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Super Heavy
B7 on the Orbital Launch Mount at Starbase in February 2023. B7 was the only booster to launch without a Vented Interstage.
Manufacturer SpaceX
Country of originUnited States
Used on SpaceX Starship
General characteristics
Height71 m (233 ft)
Diameter9 m (30 ft)
Gross mass3,600  t (3,600,000  kg; 7,937,000  lb)
Propellant mass3,400 t (3,400,000 kg; 7,496,000 lb)
Empty mass200 t (200,000 kg; 441,000 lb)
Launch history
StatusIn development
Total launches3
Failed1 ( IFT-1)
OtherFailed after staging ( IFT-2, IFT-3)
First flightApril 20, 2023
Super Heavy
Powered by33 Raptor engines
Maximum thrust7,590 tf (74,400 kN; 16,700,000 lbf)
Specific impulse327 s (3.21 km/s) (sea-level)
Propellant Liquid oxygen / Methane
Large steel cylinder with complex engine mounts and wiring
Underside of a Super Heavy booster prior to engine installation

Super Heavy is the first stage of the SpaceX Starship super heavy-lift launch vehicle, which it composes in combination with the Starship second-stage. As of 2024, Super Heavy prototypes are being flight tested. Super Heavy flew for the first time on April 20, 2023, during the first orbital launch attempt of the Starship rocket. [1]

Manufacturing

The manufacturing process starts with rolls of steel, which are unrolled, cut, and welded along the edge to create a cylinder of 9 m (30 ft) in diameter, 1.829 m (6.00 ft) in height, and 3.97 mm (0.156 in) thick, [2] and around 1600 kg (3,600 lb) in mass. [a]

These rings are stacked and welded along their edges to form the outer layer of the rocket. Domes are added early on in the assembly process, before final assembly of the tank sections begins. [3]

Usually before final assembly of the vehicle, grid fins are added to the interstage, and chines are added after stacking the propellant tanks. [4] After cryogenic testing, engines are installed, [5] followed by the vented interstage. [6] [7]

Design

Super Heavy is 71 m (233 ft) tall, 9 m (30 ft) wide, [8] and is composed of four general sections: the engine section, the fuel tank, the oxygen tank, and the interstage. [9] Elon Musk has stated that the final design will have a dry mass between 160 t (350,000 lb) and 200 t (440,000 lb), with the tanks weighing 80 t (180,000 lb) and the interstage 20 t (44,000 lb). [9]

Tanks

The propellant tanks on Super Heavy are separated by a common bulkhead, similar to the ones used on the S-II and S-IVB stages on the Saturn V rocket. [10] [11] The oxygen tank has four chines attached, which protect the COPVs and CO2 tanks for fire suppression, as well as providing lift during descent. [12] The LOX tank also contains a header tank, [13] which is used for the landing burn. A central "downcomer" pipe through the oxygen tank supplies methane to a distribution manifold just above the engines. [14]

The booster's tanks hold 3,400 t (7,500,000 lb) of propellant, [15] consisting of 2,700 t (6,000,000 lb) of liquid oxygen and 700 t (1,500,000 lb) of liquid methane. [b]

Engine Section

The engine section supports the 33 raptor engines during flight. The engines are arranged in three concentric rings, [16] with the outer ring of 20 engines lacking gimbal actuators to save weight. [17]

Raptor uses a full-flow staged combustion cycle, which has both oxygen and methane-rich turbopumps. [18] [19] Before 2014, only two full-flow staged-combustion rocket engine designs had advanced enough to undergo testing on test stands: the Soviet RD-270 project in the 1960s and the Aerojet Rocketdyne Integrated Powerhead Demonstrator in the mid-2000s. [20]

At full power, all engines produce a collective 74.4 MN (16,700,000 lbf) of thrust, [21] however, Raptor 3 may increase thrust to 90 MN (20,000,000 lbf) at sea level. [22] Boosters lack an engine skirt, and without engines, boosters are about 3 meters shorter. [23]

