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A Review of United States Air Force and Department of Defense Aerospace Propulsion Needs
A REVIEW OF UNITED STATES AIR FORCE and DEPARTMENT OF DEFENSE Aerospace Propulsion Needs
Committee on Air Force and Department of Defense Aerospace Propulsion Needs
Air Force Studies Board
Division on Engineering and Physical Sciences
NATIONAL RESEARCH COUNCIL OF THE NATIONAL ACADEMIES
THE NATIONAL ACADEMIES PRESS
Washington, D.C.
www.nap.edu
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A Review of United States Air Force and Department of Defense Aerospace Propulsion Needs
THE NATIONAL ACADEMIES PRESS
500 Fifth Street, N.W. Washington, DC 20001
NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The members of the committee responsible for the report were chosen for their special competencies and with regard for appropriate balance.
This is a report of work supported by Grant F49620-01-1-0269 between the U.S. Air Force and the National Academy of Sciences. Any opinions, findings, conclusions, or recommendations expressed in this publication are those of the author(s) and do not necessarily reflect the view of the organizations or agencies that provided support for the project.
International Standard Book Number-10 0-309-10247-2
International Standard Book Number-13 978-0-309-10247-6
Limited copies are available from:
Air Force Studies Board
National Research Council
500 Fifth Street, N.W.
Washington, DC 20001
(202) 334-3111
Additional copies are available from:
The National Academies Press
Box 285 500 Fifth Street, N.W. Washington, DC 20055 (800) 624-6242 or (202) 334-3313 (in the Washington Metropolitan Area) http://www.nap.edu
Copyright 2006 by the National Academy of Sciences. All rights reserved.
Printed in the United States of America
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A Review of United States Air Force and Department of Defense Aerospace Propulsion Needs
THE NATIONAL ACADEMIES
Advisers to the Nation on Science, Engineering, and Medicine
The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished scholars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. Upon the authority of the charter granted to it by the Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and technical matters. Dr. Ralph J. Cicerone is president of the National Academy of Sciences.
The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advising the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achievements of engineers. Dr. Wm. A. Wulf is president of the National Academy of Engineering.
The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an adviser to the federal government and, upon its own initiative, to identify issues of medical care, research, and education. Dr. Harvey V. Fineberg is president of the Institute of Medicine.
The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy’s purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The Council is administered jointly by both Academies and the Institute of Medicine. Dr. Ralph J. Cicerone and Dr. Wm. A. Wulf are chair and vice chair, respectively, of the National Research Council.
www.national-academies.org
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A Review of United States Air Force and Department of Defense Aerospace Propulsion Needs
COMMITTEE ON AIR FORCE AND DEPARTMENT OF DEFENSE AEROSPACE PROPULSION NEEDS
KENNETH E. EIC KMANN, Chair,
U.S. Air Force (retired)
DONALD W. BAHR, Independent Consultant
DILIP R. BALLAL,
University of Dayton, Ohio
YVONNE C. BRILL, Independent Consultant
DENNIS M. BUSHNELL,
NASA Langley Research Center
PAUL G.A. CIZMAS,
Texas A&M University
CHARLES H. COOLIDGE,
EADS North America Defense Company
DAVID E. CROW,
University of Connecticut
THOMAS W. EAGAR,
Massachusetts Institute of Technology
GERARD W. ELVERUM, Independent Consultant
CARL E. FRANKLIN,
International Falcon Associates, Inc.
FRANK C. GILLETTE, Independent Consultant
EDWARD M. GREITZER,
Massachusetts Institute of Technology
JEFFREY W. HAMSTRA,
Lockheed Martin Aeronautics Company
BERNARD L. KOFF,
TurboVision
MITSURU KUROSAKA,
University of Washington, Seattle
D. BRIAN LANDRUM,
University of Alabama, Huntsville
IVETT A. LEYVA,
Microcosm, Inc.*
LOURDES Q. MAURICE,
Federal Aviation Administration
NEIL E. PATON,
Liquidmetal Technologies
LAWRENCE P. QUINN,
Aerojet
ELI RESHOTKO,
Case Western Reserve University (emeritus)
KENNETH M. ROSEN,
General Aero-Science Consultants, LLC
ROBERT L. SACKHEIM,
NASA George C. Marshall Space Flight Center**
BEN T. ZINN,
Georgia Institute of Technology, Atlanta
Staff
JAMES C. GARCIA, Study Director
DANIEL E.J. TALMAGE, JR., Program Officer
CARTER W. FORD, Research Associate
WILLIAM E. CAMPBELL, Senior Program Associate
LaNITA R. JONES, Senior Program Assistant
LINDA D. VOSS, Technical Writer
*
Affiliation to April 6, 2006.
