NASA’s Orion EFT 1 crew module departs Neil Armstrong Operation and Checkout Building on Sept. 11, 2014 at the Kennedy Space Center, FL, beginning the long journey to the launch pad and planned liftoff on Dec. 4, 2014. Credit: Ken Kremer - kenkremer.com
NASA’s Orion EFT 1 crew module departs Neil Armstrong Operation and Checkout Building on Sept. 11, 2014 at the Kennedy Space Center, FL, beginning the long journey to the launch pad and planned liftoff on Dec. 4, 2014. Credit: Ken Kremer – kenkremer.com
Story updated[/caption]
KENNEDY SPACE CENTER – NASA’s first space worthy Orion crew module rolled out of its assembly facility at the Kennedy Space Center (KSC) on Thursday, Sept. 11, taking the first step on its nearly two month journey to the launch pad and planned blastoff this coming December.
The Orion spacecraft is NASA’s next generation human rated vehicle and is scheduled to launch on its maiden uncrewed mission dubbed Exploration Flight Test-1 (EFT-1) in December 2014.
Orion’s assembly was just completed this past weekend by technicians and engineers from prime contractor Lockheed Martin inside the agency’s Neil Armstrong Operations and Checkout (O & C) Facility. They have been working 24/7 to manufacture the capsule and prepare it for launch.
“I’m excited as can be,” said Scott Wilson, NASA’s Orion Manager of Production Operations at KSC during the move. “For some of us this has been ten years in the making.”
The black tiled Orion crew module (CM) was stacked atop an inert white colored service module (SM) in the O & C high bay in June. The CM/SM stack was placed on top of the Orion-to-stage adapter ring that will mate them to the booster rocket. Altogether the capsule, service module and adapter ring stack stands 40 feet tall and 16 feet in diameter.
“This is awesome,” Bob Cabana, Kennedy Space Center director and former shuttle commander, told the media during the rollout.
NASA’s Orion EFT 1 crew module enters the Payload Hazardous Servicing Facility on Sept. 11, 2014 at the Kennedy Space Center, FL, beginning the long journey to the launch pad and planned liftoff on Dec. 4, 2014. Credit: Ken Kremer – kenkremer.com
Workers subsequently covered the crew module and its thermal insulating tiles with a see through foil to shield the capsule and blanket it under a protective climate controlled atmosphere to guard against humidity.
The CM/SM stack was then lifted and placed onto a 36-wheeled transporter and moved about 1 mile to a KSC facility named the Payload Hazardous Servicing Facility (PHFS) for fueling. The move took about an hour.
“Orion will stay at the PHFS for about a month,” Wilson told me in a KSC interview during the move.
Orion will be fueled with ammonia and hyper-propellants for its flight test, said Wilson.
NASA’s completed Orion EFT 1 crew module loaded on wheeled transporter during move to the Payload Hazardous Servicing Facility (PHSF) on Sept. 11, 2014 at the Kennedy Space Center, FL. Credit: Ken Kremer – kenkremer.com
The fueled Orion will then move yet again to the Launch Abort System Facility (LASF) for the installation of the launch abort system (LAS).
The full Orion stack will rollout to Space Launch Complex 37 in early November.
“Nothing about building the first of a brand new space transportation system is easy,” said Mark Geyer, Orion Program manager.
“But the crew module is undoubtedly the most complex component that will fly in December. The pressure vessel, the heat shield, parachute system, avionics — piecing all of that together into a working spacecraft is an accomplishment. Seeing it fly in three months is going to be amazing.”
The Orion EFT-1 test flight is slated to soar to space atop the mammoth, triple barreled United Launch Alliance (ULA) Delta IV Heavy rocket from Cape Canaveral, Florida, on Dec. 4, 2014.
The state-of-the-art Orion spacecraft will carry America’s astronauts on voyages venturing farther into deep space than ever before – past the Moon to Asteroids, Mars and Beyond!
The two-orbit, four and a half hour EFT-1 flight will lift the Orion spacecraft and its attached second stage to an orbital altitude of 3,600 miles, about 15 times higher than the International Space Station (ISS) – and farther than any human spacecraft has journeyed in 40 years.
Stay tuned here for Ken’s continuing Orion, SLS, Boeing, Sierra Nevada, Orbital Sciences, SpaceX, commercial space, Curiosity, Mars rover, MAVEN, MOM and more Earth and planetary science and human spaceflight news.
Scott Wilson, NASA’s Orion Manager of Production Operations at KSC and Ken Kremer/Universe Today discuss Orion EFT-1 mission during capsule rollout on Sept. 11, 2014 at the Kennedy Space Center, FL. Credit: Ken Kremer – kenkremer.com
NASA’s first completed Orion crew module sits atop its service module at the Neil Armstrong Operations and Checkout Facility at Kennedy Space Center in Florida in early September 2014. The crew and service module will be transferred soon to another facility for fueling. Credit: NASA/Rad Sinyak
This past weekend technicians completed assembly of NASA’s first Orion crew module at the agency’s Neil Armstrong Operations and Checkout (O & C) Facility at the Kennedy Space Center (KSC) in Florida, signifying a major milestone in the vehicles transition from fabrication to full scale launch operations.
The black Orion crew module (CM) sits stacked atop the white service module (SM) in the O & C high bay photos, shown above and below.
The black area is comprised of the thermal insulating back shell tiles. The back shell and heat shield protect the capsule from the scorching heat of re-entry into the Earth’s atmosphere at excruciating temperatures reaching over 4000 degrees Fahrenheit (2200 C) – detailed in my story here.
Technicians and engineers from prime contractor Lockheed Martin subsequently covered the crew module with protective foil. The CM/SM stack was then lifted and moved for the installation of the Orion-to-stage adapter ring that will mate them to the booster rocket.
Lifting and stacking NASA’s first completed Orion crew and service modules at the Neil Armstrong Operations and Checkout Facility at Kennedy Space Center in Florida in early September 2014. Credit: NASA/Rad Sinyak
At the conclusion of the EFT-1 flight, the detached Orion capsule plunges back and hits the Earth’s atmosphere at 20,000 MPH (32,000 kilometers per hour).
“That’s about 80% of the reentry speed experienced by the Apollo capsule after returning from the Apollo moon landing missions,” Scott Wilson, NASA’s Orion Manager of Production Operations at KSC, told me during an interview at KSC.
The next step in Orion’s multi stage journey to the launch pad follows later this week with transport of the CM/SM stack to another KSC facility named the Payload Hazardous Servicing Facility (PHFS) for fueling, before moving again for the installation of the launch abort system (LAS) in yet another KSC facility.
Stacking NASA’s first completed Orion crew and service modules at the Neil Armstrong Operations and Checkout Facility at Kennedy Space Center in Florida in early September 2014. Credit: NASA/Rad Sinyak
The Orion EFT-1 test flight is slated to soar to space atop the mammoth, triple barreled United Launch Alliance (ULA) Delta IV Heavy rocket from Cape Canaveral, Florida, on Dec. 4, 2014 .
The state-of-the-art Orion spacecraft will carry America’s astronauts on voyages venturing farther into deep space than ever before – past the Moon to Asteroids, Mars and Beyond!
NASA’s first completed Orion crew and service modules being moved inside the High Bay at the Neil Armstrong Operations and Checkout Facility at Kennedy Space Center in Florida in early September 2014. Credit: NASA/Rad Sinyak
NASA is simultaneously developing a monster heavy lift rocket known as the Space Launch System or SLS, that will eventually launch Orion on its deep space missions.
The maiden SLS/Orion launch on the Exploration Mission-1 (EM-1) unmanned test flight is now scheduled for no later than November 2018 – read my story here.
