A Sound of Thunder: The Rise of the Soviet Superbooster

ITTL by 87 the H-1 is LONG out of production and is going to be replaced by the RS-27, for this to be practical the engines need to be designed for modern (90s) use, and these changes would leave the engine totally different, like the F-1B idea
so far i know is RS-27 a modified H-1,
Chamber Pressure: 40.00 bar rised to 48 bar
this increase thrust and ISP compare to H-1
and Gasgenerator output is used to feed gimballed verniers for roll control.
 
Literally as I stated. One engine was test fired, moved to the site and dunked for 48 hours, then pulled out and rinsed off, (no disassembly) and put into storage (a conex container IIRC) and left for two month and THEN disassembled and rebuilt. Pretty much the same as all the other engines tested, hence the reason for costs being about 5% of the original engine cost. IIRC, (going to have to find my copy of the report and reread it) the biggest concern was engine bell damage since it was going to land "engines" up and then rotate around to engines down in the water. They did drop several engines from various heights to simulate that roll over but I don't recall reading such damage was as common as they'd feared.
I don't think you are correct about that given the version of the partial notes from Upship, which I noted from googling you cite verbatim in full yourself here. If you have something that disagrees with this or has more detail, I'd love to have it, because it's been very hard over the years to dig up more than just people citing this specific blog posts' text.
The general test procedures were as follows:
1. First test – March, 1961. H-1 engine was:
a. Prepared and static fired.
b. Immersed in salt water to a depth of 10 feet for 2 hours, and half -submerged for 2 hours.
c. Purged. Preservations were applied.
d. Stored for 2 weeks.
e. Dismantled, inspected, cleaned, damaged parts were replaced, and engine was assembled.
f. Hot fired for short duration and full duration (150 seconds).

2. Second test – June, 1961:
a. Immersed H-1 engine to a depth of 10 feet for 1 hour, half submerged for 3 hours, and on the surface for 3 hours.
b. Waited 12 hours before purging, and applying minimum
preservatives.
c. Upon arrival at the MSFC, engine was dismantled, inspected, cleaned, damaged parts were replaced, and engine was assembled
d. Hot-fired for short duration and full duration.

3. Third test immersion in August, 1961; hot fired in March, 1962.
a. Dropped H-1 engine into water to simulate water entry conditions, immersed it, held it half-submerged, and on the surface for a total of 9 hours.
b, Engine washed with fresh water; – no preservative compounds were used.
c. Upop arrival at the MSFC, engine was dismantled, inspected, partially cleaned, ind left in storage.
d. Six months later the engine was assembled and hot-fired for short duration and full duration.

In all three cases the engine was disassembled and damaged parts swapped from the sound of it, with at least some cleaning on a piece-part level. Arguing about specific test procedures from 60+ years ago isn't totally productive, but at least some of this reporting is available unlike any data on engine tests from much more recent projects on dunking engines within the last year or three.

As you stated the engine was totally torn apart and cleaned and rebuilt, for a reusable rocket this is expensive, Falcon 9 has components designed to withstand multiple launches

One engine test is one thing, doing this routinely is another, the SSME was supposed to be able to refly without refurbishment for a few flights, while it was completely disassembled every flight, on the ground you can fire the engine whenever, when exposed to the forces of launch its a different story
SSME wasn't fully disassembled, just removed from the orbiter for inspection off the vehicle, and the Block II engines implemented in the late 90s were capable of ten flights on the vehicle, something demonstrated fully in testing (e.g. the AR-22 engine test sequence of ten firings in ten days).
 
One SSME flew 19 times on Space Shuttle
A record broken with Starlink launch on 23 February 2024
Not only flew the booster B1061 for the 19th times, one of Merlin Engines made it 22th flight !
 
Not really, no--there were individual H-1s that were fired 8 times in a single day with zero overhaul, so "total teardown and rebuild" is a pretty major change from that.

Sorry I wasn't clear but I meant every other engine tested in that program. It WAS a test program so of course they were going to tear down and rebuild the engine, seeing what (if any) damage was done by the salt water and time factors was a part of the program.

If that is in fact the case then rapidish reusability that falcon does is not practical

Why? Falcon 9 takes anywhere from 14 to 21 days for just the postflight refurbishment. Engine and stage refurbishment for the proposed recovered Saturn 1/1B booster was estimated about the same.

IIRC the SSME did the same with nearly every engine being torn apart and rebuilt each flight

At the beginning of the flights yes, after all you're doing major inspections on all equipment since it was somewhat of a 'test' article under "real world" stress. SpaceX did the same when they ramped up reuse.