**
Affiliation to May 5, 2006.
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A Review of United States Air Force and Department of Defense Aerospace Propulsion Needs
AIR FORCE STUDIES BOARD
LAWRENCE J. DELANEY, Chair, Independent Consultant
R. NOEL LONGUEMARE, Vice Chair, Independent Consultant
FRANK J. CAPPUCCIO,
Lockheed Martin Aeronautics Company
THOMAS DARCY, EADS
North America Defense Company
STEVEN D. DORFMAN,
Air Force (retired)
PAMELA A. DREW,
Boeing Integrated Defense Systems
KENNETH E. EICKMANN, Independent Consultant
JOHN V. FARR,
Stevens Institute of Technology
RAND H. FISHER,
Titan Corporation
JACQUELINE GISH,
Northrop Grumman Corporation
KENNETH C. HALL,
Duke University
WESLEY L. HARRIS,
Massachusetts Institute of Technology
LESLIE KENNE,
LK Associates
DONALD J. KUTYNA, Independent Consultant
TAYLOR W. LAWRENCE,
Raytheon Company
GREGORY S. MARTIN,
GS Martin Consulting
DEBASIS MITRA,
Bell Laboratories
CHANDRA N. KUMAR PATEL,
University of California, Los Angeles
RICHARD R. PAUL,
The Boeing Company
ROBERT F. RAGGIO,
Dayton Aerospace, Inc.
GENE W. RAY,
GMT Ventures
ELI RESHOTKO,
Case Western Reserve University (emeritus)
LOURDES SALAMANCA-RIBA,
University of Maryland, College Park
MARVIN R. SAMBUR, Independent Consultant
LYLE H. SCHWARTZ, Independent Consultant
EUGENE L. TATTINI,
Jet Propulsion Laboratory
Staff
MICHAEL A. CLARKE, Director
JAMES C. GARCIA, Senior Program Officer
DANIEL E.J. TALMAGE, JR., Program Officer
CARTER W. FORD, Research Associate
CHRIS JONES, Financial Associate
LaNITA R. JONES, Senior Program Assistant
LaSHAWN N. SIDBURY, Program Associate
DEANNA P. SPARGER, Program Administrative Coordinator
WILLIAM E. CAMPBELL, Senior Program Associate
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A Review of United States Air Force and Department of Defense Aerospace Propulsion Needs
Preface
This study responds to a request by the Deputy Assistant Secretary of the Air Force for Science, Technology, and Engineering (SAF/AQR) and the Director of Defense Research and Engineering (DDR&E) that the National Research Council (NRC) evaluate the U.S. aerospace propulsion technology base to determine if efforts under way will support necessary warfighter capabilities to 2020. The current national context for the study includes fuel prices at historically high levels, ever-increasing costs for sustaining aircraft, a decreasing domestic launch capability, and uncertainty about the availability of U.S. citizens to perform the requisite research on propulsion. All of these factors are of critical importance to U.S. national security. The committee sincerely hopes that this report—the culmination of an extremely intense effort—will enable the Air Force and Department of Defense (DoD) to make informed decisions on future aerospace propulsion needs. As chair, I want to applaud the committee members for their commitment and diligence during the study that enabled us to complete the task successfully. I also want to express the members’ thanks to the Air Force and DoD for their dedicated support throughout the study and for the efforts of National Research Council staff consisting of Michael Clarke, Jim Garcia, Daniel Talmage, Carter Ford, LaNita Jones, Bill Campbell, Liz Fikre, and Anderson intern Dionna Ali.
Kenneth E. Eickmann, Chair
Committee on Air Force and Department of Defense Aerospace Propulsion Needs
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A Review of United States Air Force and Department of Defense Aerospace Propulsion Needs
ROLE OF THE BOARD
The Air Force Studies Board (AFSB) was established in 1996 by the National Academies at the request of the Air Force. The AFSB brings to bear broad military, industrial, and academic scientific, engineering, and management expertise on Air Force technical challenges and other issues of importance to senior Air Force leaders. The board discusses potential studies of interest, develops and frames study tasks, ensures proper project planning, suggests potential committee members and reviewers for reports produced by fully independent ad hoc study committees, and convenes meetings to examine strategic issues. The board members listed on page vi were not asked to endorse the committee’s conclusions or recommendations, nor did they review the final draft of this report before its release. Board members with appropriate expertise may be nominated to serve as formal members of study committees or to review reports.
