Vice President Mike Pence (holding Orion model) receives up close tour of NASA’s Orion EM-1 deep space crew capsule (at right) being manufactured for 1st integrated flight with NASA’s SLS megarocket in 2019; with briefing from KSC Director/astronaut Robert D. Cabana during his July 6, 2017 tour of NASA's Kennedy Space Center - along with acting NASA Administrator Robert M. Lightfoot, Jr., Senator Marco Rubio and Lockheed Martin CEO Marillyn Hewson inside the Neil Armstrong Operations and Checkout Building at KSC. Credit: Ken Kremer/kenkremer.com
Vice President Mike Pence (holding Orion model) receives up close tour of NASA’s Orion EM-1 deep space crew capsule (at right) being manufactured for 1st integrated flight with NASA’s SLS megarocket in 2019; with briefing from KSC Director/astronaut Robert D. Cabana during his July 6, tour of NASA’s Kennedy Space Center – along with acting NASA Administrator Robert M. Lightfoot, Jr., Senator Marco Rubio and Lockheed Martin CEO Marillyn Hewson inside the Neil Armstrong Operations and Checkout Building at KSC. Credit: Ken Kremer/kenkremer.com
KENNEDY SPACE CENTER, FL – Vice President Mike Pence, during a whirlwind visit to NASA’s Kennedy Space Center in Florida, vowed that America would fortify our leadership in space under the Trump Administration with impressive goals by forcefully stating that “our nation will return to the moon, and we will put American boots on the face of Mars.”
“American will once again lead in space for the benefit and security of all of our people and all of the world,” Vice President Mike Pence said during a speech on Thursday, July 6, addressing a huge crowd of more than 500 NASA officials and workers, government dignitaries and space industry leaders gathered inside the cavernous Vehicle Assembly Building at the Kennedy Space Center – where Apollo/Saturn Moon landing rockets and Space Shuttles were assembled for decades in the past and where NASA’s new Space Launch System (SLS) megarocket and Orion deep space crew capsule will be assembled for future human missions to the Moon, Mars and beyond.
Pence pronounced the bold space exploration goals and a reemphasis on NASA’s human spaceflight efforts from his new perch as Chairman of the newly reinstated National Space Council just established under an executive order signed by President Trump.
“We will re-orient America’s space program toward human space exploration and discovery for the benefit of the American people and all of the world.”
Vice President Mike Pence speaks before an audience of NASA leaders, U.S. and Florida government officials, and employees inside the Vehicle Assembly Building at NASA’s Kennedy Space Center in Florida. Pence thanked employees for advancing American leadership in space. Behind the podium is the Orion spacecraft flown on Exploration Flight test-1 in 2014. Credits: NASA/Kim Shiflett
However Pence was short on details and he did not announce any specific plans, timetables or funding during his 25 minute long speech inside the iconic VAB at KSC.
It remains to been seen how the rhetoric will turn to reality and all important funding support.
The Trump Administration actually cut their NASA 2018 budget request by $0.5 Billion to $19.1 Billion compared to the enacted 2017 NASA budget of $19.6 Billion – including cuts to SLS and Orion.
By contrast, the Republican led Congress – with bipartisan support – is working on a 2018 NASA budget of around 19.8 Billion.
“Let us do what our nation has always done since its very founding and beyond: We’ve pushed the boundaries on frontiers, not just of territory, but of knowledge. We’ve blazed new trails, and we’ve astonished the world as we’ve boldly grasped our future without fear.”
“From this ‘Bridge to Space,’ our nation will return to the moon, and we will put American boots on the face of Mars.” Pence declared.
Lined up behind Pence on the podium was the Orion spacecraft flown on Exploration Flight Test-1 (EFT-1) in 2014 flanked by a flown SpaceX cargo Dragon and a mockup of the Boeing CST-100 Starliner crew capsule.
The crewed Dragon and Starliner capsules are being developed by SpaceX and Boeing under NASA contracts as commercial crew vehicles to ferry astronauts to the International Space Station (ISS).
Pence reiterated the Trump Administrations support of the ISS and working with industry to cut the cost of access to space.
Vice President Mike Pence (holding Orion model) tours manufacturing of NASA’s Orion EM-1 crew capsule during July 6 KSC visit – posing with KSC Director/astronaut Robert Cabana, acting NASA Administrator Robert M. Lightfoot, Jr., Senator Marco Rubio, Lockheed Martin CEO Marillyn Hewson and KSC Deputy Director Janet Petro inside the Neil Armstrong Operations and Checkout Building. Credit: Julian Leek
Acting NASA Administrator Robert Lightfoot also welcomed Vice President Pence to KSC and thanked the Trump Administration for its strong support of NASA missions.
“Here, of all places, we can see we’re not looking at an ‘and/or proposition’,” Lightfoot said.
