A number of factors delayed the planned maiden flight to 2018, including two anomalies with Falcon 9 launch vehicles, which required all engineering resources to be dedicated to failure analysis, halting flight operations for many months. The integration and structural challenges of combining three Falcon 9 cores were much more difficult than expected.
In July 2017, Elon Musk said, "It actually ended up being way harder to do Falcon Heavy than we thought. ... We were pretty naive about that".
The initial test flight for the first Falcon Heavy lifted off on 6 February 2018, at 20:45 UTC, carrying its dummy payload, Elon Musk's personal Tesla Roadster, beyond Mars orbit.
Musk first mentioned Falcon Heavy in a September 2005 news update, referring to a customer request from 18 months prior. Various solutions using the planned Falcon 5 (which was never flown) had been explored, but the only cost-effective, reliable iteration was one that used a 9-engine first stage—the Falcon 9. The Falcon Heavy was developed using private capital with Musk stating that the cost was more than US$500 million. No government financing was provided for its development.
By April 2011, the capabilities and performance of the Falcon 9 vehicle were better understood, SpaceX having completed two successful demonstration missions to low Earth orbit (LEO), one of which included reignition of the second-stage engine. At a press conference at the National Press Club in Washington, D.C., on 5 April 2011, Musk stated that Falcon Heavy would "carry more payload to orbit or escape velocity than any vehicle in history, apart from the Saturn V Moon rocket ... and Soviet Energia rocket". In the same year, with the expected increase in demand for both variants, SpaceX announced plans to expand manufacturing capacity "as we build towards the capability of producing a Falcon 9 first stage or Falcon Heavy side booster every week and an upper stage every two weeks".
In 2015, SpaceX announced a number of changes to the Falcon Heavy rocket, worked in parallel to the upgrade of the Falcon 9 v1.1 launch vehicle. In December 2016, SpaceX released a photo showing the Falcon Heavy interstage at the company headquarters in Hawthorne, California.
In July 2017, Musk discussed publicly the challenges of testing a complex launch vehicle like the three-core Falcon Heavy, indicating that a large extent of the new design "is really impossible to test on the ground" and could not be effectively tested independent of actual flight tests.
By September 2017, all three first stage cores had completed their static fire tests on the ground test stand. The first Falcon Heavy static fire test was conducted on 24 January 2018.
At a July 2017 meeting of the International Space Station Research and Development meeting in Washington, D.C., Musk downplayed expectations for the success of the maiden flight:
There's a real good chance the vehicle won't make it to orbit ... I hope it makes it far enough away from the pad that it does not cause pad damage. I would consider even that a win, to be honest.
In December 2017, Musk tweeted that the dummy payload on the maiden Falcon Heavy launch would be his personal Tesla Roadster playing David Bowie's "Space Oddity" (though the song actually used for the launch was "Life on Mars"), and that it would be launched into an orbit around the Sun that will reach the orbit of Mars. He released pictures in the following days. The car had three cameras attached to provide "epic views".
On December 28, 2017, the Falcon Heavy was moved to the launch pad in preparation of a static fire test of all 27 engines, which was expected on 19 January 2018. However, due to the U.S. government shutdown that began on 20 January 2018, the testing and launch were further delayed. The static fire test was conducted on 24 January 2018. Musk confirmed via Twitter that the test "was good" and later announced the rocket would be launched on 6 February 2018.
On 6 February 2018, after a delay of over two hours due to high winds, Falcon Heavy lifted off at 20:45 UTC. Its side boosters landed safely on Landing Zones 1 and 2 a few minutes later. However, only one of the three engines on the center booster that were intended to restart ignited during descent, causing the booster to be destroyed upon impacting the ocean at a speed of over 480 km/h (300 mph).
A year after the successful demo flight, SpaceX had signed five commercial contracts worth US$500–750 million, meaning that it had managed to cover the development cost of the rocket. The second flight, and first commercial one, occurred on 11 April 2019, launching Arabsat-6A, with all three boosters landing successfully for the first time.
