IACs are held every year in a different country, and they are organized by the International Astronautical Federation (IAF).  Over 2,000 participants from sixty different countries attended the Naples Congress.  The IAF is the world’s largest international aerospace technology professional organization, with its Headquarters located in Paris, France.

Micheletti also served as a Co-Chairman of the entire Propulsion Symposium, which included the presentation of over 118 technical papers, and he Chaired a Technical Session titled  “Missions Enabled by New Propulsion Technology and Systems,”which included the presentation of 13 technical papers.

The MADA/UTRS/SPG presentation was extremely well received, and several Congress participants have since contacted both Micheletti and Karabeyoglu regarding potential collaboration opportunities.

Hybrid Rocket Test

The Sunnyvale, Calif.-based company, which was formed 13 years ago to develop low-cost, lightweight, environmentally friendly sources of space propulsion and power generation, carried out what was the fifth and longest in a series of test firings. The effort started in 2005 to develop hybrid propulsion scaling tools for the U.S. Air Force Research Lab at Edwards AFB, Calif.

“At this point, I think we are at the stage where we can transition this technology to a product,” Arif Karabeyoglu, SPG’s president and chief technology officer, told a post-test news briefing. “We are at a point where we can actually start to build hybrid rocket motors that deliver the thrust forces needed with the required amount of performance.”

The 22-in. composite case hybrid will undergo additional testing to verify a predicted 5,000-lb. thrust capability at vacuum, with a cumulative 100 sec. of operating time. Thrusting can be stopped and restarted.

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Arif Karabeyoglu said the company, which has been testing its rocket prototypes in Butte since 2009, has commercially viable technology and is looking to identify partners to help get the science into orbit.

The Space Propulsion Group Inc. and the Montana Aerospace Development Association held a two-day media event this week at the test facility, located west of Butte.

Arif Karabeyoglu explains the test set up of a 22 inch hybrid rocket engine prior to Friday's test at their facility in the Butte tax increment financing industrial district near Silver Bow. Photos by Walter Hinick - Montana Standard

The company successfully test-fired two different rocket technologies — an ammonia-fueled version on Thursday and two different sized hybrid fuel rockets on Friday. It also brought in public relations professionals who specialize in aerospace to help increase SPG Inc.’s reach and reputation within the space industry.

“We’re there,” said Karabeyoglu, SPG’s president. “I think we are at a game-changing trend of how we send things and people into space.”

Karabeyoglu arrived in Butte in 2009 with nothing more than an idea — an idea in which the Air Force, NASA, and commercial aerospace companies were interested — but a mostly untested idea nonetheless.

“I would be lying if I said I was extremely confident,” he said.

But it wasn’t just the Stanford University spinoff that came with questions. Montana Aerospace Development Association and the Butte AeroTec facility were awfully low profile as well.

“They didn’t know us, didn’t know this facility,” said Dave Micheletti, chairman of MADA. “But I had a certain amount of confidence or else we never would have entered into this agreement.”

Yet, its first year was an unmitigated success. Tests on small rocket motors went well and the 16th such firing was as close as Karabeyoglu would get to a “Eureka!” moment. It was the first time the motor burned stable, efficient and safely throughout the entirety of the test. Suddenly, SPG thought its project had legs.

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Dave Micheletti, UTRS Vice President of Aerospace and Energy Operations and a researcher at MADA, said that he is excited for the opportunity to design, build, and test a small hybrid rocket motor, as well as collaborate with MIT.

In Japan, which is about the size of Montana and holds a third of the United States’ population, it is a real challenge to find a facility in which to conduct high-tech aerospace tests. However, the Butte facility is a perfect match because it has the wide open spaces necessary for testing.

Aerospace technology research is often conducted using wind tunnels. Terry Spath, a MADA researcher, said that has certain disadvantages because researchers have to account for the walls of the tunnel changing wind flows. They can use modeling to account for those effects, but the best data come from testing on a track where the equipment can be pushed through the open air. Japan’s MIT has a “high speed test sled” that conducts such tests.

Down the road, MADA could explore building tracks for testing. Micheletti said they would explore two sets of tracks, including one that is over 1,000 feet long, which is optimal for certain types of tests. In the short term, MADA will not be hiring additional researchers to conduct the project; however, Micheletti said down the road that may be necessary.