SLS will be the world’s most powerful rocket ever built.
The two-orbit, four and a half hour EFT-1 flight will lift the Orion spacecraft and its attached second stage to an orbital altitude of 3,600 miles, about 15 times higher than the International Space Station (ISS) – and farther than any human spacecraft has journeyed in 40 years.
Orion service module assembly in the Operations and Checkout facility at Kennedy Space Center – now renamed in honor of Neil Armstrong. Credit: Ken Kremer/kenkremer.com
The EFT-1 mission will test the systems critical for EM-1 and future human missions to deep space that follow.
The Orion EFT-1 capsule has come a long way over the past two years of assembly.
The bare bones, welded shell structure of the Orion crew cabin arrived at KSC in Florida from NASA’s Michoud facility in New Orleans in June 2012 and was officially unveiled at a KSC welcoming ceremony on 2 July 2012, attended by this author.
“Everyone is very excited to be working on the Orion. We have a lot of work to do. It’s a marathon not a sprint to build and test the vehicle,” said Jules Schneider, Orion Project manager for Lockheed Martin at KSC, during an exclusive 2012 interview with Universe Today inside the Orion clean room at KSC.
Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) mock up stack inside the transfer aisle of the Vehicle Assembly Building (VAB) at the Kennedy Space Center (KSC) in Florida. Service module at bottom. Credit: Ken Kremer/kenkremer.com
Stay tuned here for Ken’s continuing Orion, SLS, Boeing, Sierra Nevada, Orbital Sciences, SpaceX, commercial space, Curiosity, Mars rover, MAVEN, MOM and more Earth and planetary science and human spaceflight news.
Orion crew module back shell tiles and panels inside the Neil Armstrong Operations and Checkout Building high bay at the Kennedy Space Center in Florida. Credit: Ken Kremer – kenkremer.comOrion EFT-1 capsule under construction inside the Structural Assembly Jig at the Operations and Checkout Building (O & C) at the Kennedy Space Center (KSC); Jules Schneider, Orion Project Manager for Lockheed Martin and Ken Kremer, Universe Today. Credit: Ken Kremer – kenkremer.com
A test version of NASA’s Orion manned spacecraft descends under its three main parachutes above the U.S. Army Proving Ground in Arizona in the agency’s most difficult test of the parachutes system’s performance to prepare Orion for its first trip to space in December 2014. Credit: NASA/Rad Sinyak
A test version of NASA’s Orion deep space capsule has completed its most complex and last full flight-like parachute drop test on June 25 ahead of the maiden launch on the EFT-1 mission now slated for early December 2014.
The descent test was conducted at an altitude of 35,000 feet over the Arizona desert at the U.S. Army’s Yuma Proving Ground by pulling the test vehicle out of a huge C-17 cargo aircraft.
The test also included the addition of several added stress tests to check out the ability of the parachute system to compensate and examine capsule and astronaut crew survival via several potential failure modes.
For example, engineers rigged one of the main parachutes to skip the intermediate phase of the three-phase process to unfurl each of Orion’s three parachutes, called reefing.
“This tested whether one of the main parachutes could go directly from opening a little to being fully open without an intermediary step, proving the system can tolerate potential failures,” according to NASA.
The goal is to prove that that parachute system will slow Orion to ensure a safe landing speed for the astronaut crews returning from deep space missions to the Moon, Asteroids and eventually Mars.
The Orion crew module for Exploration Flight Test-1 is shown in the Final Assembly and System Testing (FAST) Cell, positioned over the service module just prior to mating the two sections together. Credit: NASA/Rad Sinyak
“We’ve put the parachutes through their paces in ground and airdrop testing in just about every conceivable way before we begin sending them into space on Exploration Flight Test (EFT)-1 before the year’s done,” said Orion Program Manager Mark Geyer in a state
“The series of tests has proven the system and will help ensure crew and mission safety for our astronauts in the future.”
Orion is slated to launch on its inaugural unmanned EFT-1 test flight in December 2014 atop the mammoth, triple barreled United Launch Alliance (ULA) Delta IV Heavy rocket from Cape Canaveral, Florida.
Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) mock up stack inside the transfer aisle of the Vehicle Assembly Building (VAB) at the Kennedy Space Center (KSC) in Florida. Service module at bottom. Credit: Ken Kremer/kenkremer.com
This test also marked the last time that the entire parachute sequence involving the deployment of all three 116 foot-wide main chutes will be tested before the December launch.
For some of the parachutes, this was the highest altitude drop test attempted.
“Engineers also put additional stresses on the parachutes by allowing the test version of Orion to free fall for 10 seconds, which increased the vehicle’s speed and aerodynamic pressure,” NASA noted in a statement.
The parachute deployment and unfurling can only begin after jettisoning of the spacecraft’s forward bay cover. The chutes are housed below the cover which protects the chutes until reentry into Earth’s atmosphere.
The two-orbit, four- hour EFT-1 flight will lift the Orion spacecraft and its attached second stage to an orbital altitude of 3,600 miles, about 15 times higher than the International Space Station (ISS) – and farther than any human spacecraft has journeyed in 40 years.
One of the primary goals of NASA’s eagerly anticipated Orion EFT-1 uncrewed test flight is to test the efficacy of the heat shield in protecting the vehicle – and future human astronauts – from excruciating temperatures reaching 4000 degrees Fahrenheit (2200 C) during scorching re-entry heating.
At the conclusion of the EFT-1 flight, the detached Orion capsule plunges back and re-enters the Earth’s atmosphere at 20,000 MPH (32,000 kilometers per hour).
“That’s about 80% of the reentry speed experienced by the Apollo capsule after returning from the Apollo moon landing missions,” Scott Wilson, NASA’s Orion Manager of Production Operations at KSC, told me during an interview at KSC.
The parachute system comprising of two drogue parachutes and a trio of main parachutes – nearly the size of a football field – will then unfurl to slow Orion down to just 20 mph for a safe splashdown and recovery by the US Navy in the Pacific Ocean.
The Orion EFT-1 mission will end with a splashdown in the Pacific Ocean. During the stationary recovery test of Orion at Norfolk Naval Base on Aug. 15, 2013, US Navy divers attached tow lines and led the test capsule to a flooded well deck on the USS Arlington. Credit: Ken Kremer/kenkremer.com.
Another drop test scheduled for August will test the combined failure of one drogue parachute and one main parachute, as well as new parachute design features, says NASA.
Meanwhile, Orion’s prime contractor Lockheed Martin is finishing assembly and test operations of the EFT-1 capsule inside the Operations and Checkout Facility (O & C) at the Kennedy Space Center (KSC) flying in December’s launch
Stay tuned here for Ken’s continuing Orion, Orbital Sciences, SpaceX, commercial space, Curiosity, Mars rover, MAVEN, MOM and more planetary and human spaceflight news.
Lockheed Martin and NASA engineers are installing the largest heat shield ever built onto the Orion EFT-1 spacecraft’s crew module at the Kennedy Space Center. Liftoff is slated for late Fall 2014. Credit: Lockheed Martin
Lockheed Martin and NASA engineers are installing the largest heat shield ever built onto the Orion EFT-1 spacecraft’s crew module at the Kennedy Space Center. Liftoff is slated for late Fall 2014. Credit: Lockheed Martin
Story updated[/caption]
In a key milestone, technicians at the Kennedy Space Center (KSC) in Florida have attached the world’s largest heat shield to a pathfinding version of NASA’s Orion crew capsule edging ever closer to its inaugural unmanned test flight later this Fall on a crucial mission dubbed Exploration Flight Test-1 (EFT-1).