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Acknowledgment of Reviewers
This report has been reviewed in draft form by individuals chosen for their diverse perspectives and technical expertise, in accordance with procedures approved by the National Research Council’s (NRC’s) Report Review Committee. The purpose of this independent review is to provide candid and critical comments that will assist the institution in making its published report as sound as possible and to ensure that the report meets institutional standards for objectivity, evidence, and responsiveness to the study charge. The review comments and draft manuscript remain confidential to protect the integrity of the deliberative process. We wish to thank the following individuals for their review of this report:
Peter M. Banks, Independent Consultant,
Edgar Choueiri, Princeton University,
Earl H. Dowell, Duke University,
Kenneth C. Hall, Duke University,
Hans G. Hornung, California Institute of Technology,
Kenneth K. Kuo, Pennsylvania State University,
Carl J. Meade, Northrop Grumman Corporation,
Michael M. Micci, Pennsylvania State University,
Robert E. Schafrik, GE Aircraft Engines, and
William A. Sirignano, University of California, Irvine.
Although the reviewers listed above have provided many constructive comments and suggestions, they were not asked to endorse the conclusions
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or recommendations nor did they see the final draft of the report before its release. The review of this report was overseen by Louis J. Lanzerotti, New Jersey Institute of Technology. Appointed by the National Research Council, he was responsible for making certain that an independent examination of this report was carried out in accordance with institutional procedures and that all review comments were carefully considered. Responsibility for the final content of this report rests entirely with the authoring committee and the institution.
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Contents
SUMMARY
1
1
OVERVIEW
11
Background,
11
Study Tasks,
11
Capabilities-Based Planning,
12
Propulsion Research,
17
S&T Funding,
18
The Committee’s Judgment,
19
The Reliance Program,
19
Air-Breathing Propulsion Systems,
20
Challenges Facing Air-Breathing Propulsion Systems,
20
Characteristics of Aircraft Needed by Warfighters in 2020,
20
Large Gas Turbine Engine Programs,
23
Small Gas Turbine Engine Programs,
29
Expendable Turbine Engine Programs,
31
Other Technology Programs for Aerospace Propulsion,
32
Rocket Propulsion Systems for Access to Space,
35
Anticipated Military Spacelift Propulsion Needs and Identification of Critical Technologies,
35
Current Technology for Large, First-Stage (Core), Liquid Propellant Booster Engines,
37
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A Review of United States Air Force and Department of Defense Aerospace Propulsion Needs
FALCON Small Launch Vehicles
Air-Based Vertical Launch Concept
Multimission Modular Vehicle Air-Based Launch
ORS Requirements
Affordable Responsive Spacelift Vehicle
Initiatives to Establish New Propulsion Technology Base
National Aerospace Initiative
Integrated High-Performance Rocket Propulsion Technology
Air Force Research Laboratory Efforts Under IHPRPT
Contractor Efforts Under IHPRPT Funding
Other Efforts Under Government or Industry Funding: New Engine Designs and New Propellants, Feed Systems, Pressurization, and Materials
Apparently Superior Foreign Technologies
Defining DoD and Air Force Needs for Propulsion Technology and Tools
Systems Engineering
Modeling and Simulation
Rocket Engine and Motor Test Beds
Important Technologies for Propulsion Systems
Areas That Need More Attention
Physical and Thermodynamic Properties of Fuels and Oxidizers
Propulsion Elements
Reliability of the Supply Base
Leveraging Opportunities for Access-to-Space Propulsion
Low-Cost, Responsive Launch Vehicles
Propulsion Technologies Developed by NASA
Status and Capabilities of the U.S. Rocket Propulsion Industry
References
5
ROCKET PROPULSION SYSTEMS FOR IN-SPACE OPERATIONS AND MISSILES
Introduction
Current State of the Art in On-Orbit Propulsion
Chemical Propulsion
Electric Propulsion
Promising Technologies for On-Orbit Propulsion and for Tactical and Strike Missiles
IHPRPT Targets for Propulsion Performance
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A Review of United States Air Force and Department of Defense Aerospace Propulsion Needs
Chemical Propulsion
Electric Propulsion
Propulsion for Strike and Tactical Missiles
Critical Technology Needs That Call for More Attention
Specific Needs
Other Needs