Organized by the International Astronautical Federation (IAF), IACs are held every year in a different country.  Over 2,000 participants from 40 countries attended the Cape Town Congress.  The IAF is the world’s largest international aerospace technology professional organization, with headquarters located in Paris, France.

Micheletti also chaired two separate technical sessions—Hypersonic and Combined-Cycle Propulsion, and Missions Enabled by New Propulsion Technology and Systems—both of which included ten papers presented by authors from several different countries.  Finally, the IAF held its annual planning meetings in conjunction with the Cape Town Congress; and during the meetings, Micheletti was elected co-chairperson of the IAF Space Propulsion Committee.

The MADA/SPG presentation was well-received, and several Congress participants have since approached MADA regarding potential collaboration.  MADA’s growing participation in the IAF and its annual Congresses represent significant milestones in Montana’s initiative to become internationally recognized as a leader in aerospace technology.

Max Baucus at the GE Aviation Symposium in Billings Montana

As the keynote speaker at today’s event, Baucus highlighted the fact that more than 100 people were in attendance representing more than 60 Montana businesses.

“Today, we raised the profile of Montana companies on the global scale and sent the message far and wide that Montana is ready to do businesses. My thanks go out to GE Aviation for answering our call to provide this incredible opportunity to Montana businesses. Clearly, manufacturers across the state were hungry for this shot at expanding because they showed up in force to make this one of the largest symposiums ever for GE Aviation. This highlights Montana’s dynamic manufacturing sector. It also reinforces the fact that when presented with the right opportunity – Montana businesses have the work ethic and the know-how to compete on a global scale to create good-paying jobs here at home.”

Here’s a snapshot of what people are saying about the experience:

Mary Rumsey, Director of Butte-based Synesis 7:

“Max’s support has enabled Synesis7 to save the Navy and Marines millions and at the same time make them more technologically efficient and effective.  This GE Aviation event will enable Synesis7 to demonstrate that our technology can make GE even more efficient and effective.  It is all about cost savings in industry and in government.  This event provides an excellent showcase for our technology and will hopefully enable us to create more high paying jobs in the State.”

Harold Buck Elk, CEO of Fort Peck Tech Services, a Tribally owned and operated company:

“The GE Aviation symposium presented an important opportunity for Fort Peck Tech Services to meet with GE suppliers about exploring new opportunities in their global supply chain for Fort Peck Tech’s skilled workforce of machinists and welders. We are hopeful that the connections we made at the symposium will allow us to create jobs, generate revenues and create profits so that we can continue to grow in a manner designed to assist the Fort Peck Tribes in meeting their economic development goals.”

David Micheletti, VP of Aerospace and Energy Operations, Universal Technical Resource Services (UTRS) based in Butte:

“Learning how to become a qualified supplier for GE Aviation and being able to make them aware of our technical capabilities is an outstanding opportunity for us.  UTRS is currently developing advanced aerospace materials and propulsion technologies in Butte, and we believe that GE Aviation represents a major potential customer for us.  This work shop provides the direct access we need to begin developing a working relationship with this major aerospace firm.”      

Matt Kress, shop operations executive for GE Aviation:

“We’re grateful for Senator Baucus’ support as we seek to expand GE Aviation’s supplier base in Montana. We’re thrilled by how many businesses have signed up to participate in the symposium, and we look forward to fostering prosperous new relationships with suppliers throughout Big Sky Country.”

About the GE Aviation Symposium:

The symposium provides a chance for local small businesses interested in working with GE Aviation to receive coaching and mentoring through panel discussions and one-on-one sessions.  Following the event, GE Aviation will move forward to the next phase of relationship development with companies that best match its needs and quality requirements.

As a result of past symposiums, generally 40 percent of the participating companies moved on to the next phase of potentially doing business with GE, meaning they were able to submit price quotes to GE for aerospace parts and services on a study basis. Other companies will be provided valuable feedback on the next steps toward doing business with GE and connected with state resources to help move them to the next level.

GE in Montana

Following an invitation to Baucus’ Montana Economic Development Summit in 2007, GE built its Center of Excellence in Billings, which currently employs 186 Montanans and is looking to expand and add nearly 100 more jobs. Baucus brought GE Chairman and CEO, Jeff Immelt, to tour the Billings facility and participate in his Economic Development Summit in Butte in September. As a direct result, GE connected with Butte-based foundry and titanium castings company, SeaCast to create good paying jobs for Montanans.