“We need government and commercial entities. We need large companies and small companies. We need international partners and our domestic suppliers. And we need academia to bring that innovation and excitement that they bring to the next workforce that we’re going to use to actually keep going further into space than we ever have before.”
View shows the state of assembly of NASA’s Orion EM-1 deep space crew capsule during inspection tour by Vice President Mike Pence on July 6, 2017 inside the Neil Armstrong Operations and Checkout Building at the Kennedy Space Center. 1st integrated flight with NASA’s SLS megarocket is slated for 2019. Credit: Ken Kremer/kenkremer.com
After the VAB speech, Pence went on an extensive up close inspection tour of KSC facilities led by Kennedy Space Center Director and former shuttle astronaut Robert Cabana, showcasing the SLS and Orion hardware and infrastructure critical for NASA’s plans to send humans on a ‘Journey to Mars’ by the 2030s.
“We are in a great position here at Kennedy, we made our vision a reality; it couldn’t have been done without the passion and energy of our workforce,” said Kennedy Space Center Director Cabana.
“Kennedy is fully established as a multi-user spaceport supporting both government and commercial partners in the space industry. As America’s premier multi-user spaceport, Kennedy continues to make history as it evolves, launching to low-Earth orbit and beyond.”
Vice President Mike Pence holds and inspects an Orion capsule heat shield tile with KSC Director/astronaut Robert Cabana during his July 6, 2017 tour/speech at NASA’s Kennedy Space Center – accompanied by acting NASA administrator Robert M. Lightfoot, Jr., Senator Marco Rubio and Lockheed Martin CEO Marillyn Hewson inside the Neil Armstrong Operations and Checkout Building at KSC. Credit: Ken Kremer/kenkremer.com
Pence toured the Neil Armstrong Operations and Checkout Building (O & C) where the Orion deep space capsule is being manufactured for launch in 2019 on the first integrated flight with SLS on the uncrewed EM-1 mission to the Moon and back – as I witnessed for Universe Today.
Vice President Mike Pence tours manufacturing of NASA’s Orion EM-1 crew capsule during July 6, 2017 KSC visit with KSC Director/astronaut Robert Cabana inside the Neil Armstrong Operations and Checkout Building. Credit: Julian Leek
Watch for Ken’s onsite space mission reports direct from the Kennedy Space Center and Cape Canaveral Air Force Station, Florida.
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
Orion crew module pressure vessel for NASA’s Exploration Mission-1 (EM-1) is unveiled for the first time on Feb. 3, 2016 after arrival at the agency’s Kennedy Space Center (KSC) in Florida. It is secured for processing in a test stand called the birdcage in the high bay inside the Neil Armstrong Operations and Checkout (O&C) Building at KSC. Launch to the Moon is slated in 2019 atop the SLS rocket. Credit: Ken Kremer/kenkremer.comNASA’s Space Launch System (SLS) blasts off from launch pad 39B at the Kennedy Space Center in this artist rendering showing a view of the liftoff of the Block 1 70-metric-ton (77-ton) crew vehicle configuration. Credit: NASA/MSFC
NASA’s Space Launch System (SLS) blasts off from launch pad 39B at the Kennedy Space Center in this artist rendering showing a view of the liftoff of the Block 1 70-metric-ton (77-ton) crew vehicle configuration. Credit: NASA/MSFC
NASA’s Space Launch System (SLS) blasts off from launch pad 39B at the Kennedy Space Center in this artist rendering showing a view of the liftoff of the Block 1 70-metric-ton (77-ton) crew vehicle configuration. Credit: NASA/MSFC
In order to get a better idea of the implications of the 2018 NASA budget proposal for KSC, I spoke one-on-one with Robert Cabana – one of NASA’s top officials, who currently serves as Director of the Kennedy Space Center (KSC) as well as being a former astronaut and Space Shuttle Commander. Cabana is a veteran of four space shuttle missions.
How did NASA and KSC fare with the newly announced 2018 Budget?
“We at KSC and NASA as a whole did very well with the 2018 budget,” KSC Director Robert Cabana explained during an interview with Universe Today by the Rocket Garden at the Kennedy Space Center Visitor Complex (KSCVC) in Florida.
“I think it really solidifies that the President has confidence in us, on the path that we are on,” Cabana noted while attending a student robotics competition at KSCVC sponsored by NASA.
“With only a 1 percent cut – when you look at what other agency’s got cut – this budget allows us to stay on the path that we are on.”
Trump cut NASA’s 2018 budget request by $0.5 Billion compared to the recently enacted FY 2017 budget of $19.6 Billion approved by the US Congress and signed by the President.
Other Federal science agency’s also critically vital to the health of US scientific research such as the NIH, the NSF, the EPA, DOE and NIST suffered terrible double digit slashes of 10 to 20% or more.