One of the primary goals of NASA’s eagerly anticipated Orion EFT-1 uncrewed test flight is to test the efficacy of the heat shield in protecting the vehicle – and future human astronauts – from excruciating temperatures reaching 4000 degrees Fahrenheit (2200 C) during scorching re-entry heating.
A trio of parachutes will then unfurl to slow Orion down for a splashdown in the Pacific Ocean.
Orion is NASA’s next generation human rated vehicle now under development to replace the now retired space shuttle. The state-of-the-art spacecraft will carry America’s astronauts on voyages venturing farther into deep space than ever before – past the Moon to Asteroids, Mars and Beyond!
“The Orion heat shield is the largest of its kind ever built. Its wider than the Apollo and Mars Science Lab heat shields,” Todd Sullivan told Universe Today. Sullivan is the heat shield senior manager at Lockheed Martin, Orion’s prime contractor.
The heat shield measures 16.5 feet (5 m) in diameter.
Lockheed Martin and NASA technicians mated the heat shield to the bottom of the capsule during assembly work inside the Operations and Checkout High Bay facility at KSC.
“Holes were drilled into the heat shield from the inside to the outside at the structural attached points at the underside of the crew module,” said Jules Schneider, Orion Project manager for Lockheed Martin at KSC, during a recent exclusive interview by Universe Today inside the Orion clean room at KSC.
“Then its opened up from the outside and bolted in place underneath. Closeout plugs made of Avcoat are then installed to close it up and seal the gaps,” Schneider explained.
The heat shield is constructed from a single seamless piece of Avcoat ablator, that was applied by engineers at Textron Defense System near Boston, Mass.
“They applied the Avcoat ablater material to the outside. That’s what protects the spacecraft from the heat of reentry,” Sullivan explained.
The ablative material will wear away as it heats up during the capsules atmospheric re-entry thereby preventing the 4000 degree F heat from being transferred to the rest of the capsule and saving it and the human crew from utter destruction.
Coming together! Orion’s heat shield and crew module in position for mating operations at NASA KSC. Credit: NASA
Orion EFT-1 is slated to launch in December 2014 atop the mammoth, triple barreled United Launch Alliance (ULA) Delta IV Heavy rocket, currently the most powerful booster in America’s fleet.
The Delta IV Heavy is the only rocket with sufficient thrust to launch the Orion EFT-1 capsule and its attached upper stage to its intended orbit of 3600 miles altitude above Earth – about 15 times higher than the International Space Station (ISS) and farther than any human spacecraft has journeyed in 40 years.
At the conclusion of the two-orbit, four- hour EFT-1 flight, the detached Orion capsule plunges back and re-enters the Earth’s atmosphere at 20,000 MPH (32,000 kilometers per hour).
“That’s about 80% of the reentry speed experienced by the Apollo capsule after returning from the Apollo moon landing missions,” Scott Wilson, NASA’s Orion Manager of Production Operations at KSC, told me during an interview at KSC.
“The big reason to get to those high speeds during EFT-1 is to be able to test out the thermal protection system, and the heat shield is the biggest part of that.”
“Numerous sensors and instrumentation have been specially installed on the EFT-1 heat shield and the back shell tiles to collect measurements of things like temperatures, pressures and stresses during the extreme conditions of atmospheric reentry,” Wilson explained.
Orion heat shield attached to the bottom of the capsule by engineers during assembly work inside the Operations and Checkout High Bay facility at KSC. Credit: NASA
The heat shield arrived at KSC in December 2013 loaded inside NASA’s Super Guppy aircraft while I was onsite. Read my story – here.
The data gathered during the unmanned EFT-1 flight will aid in confirming. or refuting, design decisions and computer models as the program moves forward to the first flight atop NASA’s mammoth SLS booster in late 2017 on the EM-1 mission and more human crewed missions thereafter.
Orion EFT-1 heat shield is off loaded from NASA’s Super Guppy aircraft after transport from Manchester, N.H., and arrival at the Kennedy Space Center in Florida on Dec. 5, 2013. Credit: Ken Kremer/kenkremer.com
Recently, the EFT-1 launch was postponed three months from its long planned slot in mid-September to December 2014 when NASA was ordered to make way for the accelerated launch of recently declassified US Air Force Space Surveillance satellites that were given a higher priority.
The covert Geosynchronous Space Situational Awareness Program, or GSSAP, satellites were only unveiled in Feb. 2014 during a speech by General William Shelton, commander of the US Air Force Space Command.
Despite the EFT-1 launch postponement, Kennedy Space Center Director Bob Cabana said technicians are pressing forward and continue to work around the clock at KSC in order to still be ready in time to launch by the original launch window that opens in mid- September 2014.
“The contractor teams are working to get the Orion spacecraft done on time for the December 2017 launch,” said Cabana.
“They are working seven days a week in the Operations and Checkout High Bay facility to get the vehicle ready to roll out for the EFT-1 mission and be mounted on top of the Delta IV Heavy.”
“I can assure you the Orion will be ready to go on time, as soon as we get our opportunity to launch that vehicle on its first flight test and that is pretty darn amazing.”
“Our plan is to have the Orion spacecraft ready because we want to get EFT-1 out so we can start getting the hardware in for Exploration Mission-1 (EM-1) and start processing for that vehicle that will launch on the Space Launch System (SLS) rocket in 2017,” Cabana told me
Concurrently, new American-made private crewed spaceships are under development by SpaceX, Boeing and Sierra Nevada – with funding from NASA’s Commercial Crew Program (CCP) – to restore US capability to ferry US astronauts to the International Space Station (ISS) and back to Earth by late 2017.
Read my exclusive new interview with NASA Administrator Charles Bolden explaining the importance of getting Commercial Crew online – here.
Two of the three United Launch Alliance (ULA) Delta IV heavy boosters for NASA’s upcoming Orion Exploration Flight Test-1 (EFT-1) mission were unveiled during a media event inside the Horizontal Integration Facility at Launch Complex 37 at Cape Canaveral Air Force Station in Florida. Kennedy Space Center Director Bob Cabana spoke to the media along with NASA Associate Administrator Robert Lightfoot and Tony Taliancich, ULA director of East Coast Launch Operations. Credit: Ken Kremer- kenkremer.com
Stay tuned here for Ken’s continuing Orion, Boeing, SpaceX, Orbital Sciences, commercial space, Curiosity, Mars rover, MAVEN, MOM and more planetary and human spaceflight news.
Ken Kremer Delta 4 Heavy rocket and super secret US spy satellite roar off Pad 37 on June 29, 2012 from Cape Canaveral, Florida. NASA’s Orion EFT-1 capsule will blastoff atop a similar Delta 4 Heavy Booster in December 2014. Credit: Ken Kremer- kenkremer.com[/caption]
An artist concept shows Orion as it will appear in space for the Exploration Flight Test-1 attached to a Delta IV second stage. Credit: NASA
When NASA’s next generation human spaceflight vehicle Orion blasts off on its maiden unmanned test flight later this year, a radiation experiment designed by top American high school students will soar along and play a key role in investigating how best to safeguard the health of America’s future astronauts as they venture farther into deep space than ever before – past the Moon to Asteroids, Mars and Beyond!
The student designed radiation experiment was the centerpiece of a year-long Exploration Design Challenge (EDC) competition sponsored by NASA, Orion prime contractor Lockheed Martin and the National Institute of Aerospace, and was open to high school teams across the US.
The winning experiment design came from a five-member team of High School students from the Governor’s School for Science and Technology in Hampton, Va. and was announced by NASA Administrator Charles Bolden at the opening of the 2014 U.S.A Science and Engineering Festival held in Washington, DC on April 25.