As you stated the engine was totally torn apart and cleaned and rebuilt, for a reusable rocket this is expensive,

Not as much as you might think, keep in mind that both the S1 stage and the H1 were pretty 'over-built' for the time.

Falcon 9 has components designed to withstand multiple launches

Most launcher and engines are, that comes pretty naturally when you figure in test firings and such. The ironic thing is the original idea for recovering the Saturn 1 stage was to save money and be able to test reusability but ARPA (who was sponsoring the work on a big booster) was hesitant to spend the money needed to develop a full recovery system. Note that SpaceX pulls the engines for examination and then refurbishment in pretty much the same way the SSME was for later Shuttle program use.

Not to mention in this H-1 test, i wonder if damaged components were replaced, and if so to what extent

Doesn't seem to be much needed as it was all part of the process they used.

Musk was the first to actually have the balls to flesh out the concept and do things for real

And as noted the jury is still out on if it's actually economical or practical for the current and projected flight rate. Keep in mind that the current high flight rate of Falcon is more due to internal (StarLink) launches than external.

The payload hit is why reuse isn't added, if a 20 ton-LEO launcher becomes 10 you loose a lot of capability

None that I know of are quite that bad :)
Recovery in a booster stage will always cost some payload, (currently about 15% for the Falcon 9) but there are ways to improve that such as upper stage propellant choices or things like SRB's and booster assist systems.

Helicopter-rocket catching is a fancy idea, but ya the economy is very iffy, in Vulcan-Centaurs case the idea is more as a study and not practical use as the changes would require a huge change to the rocket itself

Recovery requirements pretty much require large changes, especially if you started out as an expendable design. (Like Falcon 9 had to have major changes to accommodate reuse) It's always going to be a question of economics and design.

One engine test is one thing, doing this routinely is another, the SSME was supposed to be able to refly without refurbishment for a few flights, while it was completely disassembled every flight, on the ground you can fire the engine whenever, when exposed to the forces of launch its a different story

And eventually the SSME did achieve minimum refurbishment between flights

ITTL by 87 the H-1 is LONG out of production and is going to be replaced by the RS-27, for this to be practical the engines need to be designed for modern (90s) use, and these changes would leave the engine totally different, like the F-1B idea

As noted the RS-27 was based on the H1 engine design being essentially an H1 with manufacturing and performance 'tweaks' that were available with more modern technology and materials. The RS-27A and RS-56 was where major changes were being done. Actually leading the "RS-X" proposal of the 90s.

Ground testing and flight testing are very different, along with the complete teardowns and overhauls each engine would be a bitch to clear for flight, not to mention the normal degrading that comes with extended use

As noted they managed this with the SSME and it's what SpaceX does with the Falcon 9 engines. They pull them for maintenance and inspection and pull some refurbished ones from storage if needed to meet the next flight goal.

Randy
 
On Hermes, Let face the program was a Mess !
planned 1975 as small glider launch with Ariane 4/5 rocket, it mutated to french space shuttle in 1980s under CNES.
as became Official ESA program around 1985 it needed new rocket the Ariane 5 we know
then came 1986 Challenger disaster and Hermes needed crew escape system
From here here the program went down hill, mass increase, getting more and more complex, more expensive and delays
1992 the Germans pulled the plug the program, as they needed money for their reunification.

could had Hermes become operational program ?
yes, had the CNES Management in 1980s look into "what we need ?" and "What is meaningful for Hermes ?"
Had they someone with realist assessment what they really needed, Hermes had never become French Space shuttle...
But instead a Dyna-Soar like spacecraft that do what is needed:

- Bring ESA astronauts to US space Station or ESA space station
- Fly small experiment in orbit
- Service ESA space station Columbus Man-Tended Free Flyer
- Fly reconnaissance mission for french military


This would have safe Hermes from issues it ran in second half of the 1980s

by the way
Texas manage to land on Moon
The Intuitive Machines Nova-C lunar lander touch down safe on Target at the Malapert-A crater,
I don’t think there’s any magic answer to Hermes, what you listed were still fundamentally the goals of our Hermes (except military use, which were only studied at concept level, the French Armed Forces were already too busy with the ill-fated SAMROS then Helios in the 80s for anything like a military Hermes), yes you could slightly relax requirement of payload to orbit, Downmass, offloading requirement to Freedom and MTFF, no EVA... but there really is no magical solution that can prevent Hermes from being a long, costly and hard 10 years development from the point where production begins (a point which wasn’t reached IRL, with flights planned in the early 2000s) by companies which had no experience in either spaceplanes, crewed spacecraft or even reentry vehicles or cargo spacecraft..