KSC is the focal point for NASA’s human spaceflight programs currently under intense development by NASA – namely the Space Launch System (SLS) Mars megarocket, the Orion deep space crew capsule to be launched beyond Earth orbit (BEO) atop SLS, and the duo of Commercial Crew Program (CCP) space taxis being manufactured by Boeing and SpaceX that will ferry our astronauts to low Earth orbit (LEO) and the International Space Station (ISS).
Numerous NASA science missions also launch from the Florida Space Coast.
“At KSC the budget keeps us on a path that continues to provide a commercial crew vehicle to fly crews to the ISS in 2018,” Cabana stated.
“The budget also keeps us on track to launch SLS and Orion in 2019.”
“I think that’s really important – along with all the other stuff we are doing here at KSC.”
“From our point of view it’s a good budget. We need to press ahead and continue on with what we promised.”
Hull of the Boeing CST-100 Starliner Structural Test Article (STA)- the first Starliner to be built in the company’s modernized Commercial Crew and Cargo Processing Facility high bay at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
What’s ahead for commercial crew at KSC?
“We are moving forward with commercial crew,” Cabana told me.
“Within the next calendar year [2018] we are moving ahead with flying the first certification flight with crew to the ISS. So that’s test flights and by the end of the year an actual crewed flight to the ISS. I want to see that happen.”
Boeing and SpaceX are building private spaceships to resume launching US astronauts from US soil to the International Space Station in 2018. Credit: NASA
Industry partners Boeing and SpaceX are building the private CST-100 Starliner and Crew Dragon spaceships respectively, as part of NASA’s commercial crew initiative aimed at restoring America’s human spaceflight capability to launch our astronauts aboard American spaceships on American rockets from American soil.
Commercial Crew is a public/private partnership initiative with commercial contracts valued at $4.2 Billion and signed by Boeing and SpaceX with NASA in September 2014 under the Obama Administration.
The goal of commercial crew is to end our sole reliance on the Russian Soyuz capsule for astronaut flights to the space station since the retirement of the space shuttles back in 2011 – by manufacturing indigenous rockets and human rated spaceships.
However the CCP program suffered severe budget reductions by the US Congress for several years which forced significant work stretch-outs and delays in the maiden crew launches by both companies from 2015 to 2018 – and thus forced additional payments to the Russians for Soyuz seat purchases.
Both the Boeing Starliner and SpaceX Dragon crew vehicles can carry 4 or more astronauts to the ISS. This will enable NASA to add another crew member and thereby enlarge the ISS crew from 6 to 7 permanent residents after they become operational.
Orion crew module pressure vessel for NASA’s Exploration Mission-1 (EM-1) is unveiled for the first time on Feb. 3, 2016 after arrival at the agency’s Kennedy Space Center (KSC) in Florida. It is secured for processing in a test stand called the birdcage in the high bay inside the Neil Armstrong Operations and Checkout (O&C) Building at KSC. Launch to the Moon is slated in 2018 atop the SLS rocket. Credit: Ken Kremer/kenkremer.com
Meanwhile NASA is focusing on developing the SLS heavy lift rocket and Orion crew capsule with prime contractors Boeing and Lockheed Martin in an agency wide effort to send humans on a ‘Journey to Mars’ in the 2030s.
The European Space Agency(ESA) is also partnered with NASA and providing the service module for Orion.
What’s the status of the delivery of the European Space Agency’s service module?
“The service module will be here sometime next year,” Cabana said.
He noted that the details and exact timing are yet to be determined.
The first integrated launch of SLS and Orion on the unpiloted Exploration Mission-1 (EM-1) is now slated for sometime in 2019 after NASA recently slipped the date to the right from Fall 2018.
I asked Cabana for his insight and opinion on NASA not adding crew to Orion on the EM-1 flight.
“No we are not launching crew on the first flight [EM-1],” Cabana stated.
“With the budget that we have and what we need to do, this is the answer we got to at the end.”
“You know the crew study was still very important. It allowed us to find some things that we should still do on [EM-1], even though we are not going to launch crew on that flight.
“So we will make some further modifications that will reduce the risk even further when we do fly crew [on the next flight of EM-2].”
The newly assembled first liquid hydrogen tank, also called the qualification test article, for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine (blue) on July 22, 2016. It was lifted out of the welder (top) after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
So for 2017 what are the major milestone you hope to complete here at KSC for SLS and Orion?
“So for me here at the Kennedy Space Center, my goal for the end of this calendar year 2017 we will have completed all of the construction of all of the [ground systems] hardware and facilities that are necessary to process and launch the Space Launch System (SLS) and Orion,” Cabana elaborated.
‘We will still have a lot of work to do with the software for the spacecraft command and control systems and the ground systems.”
“But my goal is to have the hardware for the ground systems complete by the end of this year.”
