atmosphere and landing back
vertically after separating from the second stage. This feat was achieved for the first time on flight
20 with the v1.2 version in December 2015.
Falcon 9 can lift payloads of up to 22,800 kilograms (50,300 lb) to low Earth orbit, 8,300 kg
(18,300 lb) to geostationary transfer orbit (GTO) when expended, and 5,500 kg (12,100 lb) to GTO
when the first stage is recovered.[1][17][18] The heaviest GTO payloads flown have been Intelsat
35e with 6,761 kg (14,905 lb), and Telstar 19V with 7,075 kg (15,598 lb), although the latter was
launched into a lower-energy GTO orbit achieving an apogee well below the geostationary altitude.
[19]
In 2008, SpaceX won a Commercial Resupply Services (CRS) contract in NASA's Commercial
Orbital Transportation Services (COTS) program to deliver cargo to the International Space Station
(ISS) using the Falcon 9 and Dragon capsule. The first mission under this contract launched on
October 8, 2012.[20] SpaceX intends to certify the Falcon 9 to be human-rated for transporting
NASA astronauts to the ISS as part of the NASA Commercial Crew Development program.
Currently, Falcon 9 has been certified for the National Security Space Launch[21] program and
NASA Launch Services Program as "Category 3," which can launch the priciest, most important,
and most complex NASA missions.[22]
The initial Falcon 9 version 1.0 flew five times from June 2010 to March 2013; version 1.1 flew
fifteen times from September 2013 to January 2016. The "Full Thrust" version was in service from
December 2015 into 2018, with several additional upgrades within this version. The latest variant,
Block 5, was introduced in May 2018.[23] It features increased engine thrust, improved landing
legs, and other minor improvements to help recovery and reuse. The Falcon Heavy derivative,
introduced in February 2018, consists of a strengthened Falcon 9 first stage as its center core,
attached to two standard Falcon 9 first stages used as boosters.
Launcher versions
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The original Falcon 9 v1.0 flew five successful orbital launches in 2010–2013. The much larger
Falcon 9 v1.1 made its first flight in September 2013. The demonstration mission carried a very
small 500 kg (1,100 lb) primary payload, the CASSIOPE satellite;[63] larger payloads followed for
v1.1, starting with the launch of the large SES-8 GEO communications satellite.[67] Both Falcon 9
v1.0 and Falcon 9 v1.1 were expendable launch vehicles (ELVs). The Falcon 9 Full Thrust made its
first flight in December 2015. The first stage of the Falcon 9 Full Thrust version is reusable. The
current version, known as Falcon 9 Block 5, made its first flight in May 2018.
Falcon 9 v1.0
Main article: Falcon 9 v1.0
A Falcon 9 v1.0 launches with a Dragon spacecraft delivering cargo to the ISS in 2012.
The first version of the Falcon 9 launch vehicle, Falcon 9 v1.0, was an expendable launch vehicle
that was developed in 2005–2010, and was launched for the first time in 2010. Falcon 9 v1.0 made
five flights in 2010–2013, after which it was retired.
Falcon 9 v1.1
Main article: Falcon 9 v1.1
The launch of the first Falcon 9 v1.1 from SLC-4, Vandenberg AFB (Falcon 9 Flight 6) in
September 2013
The Falcon 9 v1.1 ELV is a 60 percent heavier rocket with 60 percent more thrust than the v1.0
version of the Falcon 9.[63] It includes realigned first-stage engines[71] and 60 percent longer fuel
tanks, making it more susceptible to bending during flight.[63] Development testing of the v1.1 first
stage was completed in July 2013.[72][73] The Falcon 9 v1.1, first launched in September 2013,
uses a longer first stage powered by nine Merlin 1D engines arranged in an "octagonal" pattern,[74]
[75] that SpaceX calls Octaweb. This is designed to simplify and streamline the manufacturing
process.[76]
The v1.1 first stage has a total sea-level thrust at liftoff of 5,885 kN (1,323,000 lbf), with the nine
engines burning for a nominal 180 seconds, while stage thrust rises to 6,672 kN (1,500,000 lbf) as
the booster climbs out of the atmosphere.[4] The engines have been upgraded to the more powerful
Merlin 1D. These improvements increased the payload capability from 9,000 kg (20,000 lb) to
13,150 kg (28,990 lb).[4] The stage separation system has been redesigned and reduces the number
of attachment points from twelve to three,[63] and the vehicle has upgraded avionics and software
as well.[63] Following the September 2013 launch, the second stage igniter propellant lines were
insulated to better support in-space restart following long coast phases for orbital trajectory
maneuvers.[48]
SpaceX President Gwynne Shotwell has stated the Falcon 9 v1.1 has about 30 percent more payload
capacity than published on its standard price list, the extra margin reserved for returning of stages
via powered re-entry.[77] Four extensible carbon fiber with aluminum honeycomb landing legs
were included on later flights where landings were attempted.[78][79][80]
A close-up of the newer titanium grid fins first flown for the second Iridium NEXT mission in June
2017
In February 2017, SpaceX's CRS-10 launch was the first operational launch utilizing the new
Autonomous Flight Safety System (AFSS) that is built into Falcon 9 Full Thrust launch vehicles.
