Falcon 9 Block 5

Falcon 9 Block 5

Bangabandhu-1 was the first payload launched by Falcon 9 Block 5
Function	Medium-lift launch vehicle
Manufacturer	SpaceX
Country of origin	United States
Size
Height	69.8 m (229 ft) with payload fairing 65.7 m (216 ft) with Crew Dragon 63.7 m (209 ft) with Dragon[1]
Diameter	3.7 m (12 ft)[2]
Mass	549,000 kg (1,210,000 lb)[2]
Stages	2
Capacity
Payload to LEO
Orbital inclination	28.5°
Mass	Expended: 22,800 kg (50,300 lb)[3] Reusable: 18,500 kg (40,800 lb)[4]
Payload to GTO
Orbital inclination	27°
Mass	Expended: 8,300 kg (18,300 lb)[3] Reusable: 5,500 kg (12,100 lb)[3]
Payload to TMI
Mass	4,000 kg (8,800 lb)[3]
Associated rockets
Family	Falcon 9
Based on	Falcon 9 Full Thrust
Comparable	Ariane 5 Atlas V Long March 3B/E Proton-M
Launch history
Status	Active
Launch sites	Cape Canaveral, SLC-40 Kennedy, LC-39A Vandenberg, SLC-4 Vandenberg, SLC-6 (planned)
Total launches	341
Success(es)	340
Failure(s)	1 (Starlink Group 9–3[a])
Landings	344 / 349 attempts[b]
First flight	11 May 2018 (11 May 2018) (Bangabandhu-1)
Type of passengers/cargo	SpaceX Dragon Starlink DART Euclid Galileo GPS Block IIIA IXPE KPLO Nova-C PACE Hera
First stage
Height	41.2 m (135 ft)
Diameter	3.7 m (12 ft)
Powered by	9 × Merlin 1D+
Maximum thrust	7.6 MN (1,700,000 lbf)[5][6]
Propellant	LOX / RP-1[7]
Second stage (standard)
Height	13.8 m (45 ft)
Diameter	3.7 m (12 ft)
Powered by	1 × Merlin 1D Vacuum
Maximum thrust	934 kN (210,000 lbf)[2]
Propellant	LOX / RP-1
Second stage (short nozzle)
Height	13.6 m (45 ft)
Diameter	3.7 m (12 ft)
Powered by	1 × Merlin 1D Vacuum
Maximum thrust	840 kN (190,000 lbf)[2]
Propellant	LOX / RP-1
[edit on Wikidata]

Falcon 9 Block 5 is a partially reusable, human-rated, two-stage-to-orbit, medium-lift launch vehicle^[c] designed and manufactured in the United States by SpaceX. It is the fifth major version of the Falcon 9 family and the third version of the Falcon 9 Full Thrust.^[8][9] It is powered by Merlin 1D engines burning rocket-grade kerosene (RP-1) and liquid oxygen (LOX).

The main changes from Block 3 (the original Falcon 9 Full Thrust) to Block 5 are higher-thrust engines and improvements to the landing legs along with numerous other small changes to streamline recovery and re-use of first-stage boosters and increase the production rate. Each Block 5 booster is designed to fly ten times with only minor maintenance between launches and potentially up to 100 times with periodic refurbishment.

In 2018, Block 5 succeeded the transitional Block 4 version. The maiden flight of the Block 5 launched the satellite Bangabandhu-1 on May 11, 2018. The CRS-15 mission on June 29, 2018, was the last to be launched on a Block 4 rocket, completing the transition to an all-Block 5 fleet.^[10][11]

The Block 5 design changes are principally driven by upgrades needed for NASA's Commercial Crew program and National Security Space Launch requirements.^[12] They include performance upgrades, manufacturing improvements, and increase the margin for demanding customers.^[13]

In April 2017, SpaceX CEO Elon Musk said that Block 5 will feature 7–8% more thrust by uprating the engines (from 176,000 pounds-force (780,000 N) to 190,000 pounds-force (850,000 N) per engine).^[14] Block 5 includes an improved flight control system for an optimized angle of attack on the descent, lowering landing fuel requirements.

