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Boeing X-37

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Boeing X-37

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, re-enters Earth's atmosphere, and lands as a spaceplane. The X-37 is operated by the Department of the Air Force Rapid Capabilities Office, in collaboration with 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 780 days in orbit for the fifth mission, the first to launch on a Falcon 9 rocket. The sixth mission launched on an Atlas V on 17 May 2020 and concluded on 12 November 2022, reaching 908 days in orbit. The seventh mission launched on 28 December 2023 on a Falcon Heavy rocket, entering a highly elliptical high Earth orbit, landing in March 2025 after 434 days in orbit.

In 1999, NASA selected Boeing Integrated Defense Systems to design and develop an orbital vehicle, built by the California branch of Boeing Phantom Works. Over four years, $192 million was spent on the project, with NASA contributing $109 million, the U.S. Air Force $16 million, and Boeing $67 million. In late 2002, a new $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 7,000 miles per hour (11,000 km/h) 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 because of its military applications. 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.

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 for its first free flight, scheduled for 10 March 2006, 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 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 thought to have been performed, two of which resulted in X-37 releases with successful landings. These two free flights occurred on 18 August 2006 and 26 September 2006.

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