For all SpaceX launches after March 16, 2017, the autonomous 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."[87]
On the June 25, 2017 mission carrying the second batch of ten Iridium NEXT satellites, aluminum
grid fins were replaced by titanium versions, to improve control authority and better cope with heat
during re-entry.[88]
Block 4
In 2017, SpaceX started including incremental changes to the Falcon 9 Full Thrust, internally
calling it the "Block 4" version.[89] Initially 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.[90] Block 4 was described as a transition between the Full
Thrust v1.2 "Block 3" and Block 5. It includes incremental engine thrust upgrades leading to the
final thrust for Block 5.[91] The maiden flight of the full Block 4 design (first and second stages)
was the NASA CRS-12 mission on August 14, 2017.[92]
Block 5
Main article: Falcon 9 Block 5
In October 2016, Musk described a Block 5 version that would have "a lot of minor refinements
that collectively are important, but uprated thrust and improved legs are the most significant."[93]
In January 2017, Musk added that the Block 5 version "significantly improves performance & ease
of reusability".[94] He described this version as the "final" version of the rocket.[93] The maiden
flight took place on May 11, 2018,[23] with the Bangabandhu-1 satellite.[95] The Block 5 version
of the second stage includes upgrades that enables it to operate for longer in orbit and reignite its
engine three or more times.[96]
Capabilities
Performance
Falcon 9 Full Thrust
Falcon 9 v1.0 Falcon 9 v1.1 Falcon 9 Full Thrust
Version
(retired) (retired) Blocks 1-4 (retired) Block 5 (active)[97]
[9]
9 × Merlin 1D
Stage 1 9 × Merlin 1C 9 × Merlin 1D 9 × Merlin 1D (upgraded)
(upgraded)[98]
1 × Merlin 1C 1 × Merlin 1D 1 × Merlin 1D 1 × Merlin 1D Vacuum
Stage 2
Vacuum Vacuum Vacuum FT[82][98] FT
Max. height (m) 53[99] 68.4[4] 70[3][82] 70
Diameter (m) 3.66[100] 3.66[101] 3.66[82] 3.66
Initial thrust
3,807 5,885[4] 6,804[3][82] 7,600[102]
(kN)
Takeoff mass
318[99] 506[4] 549[3] 549
(tonnes)
Fairing
N/A[a] 5.2 5.2 5.2
diameter (m)
Payload to LEO
≥ 22,800 (expendable)
(kg) 8,500– 22,800 (expendable)
13,150[4] ≥ 16,800 (reusable)[c]
(from Cape 9,000[99] [1][b]
[104]
Canaveral)
8,300[1] (expendable)
Payload to GTO ≥ 8,300 (expended)
3,400[99] 4,850[4]
(kg) About 5,300[105][18] ≥ 5,800 (reusable)[106]
(reusable)
36 / 36 (1 precluded)
Success ratio 5 / 5[d] 14 / 15[e] 25 / 25
[f]
1.
• The Falcon 9 v1.0 only launched the Dragon spacecraft; it was never launched with the
clam-shell payload fairing.