Orion Exploration Design Challenge Winning Team from Hampton,Va
NASA’s Administrator, Charles Bolden (left), President/CEO of Lockheed Martin, Marillyn Hewson (right), and astronaut Rex Walheim (back row) pose for a group photo with the winning high school team in the Exploration Design Challenge. Team ARES from the Governors School for Science and Technology in Hampton, Va. won the challenge with their radiation shield design, which will be built and flown aboard the Orion/EFT-1. Credit: NASA/Aubrey Gemignani
The goal of the EDC competition was to build and test designs for shields to minimize radiation exposure and damaging human health effects inside NASA’s new Orion spacecraft slated to launch into orbit during the Exploration Flight Test-1 (EFT-1) pathfinding mission in December 2014. See experiment design photo herein.
This radiation shielding experiment designed by High School students from the Governor’s School for Science and Technology in Hampton, Va., was chosen as the winner of the Exploration Design Challenge contest and will fly aboard NASA’s Orion EFT-1 mission in December 2014. Credit: Lockheed Martin
During the EFT-1 flight, Orion will fly through the dense radiation field that surrounds the Earth in a protective shell of electrically charged ions – known as the Van Allen Belt – that begins 600 miles above Earth.
No humans have flown through the Van Allen Belt in more than 40 years since the Apollo era.
Team ARES from Hampton VA was chosen from a group of five finalist teams announced in March 2014.
“This is a great day for Team ARES – you have done a remarkable job,” said NASA Administrator Bolden.
“I really want to congratulate all of our finalists. You are outstanding examples of the power of American innovation. Your passion for discovery and the creative ideas you have brought forward have made us think and have helped us take a fresh look at a very challenging problem on our path to Mars.”
Since Orion EFT-1 will climb to an altitude of some 3,600 miles, the mission offers scientists the opportunity to understand how to mitigate the level of radiation exposure experienced by the astronaut crews who will be propelled to deep space destinations beginning at the end of this decade.
Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) mock up stack inside the transfer aisle of the Vehicle Assembly Building (VAB) at the Kennedy Space Center (KSC) in Florida. Credit: Ken Kremer/kenkremer.com
The student teams used a simulation tool named OLTARIS, the On- Line Tool for the Assessment of Radiation in Space, used by NASA scientists and engineers to study the effects of space radiation on shielding materials, electronics, and biological systems.
Working with mentors from NASA and Lockheed Martin, each team built prototypes and used the OLTARIS program to calculate how effective their designs – using several materials at varying thicknesses – were at shielding against radiation in the lower Van Allen belt.
“The experiment is a Tesseract Design—slightly less structurally sound than a sphere, as the stresses are located away from the cube on the phalanges. The materials and the distribution of the materials inside the tesseract were determined through research and simulation using the OLTARIS program,” Lockheed Martin spokeswoman Allison Rakes told me.
The students conducted research to determine which materials were most effective at radiation shielding to protect a dosimeter housed inside – an instrument used for measuring radiation exposure.
“The final material choices and thicknesses are (from outermost to innermost): Tantalum (.0762 cm/ .030 in), Tin (.1016 cm/ .040 in), Zirconium (.0762 cm/ .030 in), Aluminum (.0762 cm/ .030 in), and Polyethylene (9.398 cm/ 3.70 in),” according to Rakes.
At the conclusion of the EFT-1 flight, the students will use the measurement to determine how well their design protected the dosimeter.
But first Team ARES needs to get their winning proposal ready for flight. They will work with a NASA and Lockheed Martin spacecraft integration team to have the experimental design approved, assembled and installed into Orion’s crew module.
All the students hard work will pay off this December when Lockheed Martin hosts Team ARES at the Kennedy Space Center in Florida to witness the liftoff of their important experiment inside Orion atop the mammoth triple barreled Delta IV Heavy booster.
46 teams from across the country submitted engineering experiment proposals to the EDC aimed at stimulating students to work on a science, technology, engineering and math (STEM) project that tackles one of the most significant dangers of human space flight — radiation exposure.
“The Exploration Design Challenge has already reached 127,000 students worldwide – engaging them in real-world engineering challenges and igniting their imaginations about the endless possibilities of space discovery,” said Lockheed Martin Chairman, President and CEO Marillyn Hewson.
The two-orbit, four- hour EFT-1 flight will lift the Orion spacecraft and its attached second stage to an orbital altitude of 3,600 miles, about 15 times higher than the International Space Station (ISS) – and farther than any human spacecraft has journeyed in 40 years.
Stay tuned here for Ken’s continuing Orion, Orbital Sciences, SpaceX, commercial space, LADEE, Curiosity, Mars rover, MAVEN, MOM and more planetary and human spaceflight news.
Delta 4 Heavy rocket and super secret US spy satellite roar off Pad 37 on June 29, 2012 from Cape Canaveral, Florida. NASA’s Orion EFT-1 capsule will blastoff atop a similar Delta 4 Heavy Booster in December 2014. Credit: Ken Kremer- kenkremer.com
Orion EFT-1 heat shield is off loaded from NASA’s Super Guppy aircraft after transport from Manchester, N.H., and arrival at the Kennedy Space Center in Florida on Dec. 5, 2013. Credit: Ken Kremer/kenkremer.com
Orion EFT-1 heat shield is off loaded from NASA’s Super Guppy aircraft after transport from Manchester, N.H., and arrival at the Kennedy Space Center in Florida on Dec. 5, 2013. Credit: Ken Kremer/kenkremer.com
Story updated[/caption]
KENNEDY SPACE CENTER, FL – The heat shield crucial to the success of NASA’s 2014 Orion test flight has arrived at the Kennedy Space Center (KSC) aboard the agency’s Super Guppy aircraft – just spacious enough to fit the precious cargo inside.
Orion is currently under development as NASA’s next generation human rated vehicle to replace the now retired space shuttle. The heat shields advent is a key achievement on the path to the spacecraft’s maiden flight.
“The heat shield which we received today marks a major milestone for Orion. It is key to the continued assembly of the spacecraft,” Scott Wilson, NASA’s Orion Manager of Production Operations at KSC, told Universe Today during an interview at the KSC shuttle landing facility while the offloading was in progress.
The inaugural flight of Orion on the unmanned Exploration Flight Test – 1 (EFT-1) mission is scheduled to blast off from the Florida Space Coast in mid September 2014 atop a Delta 4 Heavy booster, Wilson told me.
Orion EFT-1 heat shield moved off from NASA’s Super Guppy aircraft after arrival at the Kennedy Space Center in Florida on Dec. 5, 2013. Credit: Ken Kremer/kenkremer.com
The heat shield was flown in from Textron Defense Systems located near Boston, Massachusetts and offloaded from the Super Guppy on Dec. 5 as Universe Today observed the proceedings along with top managers from NASA and Orion’s prime contractor Lockheed Martin.
“The Orion heat shield is the largest of its kind ever built. Its wider than the Apollo and Mars Science Laboratory heat shields,” Todd Sullivan told Universe Today at KSC. Sullivan is the heat shield senior manager at Lockheed Martin.
The state-of-the-art Orion crew capsule will ultimately enable astronauts to fly to deep space destinations including the Moon, Asteroids, Mars and beyond – throughout our solar system.
The heat shield was one of the last major pieces of hardware needed to complete Orion’s exterior structure.
“Production of the heat shields primary structure that carries all the loads began at Lockheed Martin’s Waterton Facility near Denver,” said Sullivan. The titanium composite skeleton and carbon fiber skin were manufactured there to give the heat shield its shape and provide structural support during landing.
“It was then shipped to Textron in Boston in March,” for the next stage of assembly operations, Sullivan told me.
