The J-2 is a
liquid-fuel cryogenic rocket engine
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 f ...
used on
NASA
The National Aeronautics and Space Administration (NASA ) is an independent agency of the US federal government responsible for the civil space program, aeronautics research, and space research.
NASA was established in 1958, succeeding t ...
's
Saturn IB
The Saturn IB (also known as the uprated Saturn I) was an American launch vehicle commissioned by the NASA, National Aeronautics and Space Administration (NASA) for the Apollo program. It uprated the Saturn I by replacing the S-IV second stage (, ...
and
Saturn V
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, with multistage rocket, three stages, and powered with liquid-propellant r ...
launch vehicles. Built in the U.S. by
Rocketdyne
Rocketdyne was an American rocket engine design and production company headquartered in Canoga Park, California, Canoga Park, in the western San Fernando Valley of suburban Los Angeles, California, Los Angeles, in southern California.
The Rocke ...
, the J-2 burned
cryogenic
In physics, cryogenics is the production and behaviour of materials at very low temperatures.
The 13th IIR International Congress of Refrigeration (held in Washington DC in 1971) endorsed a universal definition of “cryogenics” and “cr ...
liquid hydrogen
Liquid hydrogen (LH2 or LH2) is the liquid state of the element hydrogen. Hydrogen is found naturally in the molecular H2 form.
To exist as a liquid, H2 must be cooled below its critical point of 33 K. However, for it to be in a fully li ...
(LH2) and
liquid oxygen
Liquid oxygen—abbreviated LOx, LOX or Lox in the aerospace, submarine and gas industries—is the liquid form of molecular oxygen. It was used as the oxidizer in the first liquid-fueled rocket invented in 1926 by Robert H. Goddard, an applica ...
(LOX) propellants, with each engine producing of
thrust
Thrust is a reaction force described quantitatively by Newton's third law. When a system expels or accelerates mass in one direction, the accelerated mass will cause a force of equal magnitude but opposite direction to be applied to that syst ...
in vacuum. The engine's preliminary design dates back to recommendations of the 1959
Silverstein Committee The Saturn Vehicle Evaluation Committee, better known as the Silverstein Committee, was a US government commission assembled in 1959 to recommend specific directions that NASA could take with the Saturn rocket program. The committee was chaired by ...
. Rocketdyne won approval to develop the J-2 in June 1960 and the first flight,
AS-201
AS-201 (or SA-201), flown February 26, 1966, was the first uncrewed test flight of an entire production Block I Apollo command and service module and the Saturn IB launch vehicle. The spacecraft consisted of the second Block I command module ...
, 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
A de Laval nozzle (or convergent-divergent nozzle, CD nozzle or con-di nozzle) is a tube which is pinched in the middle, making a carefully balanced, asymmetric hourglass shape. It is used to accelerate a compressible fluid to supersonic speeds ...
-type J-2S and
aerospike-type J-2T, which were cancelled after the conclusion of the
Apollo program.
The engine produced a
specific impulse
Specific impulse (usually abbreviated ) is a measure of how efficiently a reaction mass engine (a rocket using propellant or a jet engine using fuel) creates thrust. For engines whose reaction mass is only the fuel they carry, specific impulse i ...
(''I''
sp) of in a vacuum (or at sea level) and had a mass of approximately . Five J-2 engines were used on the Saturn V's
S-II second stage, and one J-2 was used on the
S-IVB
The S-IVB (pronounced "S-four-B") was the third stage on the Saturn V and second stage on the Saturn IB launch vehicles. Built by the Douglas Aircraft Company, it had one J-2 (rocket engine), J-2 rocket engine. For lunar missions it was fired twi ...
upper stage used on both the Saturn IB and Saturn V. Proposals also existed to use various numbers of J-2 engines in the upper stages of an even larger rocket, the planned
Nova
A nova (plural novae or novas) is a transient astronomical event that causes the sudden appearance of a bright, apparently "new" star (hence the name "nova", which is Latin for "new") that slowly fades over weeks or months. Causes of the dramati ...
. The J-2 was America's largest production LH2-fuelled rocket engine before the
RS-25
The Aerojet Rocketdyne 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 currently used on the Space Launch System (SLS).
Designed and manufactu ...
. A modernized version of the engine, the
J-2X
The J-2X is a liquid-fueled cryogenic rocket engine that was planned for use on the Ares rockets of NASA's Constellation program, and later the Space Launch System. Built in the United States by Aerojet Rocketdyne (formerly, Pratt & Whitney Rocket ...
, was considered for use on the
Earth Departure Stage
The Earth Departure Stage (EDS) is the name given to the proposed second stage of the Block 2 Space Launch System. The EDS is intended to boost the rocket's payload into a parking orbit around the Earth and from there send the payload out of low ...
of NASA's
Space Shuttle
The Space Shuttle is a retired, partially reusable low Earth orbital spacecraft system operated from 1981 to 2011 by the U.S. National Aeronautics and Space Administration (NASA) as part of the Space Shuttle program. Its official program na ...
replacement, the
Space Launch System
The Space Launch System (SLS) is an American super heavy-lift expendable launch vehicle developed by NASA. As of 2022, SLS has the highest payload capacity of any rocket in operational service, as well as the greatest liftoff thrust of any r ...