Text of Senator Baucus Keynote Address at GE Aviation Symposium August 8, 2011 (remarks as prepared for delivery)

I am told GE has hosted events like this elsewhere in the country, from rural Nevada and North Dakota, to the major metropolitan areas of Southern California and Chicago.

Today’s event in Billings, filled with only Montana companies, is one of the biggest they have ever done.

It speaks to the growth of the manufacturing sector in Montana and its importance in the long-term health of our economy.

It is also a testimony to something I’ve witnessed time and time again:

When opportunity meets good, old fashioned Montana work ethic, the possibilities are endless.

With the collection of hardworking, innovative minds in the room, I am confident today’s event will be not only the biggest, but also the most successful.

I would like to thank GE for hosting today’s event.

Events like this open windows of opportunity to small businesses across the country.

GE has been a great partner and job creator in Montana.

They came to my Economic Development Summit in Butte in 2007, met with many Montana businesses, and liked what they saw.

They have since opened a financial services office just down the road.  It employs close to 200 Montanans.

Between the contracts currently being discussed, and the conversations resulting from today’s event, I am confident their presence in our state will grow, and the jobs they create will be many.

Our state is a great place to do business and our people possess a resilient and entrepreneurial spirit that is unique to Montana.

Montanans are tough.  Our work ethic is second to none.

If you want it, Montana businesses can provide it.

In addition to our world-class agricultural sector, our budding high-tech businesses are making important advances in medical research and energy development.

Customers around the globe use Montana manufactured goods to mine, to communicate, and to fish.

Montana manufactured goods have been shipped to every state in the union, every corner of the globe, and even to orbit the earth.

Manufacturers in Montana accounted for two billion dollars in output in 2010, including 1.2 billion dollars of exported goods.

The jobs they support come with high salaries, almost fifty percent higher than non-manufacturing jobs.

These jobs are critical to the long-term growth of the Montana economy, and we will do everything we can to secure more of these jobs.

As your Senator, I am working hard to create opportunities for Montana businesses

I am leading the charge in Congress to pass our pending free trade agreements with Korea, Colombia and Panama.

These agreements would provide important access to millions of new customers.

Earlier this year, I led a trade mission of Montana businesses to Brazil and Colombia.

Next month, my office will lead a mission to the oil sands of northern Alberta.

My Economic Development Summits bring business leaders from around the globe to see what we are doing in Montana.

Today’s event is just one piece in an overall effort to create good paying jobs in Montana.

Thank you again for being here, and I wish you the best of luck in your discussions.

If you hit any red tape or need a hand along the way, give me a call or email.

Let me know if there is anything we can do to help support your efforts to grow, prosper and make this symposium a real success in the long term for your businesses and your communities.

Spokesman Don Schmidt said the Helena facility, acquired by Boeing in November from Summit Aeronautics Group, is one of the facilities that makes the main landing gear beams for the 767.

He said the contract ensures the company will keep making 767s.

“That program, due to orders, was coming to an end,” he said. “This contract really extends it out for another 20 years.”

The contract, pushed hard by members of Washington’s congressional delegation, calls for Boeing to deliver 18 combat-ready tankers by 2017 and ultimately replace 179 of the Air Force’s 400 KC-135 tankers. The tankers are able to refuel other aircraft in mid-air, and also to carry cargo and passengers.

The contract may be the final chapter in a 10-year dispute over the tankers that over the years pitted former Senate Appropriations Chairman Ted Stevens, R-Alaska, against Sen. John McCain, R-Ariz., who for years protested the Air Force plan to give the deal to Boeing under a no-bid contract.

In the end, Boeing competed for the contract against the team of its American rival Northrop Grumman Corp. and EADS (the European aerospace consortium). EADS said it would decide whether to file a protest with the U.S. Government Accountability Office on the bidding process after a closer look at the Air Force explanation for the decision.

Boeing said the contract contributes to more than 50,000 jobs nationwide, including 11,000 in Washington state.

In a statement, U.S. Sen. Max Baucus, D-Mont., called the deal “a full-circle moment” for him.

He said that 13 years ago, when Boeing decided not to add additional firms to their list of potential suppliers, it shut Helena’s Summit Design and Manufacturing out of the process; he invited Boeing representatives to Helena to meet with Summit.