“They applied the Avcoat ablater material to the outside. That’s what protects the spacecraft from the heat of reentry.”
Textron technicians just completed the final work of installing a fiberglass-phenolic honeycomb structure onto the heat shield skin. Then they filled each of the honeycomb’s 320,000 cells with the ablative material Avcoat.
Orion EFT-1 heat shield hauled off NASA’s Super Guppy aircraft after arrival at the Kennedy Space Center in Florida on Dec. 5, 2013. Credit: Ken Kremer/kenkremer.com
Each cell was X-rayed and sanded to match Orion’s exacting design specifications.
“Now we have about two and a half months of work ahead to prepare the Orion crew module before the heat shield is bolted on and installed,” Sullivan explained.
The Avcoat-treated shell will shield Orion from the extreme heat of nearly 4000 degrees Fahrenheit it experiences during the blazing hot temperatures it experiences as it returns at high speed to Earth. The ablative material will wear away as it heats up during the capsules atmospheric re-entry thereby preventing heat from being transferred to the rest of the capsule and saving it and the human crew from utter destruction.
“Testing the heat shield is one of the prime objectives of the EFT-1 flight,” Wilson explained.
“The Orion EFT-1 capsule will return at over 20,000 MPH,” Wilson told me. “That’s about 80% of the reentry speed experienced by the Apollo capsule after returning from the Apollo moon landing missions.”
“The big reason to get to those high speeds during EFT-1 is to be able to test out the thermal protection system, and the heat shield is the biggest part of that.”
Hoisting Orion heat shield at KSC for transport to Orion crew module in the Operations and Checkout Building. Credit: Ken Kremer/kenkremer.com
The two-orbit, four- hour EFT-1 flight will lift the Orion spacecraft and its attached second stage to an orbital altitude of 3,600 miles, about 15 times higher than the International Space Station (ISS) – and farther than any human spacecraft has journeyed in 40 years.
“Numerous sensors and instrumentation have been specially installed on the EFT-1 heat shield and the back shell tiles to collect measurements of things like temperatures, pressures and stresses during the extreme conditions of atmospheric reentry,” Wilson explained.
Orion managers pose with heat shield at KSC; Scott Wilson, NASA Orion deputy manager of Production Operations; Todd Sullivan, heat shield senior manager at Lockheed Martin; Stu Mcclung, NASA Orion deputy manager of Production Operations. Credit: Ken Kremer/kenkremer.com
The data gathered during the unmanned EFT-1 flight will aid in confirming. or refuting, design decisions and computer models as the program moves forward to the first flight atop NASA’s mammoth SLS booster in 2017 on the EM-1 mission and human crewed missions thereafter.
“I’m very proud of the work we’ve done, excited to have the heat shield here [at KSC] and anxious to get it installed,” Sullivan concluded.
Stay tuned here for continuing Orion, Chang’e 3, LADEE, MAVEN and MOM news and Ken’s reports from on site at Cape Canaveral & the Kennedy Space Center press site.
Dec 11: “Curiosity, MAVEN and the Search for Life on Mars”, “LADEE & Antares ISS Launches from Virginia”, Rittenhouse Astronomical Society, Franklin Institute, Phila, PA, 8 PM
Takeoff of NASA’s Super Guppy from the shuttle landing runway at the Kennedy Space Center in Florida on Dec. 5, 2013 after removal of Orion heat shield. Credit: Ken Kremer/kenkremer.com
Inside the Operations and Checkout Building high bay at NASA’s Kennedy Space Center in Florida, a crane moves the service module for the Orion spacecraft toward a lift station where it will be mated to the spacecraft adapter cone. Photo credit: NASA/Jim Grossmann
KENNEDY SPACE CENTER, FL – All of the key hardware elements being assembled for NASA’s new Orion spacecraft launching just under one year from now are nearing completion at the Kennedy Space Center (KSC) – at the same time as a crucial and successful hardware test in California this week helps ensure that the Exploration Flight Test-1 (EFT-1) vehicle will be ready for an on-time liftoff.
Orion is NASA’s first spaceship designed to carry human crews on long duration flights to deep space destinations beyond low Earth orbit, such as asteroids, the moon, Mars and beyond.
In a major construction milestone, Orion’s massive Service Module (SM) was hoisted out from the tooling stand where it was manufactured at the Operations and Checkout Building (O & C) at KSC and moved to the next assembly station where it will soon be mated to the spacecraft adapter cone.
The SM should be mated to the crew module (CM) by year’s end, Orion managers told Universe Today during my recent inspection tour of significant Orion hardware at KSC.
“We are working 24 hours a day, 7 days a week,” said Jules Schneider, Orion Project manager for Lockheed Martin at KSC, during an exclusive interview with Universe Today inside the Orion clean room at KSC. “We are moving fast!”
The three panels or fairings encapsulating a stand-in for Orion’s service module successfully detach during a test Nov. 6, 2013 at Lockheed Martin’s facility in Sunnyvale, Calif. Image Credit: Lockheed Martin
“We are bringing Orion to life. Lots of flight hardware has now been installed.”
And on the other side of the country, the Service Module design passed a key hurdle on Wednesday (Nov. 6) when the trio of large spacecraft panels that surround the SM were successfully jettisoned from the spacecraft during a systems test by Lockheed Martin that simulates what would happen during an actual flight several minutes after liftoff.
“Hardware separation events like this are absolutely critical to the mission and some of the more complicated things we do,” said Mark Geyer, Orion program manager at NASA’s Johnson Space Center in Houston. “We want to know we’ve got the design exactly right and that it can be counted on in space before we ever launch.”
Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) mock up stack inside the transfer aisle of the Vehicle Assembly Building (VAB) at the Kennedy Space Center (KSC) in Florida. Powerful quartet of LAS abort motors will fire in case of launch emergency to save astronauts lives. Credit: Ken Kremer/kenkremer.com
Lockheed Martin is the prime contractor for Orion and responsible for assembly, testing and delivery of the Orion EFT-1 spacecraft to NASA that’s slated for an unmanned test flight targeted to lift off from Cape Canaveral, Florida in September 2014.
The CM rests atop the SM similar to the Apollo Moon landing program architecture.
However in a significant difference from Apollo, the Orion fairings support half the weight of the crew module and the launch abort system during launch and ascent. The purpose is to improve performance by saving weight thus maximizing the vehicles size and capability.
The SM also provides in-space power, propulsion capability, attitude control, thermal control, water and air for the astronauts.
At Lockheed Martin’s Sunnyvale, California facility a team of engineers used a series of precisely-timed, explosive charges and mechanisms attached to the Orion’s protective fairing panels in a flight-like test to verify that the spacecraft can successfully and confidently jettison them as required during the ascent to orbit.
The trio of fairing panels protect the SM radiators and solar arrays from heat, wind and acoustics during ascent.
The three panels or fairings encapsulating a stand-in for Orion’s service module successfully detach during a test Nov. 6, 2013 at Lockheed Martin’s facility in Sunnyvale, Calif. Image Credit: Lockheed Martin
“This successful test provides the Orion team with the needed data to certify this new fairing design for Exploration Flight Test-1 (EFT-1) next year. The test also provides significant risk reduction for the fairing separation on future Orion manned missions,” said Lance Lininger, engineering lead for Lockheed Martin’s Orion mechanism systems in a statement.
This was the 2nd test of the fairing jettison system. During the first test in June, one of the three fairing panels did not completely detach due to an interference “when the top edge of the fairing came into contact with the adapter ring and kept it from rotating away and releasing from the spacecraft,” said NASA.