.
Unlike most liquid-fueled rocket engines in service at the time, the J-2 was designed to be restarted once after shutdown when flown on the Saturn V
S-IVB
The S-IVB (pronounced "S-four-B") was the third stage on the Saturn V and second stage on the Saturn IB launch vehicles. Built by the Douglas Aircraft Company, it had one J-2 (rocket engine), J-2 rocket engine. For lunar missions it was fired twi ...
third stage. The first burn, lasting about two minutes, placed the Apollo spacecraft into a low Earth
parking orbit
A parking orbit is a temporary orbit used during the launch of a spacecraft. A launch vehicle boosts into the parking orbit, then coasts for a while, then fires again to enter the final desired trajectory. The alternative to a parking orbit is ''di ...
. After the crew verified that the spacecraft was operating nominally, the J-2 was re-ignited for
translunar injection
A trans-lunar injection (TLI) is a propulsive maneuver used to set a spacecraft on a trajectory that will cause it to arrive at the Moon.
History
The first space probe to attempt TLI was the Soviet Union's Luna 1 on January 2, 1959 which wa ...
, a 6.5 minute burn which accelerated the vehicle to a course for the Moon.
Components
Thrust chamber and gimbal system
The J-2's thrust chamber assembly served as a mount for all engine components, and was composed of the thrust chamber body, injector and dome assembly, gimbal bearing assembly, and augmented spark igniter.
The thrust chamber was constructed of thick
stainless steel
Stainless steel is an alloy of iron that is resistant to rusting and corrosion. It contains at least 11% chromium and may contain elements such as carbon, other nonmetals and metals to obtain other desired properties. Stainless steel's corros ...
tubes, stacked longitudinally and furnace-brazed to form a single unit. The chamber was bell-shaped with a 27.5:1 expansion area ratio for efficient operation at altitude, and was
regeneratively cooled by the fuel. Fuel entered from a
manifold
In mathematics, a manifold is a topological space that locally resembles Euclidean space near each point. More precisely, an n-dimensional manifold, or ''n-manifold'' for short, is a topological space with the property that each point has a n ...
, located midway between the thrust chamber throat and the exit, at a pressure of more than . In cooling the chamber, the fuel made a one-half pass downward through 180 tubes and was returned in a full pass up to the thrust chamber injector through 360 tubes. Once propellants passed through the injector, they were ignited by the augmented spark igniter and burned to impart a high velocity to the expelled combustion gases to produce thrust.
The thrust chamber injector received the propellants under pressure from the turbopumps, then mixed them in a manner that produced the most efficient combustion. 614 hollow oxidizer posts were machined to form an integral part of the injector, with fuel nozzles (each
swaged to the face of the injector) threaded through and installed over the oxidizer posts in concentric rings. The injector face was porous, being formed from layers of stainless steel wire mesh, and was welded at its periphery to the injector body. The injector received LOX through the dome manifold and injected it through the oxidizer posts into the combustion area of the thrust chamber, while fuel was received from the upper fuel manifold in the thrust chamber and injected through the fuel orifices which were concentric with the oxidizer orifices. The propellants were injected uniformly to ensure satisfactory combustion. The injector and oxidizer dome assembly was located at the top of the thrust chamber. The dome provided a manifold for the distribution of the LOX to the injector and served as a mount for the gimbal bearing and the augmented spark igniter.
The augmented spark igniter (ASI) was mounted to the injector face and provided the flame to ignite the propellants in the combustion chamber. When engine start was initiated, the spark exciters energized two
spark plug
A spark plug (sometimes, in British English, a sparking plug, and, colloquially, a plug) is a device for delivering electric current from an ignition system to the combustion chamber of a spark-ignition engine to ignite the compressed fuel/air ...
s mounted in the side of the combustion chamber. Simultaneously, the control system started the initial flow of oxidizer and fuel to the spark igniter. As the oxidizer and fuel entered the combustion chamber of the ASI, they mixed and were ignited, with proper ignition being monitored by an ignition monitor mounted in the ASI. The ASI operated continuously during entire engine firing, was uncooled, and was capable of multiple reignitions under all environmental conditions.
Thrust was transmitted through the gimbal (mounted to the injector and oxidizer dome assembly and the vehicle's thrust structure), which consisted of a compact, highly loaded () universal joint consisting of a spherical, socket-type bearing. This was covered with a Teflon/fiberglass coating that provided a dry, low-friction bearing surface. The gimbal included a lateral adjustment device for aligning the combustion chamber with the vehicle, so that, in addition to transmitting the thrust from the injector assembly to the vehicle thrust structure, the gimbal also provided a pivot bearing for deflection of the thrust vector, thus providing flight attitude control of the vehicle.