Falcon Heavy consists of a structurally strengthened Falcon 9 as the "core" component, with two additional Falcon 9 first stages with aerodynamic nose-cones mounted outboard serving as strap-on boosters, conceptually similar to Delta IV Heavy launcher and proposals for the Atlas V Heavy and Russian Angara A5V. This triple first stage carries a standard Falcon 9 second stage, which in turn carries the payload in a fairing. Falcon Heavy has the second highest lift capability of any operational rocket, with a payload of 63,800 kg (140,700 lb) to low Earth orbit, 26,700 kg (58,900 lb) to Geostationary Transfer Orbit, and 16,800 kg (37,000 lb) to trans-Mars injection. The rocket was designed to meet or exceed all current requirements of human rating. The structural safety margins are 40% above flight loads, higher than the 25% margins of other rockets. Falcon Heavy was designed from the outset to carry humans into space and it would restore the possibility of flying crewed missions to the Moon or Mars.
The first stage is powered by three Falcon 9 derived cores, each equipped with nine Merlin 1D engines. The Falcon Heavy has a total sea-level thrust at liftoff of 22.82 MN (5,130,000 lbf), from the 27 Merlin 1D engines, while thrust rises to 24.68 MN (5,550,000 lbf) as the craft climbs out of the atmosphere. The upper stage is powered by a single Merlin 1D engine modified for vacuum operation, with a thrust of 934 kN (210,000 lbf), an expansion ratio of 117:1 and a nominal burn time of 397 seconds. At launch, the center core throttles to full power for a few seconds for additional thrust, then throttles down. This allows a longer burn time. After the side boosters separate, the center core throttles back up to maximum thrust. For added reliability of restart, the engine has dual redundant pyrophoric igniters (Triethylaluminium-Triethylborane) (TEA-TEB). The interstage, which connects the upper and lower stage for Falcon 9, is a carbon fiber aluminum core composite structure. Stage separation occurs via reusable separation collets and a pneumatic pusher system. The Falcon 9 tank walls and domes are made from Aluminum–lithium alloy. SpaceX uses an all-friction stir welded tank. The second stage tank of Falcon 9 is simply a shorter version of the first stage tank and uses most of the same tooling, material, and manufacturing techniques. This approach reduces manufacturing costs during vehicle production.
All three cores of the Falcon Heavy arrange the engines in a structural form SpaceX calls Octaweb, aimed at streamlining the manufacturing process, and each core includes four extensible landing legs. To control the descent of the boosters and center core through the atmosphere, SpaceX uses four retractable grid fins at the top of each of the three Falcon 9 boosters, which extend after separation. Immediately after the side boosters separate, three engines in each continues to burn for a few seconds in order to control the booster's trajectory safely away from the rocket. The grid fins then deploy as the boosters turn back to Earth, followed by the landing legs. The side boosters land softly on the ground in fully/partially reusable launch configuration. The center core continues to fire until stage separation. In fully reusable launches, its grid fins and legs deploy and the center core touches down on a drone ship. If boosters are expended, then the landing legs and grid fins are omitted from the vehicle. The landing legs are made of carbon fiber with aluminum honeycomb structure. The four legs stow along the sides of each core during liftoff and extend outward and down just before landing.
The initial concept (Falcon 9-S9 2005) envisioned payloads of 24.75 t (54,600 lb) to LEO, but by April 2011 this was projected to be up to 53 t (117,000 lb) with geostationary transfer orbit (GTO) payloads up to 12 t (26,000 lb). Later reports in 2011 projected higher payloads beyond LEO, including 19 t (42,000 lb) to geostationary transfer orbit, 16 t (35,000 lb) to translunar trajectory, and 14 t (31,000 lb) on a trans-Martian orbit to Mars.
By late 2013, SpaceX raised the projected GTO payload for Falcon Heavy to 21.2 t (47,000 lb).