Interstage

The interstage is also equipped with four electrically actuated grid fins, each with a mass of 3 t (6,600 lb). [24] Adjacent pairs of grid fins are only spaced sixty degrees apart instead of being orthogonal (as is the case on Falcon 9) to provide more authority in the pitch axis. [25] Unlike Falcon 9, the grid fins do not retract and remain extended during ascent. [9] During unpowered flight in the vacuum of space, control authority is provided by cold gas thrusters fed with residual ullage gas. [26] [27] The interstage also has protruding hardpoints, located between grid fins, allowing the booster to be lifted or caught by the launch tower. [28]

After the first Starship test flight, all boosters have an additional 1.8 m [2] tall vented interstage to enable hot staging. [29] During hot staging, super heavy shuts down all but 3 of its engines, [30] [31] while the second stage fires its engines before separating. [30] The vented interstage contains a dome to shield the top of super heavy from the second stage's engines. [29] [31] Elon Musk has claimed that this change might result in a 10% increase in the payload to low Earth orbit. [31]

Planned mission profile

Animation of Super Heavy's integration to the launch mount, using mechanical arms.

About forty two minutes before flight, propellant load of the booster begins. [32] At the T – 19:40 mark, engine chill begins on the booster. [33] This is to protect the engine's turbopumps from thermal shock. At three seconds before a flight, the thirty-three engines startup sequence begins. [33]

A short animation of Super Heavy's landing on Mechanical arms. The planned landing speed is a few times slower.

After liftoff, the engines burn for 169 seconds, at which point 30 of its engines shut off, leaving only the center three engines running at 50% thrust. [33] The ship ignites its engines while still attached to the booster and separates, while the booster rotates for the boostback burn. The boostback burn uses all 13 central engines and lasts for 54 seconds. [33] About six minutes after launch, the engines reignite, [34] and the booster is caught by a pair of mechanical arms. [35]

Development

List of Prototype Boosters
Name First spotted [c] First static fire Maiden flight Decommissioned Construction site Status Flights
BN1 [36] September 2020 [37] — [38] — [38] March 30, 2021 [38] Boca Chica, Texas Scrapped [39] [40] 0
BN3/B3 March 28, 2021 [41] [42] July 19, 2021 [43] — August 14, 2021 Boca Chica, Texas Scrapped [44] 0
B4 July 2, 2021 [45] — — March 25, 2022 Boca Chica, Texas Scrapped 0
B5 July 20, 2021 [46] — — December 2021 Boca Chica, Texas Scrapped 0
B7 Late October/Early November 2021 August 9, 2022 [47] April 20, 2023 April 20, 2023 Boca Chica, Texas Destroyed in flight 1
B8 January 2022 [48] — — January 2023 Boca Chica, Texas Scrapped 0
B9 21 October 2021 August 6, 2023 November 18, 2023 November 18, 2023 Boca Chica, Texas Destroyed after staging [49] 1
B10 July 2022 December 29, 2023 March 14, 2024 March 14, 2024 Boca Chica, Texas Destroyed during landing attempt 1
B11 Late 2022 April 5, 2024 Not yet Not yet Boca Chica, Texas In Mega Bay 1 for pre-flight modifications 0
B12 December 2022 Not yet Not yet Not yet Boca Chica, Texas On Engine Installation Stand 1 in Mega Bay 1, receiving engines 0
B13 December 2022 Not yet Not yet Not yet Boca Chica, Texas In Mega Bay 1, awaiting rollout to Massey's for cryogenic testing 0
B14 March 2023 Not yet Not yet Not yet Boca Chica, Texas Under Construction 0
B15 October 2023 Not yet Not yet Not yet Boca Chica, Texas Under Construction 0
B16 [50] March 2024 Not yet Not yet Not yet Boca Chica, Texas Under Construction 0
B17 [50] March 2024 Not yet Not yet Not yet Boca Chica, Texas Under Construction 0
  1. ^ This is based on the dimensions of the ring and 304L stainless steel's density of 7.93 g/cm3. [1]
  2. ^ 78% of 3,600 t (7,900,000 lb) [9] is 2,700 t (6,000,000 lb) of liquid oxygen.
  3. ^ The date of the first part for the booster being spotted

Ground Testing (BN1-BN3/B3)

BN1

BN1 was the first Super-Heavy Booster prototype, a pathfinder that was not intended for flight tests. [51] Sections of the ~66 m (217 ft) tall test article were manufactured throughout the fall. [37] Section stacking began in December 2020. [52] BN1 was fully stacked inside the High Bay on March 18, [53] and was scrapped on March 30, 2021. [38]