SCARLET: An Existing Technology That Could Be Leveraged
Current Work on Propulsion
Solid Propellant Motors
Hybrid Motors
Gelled Propellant Motors
Opportunities for Transformation in Accomplishing Responsive Global Reach and ABM Missions
Air-Based Vertical Launch Concept
Multimission Modular Vehicle Concept
Critical Enabling Technologies
Final Observation
References
6
CROSS-CUTTING TECHNOLOGIES
Introduction
Fuels
Gas Turbines
High-Altitude, Long-Endurance Unmanned Aircraft Systems
Expendable Missiles with Turbine Engines
Hypersonic and Scramjet Vehicles
Pulsed Detonation Engines
Combined Cycle Engines
Liquid Hydrocarbon Propellants for Rockets
Modeling and Simulation of Complex Hydrocarbon Fuels
Fuel Cost and Logistics Barriers and Alternative Fuels
Materials
High-Temperature Structural Materials
Combustion and Thermal Management
References
7
STRATEGIES, ISSUES, AND FUNDING TRENDS
Maximizing the Return on Investment
Using the Air Logistics Center to Enhance Technology Transition
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Spiral Development
Government and Industry Collaboration
Shortening the Demonstration Time
Reliance Program
Innovative Contracting Mechanisms
Mitigating Technology Risks
Additional Issues
Infrastructure
Education
Basic Research
Leveraging Other National Resources
Foreign Aerospace Propulsion Efforts
Gas Turbine Engines
Pulse Detonation Engines and Rockets
Ramjets
Hypersonics
Rockets
Space Propulsion
Environmental Issues
Past and Projected Funding for S&T
References
APPENDIXES
A Biographical Sketches of Committee Members
B Meetings and Speakers
C Site Visits
D Background Information on the Delta IV and Atlas V Families of Large Launch Vehicles
E Background Information on FALCON Launch Vehicle Concepts
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Acronyms
AATE Affordable Advanced Turbine Engine
ABM antiballistic missile
ABVL air-based vertical launch
ACS assembly and command ship
AEDC Arnold Engineering Development Center
AFOSR Air Force Office of Scientific Research
AFRL Air Force Research Laboratory
AFSB Air Force Studies Board
AFSPC Air Force Space Command
AIAA American Institute of Aeronautics and Astronautics
AMROC American Rocket Company
AoA analysis of alternatives
AP ammonium perchlorate
AR nozzle area ratio
ARES Affordable Responsive Spacelift (vehicle)
AT&L acquisition, technology, and logistics
BAE British Aerospace
BMDO Ballistic Missile Defense Organization
C4ISR command, control, communications, computers, intelligence, surveillance, and reconnaissance
CADB Chemiautomatics Design Bureau
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CADM computer-aided design and manufacturing
CCA cooled cooling air
CDR critical design review
CEV crew exploration vehicle
CFD computational fluid dynamics
CIP Component Improvement Program
CMC ceramic matrix composite
CNT carbon nanotube
COBRA Co-optimized Booster for Reusable Applications
CONOPS concept of operations
CRRA capabilities review and risk assessment
CSAR Center for the Simulation of Advanced Rockets
CUIP Constellation University Institutes Project
CVC constant volume combustor
DARPA Defense Advanced Research Projects Agency
DCR dual-combustor ramjet
DDR&E Director of Defense Research and Engineering
DoD Department of Defense
DOE Department of Energy
DTAP Defense Technology Area Plan
ECEP engine capability enhancement program
EELV evolved expendable launch vehicle
EHF extremely high frequency
EMA electromechanical actuator
EMDP engine model derivative program
EMTVA electromechanical thrust vector assembly
EOP Executive Office of the President
EP electric propulsion
EPDM ethylene propylene diene monomer
ESA European Space Agency
ETO Earth-to-orbit
FAA Federal Aviation Administration
FADEC fuel-authority digital engine/electronic control
FALCON Force Application and Launch from the Continental United States
FATE Future Affordable Turbine Engine
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FBM fleet ballistic missile
FCS Future Combat Systems
FEM finite-element model
FY fiscal year
GE General Electric
GEM graphite epoxy motor
GITVC gas injection thrust vector control
GLOW gross liftoff weight
GOTChA goals, objectives, technical challenges, and approaches
GTE gas turbine engine
GTO geosynchronous transfer orbit
H2 hydrogen
H2O2 hydrogen peroxide
HAN hydroxylammonium nitrate
HCV hypersonic cruise vehicle
HEDM high-energy-density materials
HiReTS high Reynolds number thermal stability
HiSTED High-Speed Turbine Engine Demonstration
HPDP hybrid propulsion development program
HTPB hydroxyl-terminated polybutadiene
HTV hypersonic technology vehicle
HUMS health and usage monitoring system