In April 2017, the projected LEO payload for Falcon Heavy was raised from 54.4 to 63.8 t (120,000 to 141,000 lb). The maximum payload is achieved when the rocket flies a fully expendable launch profile, not recovering any of the three first-stage boosters. With just the core booster expended, and two side-boosters recovered, Musk estimates the payload penalty to be around 10%, which would still yield over 57 t (126,000 lb) of lift capability to LEO. Returning all three boosters to the launch site rather than landing them on drone ships would yield about 30 t of payload to LEO.
Maximum theoretical payload capacityFrom 2013 to 2016, SpaceX conducted parallel development of a reusable rocket architecture for Falcon 9, that applies to parts of Falcon Heavy as well. Early on, SpaceX had expressed hopes that all rocket stages would eventually be reusable. SpaceX has since demonstrated routine land and sea recovery of the Falcon 9 first stage, and have successfully recovered multiple payload fairings. In the case of Falcon Heavy, the two outer cores separate from the rocket earlier in the flight, and are thus moving at a lower velocity than in a Falcon 9 launch profile. For the first flight of Falcon Heavy, SpaceX had considered attempting to recover the second stage, but did not execute this plan.
Falcon Heavy was originally designed with a "propellant crossfeed" capability, whereby the center core engines would be supplied with fuel and oxidizer from the two side cores until their separation. This approach had previously been proposed by Vladimir Chelomei for the UR-700 launch system. Operating all engines at full thrust from launch, with fuel supplied mainly from the side boosters, would deplete the side boosters sooner, allowing their earlier separation to reduce the mass being accelerated. This would leave most of the center core propellant available after booster separation.
Musk stated in 2016 that crossfeed would not be implemented. Instead, the center booster throttles down shortly after liftoff to conserve fuel, and resumes full thrust after the side boosters have separated.
The published prices for Falcon Heavy launches have changed as development progressed, with announced prices for the various versions of Falcon Heavy priced at US$80–125 million in 2011, US$83–128 million in 2012, US$77–135 million in 2013, US$85 million for up to 6.4 t (14,000 lb) to GTO in 2014, US$90 million for up to 8 t (18,000 lb) to GTO in 2016.
From 2017 to early 2022, the price has been stated at US$150 million for 63.8 t (141,000 lb) to LEO or 26.7 t (59,000 lb) to GTO (fully expendable). This equates to a price of US$2,350 per kg to LEO and US$5,620 per kg to GTO. In 2022, the published price for a reusable launch was $97 million. In 2022 NASA contracted with SpaceX to launch the Nancy Grace Roman Space Telescope on a Falcon Heavy for approximately $255 million, including launch service and other mission related costs.
The nearest competing U.S. rocket was ULA's Delta IV Heavy with a LEO payload capacity of 28.4 t (63,000 lb) costs US$12,340 per kg to LEO and US$24,630 per kg to GTO. The Delta IV Heavy was retired in 2024.
In April 2015, SpaceX sent the U.S. Air Force an updated letter of intent outlining a certification process for its Falcon Heavy rocket to launch national security satellites. The process includes three successful flights of the Falcon Heavy including two consecutive successful flights, and the letter stated that Falcon Heavy can be ready to fly national security payloads by 2017. But in July 2017, SpaceX announced that the first test flight would take place in December 2017, pushing the second launch (Space Test Program 2) to June 2018. In May 2018, on the occasion of the first launch of the Falcon 9 Block 5 variant, a further delay to October 2018 was announced, and the launch was eventually pushed to 25 June 2019. The STP-2 mission used three Block 5 cores.
The Block 5-second stage allowed multiple reignitions to place its many payloads in multiple orbits. The launch was planned to include a 5 t (11,000 lb) ballast mass, but the ballast mass was later omitted from the 3.7 t (8,200 lb) total mass for the payload stack.
In March 2020, Falcon Heavy won the first award to a resupply mission to the Lunar Gateway, placing a new Dragon XL spacecraft on a translunar injection orbit.
If the boosters and center core are recovered, it only qualifies as a heavy-lift launch vehicle. /wiki/Heavy-lift_launch_vehicle
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