BN3/B3

BN3 (Booster 3) [54] was used for ground tests. A cryogenic proof test was completed on July 13, 2021. [55] [56] Booster 3 completed stacking in the High Bay on June 29, 2021, [57] and moved to the test pad without engines. [58] Three engines were subsequently added. [59]

A static fire test was conducted on July 19, 2021. [43] BN3/Booster 3 was partially scrapped on August 15, 2021, while the LOX tank remained welded to the Test Stand. [44] The LOX tank was taken off the Test Stand on January 13, 2022. [60]

Orbital Launches (B4-subsequent)

B4–B6

Booster 4 in the High Bay

Booster 4 first became visible on July 3, 2021. Musk ordered several hundred SpaceX employees at Hawthorne to relocate to Boca Chica to accelerate the development of SN20, BN4, and the Orbital Launch Platform [59] in an attempt to put the Starship system on the pad by August 5, 2021. [61] BN4 was fully stacked on August 1, with a full complement of 29 engines installed on August 2, 2021. [62] Grid fins were added to support atmospheric reentry testing.

SN20 was stacked on top of Booster 4 on August 6, 2021 for a fitting test, making it the tallest rocket ever fully integrated, [63] until September 5, 2023, when S25 was stacked onto B9. Booster 4 was then returned to the High Bay for secondary wiring. On September 9, 2021, Booster 4 came again to the launch site on top of the Orbital Launch mount. [64] B4 completed its first cryogenic proof test (17 December 2021), [65] and a pneumatic proof test on December 19, 2021. It underwent another cryogenic proof test and a full-load cryogenic proof test. B4 and Ship 20 were then retired. [56]

On March 6, 2024, B4s grid fins were removed. [66] It was moved to the Mega Bay on March 21, 2024, [67] where it was scrapped on March 22, 2024. [68]

Parts for B5 were observed as early as 19 July 2021. [46] Stacking for BN5 completed in November, although on 8 December 2021, B5 was retired alongside SN15 and SN16. It was later scrapped.

B6 was converted into Test Tank B6.1. [69]

B7

See also: SpaceX Starship integrated flight test 1

Parts for B7 were first spotted on September 29, 2021. B7 was placed on the orbital launch mount on March 31. 2022. After completing a cryogenic proof test on April 4, 2022, it was placed onto the new booster test stand on April 8, 2022. B7 completed another cryogenic test on April 14, 2022, but the downcomer suffered a failure and ruptured. On April 18, 2022, B7 returned to the production site for repairs. On May 5, 2022, B7 was again placed on the orbital launch mount. B7 then completed two cryogenic tests on May 9 and May 11, 2022. It was then returned to the production site and entered the new Mega Bay 1, for repairs and additional equipment, upgraded grid fins and engines, and two more 'chines' or 'strakes' (triangular structures placed on the aft section to aid in aerodynamic control). [70] On July 11, 2022, B7 experienced an anomaly during an attempted 33 engine spin prime test, resulting in a detonation underneath the engines. [71] The booster then rolled back to Mega Bay 1. [72] On August 4, 2022, B7 was transported back to the orbital launch pad with 20 outer Raptor engines, [73] and completed its first single-engine static fire test on August 9, 2022. B7 completed a 20-second static fire on August 11, 2022, the longest static fire on a Starship prototype to date. [74] Following these successful tests, it returned to the production site to receive the remaining 13 engines. [75] B7 was lifted back onto the launch mount using the chopsticks catching and lifting system on August 23, 2022. [76] It underwent further testing including its 13 inner engines on August 26, 2022. On August 31, 2022, B7 completed a multi-engine static fire. [77] This was followed by multiple spin prime tests, [78] [79] [80] and a seven-engine static fire on September 19, 2022. [80] B7 again returned to the Mega Bay on 21 September 2022. [81] After receiving additional upgrades it was again lifted on the launch pad on October 8, 2022. [82] Ship 24 was stacked on top B7 on October 12, 2022, [83] and was removed after completing multiple cryogenic load tests. [84] [85] [86] B7 then completed a spin prime test of multiple engines on November 12, 2022, [87] and a 14 engine static fire test on November 14, 2022, [88] and finally an 11 engine static fire in an autogenous pressurization test on November 29, 2022. [89] On December 9, 2022, B7 rolled back to Mega Bay 1 [90] for further shielding. In January 2023, Booster 7 was rolled back to the launch site where it was stacked with Ship 24 on the OLM for partial and full Wet Dress Rehearsals [91] before Ship 24 was detached and sent to the Rocket Garden for final TPS work. On February 9, 2023, Booster 7 attempted a 10-second duration 33-engine static fire where 31 of the 33 engines successfully fired for the full duration. [92] One of its engines was disabled just before testing, and one engine shutdown prematurely. On April 20, 2023, it was intentionally destroyed in the SpaceX Starship First Integrated Flight Test after losing connection to its engines.

