High-end concept to launch micro-satellites into low-earth-orbit based on combination of a two-stage rocket and a railgun-system

The electromagnetic railgun technology appears to be an interesting alternative to launch small payloads into Low Earth Orbit (LEO), as this may introduce lower launch costs. A high-end solution, based upon present state of the art technology, has been investigated to derive the technical boundary conditions for the application of such a new system. This paper presents the main concept and the design aspects of such propelled projectiles with special emphasis on flight mechanics aero-/thermodynamics, materials and propulsion characteristics. Launch angles and trajectory optimisation analyses are carried out by means of 3 degree of freedom simulations (3DOF). The aerodynamic form of the projectile is optimised to provoke minimum drag and low heat loads. The surface temperature distribution for critical zones is calculated with DLR developed Navier-Stokes codes TAU, HOTSOSE, whereas the engineering tool HF3T is used for time dependent calculations of heat loads and temperatures on project surface and inner structures. Furthermore, competing propulsions systems are considered for the rocket engines of both stages. The structural mass is analysed mostly on the basis of carbon fibre reinforced materials as well as classical aerospace metallic materials. Finally, this paper gives a critical overview of the technical feasibility and cost of small rockets for such missions.