What are those KSC facilities?
“Those facilities include the VAB [Vehicle Assembly Building] which will be complete to accept the mobile launcher in September and pad 39B will be complete in August,” Cabana said.
“The RPSF is already complete. The NPFF is already complete and we are doing testing in there. The LASF [Launch Abort System Facility] is complete – where they put the abort rocket on.”
“The Mobile Launcher will be complete from a structural point of view, with all the systems installed by the end of the year [including the umbilical’s and while room].”
Floor level view of the Mobile Launcher and enlarged exhaust hole with 380 foot-tall launch tower astronauts will ascend as their gateway for missions to the Moon, Asteroids and Mars. The ML will support NASA’s Space Launch System (SLS) and Orion spacecraft for launches from Space Launch Complex 39B the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
Watch for Ken’s onsite CRS-11 mission reports direct from the Kennedy Space Center and Cape Canaveral Air Force Station, Florida.
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
View of the Vehicle Assembly Building (VAB), Launch Control Center and Mobile Launcher from the KSC Launch Complex 39 Press Site. NASA is upgrading the VAB with new platforms to assemble and launch NASA’s Space Launch System rocket at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
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Learn more about the SpaceX Dragon CRS-11 resupply launch to ISS, NASA missions and more at Ken’s upcoming outreach events at Kennedy Space Center Quality Inn, Titusville, FL:
May 30/31: “SpaceX CRS-11 and CRS-10 resupply launches to the ISS, Inmarsat 5 and NRO Spysat, EchoStar 23, SLS, Orion, Commercial crew capsules from Boeing and SpaceX , Heroes and Legends at KSCVC, ULA Atlas/John Glenn Cygnus launch to ISS, SBIRS GEO 3 launch, GOES-R weather satellite launch, OSIRIS-Rex, Juno at Jupiter, InSight Mars lander, SpaceX and Orbital ATK cargo missions to the ISS, ULA Delta 4 Heavy spy satellite, Curiosity explores Mars, Pluto and more,” Kennedy Space Center Quality Inn, Titusville, FL, evenings
Robert Cabana, Director of NASA’s Kennedy Space Center (KSC) and former Space Shuttle Commander, and Ken Kremer/Universe Today discuss the newly proposed NASA FY2018 budget backdropped by the Rocket Garden at the Kennedy Space Center Visitor Complex, FL in May 2017. Credit: Ken Kremer/kenkremer.com
NASA acting administrator Robert Lightfoot outlines NASA’s Fiscal Year 2018 budget proposal during a ‘State of NASA’ speech to agency employees held at NASA HQ on May 23, 2017. Credit: NASA TV/Ken Kremer
NASA acting administrator Robert Lightfoot outlines NASA’s Fiscal Year 2018 budget proposal during a ‘State of NASA’ speech to agency employees held at NASA HQ on May 23, 2017. Credit: NASA TV/Ken Kremer
The Trump Administration has proposed a $19.1 Billion NASA budget request for Fiscal Year 2018, which amounts to a $0.5 Billion reduction compared to the recently enacted FY 2017 NASA Budget. Although it maintains many programs such as human spaceflight, planetary science and the Webb telescope, the budget also specifies significant cuts and terminations to NASA’s Earth Science and manned Asteroid redirect mission as well as the complete elimination of the Education Office.
Overall NASA’s FY 2018 budget is cut approximately 3%, or $560 million, for the upcoming fiscal year starting in October 2017 as part of the Trump Administration’s US Federal Budget proposal rolled out on May 23, and quite similar to the initial outline released in March.
The cuts to NASA are smaller compared to other Federal science agencies also absolutely vital to the health of US scientific research – such as the NIH, the NSF, the EPA, DOE and NIST which suffer unconscionable double digit slashes of 10 to 20% or more.
The highlights of NASA’s FY 2018 Budget were announced by NASA acting administrator Robert Lightfoot during a ‘State of NASA’ speech to agency employees held at NASA HQ, Washington, D.C. and broadcast to the public live on NASA TV.
Lightfoot’s message to NASA and space enthusiasts was upbeat overall.
“What this budget tells us to do is to keep going!” NASA acting administrator Robert Lightfoot said.
“Keep doing what we’ve been doing. It’s very important for us to maintain that course and move forward as an agency with all the great things we’re doing.”
“I want to reiterate how proud I am of all of you for your hard work – which is making a real difference around the world. NASA is leading the world in space exploration, and that is only possible through all of your efforts, every day.”
“We’re pleased by our top line number of $19.1 billion, which reflects the President’s confidence in our direction and the importance of everything we’ve been achieving.”
Thus Lightfoot’s vision for NASA has three great purposes – Discover, Explore, and Develop.