• Payload was restricted to 10,886 kg (24,000 lb) due to structural limit of the payload adapter
fitting (PAF).[103]
• Conversion of 18.5 US tons to 16.8 metric tons (1,000kg)
• On SpaceX CRS-1, the primary payload, Dragon, was successful. A secondary payload was
placed in an incorrect orbit because of a changed flight profile due to the malfunction and
shut-down of a single first-stage engine. Likely enough fuel and oxidizer remained on the
second stage for orbital insertion, but not enough to be within NASA safety margins for the
protection of the International Space Station.[107]
• The only failed mission of the Falcon 9 v1.1 was SpaceX CRS-7, which was lost during its
first stage operation due to an overpressure event in the second stage oxygen tank.
6. One rocket and payload were destroyed before launch, during preparation for a routine static
fire test.[108]
Reliability
SpaceX had predicted that its launches would have high reliability based on the philosophy that
"through simplicity, reliability and low cost can go hand-in-hand" by 2011.[109] As of 17 February
2020 Falcon 9 has achieved 82 out of 84 full mission successes (97.6%), with SpaceX CRS-1
succeeding in the primary mission but leaving a secondary payload in a wrong orbit and SpaceX
CRS-7 destroyed in flight. In addition Amos-6 was destroyed on the launch pad during fueling for
an engine test. For comparison, present industry benchmark, the Russian Soyuz series has
performed more than 1,700 launches[110] with a success rate of 97.4%,[111] the Russian Proton
series has performed 422 launches a success rate of 88.6%, the European Ariane 5 has performed
105 launches with a success rate of 95.2%, and Chinese Long March series has performed 314
launches with a success rate of 94.9%.
As with the company's smaller Falcon 1 vehicle, Falcon 9's launch sequence includes a hold-down
feature that allows full engine ignition and systems check before liftoff. After first-stage engine
start, the launcher is held down and not released for flight until all propulsion and vehicle systems
are confirmed to be operating normally. Similar hold-down systems have been used on other launch
vehicles such as the Saturn V[112] and Space Shuttle. An automatic safe shut-down and unloading
of propellant occurs if any abnormal conditions are detected.[5] Prior to the launch date, SpaceX
always completes a test of the Falcon 9 culminating in a firing of the first stage's Merlin 1D engines
for three-and-a-half seconds to verify performance.[113]
Falcon 9 has triple redundant flight computers and inertial navigation, with a GPS overlay for
additional orbit insertion accuracy.[5]
Engine-out capability
Like the Saturn rocket series from the Apollo program, the presence of multiple first-stage engines
allows for mission completion even if one of the first-stage engines fails during flight.[5][114]
Detailed descriptions of several aspects of destructive engine failure modes and designed-in engine-
out capabilities were made public by SpaceX in a 2007 "update" that was publicly released.[115]
SpaceX emphasized over several years that the Falcon 9 first stage is designed for engine out
capability.[5] The SpaceX CRS-1 mission in October 2012 was a partial success after an engine
failure in the first stage: engine no. 1 experienced a loss of pressure at 79 seconds, and then shut
down. To compensate for the resulting loss of acceleration, the first stage had to burn 28 seconds
longer than planned, and the second stage had to burn an extra 15 seconds. That extra burn time of
the second stage reduced its fuel reserves, so that the likelihood that there was sufficient fuel to
reach the planned orbit above the space station with the secondary payload dropped from 99% to
95%. Because NASA had purchased the launch and therefore contractually controlled a number of
mission decision points, NASA declined SpaceX's request to restart the second stage and attempt to
deliver the secondary payload into the correct orbit. This risk was understood by the secondary
payload customer at time of the signing of the launch contract. As a result, the secondary payload
satellite reentered the atmosphere a few days after launch.[8]
Reusability
Main article: SpaceX reusable launch system development program
Mini-BFR ship reentry test vehicle, designed as a modified Falcon 9 second stage
In November 2018, SpaceX announced work on a heavily modified Falcon 9 second stage that
would be used for atmospheric reentry testing of a number of technologies needed for the full-scale
Starship, including an ultra-light heat shield and high-Mach control surfaces. Musk indicated it
would be "upgraded to be like a mini-BFR ship" but that the stage would not be used for landing
tests, as the company already believes it has a good handle on propulsive landings. In November
2018, the first test flight of the modified stage was planned to be no earlier than mid-2019.[139] In
the event, the design work did not proceed all the way to flight testing, and no reentry tests were
done using a returning Falcon 9 second stage. All SpaceX second stage design/development work
for atmospheric reentry moved to the two Starship orbital prototype vehicles, which will begin
flight tests no earlier than October 2019.[140]