B8

The first part of the booster, the engine thrust puck, was spotted on October 5, 2021. Other parts for B8 were observed on February 3, 2022. [93] The booster was fully stacked on July 8, 2022. [94] It was moved to the launch site on September 19, 2022, though it was not tested there. [95] Booster 8 was scrapped in January 2023 in favor of Booster 9. Booster 8's hydraulic power units were used to replace Booster 7s, along with several other parts, including the engine shielding. [96] [97]

B9

See also: SpaceX Starship integrated flight test 2

The engine thrust puck of the booster was first spotted on October 24, 2021. The vehicle finished stacking in late 2022 and was moved to the OLS cryo station on December 15, 2022. Two cryogenic proof tests were conducted on December 21 and December 29, both of which were successful. The booster was rolled back to Mega Bay 1 on January 10, 2023. Among many other upgrades, Booster 9 was the first to feature an electric thrust vector control (often abbreviated to ETVC) gimbaling system of the raptor engines. This system replaced the hydraulic power units that were used until Booster 8. On July 20, Booster 9 was rolled out to the launch site. Later, on the night of July 20 to July 21, it was lifted onto the Orbital Launch Mount in preparation for its testing campaign. [98] On July 23 Booster 9 performed a cryogenic prof test on the orbital launch mount. [99] This was followed by a spin prime on August 4. On August 6, Booster 9 fired 29 engines for 2.7 seconds, instead of the planned 33 engines for 5 seconds. It was then moved off of the Orbital Launch Mount and rolled back to Mega Bay 1, where its vented interstage was added on August 16. [100] B9 was moved back onto the Orbital Launch Mount on August 22 and underwent another spin prime test the next day. [101] On August 25, Booster 9 underwent a static fire of all 33 engines, lasting around 6 seconds. Two engines shut off early during the test. [102] [103] On September 5, Ship 25 (S25) was lifted onto B9 for the first time. [104] On September 14, S25 was removed from B9, followed one week later by the vented interstage. [104] On September 26, the vented interstage was lifted onto B9, only to be removed on October 9. [104] It was lifted back onto B9 on October 16, along with S25. [105] S25 was removed on October 17, and then lifted back onto B9 on October 20. On October 22, B9 underwent two partial cryogenic tests, while S25 was not tested. This was followed by a deluge test, also on October 22. [106] On October 24, B9 and S25 completed a wet dress rehearsal (WDR), [107] which was followed by another deluge test on the same day. [108] On October 26, S25 was removed from B9, presumably for flight termination system (FTS) installation. [109] This was followed by the removal of the vented interstage one day later. [110] The vented interstage was then placed back on B9 on October 28. [111] [112] On November 9, B9's FTS was installed. On November 10, S25 was stacked onto B9, [113] and then destacked on November 11. [114] The vented interstage was removed the next day. [115] On November 15, the vented interstage was reattached to B9, [116] followed by the stacking of S25 for the Second Integrated Flight Test. [117] Due to a failed grid fin actuator, S25 was destacked on November 16, and restacked on November 17. [118] The following day, November 18, Booster 9 as well as Ship 25, lifted off with all engines burning at 7:02 am CST. Following the successful separation from S25, B9 was destroyed after several engine failures during the boost-back burn. [119]

B10

Grid fins and corrugation on Booster 10's methane tank (right, foreground), March 12, 2023

B10 and subsequent vehicles are similar to B9, with the main difference being the usage of elliptical domes. [120] [121]