Inside the Operations and Checkout Building high bay at NASA’s Kennedy Space Center in Florida, a crane moves the service module for the Orion spacecraft toward a lift station where it will be mated to the spacecraft adapter cone. Photo credit: NASA/Jim Grossmann
2013 has been an extremely busy and productive year for the Orion EFT-1 team.
“There are many significant Orion assembly events ongoing this year,” said Larry Price, Orion deputy program manager at Lockheed Martin, in an interview with Universe Today at Lockheed Space Systems in Denver.
“This includes the heat shield construction and attachment, power on, installing the plumbing for the environmental and reaction control system, completely outfitting the crew module, attached the tiles, building the service module and finally mating the crew and service modules (CM & SM),” Price told me.
Technicians work inside the Orion crew module being built at Kennedy Space Center to prepare it for its first power on. Turning the avionics system inside the capsule on for the first time marks a major milestone in Orion’s final year of preparations before its first mission, Exploration Flight Test 1 Credit: Lockheed Martin
The two-orbit, four- hour flight will lift the Orion spacecraft and its attached second stage to an orbital altitude of 3,600 miles, about 15 times higher than the International Space Station (ISS) – and farther than any human spacecraft has journeyed in 40 years.
Technicians work inside the Orion crew module being built at Kennedy Space Center to prepare it for its first power on. Turning the avionics system inside the capsule on for the first time marks a major milestone in Orion’s final year of preparations before its first mission, Exploration Flight Test 1
Credit: Lockheed Martin
Technicians work inside the Orion crew module being built at Kennedy Space Center to prepare it for its first power on. Turning the avionics system inside the capsule on for the first time marks a major milestone in Orion’s final year of preparations before its first mission, Exploration Flight Test 1. Credit: Lockheed Martin Story and imagery updated[/caption]
KENNEDY SPACE CENTER, FL – Orion, the first NASA spaceship that will ever carry Earthlings to deep space destinations, has at last been “powered on” for the first time at the manufacturing facility at the Kennedy Space Center (KSC) where it’s the centerpiece of a beehive humming 24/7 with hi tech processing activities in all directions.
“Power On” marks a major milestone ahead of the maiden space bound Orion test flight dubbed “EFT-1” – now at T-Minus 1 year and counting!
NASA and prime contractor Lockheed Martin recently granted Universe Today an exclusive in depth inspection tour of the impressive Orion EFT-1 crew module, service module and associated hardware destined for the crucial unmanned test flight slated for liftoff from Cape Canaveral in September 2014.
“We are moving fast!” said Jules Schneider, Orion Project manager for Lockheed Martin at KSC, during an exclusive interview with Universe Today as we spoke beside the Orion EFT-1 spacecraft inside the clean room.
“We are bringing Orion to life. Lots of flight hardware has now been installed.”
Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) mock up stack inside the transfer aisle of the Vehicle Assembly Building (VAB) at the Kennedy Space Center (KSC) in Florida. Powerful quartet of LAS abort motors will fire in case of launch emergency to save astronauts lives. Credit: Ken Kremer/kenkremer.com
“We are working 24 hours a day, 7 days a week,” Schneider told me.
Some 200 people are actively employed on building Orion by Lockheed Martin at the Kennedy Space Center.
“There are many significant Orion assembly events ongoing this year,” said Larry Price, Orion deputy program manager at Lockheed Martin, in an interview with Universe Today at Lockheed Space Systems in Denver.
“This includes the heat shield construction and attachment, power on, installing the plumbing for the environmental and reaction control system, completely outfitting the crew module, attached the tiles, building the service module and finally mating the crew and service modules (CM & SM),” Price told me.
I have been very fortunate to periodically visit Orion up close over the past year and half to evaluate the testing and assembly progress inside the Operations and Checkout Building at KSC where the vehicle is now rapidly coming together, since the bare bones pressure vessel arrived to great fanfare in June 2012.
For the first time Orion looked to my eyes like a real spaceship, rather than the backbone shell outfitted with hundreds of important test harnesses, strain gauges and wiring to evaluate its physical and structural integrity.
Technicians work inside the Orion crew module being built at Kennedy Space Center to prepare it for its first power on. Turning the avionics system inside the capsule on for the first time marks a major milestone in Orion’s final year of preparations before its first mission, Exploration Flight Test 1. Credit: Lockheed Martin
Engineers and technicians at KSC have removed the initial pressure testing gear and are now installing all the flight systems and equipment – such as avionics, instrumentation, flight computers, thrusters, wiring, plumbing, heat shield and much more – required to transform the initial empty shell into a fully functioning spacecraft.
“The Orion skeleton was here before. Now we are putting in all of the other systems,” Schneider explained to me.
“We are really busy.”
“So far over 66,000 Orion parts have been shipped to KSC from over 40 US states,” Price explained.
The heat shield was due to arrive soon and technicians were drilling its attachment ring holes as I observed the work in progress.
“The propulsion, environmental control and life support systems are now about 90% in. The ammonia and propylene glycol loops for the thermal control system are in. Many of the flight harnesses are installed.”
“All of the reaction control thrusters are in – fueled by hydrazine – as well as the two hydrazine tanks and a helium tank. Altogether there are 12 hydrazine pods with two thrusters each,” Schneider elaborated.
The power distribution unit (PDU) – which basically functions as Orion’s computer brains – was installed just prior to my visit. All four PDU’s – which issue commands to the vehicle – were built by Honeywell.
Technicians were actively installing fiber optic and coaxial cables as I watched. They also were conducting leak tests on the environmental control coolant (ECLS) systems which had to be completed before the ‘power on’ testing could begin – in order to cool the avionics systems.
Thermal protection system (TPS) tiles were being bonded to the back panels which ring Orion. The TPS panels get attached early in 2014.
“This is real stuff,” said Schneider gleefully.
Inside the Operations and Checkout Building high bay at NASA’s Kennedy Space Center in Florida, a tile technician works on a section of thermal protection system tiles seen by Universe Today and that will be installed on the Orion crew module. Credit: NASA/Dimitri Gerondidakis
NASA says that “the preliminary data indicate Orion’s vehicle management computer, as well as its innovative power and data distribution system — which use state-of-the-art networking capabilities — performed as expected” during the initial crew module power on.
About two months or so of power on functional testing of various systems will follow.
Just like the configuration used in the Apollo era, the Orion crew module will sit atop a service module – and that work is likewise moving along at a rapid clip.
“The Orion service module (SM) is also almost complete,” Schneider said as he showed me the service module structure.
“Structurally the SM is 90% done. The active thermal control system is in and all the fluid systems are welded in and pressure tested.”
Cutaway diagram of Orion components including crew module and service module and adapters. Credit: NASA
Orion EFT-1 will blastoff atop a mammoth United Launch Alliance Delta IV Heavy rocket – the most powerful booster in America’s arsenal since the shuttle’s retirement in 2011.
The crew module and service module (CM/SM) will be mated inside the O&C and then be placed onto a mission adapter that eventually attaches to the top of the Delta IV Heavy booster.
They will be mated at the exact same spot in the O&C Building where the Apollo era command and service modules were stacked four decades ago.
Currently, the schedule calls for the Orion CM/SM stack to roll out to Kennedy’s Payload Hazardous Services Facility (PHSF) for servicing and fueling late this year, said Larry Price.
After that the CM/SM stack is transported to the nearby Launch Abort System Facility (LASF) for mating to the emergency Launch Abort System (LAS).
All that work could be done around March 2014 so that ground operations preparing for launch can commence, according to Price.
“In March 2014 we’ll be ready for ground ops. The normal launch processing flow starts in June 2014 leading to Orion’s launch from pad 37 in September 2014.”