I do think that Hermes is slightly overrated compared to contemporary or similar spaceplanes, even from a technical point of view !
HOPE at least went to a full structural prototype, and would benefit from latter reentry and drop test experiments, MAKS May never have had the funding for it, but it had also had a structural prototype (both tanks and airframe, as well as a working subscale prototype of its main engine and proven orbital engine), benefited from the huge Contemporary experience of Buran’s maker molnya. They may not be as sexy as Hermes, but these two projects were arguably more technically sound than Hermes! Sometime when people talk about Hermes they make it sounds like it was as advanced as say, the Dyna-soar... bulls***, Hermes was closer to the SLI Orbital Space Plane than the Dyna Soar.

And again, that’s not talking about the organisational and political point of view. So yeah, IMO the only way to make Hermes happen is to fundamentally change its entire context, both political organisational and technical.
 
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I do think that Hermes is slightly overrated compared to contemporary or similar spaceplanes, even from a technical point of view !

Why they use glider ?
Since 1960s under ELDO were plans for Glider launch by Europa IV rocket.
CNES study next Hermes also under SOLARIS for manned capsule.
So far i know, CNES favour Hermes for landing on runway, either a launch site or in France.
because French Navy were unable to do recovery operation for manned capsule in ocean during that time.
 
SSME wasn't fully disassembled, just removed from the orbiter for inspection off the vehicle, and the Block II engines implemented in the late 90s were capable of ten flights on the vehicle, something demonstrated fully in testing (e.g. the AR-22 engine test sequence of ten firings in ten days).
Did not know that, from what i read (wikipedia mostly in this specific case) the engines were rebuilt each flight, but in hindsight that is probably just the early engines
Most launcher and engines are, that comes pretty naturally when you figure in test firings and such. The ironic thing is the original idea for recovering the Saturn 1 stage was to save money and be able to test reusability but ARPA (who was sponsoring the work on a big booster) was hesitant to spend the money needed to develop a full recovery system. Note that SpaceX pulls the engines for examination and then refurbishment in pretty much the same way the SSME was for later Shuttle program use.

S-1 was a monster of tanks, i doubt it could land in the ocean without sustaining damage (unlike Titan which had to get sunk by the Navy a few times)

All this makes me question NASA's fisical responibility, considering this led nowhere, same with J-2 derivatives
And as noted the jury is still out on if it's actually economical or practical for the current and projected flight rate. Keep in mind that the current high flight rate of Falcon is more due to internal (StarLink) launches than external.
Its still business, given that the constellation idea is catching on means that it works, though it needs to get regulated as multiple countries want the same, and due to it being LEO it means that we might hit 10000 LEO satellites quickly
Recovery in a booster stage will always cost some payload, (currently about 15% for the Falcon 9) but there are ways to improve that such as upper stage propellant choices or things like SRB's and booster assist systems.
In Falcon 9's case it was grown and modified for more lift over time, by the time Falcon Heavy was ready the payloads Heavy was designed for early on were launched on Falcon 9, which is why it took a while for Falcon Heavy to get more launches
Recovery requirements pretty much require large changes, especially if you started out as an expendable design. (Like Falcon 9 had to have major changes to accommodate reuse) It's always going to be a question of economics and design.
Given that the vast majority are on paper it must be uneconomical to fly reusable stuff
As noted the RS-27 was based on the H1 engine design being essentially an H1 with manufacturing and performance 'tweaks' that were available with more modern technology and materials. The RS-27A and RS-56 was where major changes were being done. Actually leading the "RS-X" proposal of the 90s.
Nowadays we use better materials then the 60s, that testing has little bearing on the RS-27 or RS-56 due to the different materials and alloy's used, not to mention the computer systems wiring installed and other stuff that would get wrecked
As noted they managed this with the SSME and it's what SpaceX does with the Falcon 9 engines. They pull them for maintenance and inspection and pull some refurbished ones from storage if needed to meet the next flight goal.
In your own words the H-1 was completely dismantled and cleaned and HAD PARTS REPLACED, this is not similar to NASA and SpaceX doing inspections (without complete teardown) on SSME and Merlin
so far i know is RS-27 a modified H-1,
Chamber Pressure: 40.00 bar rised to 48 bar
this increase thrust and ISP compare to H-1
and Gasgenerator output is used to feed gimballed verniers for roll control.
The technology, alloys and stuff would make the engines different, expecially if the 56 gets made
Why they use glider ?
Since 1960s under ELDO were plans for Glider launch by Europa IV rocket.
CNES study next Hermes also under SOLARIS for manned capsule.
So far i know, CNES favour Hermes for landing on runway, either a launch site or in France.
because French Navy were unable to do recovery operation for manned capsule in ocean during that time.
Basically it sounds like the French were wanting it to be a french thing that flys ESA astronauts, while ESA wanted a ESA launcher