See also: SpaceX Starship integrated flight test 3

B10 was fully stacked in March 2023. [122] On July 19, 2023, B10 underwent a cryogenic proof test. It was later moved to the rocket garden and was then moved to Mega Bay 1. However, on September 10, 2023, B10 was moved back to Massey's on a Thrust Simulator Stand. A cryogenic test was performed 3 days later. [123] As of September 13, 2023, it is unknown whether the Thrust Simulator was used during the test. It was moved back to Mega Bay 1 on September 20, 2023, for engine and interstage installation. On December 4, 2023, B10 received its vented interstage. [6] On December 5, 2023, B10 was moved to the Rocket Garden, [124] and SpaceX confirmed that B10 would be used for IFT-3 shortly after that. [125] On December 18, 2023, B10 was moved to the orbital launch site, [126] followed by a lift onto the OLM the next day. [127] A static fire was attempted on December 21, 2023, however, it was aborted for unknown reasons. On December 29, 2023, B10 conducted a 33 engine static fire test, [128] [129] followed by its removal from the OLM on December 30, 2023. [130] On January 2, 2024, B10 was moved back to the Production Site. [131] B10s vented interstage was removed on January 15, 2024, [132] and reinstalled on January 26. [133] On February 8, B10 was removed from Engine Installation Stand 3, [134] before being transported to the Orbital Launch Site for a Wet Dress Rehearsal. [135] On February 9, 2024, B10 was lifted onto the OLM, [136] [137] [138] and on February 10, 2024, S28 was lifted onto B10. [139] S28 was destacked on February 12, 2024, [140] potentially due to an issue with the Vented Interstage. [141] On February 13, 2024, S28 was restacked onto B10. [142] [143] On February 14, 2024, a Wet Dress Rehearsal attempt was aborted. [144] A second Wet Dress Rehearsal was attempted on February 16, 2024, and it was also aborted. [145] On February 18, 2024, S28 was destacked. [146] On February 19, 2024, B10 was removed from the OLM, [147] and on February 20, 2024, B10 was moved into the Mega Bay, [148] where it was lifted onto Engine Installation Stand 3. [149] On February 28, 2024, B10 was moved back to the Launch Site, [150] [151] before being lifted onto the OLM. [152] S28 was stacked on B10 on March 1, 2024. [153] On March 3, 2024, B10 and S28 completed a Wet Dress Rehearsal, [154] followed by a destack for FTS arming on March 5, 2024. [155] The FTS was armed on March 8, 2024, [156] followed by S28 being restacked on March 10, 2024. [157] [158] On March 14, 2024, B10 was launched with S28 on IFT-3, completing both ascent and the boostback burns with zero engine failures, before experiencing a Rapid Unscheduled Disassembly (RUD) following a failed landing burn in which only three engines started up with two failing shortly thereafter. [159]

B11 and subsequent

In June 2023, B11 was fully stacked. [160] On October 12, 2023, B11 was moved to Massey's test site on a Thrust Simulator Stand, where it was cryo-tested two days later. It was then tested on October 18, 2023. On November 19, 2023, B11 was moved back to Mega Bay 1 for engine and interstage installation. [161] On February 2, 2024, SpaceX released an image of B11, with multiples engines being visible. [162] It was moved to the Launch Site for static fire testing on April 4, 2024, [163] before being lifted onto OLM A. [164] It conducted a 33 engine static fire on April 5, 2024. [165] On April 7, it was removed from OLM A, [166] [167] and rolled back to Mega Bay 1 for pre-flight modifications. [168] [167]

B12 began assembly in June 2023. [160] On December 11, 2023, B12 was moved onto engine installation 1. [169] [170] On December 28, 2023, B12 was moved onto a Thrust Simulator Stand, before being moved to Masseys for cryogenic testing. [171] On January 10, 2024, B12 underwent its first cryogenic test, [172] and it underwent a second test on January 12, 2024. [173] B12 was moved to the rocket garden in Mid January, 2024, [174] an on January 24, 2024, B12 was moved into Mega Bay 1, presumably for engine and interstage installation. [175] On February 2, 2024, SpaceX released an image showing the process of engine installation on B12 had begun. [162]