For reusability endurance:

• expected to be able to fly ten times with only minor maintenance between launches^[15][16] achieved in 2021^[17]
• potentially fly up to 100 times with periodic refurbishment^[16][15][18]
• a reusable heat shield protecting the engines and plumbing at the base of the rocket;
• more temperature-resistant cast and machined titanium grid fins;^[19]
• a thermal-protection coating on the first stage to limit reentry heating damage, including a black thermal protection layer on the landing legs, raceway, and interstage;
• redesigned and requalified more robust and longer life valves;
• redesigned composite overwrapped pressure vessels (COPV 2.0) for helium, to avoid oxygen freezing inside the structure of the tanks that lead to rupture.

For rapid reusability:

• reduced refurbishment between flights;^[16]
• a set of retractable landing legs for rapid recovery and shipping.^[20]
• the Octaweb^[21] structure is bolted together instead of welded, reducing manufacturing time.^[22]

Since the debut of Block 5, SpaceX has continued to iterate on its design, manufacturing processes, and operational procedures.^[23] Among other changes, the initial Block 5 boosters did not have the redesigned composite overwrapped pressure vessel (COPV2) tanks.^[24] The first booster with COPV2 tanks was booster B1047 on the Es'hail 2 mission on November 15, 2018, and the second booster using the COPV2 tanks was CRS-16/B1050, which had its first launch on December 5, 2018.^[25] Later Block 5 boosters are also easier to prepare for flight, so SpaceX "prefer to retire" older cores by assigning them to expendable missions when possible.^[26]

A pressure relief valve was added to the grid fins’ hydraulic system following a stall that resulted in a landing failure in 2018.^[27][28] Similarly, after a booster was damaged at sea in 2022, much of the fleet was upgraded with "self-leveling" landing legs. These legs help ensure the booster can be properly secured to the Octograbber, even in suboptimal sea states.^[29]

To improve the rocket's performance, SpaceX has tweaked throttle settings and separation timings.^[23][30]

SpaceX CRS-18 featured a Falcon mission-extension kit to the standard second stage, which equipped the second stage with a dark-painted band (for thermal control), extra COPVs for pressurization control, and additional TEA-TEB ignition fluid. The upgrades afforded the second stage with the endurance needed to inject the payloads directly into geosynchronous or high energy orbit where the second stage needs hours after launch.^[31] Based on mission requirements, they are Medium Coast & Long Coast kits, i.e., the number of helium bottles for pressurization and added batteries for power and other hardware to make sure that the fuel and stages systems operate as long as needed.^[32][33]

The Transporter-7 mission marked the debut of a second stage with a Merlin 1D Vacuum engine with a shorter nozzle extension designed to accelerate production and reduce costs. Unlike the first stage, the second stage on the Falcon 9 is not reused. This variant sacrifices 10% thrust in exchange for a 75% reduction in material usage, primarily the rare metal niobium. As a result, SpaceX can triple its launch frequency using the same amount of this critical resource. Due to its reduced performance, this nozzle is exclusively used on missions with lower performance requirements.^[32][34][35]

The NASA certification processes of the 2010s specified seven flights of any launch vehicle without major design changes before the vehicle would be NASA-certified for human spaceflight, and allowed to fly NASA astronauts.^[24][25]

The Block 5 design launched astronauts for the first time on May 30, 2020, on a NASA-contracted flight, Crew Dragon Demo-2.^[36] This was the first crewed orbital spaceflight launched from the United States since the final Space Shuttle mission in 2011, and the first ever operated by a commercial provider.^[37]

Specifications and characteristics are as follows:^[38][39][40]

• List of Falcon 9 and Falcon Heavy launches
• List of Falcon 9 Block 5 first-stage boosters

• Link to Falcon User's Guide Archived December 2, 2020, at the Wayback Machine, by SpaceX. Updated in January 2019 specifically for Block 5 upgrades.