Given French involvment in all levels the astronaut roster would be prioritized for french astronauts, which would politically divide the other countries who might have an issue with using their tax dollars to fly another countries astronaut, unlike the US or Soviet Union where this wasn't an issue
It would never have flown, given the small size of the design its not suprising the weight became an issue, unlike Shuttle where the growth wasn't as much of an issue (remided easier)
 
Given that the vast majority are on paper it must be uneconomical to fly reusable stuff
The vast majority of all rockets ever designed were only on paper, so it's not a surprise that the vast majority of reusable rockets ever designed are also on paper, too.
 
Basically it sounds like the French were wanting it to be a french thing that flys ESA astronauts, while ESA wanted a ESA launcher
yes it exactly happen like this, since France was building Ariane rocket for ESA.
That also the reason with Hermes escalated, from simple glider to Mini space shuttle with cargo bay until 1985.
once the Russian offered Soyuz seats to ESA , the Europan Manned Spacecraft Program was dead...
currently offer now SpaceX seats or even entire crew Dragon for paying customer like: NASA, Inspiration4, AXIOM, ESA.
 
The vast majority of all rockets ever designed were only on paper, so it's not a surprise that the vast majority of reusable rockets ever designed are also on paper, too.
Ya, what i meant was that, the reusable designs wern't economical to develop in the first place due to high development costs and penatlies for weight
with the rest of designs it varies on practicality, Saturn Derivatives were too expensive with only limited use (NASA) as DoD wasn't interested, Modular Nova was a pipe dream
besides everybody has an idea, and 1 percent of those ideas are put on paper, while 99.999 percent of them don't see hardware made
Like Atlas V Heavy, it could work, just that the payloads heavy enough to need it flew on Delta-IV Heavy

yes it exactly happen like this, since France was building Ariane rocket for ESA.
That also the reason with Hermes escalated, from simple glider to Mini space shuttle with cargo bay until 1985.
once the Russian offered Soyuz seats to ESA , the Europan Manned Spacecraft Program was dead...
currently offer now SpaceX seats or even entire crew Dragon for paying customer like: NASA, Inspiration4, AXIOM, ESA.
To me it sounds like each side wanted to get the minority in costs while having the priority France wanting ESA to pay for part of it, while maintaining French Dominance, ESA wanted a European manned ship but with the costs shared with France

They wanted a cargo bay for various reasons, mostly bringing stuff to the Free Flyer, its late game redesigns that cost the most in weight, as you need to redesign a shitload but want to preserve completed work, it was such a small design and thats why weight was an issue

given ESA is by definition a international space coalition (or cooperative space alliance/coalition) cost splitting would always be wierd, some countries would want the goodies (payload space and astronaut seats) for little cost.
 
Ya, what i meant was that, the reusable designs wern't economical to develop in the first place due to high development costs and penatlies for weight
with the rest of designs it varies on practicality, Saturn Derivatives were too expensive with only limited use (NASA) as DoD wasn't interested, Modular Nova was a pipe dream
besides everybody has an idea, and 1 percent of those ideas are put on paper, while 99.999 percent of them don't see hardware made
Like Atlas V Heavy, it could work, just that the payloads heavy enough to need it flew on Delta-IV Heavy
There are hundreds if not thousands of never-funded or funded-to-study-and-never-built LVs out there. RLVs aren't special in 99% of them never being built, and high development cost isn't special to RLVs either.
 
Wow, a double win! Thanks to everyone who voted!

614918EF-C987-427E-B67E-E5925BACF4D4.png
 
There are hundreds if not thousands of never-funded or funded-to-study-and-never-built LVs out there. RLVs aren't special in 99% of them never being built, and high development cost isn't special to RLVs either.
What i was first referring to was reusable derivatives for FLOWN hardware, like Winged Atlas, the multitude of S-1C reuse ideas, the Space Shuttle reusable flyback LRB's and many, many other idea's
And specificially how uneconomical said conversions were for these rockets, on this site we tend to act like old concepts could work without a hitch and that obscure designs could have saved space travel etc. Randy's resusable H-1 has issues but has little bearing on the Delta II's RS-27 due to different materials, technology and techniques, and the reusable Saturn 1 stage would be a bitch to work on due to the clustered tank design