Propellant Feed System
The propellant feed system consists of separate fuel and oxidizer turbopumps (the bearings of which were lubricated by the fluid being pumped because the extremely low
operating temperature
An operating temperature is the allowable temperature range of the local ambient environment at which an electrical or mechanical device operates. The device will operate effectively within a specified temperature range which varies based on the de ...
of the engine precluded use of lubricants or other fluids), several valves (including the main fuel valve, main oxidizer valve, propellant utilization valve and fuel and oxidizer bleed valves), fuel and oxidizer flowmeters, and interconnecting lines.
Fuel turbopump
The fuel turbopump, mounted on the thrust chamber, was a turbine-driven, axial flow pumping unit consisting of an inducer, a seven-stage rotor, and a stator assembly. It was a high-speed pump operating at 27,000 rpm, and was designed to increase hydrogen pressure from (absolute) through high-pressure ducting at a flowrate which develops . Power for operating the turbopump was provided by a high-speed, two-stage turbine. Hot gas from the gas generator was routed to the turbine inlet manifold which distributed the gas to the inlet nozzles where it was expanded and directed at a high velocity into the first stage turbine wheel. After passing through the first stage turbine wheel, the gas was redirected through a ring of stator blades and enters the second stage turbine wheel. The gas left the turbine through the exhaust ducting. Three dynamic seals in series prevented the pump fluid and turbine gas from mixing. Power from the turbine was transmitted to the pump by means of a one-piece shaft.
Oxidizer turbopump
The oxidizer turbopump was mounted on the thrust chamber diametrically opposite the fuel turbopump. It was a single-stage
centrifugal pump
Centrifugal pumps are used to transport fluids by the conversion of rotational kinetic energy to the hydrodynamic energy of the fluid flow. The rotational energy typically comes from an engine or electric motor. They are a sub-class of dynamic ...
with
direct turbine drive. The oxidizer turbopump increases the pressure of the LOX and pumps it through high-pressure ducts to the thrust chamber. The pump operated at 8,600 rpm at a discharge pressure of (absolute) and developed . The pump and its two turbine wheels are mounted on a common shaft. Power for operating the oxidizer turbopump was provided by a high-speed, two-stage turbine which was driven by the exhaust gases from the gas generator. The turbines of the oxidizer and fuel turbopumps were connected in a series by exhaust ducting that directed the discharged exhaust gas from the fuel turbopump turbine to the inlet of the oxidizer turbopump turbine manifold. One static and two dynamic seals in series prevented the turbopump oxidizer fluid and turbine gas from mixing.
Beginning the turbopump operation, hot gas entered the nozzles and, in turn, the first stage turbine wheel. After passing through the first stage turbine wheel, the gas was redirected by the stator blades and entered the second stage turbine wheel. The gas then left the turbine through exhaust ducting, passed through the heat exchanger, and exhausted into the thrust chamber through a manifold directly above the fuel inlet manifold. Power from the turbine was transmitted by means of a one-piece shaft to the pump. The velocity of the LOX was increased through the inducer and impeller. As the LOX entered the outlet volute, velocity was converted to pressure and the LOX was discharged into the outlet duct at high pressure.
Fuel and oxidizer flowmeters
The fuel and oxidizer flowmeters were helical-vaned, rotor-type flowmeters. They were located in the fuel and oxidizer high-pressure ducts. The flowmeters measured propellant flowrates in the high-pressure propellant ducts. The four-vane rotor in the hydrogen system produced four electrical impulses per revolution and turned approximately 3,700 rpm at nominal flow. The six-vane rotor in the LOX system produced six electrical impulses per revolution and turned at approximately 2,600 rpm at nominal flow.
Valves
The propellant feed system required a number of valves to control the operation of the engine by changing the flow of propellant through the engine's components:
*The main fuel valve was a butterfly-type valve, spring-loaded to the closed position, pneumatically operated to the open position, and pneumatically assisted to the closed position. It was mounted between the fuel high-pressure duct from the fuel turbopump and the fuel inlet manifold of the thrust chamber assembly. The main fuel valve controlled the flow of fuel to the thrust chamber. Pressure from the ignition stage control valve on the pneumatic control package opened the valve during engine start and, as the gate started to open, it allowed fuel to flow to the fuel inlet manifold.
*The main oxidizer valve (MOV) was a butterfly-type valve, spring-loaded to the closed position, pneumatically operated to the open position, and pneumatically assisted to the closed position. It was mounted between the oxidizer high-pressure duct from the oxidizer turbopump and the oxidizer inlet on the thrust chamber assembly. Pneumatic pressure from the normally closed port of the mainstage control solenoid valve was routed to both the first and second stage opening actuators of the main oxidizer valve. Application of opening pressure in this manner, together with controlled venting of the main oxidizer valve closing pressure through a thermal-compensating orifice, provided a controlled ramp opening of the main oxidizer valve through all temperature ranges. A sequence valve, located within the MOV assembly, supplied pneumatic pressure to the opening control part of the gas generator control valve and through an orifice to the closing part of the oxidizer turbine bypass valve.