“NASA has a historic and enduring purpose. It can be summarized in three major strategic thrusts: Discover, Explore, and Develop. These correspond to our missions of scientific discovery, missions of exploration, and missions of new technology development in aeronautics and space systems.”
“We’ve had a horizon goal for some time now of reaching Mars, and this budget sustains that work and also provides the resources to keep exploring our solar system and look beyond it.”
Lightfoot also pointed to upcoming near term science missions- highlighting a pair of Mars landers – InSIGHT launching next year as well as the Mars 2020 rover. Also NASA’s next great astronomical observatory – the James Webb Space Telescope (JWST).
“In science, this budget supports approximately 100 missions: 40 missions currently preparing for launch & 60 operating missions.”
“The James Webb Space Telescope is built!” Lightfoot gleefully announced.
“It’s done testing at Goddard and now has moved to Johnson for tests to simulate the vacuum of space.”
JWST is the scientific successor to the Hubble Space Telescope and slated for launch in Oct. 2018. The budget maintains steady support for Webb.
The 18-segment gold coated primary mirror of NASA’s James Webb Space Telescope is raised into vertical alignment in the largest clean room at the agency’s Goddard Space Flight Center in Greenbelt, Maryland, on Nov. 2, 2016. The secondary mirror mount booms are folded down into stowed for launch configuration. Credit: Ken Kremer/kenkremer.com
The Planetary Sciences division receives excellent support with a $1.9 Billion budget request. It includes solid support for the two flagship missions – Mars 2020 and Europa Clipper as well as the two new Discovery class missions selected -Lucy and Psyche.
“The budget keeps us on track for the next selection for the New Frontiers program, and includes formulation of a mission to Jupiter’s moon Europa.”
“SLS and Orion are making great progress. They are far beyond concepts, and as I mentioned, components are being tested in multiple ways right now as we move toward the first flight of that integrated system.”
NASA is currently targeting the first integrated launch of SLS and Orion on the uncrewed Exploration Mission-1 (EM-1) for sometime in 2019.
NASA would have needed an additional $600 to $900 to upgrade EM-1 with humans.
Unfortunately Trump’s FY 2018 NASA budget calls for a slight reduction in development funding for both SLS and Orion – thus making a crewed EM-1 flight fiscally unviable.
The newly assembled first liquid hydrogen tank, also called the qualification test article, for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine (blue) on July 22, 2016. It was lifted out of the welder (top) after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
The budget request does maintain full funding for both of NASA’s commercial crew vehicles planned to restore launching astronauts to low Earth orbit (LEO) and the ISS from US soil on US rockets – namely the crewed Dragon and CST-100 Starliner – currently under development by SpaceX and Boeing – thus ending our sole reliance on Russian Soyuz for manned launches.
“Working with commercial partners, NASA will fly astronauts from American soil on the first new crew transportation systems in a generation in the next couple of years.”
“We need commercial partners to succeed in low-Earth orbit, and we also need the SLS and Orion to take us deeper into space than ever before.”
Orion crew module pressure vessel for NASA’s Exploration Mission-1 (EM-1) is unveiled for the first time on Feb. 3, 2016 after arrival at the agency’s Kennedy Space Center (KSC) in Florida. It is secured for processing in a test stand called the birdcage in the high bay inside the Neil Armstrong Operations and Checkout (O&C) Building at KSC. Launch to the Moon is slated in 2018 atop the SLS rocket. Credit: Ken Kremer/kenkremer.com
However the Trump Administration has terminated NASA’s somewhat controversial plans for the Asteroid Redirect Mission (ARM) – initiated under the Obama Administration – to robotically retrieve a near Earth asteroid and redirect it to lunar orbit for a visit by a crewed Orion to gather unique asteroidal samples.
“While we are ending formulation of a mission to an asteroid, known as the Asteroid Redirect Mission, many of the central technologies in development for that mission will continue, as they constitute vital capabilities needed for future human deep space missions.”
Key among those vital capabilities to be retained and funded going forward is Solar Electric Propulsion (SEP).
“Solar electric propulsion (SEP) for our deep space missions is moving ahead as a key lynchpin.”
The Trump Administration’s well known dislike for Earth science and disdain of climate change has manifested itself in the form of the termination of 5 current and upcoming science missions.
NASA’s FY 2018 Earth Science budget suffers a $171 million cut to $1.8 Billion.
“While we are not proposing to move forward with Orbiting Carbon Observatory-3 (OCO-3), Plankton, Aerosol, Cloud, ocean Ecosystem (PACE), Climate Absolute Radiance and Refractivity Observatory Pathfinder (CLARREO PF), and the Radiation Budget Instrument (RBI), this budget still includes significant Earth Science efforts, including 18 Earth observing missions in space as well as airborne missions.”
The DSCOVR Earth-viewing instruments will also be shut down.