“It’s very exciting and a tribute to the NASA and contractor teams,” Price said.
The 2014 uncrewed flight will be loaded with a wide variety of instruments to evaluate how the spacecraft behaves during launch, in space and then through the searing heat of reentry.
The two-orbit, four- hour flight will lift the Orion spacecraft and its attached second stage to an orbital altitude of 3,600 miles, about 15 times higher than the International Space Station (ISS) – and farther than any human spacecraft has journeyed in 40 years.
An artist concept shows Orion as it will appear in space for the Exploration Flight Test-1 attached to a Delta IV second stage. Credit: NASA
Although the mission will only last a few hours it will be high enough to send the vehicle plunging back into the atmosphere and a Pacific Ocean splashdown to test the craft and its heat shield at deep-space reentry speeds of 20,000 mph and endure temperatures of 4,000 degrees Fahrenheit – like those of the Apollo moon landing missions.
The Orion EFT-1 mission will end with a splashdown in the Pacific Ocean. During the stationary recovery test of Orion at Norfolk Naval Base on Aug. 15, 2013, US Navy divers attached tow lines and led the test capsule to a flooded well deck on the USS Arlington. Credit: Ken Kremer/kenkremer.com.
The EFT-1 mission will provide engineers with critical data about Orion’s heat shield, flight systems and capabilities to validate designs of the spacecraft, inform design decisions, validate existing computer models and guide new approaches to space systems development. All these measurements will aid in reducing the risks and costs of subsequent Orion flights before it begins carrying humans to new destinations in the solar system.
“The Orion hardware and the Delta IV Heavy booster for the EFT-1 launch are on target for launch in 2014,” Scott Wilson, NASA’s Orion Manager of Production Operations, told Universe Today in an interview.
Learn more about Orion, MAVEN, Mars rovers and more at Ken’s upcoming presentations
Nov 14-19: “MAVEN Mars Launch and Curiosity Explores Mars, Orion and NASA’s Future”, Kennedy Space Center Quality Inn, Titusville, FL, 8 PM
Dec 11: “Curiosity, MAVEN and the Search for Life on Mars”, “LADEE & Antares ISS Launches from Virginia”, Rittenhouse Astronomical Society, Franklin Institute, Phila, PA, 8 PM
Orion EFT-1 capsule under construction inside the Structural Assembly Jig at the Operations and Checkout Building (O & C) at the Kennedy Space Center (KSC); Jules Schneider, Orion Project Manager for Lockheed Martin and Ken Kremer, Universe Today. Credit: Ken Kremer – kenkremer.com
NASA Orion spacecraft blasts off atop 1st Space Launch System rocket in 2017 - attached to European provided service module – on an enhanced m mission to Deep Space where an asteroid could be relocated as early as 2021. Credit: NASA
NASA Orion spacecraft blasts off atop 1st Space Launch System rocket in 2017 – attached to European provided service module – on an ambitious mission to explore Deep Space some 40,000 miles beyond the Moon, where an asteroid could be relocated as early as 2021. Credit: NASA Story updated with further details[/caption]
NASA managers have announced a bold new plan to significantly alter and upgrade the goals and complexity of the 1st mission of the integrated Orion/Space Launch System (SLS) human exploration architecture – planned for blastoff in late 2017.
The ambitious first flight, called Exploration Mission 1 (EM-1), would be targeted to send an unpiloted Orion spacecraft to a point more than 40,000 miles (70,000 kilometers) beyond the Moon as a forerunner supporting NASA’s new Asteroid Redirect Initiative – recently approved by the Obama Administration.
The EM-1 flight will now serve as an elaborate harbinger to NASA’s likewise enhanced EM-2 mission, which would dispatch a crew of astronauts for up close investigation of a small Near Earth Asteroid relocated to the Moon’s vicinity.
Orion crew module separates from Space Launch System (SLS) upper stage. Credit: NASA
Until recently NASA’s plan had been to launch the first crewed Orion atop the 2nd SLS rocket in 2021 to a high orbit around the moon on the EM-2 mission, said NASA Associate Administrator Lori Garver in an prior interview with me at the Kennedy Space Center.
Concept of NASA spacecraft with Asteroid capture mechanism deployed to redirect a small space rock to a stable lunar orbit for later study by astronauts aboard Orion crew capsule. Credit: NASA.
The enhanced EM-1 flight would involve launching an unmanned Orion, fully integrated with the Block 1 SLS to a Deep Retrograde Orbit (DRO) near the moon, a stable orbit in the Earth-moon system where an asteroid could be moved to as early as 2021.
Orion’s mission duration would be nearly tripled to 25 days from the original 10 days.
“The EM-1 mission with include approximately nine days outbound, three to six days in deep retrograde orbit and nine days back,” Brandi Dean, NASA Johnson Space Center spokeswoman told Universe Today exclusively.
The proposed much more technologically difficult EM-1 mission would allow for an exceptionally more vigorous work out and evaluation of the design of all flight systems for both Orion and SLS before risking a flight with humans aboard.
Asteroid Capture in Progress
A slew of additional thruster firings would exercise the engines to change orbital parameters outbound, around the moon and inbound for reentry.
The current Deep Retrograde Orbit (DRO) plan includes several thruster firings from the Orion service module, including a powered lunar flyby, an insertion at DRO, an extraction maneuver from the DRO and a powered flyby on return to Earth.
Orion would be outfitted with sensors to collect a wide variety of measurements to evaluate its operation in the harsh space environment.
“EM-1 will have a compliment of both operational flight instrumentation and development flight instrumentation. This instrumentation suite gives us the ability to measure many attributes of system functionality and performance, including thermal, stress, displacement, acceleration, pressure and radiation,” Dean told me.
The EM-1 flight has many years of planning and development ahead and further revisions prior to the 2017 liftoff are likely.
“Final flight test objectives and the exact set of instrumentation required to meet those objectives is currently under development,” Dean explained.
Orion is NASA’s next generation manned space vehicle following the retirement of NASA’s trio of Space Shuttles in 2011.
The SLS launcher will be the most powerful and capable rocket ever built by humans – exceeding the liftoff thrust of the Apollo era Moon landing booster, the mighty Saturn V.
“We sent Apollo around the moon before we landed on it and tested the space shuttle’s landing performance before it ever returned from space.” said Dan Dumbacher, NASA’s deputy associate administrator for exploration systems development, in a statement.
“We’ve always planned for EM-1 to serve as the first test of SLS and Orion together and as a critical step in preparing for crewed flights. This change still gives us that opportunity and also gives us a chance to test operations planning ahead of our mission to a relocated asteroid.”
Both Orion and SLS are under active and accelerating development by NASA and its industrial partners.
The 1st Orion capsule is slated to blast off on the unpiloted EFT-1 test flight in September 2014 atop a Delta IV Heavy rocket on a two orbit test flight to an altitude of 3,600 miles above Earth’s surface.
Technicians work on mockups of the Orion crew capsule, Service Module and 6 ton Launch Abort System (LAS) to simulate critical assembly techniques inside the Vehicle Assembly Building (VAB) at NASA’s Kennedy Space Center (KSC) in Florida for the EFT-1 mission due to liftoff in September 2014. Credit: Ken Kremer/kenkremer.com
It will then reenter Earth’s atmosphere at speeds of about 20,000 MPH (11 km/sec) and endure temperatures of 4,000 degrees Fahrenheit in a critical test designed to evaluate the performance of Orion’s heatshield and numerous spacecraft systems.
Orion EFT-1 is already under construction at the Kennedy Space Center (KSC) by prime contractor Lockheed Martin – read my earlier story here.
Integration and stacking tests with Orion’s emergency Launch Abort System are also in progress at KSC – details here.