I know the hugely vast majority of launch vehicles are not built, same with planes and cars and and trillions of other things
 
To me it sounds like each side wanted to get the minority in costs while having the priority France wanting ESA to pay for part of it, while maintaining French Dominance, ESA wanted a European manned ship but with the costs shared with France
after fiasco of Europa Rocket and death of ELDO
France start the Ariane Project with 60% finance (40 % by Germany) under CNES and french companies using European parts
with success of Ariane 1-4, was France the only provider for Launch system to ESA in 1980s . (Italy Vega rocket and Russian Soyuz came much later)

ESA wanted bigger rocket for 1990s, CNES a launch vehicle for Manned mini Shuttle, so both came to agreement.
but Hermes ran into problems and got chancel in 1990s, while Ariane 5 got build and used until 2023...
 
There's a fascinating new piece from RussianSpaceWeb about the planned public announcement of the N-1/Groza system if it were successful:
Keeping this in mind, on Feb. 4, 1969, Yuri Mozhorin, Head of the press group within the State Commission overseeing the launch campaign, compiled a plan for public information releases for the N1 No. 3L launch, then expected on Feb. 21, 1969. The memo detailing the policy, complete with the drafts of official press releases, was sent to the Chairman of the State Commission Mstislav Keldysh on Feb. 9, 1969, just in time for its critical meeting authorizing the rollout of the first flight-worthy N1 to the pad.

Mozhorin noted that Soviet propaganda had already started a disinformation campaign aiming to convince the world that the USSR had prioritized Earth-orbiting stations over the lunar program: "...Due to delays of the N1-L3 program relative to the Apollo program and completed flights of Soyuz-3, Soyuz-4 and Soyuz-5 spacecraft, a certain political platform was formulated and successfully implemented through propaganda organs stressing, first of all, the consistent and even development of all Soviet space programs along different directions, and, second, the further development of the near-space exploration program with the help of large orbital stations," Mozhorin wrote.

The obvious conclusion was to camouflage the "Moon rocket" in similar "half-truths," so its public appearance would not contradict the newly constructed narrative and would give the USSR the option to completely deny its very participation in the Moon Race (as it would eventually happen).

The document advised avoiding any admission that a Moon rocket was in the works. "...The announcement about the development of a new powerful N1 launch vehicle in connection with the flight of the unpiloted L1A spacecraft is unadvisable, because it would be associated with the escalation of the Soviet lunar program," Mozhorin wrote, "...Therefore, it is unadvisable to tie ourselves to certain commitments especially because there were no materials in the open press about the (smaller) 8K82K launch vehicle (also developed for the Soviet lunar program)."

At the same time, Mozhorin proposed three variants of public statements depending on the level of success of the N1 launch, which would not be possible to hide once the rocket's huge payload reached Earth orbit, where it was expected to remain for at least one day.

Based on recent experience with the launches of the L1 circumlunar missions, announced as Zond, there was a chance that the first three booster stages of the N1 rocket would put its payload into an initial parking orbit around the Earth, but the Block G fourth stage would not succeed with inserting it into a trans-lunar trajectory.

Under these circumstances, Mozhorin proposed to issue an official communique on the second day of the flight, identifying the launch as that of a heavy Kosmos satellite intended to test a powerful launch vehicle for delivery of heavy scientific stations into the Earth's orbit and for sending large robotic probes toward the planets of the Solar System.

However, had the N1 succeed with inserting its payload on a trans-lunar trajectory, the Soviet press would have remained silent about the launch for the first two days of the flight, according to Mozhorin's proposal.

Once the nominal Moon-bound trajectory was confirmed, the launch of the Zond-7 mission would be announced using the official communique about the launch of the Zond-6 mission in November 1968 as a template. Further communiques would be issued after the successful lunar orbit insertion, another one after the successful trans-Earth trajectory insertion and, finally, the third one would be published after landing.

There was also a scenario, where the launch would miss the time window for "intercepting" the Moon and instead enter a highly elliptical orbit with an apogee (the farthest point) 500,000 kilometers from Earth, crossing the lunar orbit and turning back toward Earth in deep space. In this case, the Soviet press would also stay silent for two days, until the nominal deep-space trajectory had been confirmed. The subsequent official announcements would also identify the mission as the Zond-7 deep-space research flight and would be concluded with a post-landing communique. (1031)
I'm not sure if nixonhead was aware of these documents when he wrote the ITTL press release, but in any case he nailed it- the announcement of Zond 9 as a "research satellite" for "deep space science" is almost verbatim what the Soviets were planning to announce in OTL.
 
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