The Boeing staff was impressed enough to then recommend Summit be added to Boeing’s list of suppliers, according to Baucus, and it has been supplying Boeing aircraft ever since.

Baucus said Boeing officials told him the company spends more than $7.5 million annually in Montana with 30 suppliers and vendors.

By Sanjay Talwani  for Independent Record helenair.com

Reporter Sanjay Talwani: 447-4086 or sanjay.talwani@helenair.com

The first project titled “Solid Fuel Ramjet Technology Development and Testing” was awarded in December 2009, and it involves the development of a test-bench that will be capable of testing and evaluating various Solid Fuel RamJet (SFRJ) propulsion technologies. Initially, the test-bench is being used to test a paraffin wax propellant-based SFRJ technology that is being developed by SPG. SPG is a Stanford University-affiliated company that is developing advanced aerospace propulsion and energy technologies for both the U.S. government and private-sector. Ramjet propulsion technology is considered to be an attractive alternative to rockets for a number of high-speed flight applications because ramjets utilize oxygen in the atmosphere for combustion, as opposed to rockets that must carry an on-board oxygen supply. SPG’s paraffin wax technology offers additional advantages since its paraffin wax propellant does not require any plumbing hardware (resulting in significant weight savings), and it is extremely safe and environmentally friendly. The project is utilizing test hardware that MADA and the State of Montana moved to the Butte AeroTec Facility from Mojave, CA in 2007. This new Butte AeroTec capability represents a unique resource for the nation’s aerospace industry to test and evaluate advanced RamJet propulsion technologies and systems.

The second program titled “Development Of Ammonia-Based Fuels For Environmentally Friendly Power Generation” was initiated in November 2010 and involves the development and testing of Ammonia fuels technology for “Green” electric power generation. MADA and SPG are testing and evaluating Ammonia combustors utilizing the newly developed SFRJ test-bench. Ammonia is a very efficient combustion fuel because it contains a high concentration of hydrogen. Since Ammonia does not possess any carbon, it is also believed to be an attractive alternative to hydrocarbon-based fuels for power generation applications. Additionally, Ammonia can help mitigate the “Stranded-Energy” issues (i.e., limited access to electric power distribution grids) associated with renewable energy technologies such as wind and solar; as Ammonia could be produced at the wind/solar generation sites and then shipped by truck, rail, or pipeline to central power generation facilities to be combusted to produce carbon dioxide-free electricity. Finally, since Ammonia is a primary component in fertilizers, the project could significantly benefit the nation’s agriculture industry.

For additional information on MADA, the Butte AeroTec Facility, or these MBRCT projects, please contact David Micheletti at (406) 490-1395 or dmicheletti@utrs.com.

A rocket anchored to the ground at the Butte AeroTec facility consumes fuel made with candle wax and liquid oxygen.

The Butte AeroTec Facility involves a public-private partnership which includes MADA, SPG, Rhodia, Inc., State of Montana, City-County of Butte Silver Bow, Universal Technical Resource Services, Inc. (UTRS), Montana Economic Revitalization and Development Institute (MERDI), Butte Local Development Corporation (BLDC), Port of Montana, and Bert Mooney Airport Authority. The establishment of Butte AeroTec involved the re-location of aerospace propulsion test hardware from Mojave, CA to Butte, MT, as well as the modification of existing facilities at Rhodia Corporation’s former Butte, MT phosphorous production facility. The State of Montana funded the relocation of the test hardware from Mojave to Butte; and the City-County of Butte-Silver Bow has funded the development of new infrastructure at Butte AeroTec. Additionally, Butte AeroTec has been conducting Solid Fuel RamJet and Ammonia Fuels technology development and testing for the Montana Department of Commerce and Fuel Systems Safety Testing for the Virgin Galactic Corporation/Scaled Composites, Inc. SpaceShip II Commercial Space Vehicle.

The commissioning of Butte AeroTec represents a significant milestone in MADA’s initiative to make advanced energy and aerospace technology a significant part of Montana’s economy. MADA and its partners are now offering Butte AeroTec and its services as a user-friendly/low-cost alternative test and evaluation facility for advanced energy and aerospace technology customers.

Butte AeroTec Facility Hybrid Rocket Motor Test.