*The propellant utilization (PU) valve was an electrically operated, two-phase, motor-driven, oxidizer transfer valve and is located at the oxidizer turbopump outlet
volute
A volute is a spiral, scroll-like ornament that forms the basis of the Ionic order, found in the capital of the Ionic column. It was later incorporated into Corinthian order and Composite column capitals. Four are normally to be found on an Ion ...
. The propellant utilization valve ensured the simultaneous exhaustion of the contents of the propellant tanks. During engine operation, propellant level sensing devices in the vehicle propellant tanks controlled the valve gate position for adjusting the oxidizer flow to ensure simultaneous exhaustion of fuel and oxidizer.
:*An additional function of the PU Valve was to provide thrust variations in order to maximize payload. The second stage, for example, operated with the PU valve in the closed position for more than 70% of the firing duration. This valve position provided of thrust at a 5.5:1 propellant (oxidizer to fuel by weight) mixture ratio (when the PU valve was fully open, the mixture ratio was 4.5:1 and the thrust level was ), though with a higher specific impulse due to more unburned hydrogen in the exhaust. During the latter portion of the flight, the PU valve position was varied to provide simultaneous emptying of the propellant tanks. The third stage also operated at the high-thrust level for the majority of the burning time in order to realize the high thrust benefits. The exact period of time at which the engine operated with the PU valve closed varied with individual mission requirements and propellant tanking levels.
*The propellant bleed valves used in both the fuel and oxidizer systems were poppet-type, which were spring-loaded to the normally open position and pressure-actuated to the closed position. Both propellant bleed valves were mounted to the bootstrap lines adjacent to their respective turbopump discharge flanges. The valves allowed propellant to circulate in the propellant feed system lines to achieve proper operating temperature prior to engine start, and were engine controlled. At engine start, a helium control solenoid valve in the pneumatic control package was energized allowing pneumatic pressure to close the bleed valves, which remained closed during engine operation.
Gas generator and exhaust system
The gas generator system consisted of the gas generator, gas generator control valve, turbine exhaust system and exhaust manifold, heat exchanger, and oxidizer turbine bypass valve.
Gas generator
The gas generator itself was welded to the fuel pump turbine manifold, making it an integral part of the fuel turbopump assembly. It produced hot gases to drive the fuel and oxidizer turbines and consisted of a combustor containing two spark plugs, a control valve containing fuel and oxidizer ports, and an injector assembly. When engine start was initiated, the spark exciters in the electrical control package were energized, providing energy to the spark plugs in the gas generator combustor. Propellants flowed through the control valve to the injector assembly and into the combustor outlet, before being directed to the fuel turbine and then to the oxidizer turbine.
Valves
*The gas generator control valve was a pneumatically operated poppet-type that was spring-loaded to the closed position. The fuel and oxidizer poppets were mechanically linked by an actuator. The valve controlled the flow of propellants through the gas generator injector. When the mainstage signal was received, pneumatic pressure was applied against the gas generator control valve actuator assembly which moved the piston and opened the fuel poppet. During the fuel poppet opening, an actuator contacted the piston that opened the oxidizer poppet. As the opening pneumatic pressure decayed, spring loads closed the poppets.
*The oxidizer turbine bypass valve was a normally open, spring-loaded, gate type valve. It was mounted in the oxidizer turbine bypass duct and equipped with a nozzle, the size of which was determined during engine calibration. The valve in its open position depressed the speed of the oxygen pump during start, and in its closed position acted as a calibration device for the turbopump performance balance.
Turbine exhaust system
The turbine exhaust ducting and turbine exhaust hoods were of welded sheet metal construction. Flanges utilizing dual seals were used at component connections. The exhaust ducting conducted turbine exhaust gases to the thrust chamber exhaust manifold which encircled the combustion chamber approximately halfway between the throat and the nozzle exit. Exhaust gases passed through the heat exchanger and exhaust into the main combustion chamber through 180 triangular openings between the tubes of the combustion chamber.
Heat exchanger
The heat exchanger was a shell assembly, consisting of a duct, bellows, flanges, and coils. It was mounted in the turbine exhaust duct between the oxidizer turbine discharge manifold and the thrust chamber. It heated and expanded helium gas for use in the third stage or converted LOX to gaseous oxygen for the second stage for maintaining vehicle oxidizer tank pressurization. During engine operation, either LOX was tapped off the oxidizer high-pressure duct or helium was provided from the vehicle stage and routed to the heat exchanger coils.