NASA’s Office of Education will also be terminated completely under the proposed FY 2018 budget and the $115 million of funding excised.
“While this budget no longer supports the formal Office of Education, NASA will continue to inspire the next generation through its missions and the many ways that our work excites and encourages discovery by learners and educators. Let me tell you, we are as committed to inspiring the next generation as ever.”
Congress will now have its say and a number of Senators, including Republicans says Trumps budget is DOA.
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
The announcement to forgo adding crew to the flight dubbed Exploration Mission-1 (EM-1) was made by NASA acting Administrator Robert Lightfoot during a briefing with reporters on May 13.
“We appreciate the opportunity to evaluate the possibility of this crewed flight,” said NASA acting Administrator Robert Lightfoot during the briefing.
“The bi-partisan support of Congress and the President for our efforts to send astronauts deeper into the solar system than we have ever gone before is valued and does not go unnoticed. Presidential support for space has been strong.”
Although the outcome of the study determined that NASA could be “technically capable of launching crew on EM-1,” top agency leaders decided that there was too much additional cost and technical risk to accommodate and retire in the limited time span allowed.
Lightfoot said it would cost in the range of $600 to $900 million to add the life support systems, display panels and other gear required to Orion and SLS in order to enable adding astronauts to EM-1.
“It would be difficult to accommodate changes needed to add crew at this point in mission planning.”
Thus NASA will continue implementing the current baseline plan for EM-1 that will eventually lead to deep space human exploration missions starting with the follow on EM-2 mission which will be crewed.
NASA’s Space Launch System (SLS) blasts off from launch pad 39B at the Kennedy Space Center in this artist rendering showing a view of the liftoff of the Block 1 70-metric-ton (77-ton) crew vehicle configuration. Credit: NASA/MSFC
Had the crewed lunar SLS/Orion flight been approved it would have roughly coincided with the 50th anniversary the first human lunar landing by NASA astronauts Neil Armstrong and Buzz Aldrin during the Apollo 11 mission in July 1969.
Instead NASA will keep to the agencies current flight plan.
The first SLS/Orion crewed flight is slated for Exploration Mission-2 (EM-2) launching no earlier than 2021.
If crew had been added to EM-1 it would have essentially adopted the mission profile currently planned for Orion EM-2.
“If the agency decides to put crew on the first flight, the mission profile for Exploration Mission-2 would likely replace it, which is an approximately eight-day mission with a multi-translunar injection with a free return trajectory,” said NASA earlier. It would be similar to Apollo 8 and Apollo 13.
Orion is designed to send astronauts deeper into space than ever before, including missions to the Moon, asteroids and the Red Planet.
Orion crew module pressure vessel for NASA’s Exploration Mission-1 (EM-1) is unveiled for the first time on Feb. 3, 2016 after arrival at the agency’s Kennedy Space Center (KSC) in Florida. It is secured for processing in a test stand called the birdcage in the high bay inside the Neil Armstrong Operations and Checkout (O&C) Building at KSC. Launch to the Moon is slated in 2018 atop the SLS rocket. Credit: Ken Kremer/kenkremer.com
NASA is developing SLS and Orion for sending humans initially to cislunar space and eventually on a ‘Journey to Mars’ in the 2030s.
They are but the first hardware elements required to carry out such an ambitious initiative.
Looking up from beneath the enlarged exhaust hole of the Mobile Launcher to the 380 foot-tall tower astronauts will ascend as their gateway for missions to the Moon, Asteroids and Mars. The ML will support NASA’s Space Launch System (SLS) and Orion spacecraft during Exploration Mission-1 at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
Composite view of the interim cryogenic propulsion stage (ICPS) for first flight of NASA's Space Launch System (SLS) rocket at United Launch Alliance manufacturing facility in Decatur, Alabama in December 2016 (left) and arrival of ICPS in a canister aboard the firm’s Delta Mariner barge on March 7, 2017 (right). Credits: ULA (left) and Ken Kremer/kenkremer.com (right)
Composite view of the interim cryogenic propulsion stage (ICPS) for first flight of NASA’s Space Launch System (SLS) rocket at United Launch Alliance manufacturing facility in Decatur, Alabama in December 2016 (left) and arrival of ICPS in a canister aboard the firm’s Delta Mariner barge on March 7, 2017 (right). Credits: ULA (left) and Ken Kremer/kenkremer.com (right)
PORT CANAVERAL – Bit by bit, piece by piece, the first of NASA’s SLS megarockets designed to propel American astronauts on deep space missions back to the Moon and beyond to Mars is at last coming together on the Florida Space Coast. And the first big integrated piece of actual flight hardware – the powerful second stage named the Interim Cryogenic Propulsion Stage (ICPS) – has just arrived by way of barge today (Mar. 7) at Port Canaveral, Fl.
