X-37B OTV-2 Landing (June 2012)

The Boeing X-37, also known as the Orbital Test Vehicle (OTV), is a reusable robotic spacecraft. It is boosted into space by a launch vehicle, then re-enters Earth's atmosphere and lands as a spaceplane. The X-37 is operated by the United States Space Force for orbital spaceflight missions intended to demonstrate reusable space technologies. It is a 120-percent-scaled derivative of the earlier Boeing X-40. The X-37 began as a NASA project in 1999, before being transferred to the United States Department of Defense in 2004. Until 2019, the program was managed by Air Force Space Command.

An X-37 first flew during a drop test in 2006; its first orbital mission was launched in April 2010 on an Atlas V rocket, and returned to Earth in December 2010. Subsequent flights gradually extended the mission duration, reaching in orbit for the fifth mission, the first to launch on a Falcon 9 rocket. The latest mission, the sixth, launched on an Atlas V on 17 May 2020 and concluded on 12 November 2022, reaching a total of 908 days in orbit.

Development

Origins

In 1999, NASA selected Boeing Integrated Defense Systems to design and develop an orbital vehicle, built by the California branch of Boeing's Phantom Works. Over a four-year period, a total of US$192 million was spent on the project, with NASA contributing US$109 million, the U.S. Air Force US$16 million, and Boeing US$67 million. In late 2002, a new US$301 million contract was awarded to Boeing as part of NASA's Space Launch Initiative framework.

The aerodynamic design of the X-37 was derived from the larger Space Shuttle orbiter, hence the X-37 has a similar lift-to-drag ratio, and a lower cross range at higher altitudes and Mach numbers compared to DARPA's Hypersonic Technology Vehicle. An early requirement for the spacecraft called for a total mission delta-v of for orbital maneuvers. An early goal for the program was for the X-37 to rendezvous with satellites and perform repairs. The X-37 was originally designed to be carried into orbit in the cargo bay of the Space Shuttle, but underwent redesign for launch on a Delta IV or comparable rocket after it was determined that a shuttle flight would be uneconomical.

The X-37 was transferred from NASA to the Defense Advanced Research Projects Agency (DARPA) on 13 September 2004. Thereafter, the program became a classified project. DARPA promoted the X-37 as part of the independent space policy that the United States Department of Defense has pursued since the 1986 ''Challenger'' disaster.

Glide testing

The X-37A vehicle that was used as an atmospheric drop test glider had no propulsion system. Instead of an operational vehicle's payload bay doors, it had an enclosed and reinforced upper fuselage structure to allow it to be mated with a mothership. In September 2004, DARPA announced that for its initial atmospheric drop tests the X-37A would be launched from the Scaled Composites White Knight, a high-altitude research aircraft.

On 21 June 2005, the X-37A completed a captive-carry flight underneath the White Knight from Mojave Spaceport in Mojave, California. Through the second half of 2005, the X-37A underwent structural upgrades, including the reinforcement of its nose wheel supports. The X-37A's public debut was scheduled for its first free flight on 10 March 2006, but was canceled due to an Arctic storm. The next flight attempt, on 15 March 2006, was canceled due to high winds.

On 24 March 2006, the X-37A flew again, but a datalink failure prevented a free flight, and the vehicle returned to the ground still attached to its White Knight carrier aircraft. On 7 April 2006, the X-37A made its first free glide flight. During landing, the vehicle overran the runway and sustained minor damage. Following the vehicle's extended downtime for repairs, the program moved from Mojave to Air Force Plant 42 (KPMD) in Palmdale, California, for the remainder of the flight test program. White Knight continued to be based at Mojave, though it was ferried to Plant 42 when test flights were scheduled. Five additional flights were performed,Source of flights: mission markings posted on side of White Knight aircraft. two of which resulted in X-37 releases with successful landings. These two free flights occurred on 18 August 2006 and 26 September 2006.

X-37B Orbital Test Vehicle

On 17 November 2006, the U.S. Air Force announced that it would develop its own variant from NASA's X-37A. The Air Force version was designated the X-37B Orbital Test Vehicle (OTV). The OTV program was built on earlier industry and government efforts by DARPA, NASA, and the Air Force under the leadership of the Air Force Rapid Capabilities Office in partnership with NASA and the Air Force Research Laboratory. Boeing was the prime contractor for the OTV program. The X-37B was designed to remain in orbit for up to 270 days at a time. The Secretary of the Air Force stated that the OTV program would focus on "risk reduction, experimentation, and operational concept development for reusable space vehicle technologies, in support of long-term developmental space objectives".

The X-37B was originally scheduled for launch in the payload bay of the Space Shuttle, but following the Space Shuttle ''Columbia'' disaster, it was transferred to a Delta II 7920. The X-37B was subsequently transferred to a shrouded configuration on the Atlas V rocket, following concerns over the unshrouded spacecraft's aerodynamic properties during launch. Following their missions, X-37B spacecraft primarily land on a runway at Vandenberg Air Force Base, California, with Edwards Air Force Base as a secondary site. In 2010, manufacturing work began on the second X-37B which conducted its maiden mission in March 2011.