Start tank assembly system
This system was made up of an integral helium and hydrogen start tank, which contained the hydrogen and helium gases for starting and operating the engine. The gaseous hydrogen imparted initial spin to the turbines and pumps prior to gas generator combustion, and the helium was used in the control system to sequence the engine valves. The spherical helium tank was positioned inside the hydrogen tank to minimize engine complexity. It held of helium. The larger spherical hydrogen gas tank had a capacity of . Both tanks were filled from a ground source prior to launch and the gaseous hydrogen tank was refilled during engine operation from the thrust chamber fuel inlet manifold for subsequent restart in third stage application.
Control system
The control system included a pneumatic system and a solid-state electrical sequence controller packaged with spark exciters for the gas generator and the thrust chamber spark plugs, plus interconnecting electrical cabling and pneumatic lines, in addition to the flight instrumentation system. The pneumatic system consisted of a high-pressure helium gas storage tank, a regulator to reduce the pressure to a usable level, and electrical solenoid control valves to direct the central gas to the various pneumatically controlled valves. The electrical sequence controller was a completely self-contained, solid-state system, requiring only DC power and start and stop command signals. Pre-start status of all critical engine control functions was monitored in order to provide an "engine ready" signal. Upon obtaining "engine ready" and "start" signals, solenoid control valves were energized in a precisely timed sequence to bring the engine through ignition, transition, and into main-stage operation. After shutdown, the system automatically reset for a subsequent restart.
Flight instrumentation system
The flight instrumentation system is composed of a primary instrumentation package and an auxiliary package. The primary package instrumentation measures those parameters critical to all engine static firings and subsequent vehicle launches. These include some 70 parameters such as pressures, temperatures, flows, speeds, and valve positions for the engine components, with the capability of transmitting signals to a ground recording system or a telemetry system, or both. The instrumentation system is designed for use throughout the life of the engine, from the first static acceptance firing to its ultimate vehicle flight. The auxiliary package is designed for use during early vehicle flights. It may be deleted from the basic engine instrumentation system after the propulsion system has established its reliability during research and development vehicle flights. It contains sufficient flexibility to provide for deletion, substitution, or addition of parameters deemed necessary as a result of additional testing. Eventual deletion of the auxiliary package will not interfere with the measurement capability of the primary package.
Engine operation
Start sequence
Start sequence was initiated by supplying energy to two spark plugs in the gas generator and two in the augmented spark igniter for ignition of the propellants. Next, two solenoid valves were actuated; one for helium control, and one for ignition phase control. Helium was routed to hold the propellant bleed valves closed and to purge the thrust chamber LOX dome, the LOX pump intermediate seal, and the gas generator oxidizer passage. In addition, the main fuel and ASI oxidizer valves were opened, creating an ignition flame in the ASI chamber that passed through the center of the thrust chamber injector.
After a delay of 1, 3, or 8 seconds, during which time fuel was circulated through the thrust chamber to condition the engine for start, the start tank discharge valve was opened to initiate turbine spin. The length of the fuel lead was dependent upon the length of the Saturn V first stage boost phase. When the engine was used in the S-II stage, a 1-second fuel lead was necessary. The S-IVB, on the other hand, utilized a 1-second fuel lead for its initial start and an 8-second fuel lead for its restart.
After an interval of 0.450 seconds, the start tank discharge valve was closed and a mainstage control solenoid was actuated to:
#Turn off gas generator and thrust chamber helium purges
#Open the gas generator control valve (hot gases from the gas generator now drive the pump turbines)
#Open the main oxidizer valve to the first position (14 degrees) allowing LOX to flow to the LOX dome to burn with the fuel that has been circulating through the injector
#Close the oxidizer turbine bypass valve (a portion of the gases for driving the oxidizer turbopump were bypassed during the ignition phase)
#Gradually bleed the pressure from the closing side of the oxidizer valve pneumatic actuator controlling the slow opening of this valve for smooth transition into mainstage.
Energy in the spark plugs was cut off and the engine was operating at rated thrust. During the initial phase of engine operation, the gaseous hydrogen start tank would be recharged in those engines having a restart requirement. The hydrogen tank was repressurized by tapping off a controlled mixture of LH2 from the thrust chamber fuel inlet manifold and warmer hydrogen from the thrust chamber fuel injection manifold just before entering the injector.
Flight mainstage operation
During mainstage operation, engine thrust could be varied between by actuating the propellant utilization valve to increase or decrease oxidizer flow. This was beneficial to flight trajectories and for overall mission performance to make greater payloads possible.
Cutoff sequence
When the engine cutoff signal was received by the electrical control package, it de-energized the main-stage and ignition phase solenoid valves and energized the helium control solenoid de-energizer timer. This, in turn, permitted closing pressure to the main fuel, main oxidizer, gas generator control, and augmented spark igniter valves. The oxidizer turbine bypass valve and propellant bleed valves opened and the gas generator and LOX dome purges were initiated.