The ICPS will propel NASA’s new Orion crew capsule on its maiden uncrewed mission around the Moon – currently slated for blastoff on the inaugural SLS monster rocket on the Exploration Mission-1 (EM-1) mission late next year.
SLS-1/Orion EM-1 will launch from pad 39B at NASA’s Kennedy Space Center in late 2018. The SLS will be the most powerful rocket in world history.
NASA is currently evaluating whether to add a crew of 2 astronauts to the SLS-1 launch which would result in postponing the inaugural liftoff into 2019 – as I reported here. The interim cryogenic propulsion stage (ICPS) for first flight of NASA’s Space Launch System (SLS) rocket arrived at Port Canaveral, Florida on March 7, 2017 loaded inside a shipping canister (right) aboard the ULA Delta Mariner barge that set sail from Decatur, Alabama a week ago. The ICPS shared the shipping voyage along with a ULA Delta IV first stage rocket core seen at left. Credit: Ken Kremer/kenkremer.com
The SLS upper stage – designed and built by United Launch Alliance (ULA) and Boeing – arrived safely by way of the specially-designed ship called the Delta Mariner early Tuesday morning, Mar. 7, into the channel of Port Canaveral, Florida – as witnessed by this author.
“We are proud to be working with The Boeing Company and NASA to further deep space exploration!” ULA said in a statement.
Major assembly of the ICPS was completed at ULA’s Decatur, Alabama, manufacturing facility in December 2016.
The interim cryogenic propulsion stage (ICPS) for the first flight of NASA’s Space Launch System (SLS) rocket has arrived by way of barge at Cape Canaveral Air Force Station in Florida on March 7, 2017. The ICPS will be moved to United Launch Alliance’s Delta IV Operation Center at the Cape for processing for the SLS-1/Orion EM-1 launch currently slated for late 2018 launch from pad 39B at NASA’s Kennedy Space Center. Credit: ULA
The ICPS is the designated upper stage for the first maiden launch of the initial Block 1 version of the SLS.
It is based on ULA’s Delta Cryogenic Second Stage which has successfully flown numerous times on the firm’s Delta IV family of rockets.
In the event that NASA decides to add a two person crew to the EM-1 mission, Bill Hill, NASA’s deputy associate administrator for Exploration Systems Development in Washington, D.C., stated that the agency would maintain the Interim Cryogenic Propulsion stage for the first flight, and not switch to the more advanced and powerful Exploration Upper Stage (EUS) planned for first use on the EM-2 mission.
The ULA Delta Mariner barge arriving in Port Canaveral, Florida on March 7, 2017 after transporting the interim cryogenic propulsion stage (ICPS) hardware for the first flight of NASA’s Space Launch System (SLS) rocket from Decatur, Alabama. SLS-1 launch from the Kennedy Space Center is slated for late 2018. Credit: Ken Kremer/kenkremer.com
The ICPS was loaded onto the Delta Mariner and departed Decatur last week to began its sea going voyage of more than 2,100 miles (3300 km). The barge trip normally takes 8 to 10 days.
“ULA has completed production on the interim cryogenic propulsion stage (ICPS) flight hardware for NASA’s Space Launch System and it’s on the way to Cape Canaveral aboard the Mariner,” ULA noted in a statement last week.
The 312-foot-long (95-meter-long) ULA ship docked Tuesday morning at the wharf at Port Canaveral to prepare for off loading from the roll-on, roll-off vessel.
The Delta Mariner can travel on both rivers and open seas and navigate in waters as shallow as nine feet.
“ICPS, the first integrated SLS hardware to arrive at the Cape, will provide in-space propulsion for the SLS rocket on its Exploration Mission-1 (EM-1) mission,” according to ULA.
The next step for the upper stage is ground transport to United Launch Alliance’s Delta IV Operation Center on Cape Canaveral Air Force Station in Florida for further testing and processing before being moved to the Kennedy Space Center.
ULA will deliver the ICPS to NASA in mid-2017.
“It will be the first integrated piece of SLS hardware to arrive at the Cape and undergo final processing and testing before being moved to Ground Systems Development Operations at NASA’s Kennedy Space Center,” said NASA officials.
“The ICPS is a liquid oxygen/liquid hydrogen-based system that will provide the thrust needed to send the Orion spacecraft and 13 secondary payloads beyond the moon before Orion returns to Earth.”
The upper stage is powered by a single RL-10B-2 engine fueled by liquid hydrogen and oxygen and generates 24,750 pounds of thrust. It measures 44 ft 11 in (13.7 m ) in length and 16 ft 5 in (5 m) in width.