HyCAUSE hypersonic collaboration between Australia and United States experiment
HyFly Hypersonics Flight Demonstration
HyTech hypersonic technology
HyTOP Hybrid Technology Options Project
Isp specific impulse
IBR integrally bladed rotor
IC internal combustion
ICAO International Civil Aviation Organization
ICBM intercontinental ballistic missile
IHPRPT Integrated High-Payoff Rocket Propulsion Technology
IHPTET Integrated High-Performance Turbine Engine Technology
IM insensitive munitions
IOC initial operational capability
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IPD integrated powerhead demonstrator
IR&D independent research and development
ITAPS integrated total aerospace power system
ITEP Improved Turbine Engine Program
JASSM joint air-to-surface standoff missile
JCIDS joint capabilities integration and development system
JHL joint heavy lift
JSF Joint Strike Force
JTAGG joint turbine advanced gas generator
lbf pound force
lbf/sec pound force per second
LEO low Earth orbit
LH2 liquid hydrogen
LISA Laser Interferometer Space Antenna
LOx liquid oxygen
LP launch platform
ManTech Manufacturing Technology
MBSAT Mobile Broadcasting Satellite
MHD magnetohydrodynamic
MMH monomethylhydrazine
MMMV multimission modular vehicle
MON mixed oxides of nitrogen
M&S modeling and simulation
MSFC Marshall Space Flight Center
N2H4 monopropellant hydrazine
N2O nitrous oxide
N2O4 dinitrogen tetroxide
NAI National Aerospace Initiative
NASA National Aeronautics and Space Administration
NEXT NASA’s Evolutionary Xenon Thruster
NGLT Next-Generation Launch Technology
NOx nitrogen oxides
NPSH net positive suction head
NRC National Research Council
NSSK North-South station keeping
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NSSS National Security Space Strategy
OAM orbit adjust module
OC-ALC Oklahoma City Air Logistics Center
OEM original equipment manufacturer
ORS operationally responsive spacelift
ORSC oxygen-rich staged combustion
OSC Orbital Sciences Corporation
OSD Office of the Secretary of Defense
OSP Orbital Suborbital Program
OSTP Office of Science and Technology Policy
OUSD Office of the Undersecretary of Defense
Pc chamber pressure
PBR Presidential Budget Request
PDE pulsed detonation engine
PDR pulsed detonation rocket/preliminary design review
PDW pulse detonation wave
POM program objectives memorandum
POSS polyhedral oligomeric silsesquioxane
PPT pulsed plasma thruster
PPU power processing unit
PR propulsion and power
PRV personnel recovery vehicle
psi pounds per square inch
psia pounds per square inch absolute
P-STAR propulsion sizing, thermal analysis, accountability, and weight relationship first-order modeling tool
RATTLRS Revolutionary Approach to Time-Critical Long-Range Strike
RCE reaction control engine
REAP2 Rocket Engine Advancement Progra
R&D research and development
RDT&E research, development, testing, and evaluation
RDX royal demolition explosive
ROM rough order of magnitude
SAF Secretary of the Air Force
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SCARLET solar concentrator array with refractive linear element technology
SCAT secondary combustion augmented thruster
SDD system design and development
SECDEF Secretary of Defense
SED single-engine demonstrator
SFC specific fuel consumption
SFS sequential feed system
SHFE small heavy fuel engine
SHP shaft horsepower
SLBM submarine-launched ballistic missile
SLI Space Launch Initiative
SLV small launch vehicle
SMART 1 small missions for advanced research in technology 1
SMP FY06 Strategic Master Plan for FY06 and Beyond
SPT stationary plasma thruster
SRB solid rocket booster
SRM solid rocket motor
SSME space shuttle main engine
S&T science and technology
STOL short takeoff and landing
STOVL short takeoff and vertical landing
SVTI Space Vehicle Technology Institute
TARA technology area review and assessment
TBC thermal barrier coating
THAAD terminal high-altitude area defense
TM thermal management
TOW tube-launched, optically tracked, wire-guided missile
TPA turbopump assembly
TRL technology readiness level
TVC thrust vector control
T/W thrust to weight
UAH University of Alabama at Huntsville
UAS unmanned aircraft system
UCAV unmanned combat air vehicle
UCC ultracompact combustor
UER unscheduled engine removal
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USAF U.S. Air Force
USET upper-stage engine technology
VAATE Versatile, Affordable, Advanced Turbine Engine
VaPak vapor pressurization technology
V/STOL vertical or short takeoff and landing
VTOL vertical takeoff and landing
XIPS Xenon Ion Propulsion System
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