Engine restart
To provide third stage restart capability for the Saturn V, the J-2 gaseous hydrogen start tank was refilled in 60 seconds during the previous firing after the engine had reached steady-state operation (refill of the gaseous helium tank was not required because the original ground-fill supply was sufficient for three starts). Prior to engine restart, the stage
ullage
Ullage or headspace is the unfilled space in a container, particularly with a liquid.
Etymology
The word ''ullage'' comes from the Latin word ''oculus'', used by the Romans to refer to a barrel cork hole. This word was, in turn, taken in medieval ...
rockets were fired to settle the propellants in the stage propellant tanks, ensuring a liquid head to the turbopump inlets. In addition, the engine propellant bleed valves were opened, the stage recirculation valve was opened, the stage prevalve was closed, and a LOX and LH
2 circulation was effected through the engine bleed system for five minutes to condition the engine to the proper temperature to ensure proper engine operation. Engine restart was initiated after the "engine ready" signal was received from the stage. This was similar to the initial "engine ready". The hold time between cutoff and restart was from a minimum of 1.5 hours to a maximum of 6 hours, depending upon the number of Earth orbits required to attain the lunar window for translunar trajectory.
History
Development
Inspiration for the J-2 dates back to various NASA studies conducted in the late 1950s, of LH2-fuelled engines producing thrust of up to following the success of the
RL-10
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 of thrust per engine in vacuum. Three RL10 ve ...
used on the
Atlas-Centaur
The Atlas-Centaur was a United States expendable launch vehicle derived from the SM-65 Atlas D missile. Launches were conducted from Launch Complex 36 at the Cape Canaveral Air Force Station (CCAFS) in Florida.
Early development
Convair, ...
's
Centaur
A centaur ( ; grc, κένταυρος, kéntauros; ), or occasionally hippocentaur, is a creature from Greek mythology with the upper body of a human and the lower body and legs of a horse.
Centaurs are thought of in many Greek myths as being ...
upper stage. As ever-heavier launch vehicles entered consideration, NASA began to look at engines producing thrusts of up to , with development being officially authorized following the 1959 report of the
Saturn Vehicle Evaluation Committee. A source evaluation board was formed to nominate a contractor from five bidding companies, and approval was given on 1 June 1960 for
Rocketdyne
Rocketdyne was an American rocket engine design and production company headquartered in Canoga Park, California, Canoga Park, in the western San Fernando Valley of suburban Los Angeles, California, Los Angeles, in southern California.
The Rocke ...
to begin development of a "high-energy rocket engine, fuelled by LOX and hydrogen, to be known as the J-2". The final contract, awarded in September 1960, was the first to explicitly require the design "insure maximum safety for
crewed flight."
Rocketdyne launched the development of the J-2 with an analytical computer model that simulated engine operations and aided in establishing design configurations. The model was supported by a full-sized mockup which was used throughout development to judge the positioning of the engine's components. The first experimental component, the engine's
injector
An injector is a system of ducting and nozzles used to direct the flow of a high-pressure fluid in such a way that a lower pressure fluid is entrained in the jet and carried through a duct to a region of higher pressure. It is a fluid-dynamic ...
, was produced within two months of the contract being awarded, and testing of the engine's components began at Rocketdyne's
Santa Susana Field Laboratory
The Santa Susana Field Laboratory (SSFL), formerly known as Rocketdyne, is a complex of industrial research and development facilities located on a portion of Southern California in an unincorporated area of Ventura County in the Simi Hills betw ...
in November 1960. Other test facilities, including a vacuum chamber and full-size engine test stand, were used during the development, with the engine's
turbopump
A turbopump is a propellant pump with two main components: a rotodynamic pump and a driving gas turbine, usually both mounted on the same shaft, or sometimes geared together. They were initially developed in Germany in the early 1940s. The purpos ...
s entering testing in November 1961, the ignition system in early 1962, and the first prototype engine running a complete 250-second test run in October 1962. In addition to flight hardware, five engine simulators were also used during the development process, assisting in the design of the engine's electrical and mechanical systems. Contracts were signed between NASA and Rocketdyne in the summer of 1962, requiring 55 J-2 engines to be produced to support the final designs for the
Saturn rockets, which required five engines for each
S-II second stage of the
Saturn V
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, with multistage rocket, three stages, and powered with liquid-propellant r ...
and one engine for each
S-IVB
The S-IVB (pronounced "S-four-B") was the third stage on the Saturn V and second stage on the Saturn IB launch vehicles. Built by the Douglas Aircraft Company, it had one J-2 (rocket engine), J-2 rocket engine. For lunar missions it was fired twi ...
Saturn IB
The Saturn IB (also known as the uprated Saturn I) was an American launch vehicle commissioned by the NASA, National Aeronautics and Space Administration (NASA) for the Apollo program. It uprated the Saturn I by replacing the S-IV second stage (, ...
and Saturn V third stage.