On 8 October 2014, NASA confirmed that X-37B vehicles would be housed at Kennedy Space Center in Orbiter Processing Facilities (OPF) 1 and 2, hangars previously occupied by the Space Shuttle. Boeing had said the space planes would use OPF-1 in January 2014, and the Air Force had previously said it was considering consolidating X-37B operations, housed at Vandenberg Air Force Base in California, nearer to their launch site at Cape Canaveral. NASA also stated that the program had completed tests to determine whether the X-37B, one-fourth the size of the Space Shuttle, could land on the former Shuttle runways. NASA furthermore stated that renovations of the two hangars would be completed by the end of 2014; the main doors of OPF-1 were marked with the message "Home of the X-37B" by this point.

Most of the activities of the X-37B project are secret. The official U.S. Air Force statement is that the project is "an experimental test program to demonstrate technologies for a reliable, reusable, uncrewed space test platform for the U.S. Air Force". The primary objectives of the X-37B are twofold: reusable spacecraft technology and operating experiments which can be returned to Earth. The Air Force states that this includes testing avionics, flight systems, guidance and navigation, thermal protection, insulation, propulsion, and re-entry systems.

Speculation regarding purpose

In May 2010, Tom Burghardt speculated on ''Space Daily'' that the X-37B could be used as a spy satellite or to deliver weapons from space. The Pentagon subsequently denied claims that the X-37B's test missions supported the development of space-based weapons.

In January 2012, allegations were made that the X-37B was being used to spy on China's Tiangong-1 space station module. Former U.S. Air Force orbital analyst Brian Weeden later refuted this claim, emphasizing that the different orbits of the two spacecraft precluded any practical surveillance flybys.

In October 2014, ''The Guardian'' reported the claims of security experts that the X-37B was being used "to test reconnaissance and spy sensors, particularly how they hold up against radiation and other hazards of orbit".

In November 2016, the ''International Business Times'' speculated that the U.S. government was testing a version of the EmDrive electromagnetic microwave thruster on the fourth flight of the X-37B. In 2009, an EmDrive technology transfer contract with Boeing was undertaken via a State Department TAA and a UK export license, approved by the UK Ministry of Defence. Boeing has since stated that it is no longer pursuing this area of research. The U.S. Air Force has stated that the X-37B is testing a Hall-effect thruster system for Aerojet Rocketdyne.

In July 2019, former United States Secretary of the Air Force Heather Wilson explained that when an X-37B was in an elliptic orbit it could, at perigee, use the thin atmosphere to make an orbit change preventing some observers from discovering the new orbit for a while, permitting secret activities.

Astronomer Jonathan McDowell, editor of ''Jonathan's Space Report'', has stated that satellites launched from the X-37B were not reported, as required by the Registration Convention, to the United Nations Office for Outer Space Affairs so other parties to the convention would not know about them.

The Chinese Space Program landed its first reusable winged space plane on 6 September 2020. It was reported to weigh , and be long, i.e. closer to size of the X-37 than the space shuttle. Knowledgeable commentators speculated that the Chinese built their space plane to follow the US's X-37 example.

Processing

Processing for the X-37 is carried out inside Bays 1 and 2 of the Orbiter Processing Facility (OPF) at Kennedy Space Center in Florida, where the vehicle is loaded with its top-secret payload. The X-37 is then placed inside a fairing along with its stage adapter and transported to the launch site. Previous launch sites have included SLC-41 and Kennedy Space Center LC-39A.

Landing is done at one of three sites across the US: the Shuttle Landing Facility at Kennedy Space Center, Vandenberg Space Force Base, or Edwards Air Force Base. To return to Kennedy Space Center, the X-37 is placed into a payload canister and loaded into a Boeing C-17 cargo plane. Once at Kennedy, the X-37 is unloaded and towed to the OPF, where it is prepared for its next flight. Technicians must wear protective suits due to toxic hypergolic gases.

Design

The X-37 Orbital Test Vehicle is a reusable robotic spaceplane. It is an approximately 120-percent-scale derivative of the Boeing X-40, measuring over in length, and features two angled tail fins. The X-37 launches atop an Atlas V 501 or a SpaceX Falcon 9 rocket. The spaceplane is designed to operate in a speed range of up to Mach 25 on its reentry.

The technologies demonstrated in the X-37 include an improved thermal protection system, enhanced avionics, an autonomous guidance system and an advanced airframe. The spaceplane's thermal protection system is built upon previous generations of atmospheric reentry spacecraft, incorporating silica ceramic tiles. The X-37's avionics suite was used by Boeing to develop its CST-100