B13s assembly was completed on February 3, 2024. [176]

Test articles

Super Heavy test articles
Name First spotted Decommissioned Construction site Cur. location Status Tests
TT1 January 2020 [177] 10 January 2020 [178] Boca Chica, Texas — Intentionally destroyed [178] 1
TT2 January 2020 [179] 29 January 2020 [180] Boca Chica, Texas — Intentionally destroyed [180] 2
BN2.1 [181] 3 June 2021 [182] 25 June 2021 Boca Chica, Texas Production Site Retired 2
GSE 4.1 August 2021 18 January 2022 Boca Chica, Texas — Intentionally destroyed [183] 2
B2.1 October 2021 6 December 2022 Boca Chica, Texas Production Site Retired[ citation needed] 3
B6.1 December 2021 May 2023 Boca Chica, Texas — Intentionally destroyed 1
B7.1 2022 Not yet Boca Chica, Texas Massey's Scrapped 6
EDOME 2022 Late October 2022 Boca Chica, Texas — Intentionally destroyed 2
HSLH July 2023 October 2023 Boca Chica, Texas — Scrapped 2 [184]
EDOME 2 September 2023 December 2023 Boca Chica, Texas — Scrapped 1
B14.1 March 2024 — Boca Chica, Texas Production Site Under Construction 0

General test articles

Test Tank 1 (TT1) was a subscale test tank consisting of two forward bulkheads connected by a small barrel section. TT1 was used to test new materials and construction methods. On January 10, 2020, TT1 was tested to failure as part of an ambient temperature test, reaching a pressure of 7.1  bar (103  psi). [178]

Test Tank 2 (TT2) was another subscale test tank similar to TT1. On 27 January 2020, TT2 underwent an ambient temperature pressure test where it reached a pressure of 7.5 bar (109 psi) before a leak occurred. [185] Two days later, it underwent a cryogenic proof test to destruction, bursting at 8.5 bar (123 psi). [186] [180]

GSE 4.1 was first spotted in August 2021, and was the first ground support equipment (GSE) test tank built, made from parts of GSE 4. It underwent a cryogenic proof test on August 2023 before it was rolled to Sanchez's site. [187] It was rolled back to the launch site in November 2021, where it underwent an apparent cryogenic proof test to failure on January 18, 2022, where it burst at an unknown pressure. [188]

EDOME was a test tank created to test flatter domes, possibly used on future Starship prototypes. It was moved to the launch site in July 2022, and then back to the production site the next month, after not undergoing any tests. [69] It was later moved from the production site to the Massey's Test site in late September 2022, where it was damaged during a cryogenic pressure test to failure. [69] After repairs, it was tested to destruction in late October 2022. [69]

EDOME 2 was a test tank which is likely designed to continue testing a flatter dome design. As of October 4, 2023, its official designation is unknown. It was tested once, before being scrapped for unknown reasons. [189]

Super Heavy-based test articles

BN2.1 was rolled out on June 3, 2021 [182] for cryogenic tests. It conducted two tests, the first on June 8, 2023, [190] and the second on June 17, 2023. [191]

B2.1 (not BN2.1) conducted three cryogenic tests on December 1, 2021, December 2, 2021, and December 3, 2021. [192] [193]

B6.1 was originally intended to be the third super heavy to launch, but was repurposed as a test tank. [69] In May 2023, it was used to test the modified FTS system, after the FTS on B7 and S24 failed to destroy the vehicle. [194]

B7.1 was first cryogenically proof tested on 28 June 2022, [195] and tested again on 19 July 2022. [196] During a suspected pressurize to failure test two days later, it received minor damage. [197] After repairs, it underwent a fourth cryogenic proof test on July 27, 2022, a fifth on September 1, 2022, and a sixth five days later. It then rolled back to the production site on September 16, 2022. [198] B7.1 was then moved to the Massey's test site in September 2022, and then scrapped in December 2023. [199]

Hot Stage Load Head (HSLH) is a test article designed for verify the structural integrity of the interstage of Super Heavy Boosters 9+. [200] It was transported to the Massey's test site on July 30, 2023, [201] before being loaded onto the Can Crusher testing device. [202] In mid October 2023, it was moved back to the production site, [203] where it was disassembled. [204]

See also

References

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