The J-2 entered production in May 1963, with concurrent testing programs continuing to run at Rocketdyne and at
MSFC during the manufacturing run. The first production engine, delivered in April 1964, went for static tests on the S-IVB test stage at the
Douglas
Douglas may refer to:
People
* Douglas (given name)
* Douglas (surname)
Animals
*Douglas (parrot), macaw that starred as the parrot ''Rosalinda'' in Pippi Longstocking
*Douglas the camel, a camel in the Confederate Army in the American Civil W ...
test facility near Sacramento, California and underwent its first full-duration (410 seconds) static test in December 1964. Testing continued until January 1966, with one engine in particular igniting successfully in 30 successive firings, including five tests at full duration of 470 seconds each. The total firing time of 3774 seconds represented a level of accumulated operational time almost eight times greater than the flight requirements. As successful single-engine tests moved toward their completion, integration tests of the propulsion system with the S-IVB accelerated with the availability of more production engines. The first operational flight,
AS-201
AS-201 (or SA-201), flown February 26, 1966, was the first uncrewed test flight of an entire production Block I Apollo command and service module and the Saturn IB launch vehicle. The spacecraft consisted of the second Block I command module ...
, was scheduled in early 1966 for the Saturn IB using the S-IB first stage and the S-IVB as the second stage.
The first all-up test of a complete S-IVB, including its single J-2, in July 1965 was inconclusive when a component malfunction in one of the pneumatic consoles prematurely ended the test after a successful propellant loading and automatic countdown. Confidence in the design was regained in August, however, when the same stage, S-IVB-201, performed flawlessly on a full-duration firing of 452 seconds, which was the first engine test sequence to be controlled entirely by computers. The J-2 was cleared for flight and, on 26 February 1966, AS-201 went through a flawless launch.
In July 1966, NASA confirmed J-2 production contracts through 1968, by which time Rocketdyne agreed to finish deliveries of 155 J-2 engines, with each engine undergoing a flight qualification firing at the Santa Susana Field Laboratory before delivery to NASA. Reliability and development testing continued on the engine, with two uprated versions being used by NASA in the later flights of the Apollo program.
Upgrades
J-2S
An experimental program to improve the performance of the J-2 started in 1964 as the J-2X (not to be confused with a
later variant by the same name). The main change to the original J-2 design was a change from the
gas generator cycle to a
tap-off cycle
The combustion tap-off cycle is a power cycle of a bipropellant rocket engine. The cycle takes a small portion of hot exhaust gas from the rocket engine's combustion chamber and routes it through turbopump turbines to pump fuel before being exhaus ...
that supplied hot gas from a tap on the combustion chamber instead of a separate burner. In addition to removing parts from the engine, it also reduced the difficulty of starting up the engine and properly timing various combustors.
Additional changes included a throttling system for wider mission flexibility, which also required a variable mixture system to properly mix the fuel and oxygen for a variety of different operating pressures. It also included a new "Idle Mode" that produced little thrust for on-orbit maneuvering or to settle the fuel tanks on-orbit prior to a burn.
During the experimental program, Rocketdyne also produced a small run of six pre-production models for testing, the J-2S. These were test fired many times between 1965 and 1972, for a total of 30,858 seconds burn time. In 1972 it became clear no follow-on orders for Saturn boosters were coming, and the program shut down. NASA did consider using the J-2S on a number of different missions, including powering the
Space Shuttle
The Space Shuttle is a retired, partially reusable low Earth orbital spacecraft system operated from 1981 to 2011 by the U.S. National Aeronautics and Space Administration (NASA) as part of the Space Shuttle program. Its official program na ...
in a number of early designs as well as on the
Comet HLLV.
J-2T
While work on the J-2S continued, NASA also funded a design effort to use the J-2S turbomachinery and plumbing to a
toroid
In mathematics, a toroid is a surface of revolution with a hole in the middle. The axis of revolution passes through the hole and so does not intersect the surface. For example, when a rectangle is rotated around an axis parallel to one of its ...
al combustion chamber with a new
aerospike nozzle. This would improve performance even further. Two versions were built, the J-2T-200k that provided thrust,
allowing it to be "dropped in" to the existing S-II and S-IVB stages, and the J-2T-250k of .
Like the J-2S, work on the J-2T had progressed to a lengthy series of ground-based test runs, but further development ended in the post-Apollo draw-down.
J-2X
What became a different engine with a similar name, called the J-2X,
was chosen in 2007 for the
Project Constellation
The Constellation program (abbreviated CxP) was a crewed spaceflight program developed by NASA, the space agency of the United States, from 2005 to 2009. The major goals of the program were "completion of the International Space Station" and a ...
crewed lunar landing program. A single J-2X engine, generating of thrust, was to be used to power the
Earth Departure Stage
The Earth Departure Stage (EDS) is the name given to the proposed second stage of the Block 2 Space Launch System. The EDS is intended to boost the rocket's payload into a parking orbit around the Earth and from there send the payload out of low ...
(EDS).