NASA says the SLS is also in the midst of a extensive review process called the Preliminary Design Review (PDR) to ensure that all launch vehicle components and systems will achieve the specified performance targets and be completed in time to meet the 2017 launch date. The PDR will be completed later this summer.
NASA’s goal with Orion/SLS is to send humans to the Moon and other Deep Space destinations like Asteroids and Mars for the first time in over forty years since the final manned lunar landing by Apollo 17 back in 1972.
NASA Headquarters will make a final decision on upgrading the EM-1 mission after extensive technical reviews this summer.
Image caption: Orion EFT-1 crew cabin construction ongoing inside the Structural Assembly Jig at the Operations and Checkout Building (O & C) at the Kennedy Space Center (KSC). This is the inaugural space-bound Orion vehicle due to blastoff from Florida in September 2014 atop a Delta 4 Heavy rocket. Credit: Ken Kremer
NASA is thrusting forward and making steady progress toward launch of the first space-bound Orion crew capsule -designed to carry astronauts to deep space. The agency aims for a Florida blastoff of the uncrewed Exploration Flight Test-1 mission (EFT-1) in September 2014 – some 20 months from now – NASA officials told Universe Today.
I recently toured the Orion spacecraft up close during an exclusive follow-up visit to check the work in progress inside the cavernous manufacturing assembly facility in the Operations and Checkout Building (O & C) at the Kennedy Space Center (KSC). Vehicle assemblage is run under the auspices of prime contractor Lockheed Martin Space Systems Corporation.
A lot of hardware built by contractors and subcontractors from all across the U.S. is now arriving at KSC and being integrated with the EFT-1 crew module (CM), said Jules Schneider, Orion Project manager for Lockheed Martin at KSC, during an interview with Universe Today beside the spacecraft at KSC.
“Everyone is very excited to be working on the Orion. We have a lot of work to do. It’s a marathon not a sprint to build and test the vehicle,” Schneider explained to me.
My last inspection of the Orion was at the official KSC unveiling ceremony on 2 July 2012 (see story here). The welded, bare bones olive green colored Orion shell had just arrived at KSC from NASA’s Michoud facility in New Orleans. Since then, Lockheed and United Space Alliance (USA) technicians have made significant progress outfitting the craft.
Workers were busily installing avionics, wiring, instrumentation and electrical components as the crew module was clamped in place inside the Structural Assembly Jig during my follow-up tour. The Jig has multiple degrees of freedom to move the capsule and ease assembly work.
“Since July and to the end of 2012 our primary focus is finishing the structural assembly of the crew module,” said Schneider.
“Simultaneously the service module structural assembly is also ongoing. That includes all the mechanical assembly inside and out on the primary structure and all the secondary structure including the bracketry. We are putting in the windows and gussets, installing the forward bay structure leading to the crew tunnel, and the aft end CM to SM mechanism components. We are also installing secondary structures like mounting brackets for subsystem components like avionics boxes and thruster pods as parts roll in here.”
Image caption: Window and bracket installation on the Orion EFT-1 crew module at KSC. Credit: Ken Kremer
“A major part of what we are doing right now is we are installing a lot of harnessing and test instrumentation including alot of strain gauges, accelerometers, thermocouples and other gauges to give us data, since that’s what this flight is all about – this is a test article for a test flight.
“There is a huge amount of electrical harnesses that have to be hooked up and installed and soldered to the different instruments. There is a lot of unique wiring for ground testing, flight testing and the harnesses that will be installed later along with the plumbing. We are still in a very early stage of assembly and it involves alot of very fine work,” Schneider elaborated. Ground test instrumentation and strain gauges are installed internally and externally to measure stress on the capsule.
Construction of the Orion service module is also moving along well inside the SM Assembly Jig at an adjacent work station. The SM engines will be mass simulators, not functional for the test flight.
Image caption: Orion EFT-1 crew cabin and full scale mural showing Orion Crew Module atop Servivce Module inside the O & C Building at the Kennedy Space Center, Florida. Credit: Ken Kremer
The European Space Agency (ESA) has been assigned the task of building the fully functional SM to be launched in 2017 on NASA’s new SLS rocket on a test flight to the moon and back.
Although Orion’s construction is proceeding apace, there was a significant issue during recent proof pressure testing at the O & C when the vehicle sustained three cracks in the aft bulkhead of the lower half of the Orion pressure vessel.
“The cracks did not penetrate the pressure vessel skin, and the structure was holding pressure after the anomaly occurred,” Brandi Dean, a NASA Public Affairs Officer told me. “The failure occurred at 21.6 psi. Full proof is 23.7 psi.”
“A team composed of Lockheed Martin and NASA engineers have removed the components that sustained the cracks and are developing options for repair work. Portions of the cracked surface were removed and evaluated, letting the team eliminate problems such as material contamination, manufacturing issues and preexisting defects from the fault tree. The cracks are in three adjacent, radial ribs of this integrally machined, aluminum bulkhead,” Dean stated.
Image caption: NASA graphic of 3 cracks discovered during recent proof pressure testing. Credit: NASA
The repairs will be subjected to rigorous testing to confirm their efficacy as part of the previously scheduled EFT-1 test regimen.
A great deal of work is planned over the next few months including a parachute drop test just completed this week and more parachute tests in February 2013. The heat shield skin and its skeleton are being manufactured at a Lockheed facility in Denver, Colorado and shipped to KSC. They are due to be attached in January 2013 using a specialized tool.
“In March 2013, we’ll power up the crew module at Kennedy for the first time,” said Dean.
Orion will soar to space atop a mammoth Delta IV Heavy booster rocket from Launch Complex 37 at Cape Canaveral Air Force Station in Florida. Construction and assembly of the triple barreled Delta IV Heavy is the pacing item upon which the launch date hinges, NASA officials informed me.
Following the forced retirement of NASA’s space shuttles, the United Launch Alliance Delta IV Heavy is now the most powerful booster in the US arsenal and heretofore has been used to launch classified military satellites. Other than a specialized payload fairing built for Orion, the rocket will be virtually identical to the one that boosted a super secret U.S. National Reconnaissance Office (NRO) spy satellite to orbit on June 29, 2012 (see my launch story here).
Orion will fly in an unmanned configuration during the EFT-1 test flight and orbit the Earth two times – reaching an altitude of 3,600 miles which is 15 times farther than the International Space Station’s orbital position. The primary objective is to test the performance of Orion’s heat shield at the high speeds and searing temperatures generated during a return from deep space like those last experienced in the 1970’s by the Apollo moon landing astronauts.
The EFT-1 flight is not the end of the road for this Orion capsule.
“Following the EFT-1 flight, the Orion capsule will be refurbished and reflown for the high altitude abort test, according to the current plan which could change depending on many factors including the budget,” explained Schneider.
“NASA will keep trying to do ‘cool’ stuff”, Bill Gerstenmaier, the NASA Associate Administrator for Human Space Flight, told me.
Stay tuned – Everything regarding human and robotic spaceflight depends on NASA’s precarious budget outlook !
Image caption: Orion EFT-1 crew cabin assemblage inside the Structural Assembly Jig at the Operations and Checkout Building (O & C) at the Kennedy Space Center (KSC); Jules Schneider, Orion Project Manager for Lockheed Martin and Ken Kremer. Credit: Ken Kremer
Delta 4 Heavy rocket and super secret US spy satellite roar off Pad 37 on June 29, 2012 from Cape Canaveral, Florida. NASA’s Orion EFT-1 capsule will blastoff atop a similar Delta 4 Heavy Booster in December 2014. Credit: Ken Kremer- kenkremer.com[/caption]