NASA began construction of a new test stand for altitude testing of J-2X engines at
Stennis Space Center (SSC) on 23 August 2007. Between December 2007 and May 2008, nine tests of heritage J-2 engine components were conducted at SSC in preparation for the design of the J-2X engine.
The new J-2X is designed to be more efficient and simpler to build than its Apollo J-2 predecessor, and cost less than the
Space Shuttle Main Engine
The Aerojet Rocketdyne 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 currently used on the Space Launch System (SLS).
Designed and manufacture ...
(SSME).
Design differences include the removal of
beryllium
Beryllium is a chemical element with the symbol Be and atomic number 4. It is a steel-gray, strong, lightweight and brittle alkaline earth metal. It is a divalent element that occurs naturally only in combination with other elements to form mi ...
, modern electronics, a centrifugal turbo pump versus the axial turbo pump of the J-2, a different chamber and nozzle expansion ratios, a channel-walled combustion chamber versus the tube-welded chamber of the J-2, a redesign of all the electronics, supersonic injection and the use of 21st-century joining techniques.
On July 16, 2007
NASA
The National Aeronautics and Space Administration (NASA ) is an independent agency of the US federal government responsible for the civil space program, aeronautics research, and space research.
NASA was established in 1958, succeeding t ...
officially announced the award to
Pratt & Whitney Rocketdyne
Pratt & Whitney Rocketdyne (PWR) was an American company that designed and produced rocket engines that use liquid rocket propellants, liquid propellants. It was a division of Pratt & Whitney, a fully owned subsidiary of United Technologies Corpo ...
, Inc. of a $1.2 billion contract "for design, development, testing and evaluation of the J-2X engine" intended to power the upper stages of the
Ares I
Ares I was the crew launch vehicle that was being developed by NASA as part of the Constellation program. The name "Ares" refers to the Greek deity Ares, who is identified with the Roman god Mars. Ares I was originally known as the "Crew Launch ...
and
Ares V
The Ares V (formerly known as the Cargo Launch Vehicle or CaLV) was the planned cargo launch component of the cancelled NASA Constellation program, which was to have replaced the Space Shuttle after its retirement in 2011. Ares V was also plan ...
launch vehicles. On Sept. 8, 2008 Pratt & Whitney Rocketdyne announced successful testing of the initial J-2X gas generator design. The completion of a second round of successful gas generator tests was announced on September 21, 2010.
Project Constellation was cancelled by President
Barack Obama
Barack Hussein Obama II ( ; born August 4, 1961) is an American politician who served as the 44th president of the United States from 2009 to 2017. A member of the Democratic Party, Obama was the first African-American president of the U ...
on October 11, 2010, but development of the J-2X has continued for its potential as the second stage engine for the new, heavy-lift
Space Launch System
The Space Launch System (SLS) is an American super heavy-lift expendable launch vehicle developed by NASA. As of 2022, SLS has the highest payload capacity of any rocket in operational service, as well as the greatest liftoff thrust of any r ...
. The first hot-fire test of the J-2X was scheduled for late June, 2011.
On November 9, 2011
NASA
The National Aeronautics and Space Administration (NASA ) is an independent agency of the US federal government responsible for the civil space program, aeronautics research, and space research.
NASA was established in 1958, succeeding t ...
conducted a successful firing of the J-2X engine of 499.97 seconds in duration.
On February 27, 2013
NASA
The National Aeronautics and Space Administration (NASA ) is an independent agency of the US federal government responsible for the civil space program, aeronautics research, and space research.
NASA was established in 1958, succeeding t ...
continued testing of the J-2X engine of 550 seconds in duration at NASA's Stennis Space Center.
Image:J-2X concept image June 2006.png, Concept image of the J-2X engine.
Image:Test of the J-2X Engine.JPG, Test of the J-2X engine 'workhorse' gas generator.
Image:NASA's J-2X Engine.jpg, Cold Flow nozzle testing for the J2X program.
Specifications
See also
*
Comparison of orbital rocket engines
References
;Manuals
Technical Manual R-3825-1: Engine Data J-2 Rocket EngineTechnical Manual R-3825-1B: Operating Instructions J-2 Rocket EngineTechnical Manual R-3825-3 Volume I: Maintenance And Repair J-2 Rocket EngineTechnical Manual R-3825-3 Volume II: Maintenance and Repair J-2 Rocket EngineTechnical Manual R-3825-4: Illustrated Parts Breakdown J-2 Rocket EngineTechnical Manual R-3825-5 Volume I: Ground Support Equipment and Repair J-2 Rocket EngineTechnical Manual R-3825-5 Volume II: Ground Support Equipment Maintenance and Repair J-2 Rocket EngineTechnical Manual R-3825-8: Operation And Maintenance Components Handler Equipment J-2 Rocket Engine
{{DEFAULTSORT:J-2 (Rocket Engine)
Rocket engines using hydrogen propellant
Rocketdyne engines
North American Aviation
Apollo program hardware
Rocket engines using the gas-generator cycle
Rocket engines of the United States