The interim cryogenic propulsion stage (ICPS) for the first flight of NASA’s Space Launch System (SLS) rocket as it completed major assembly at United Launch Alliance in Decatur, Alabama in December 2016. The ICPS just arrived by way of barge at Cape Canaveral Air Force Station in Florida on March 7, 2017. It will propel the Orion EM-1 crew module around the Moon. The SLS-1/Orion EM-1 launch is currently slated for late 2018 launch from NASA’s Kennedy Space Center. Credit: ULA
All major elements of the SLS will be assembled for flight inside the high bay of NASA’s iconic Vehicle Assembly Building which is undergoing a major overhaul to accommodate the SLS. The VAB high bay was extensively refurbished to convert it from Space Shuttle to SLS assembly and launch operations.
NASA’s Space Launch System (SLS) blasts off from launch pad 39B at the Kennedy Space Center in this artist rendering showing a view of the liftoff of the Block 1 70-metric-ton (77-ton) crew vehicle configuration. Credit: NASA/MSFC
For SLS-1 the mammoth booster will launch in its initial 70-metric-ton (77-ton) Block 1 configuration with a liftoff thrust of 8.4 million pounds – more powerful than NASA’s Saturn V moon landing rocket.
Components of the SLS-1 rocket are being manufactured at NASA’s Michoud Assembly Facility and elsewhere around the country by numerous suppliers.
Michoud is building the huge liquid oxygen/liquid hydrogen SLS core stage fuel tank, derived from the Space Shuttle External Tank (ET) – as I detailed here.
The liquid hydrogen tank qualification test article for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally after final welding was completed at NASA’s Michoud Assembly Facility in New Orleans in July 2016. Credit: Ken Kremer/kenkremer.com
The ICPS sits on top of the SLS core stage.
The next Delta IV rocket launching with a Delta Cryogenic Second Stage is tentatively slated for March 14 from pad 37 at the Cape.
The Orion EM-1 capsule is currently being manufactured at the Neil Armstrong Operations and Checkout Building at the Kennedy Space Center by prime contractor Lockheed Martin.
Orion crew module pressure vessel for NASA’s Exploration Mission-1 (EM-1) is unveiled for the first time on Feb. 3, 2016 after arrival at the agency’s Kennedy Space Center (KSC) in Florida. It is secured for processing in a test stand called the birdcage in the high bay inside the Neil Armstrong Operations and Checkout (O&C) Building at KSC. Launch to the Moon is slated in 2018 atop the SLS rocket. Credit: Ken Kremer/kenkremer.com
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
NASA’s Space Launch System rocket will be the most powerful rocket in the world and, with the agency’s Orion spacecraft, will launch America into a new era of exploration to destinations beyond Earth’s orbit. Their first integrated mission is planned as uncrewed, but NASA now is assessing the feasibility of adding crew. Credits: NASA/MSFC
NASA’s Space Launch System rocket will be the most powerful rocket in the world and, with the agency’s Orion spacecraft, will launch America into a new era of exploration to destinations beyond Earth’s orbit. Their first integrated mission is planned as uncrewed, but NASA now is assessing the feasibility of adding crew. Credits: NASA/MSFC
KENNEDY SPACE CENTER, FL – At the request of the new Trump Administration, NASA has initiated a month long study to determine the feasibility of converting the first integrated unmanned launch of the agency’s new Space Launch System (SLS) megarocket and Orion capsule into a crewed mission that would propel two astronauts to the Moon and back by 2019 – 50 years after the first human lunar landing.
Top NASA officials outlined the details of the study at a hastily arranged media teleconference briefing on Friday, Feb 24. It will examine the feasibility of what it would take to add a crew of 2 astronauts to significantly modified maiden SLS/Orion mission hardware and whether a launch could be accomplished technically and safely by the end of 2019.
On Feb. 15, Acting Administrator Robert Lightfoot announced that he had asked Bill Gerstenmaier, associate administrator for NASA’s Human Exploration and Operations Mission Directorate in Washington, to start detailed studies of what it would take to host astronauts inside the Orion capsule on what the agency calls Exploration Mission-1, or EM-1.
Gerstenmaier, joined by Bill Hill, deputy associate administrator for Exploration Systems Development in Washington, at the briefing said a team was quickly assembled and the study is already underway.
They expect the study to be completed in early spring, possibly by late March and it will focus on assessing the possibilities – but not making a conclusion on whether to actually implement changes to the current uncrewed EM-1 flight profile targeted for blastoff later in 2018.
“I want to stress to you this is a feasibility study. So when we get done with this we won’t come out with a hard recommendation, one way or the other,” Gerstenmaier stated.
“We’re going to talk about essentially the advantages and disadvantages of adding crew to EM-1.”
“We were given this task a week ago, appointed a team and have held one telecon.”
“Our priority is to ensure the safe and effective execution of all our planned exploration missions with the Orion spacecraft and Space Launch System rocket,” said Gerstenmaier.
“This is an assessment and not a decision as the primary mission for EM-1 remains an uncrewed flight test.”
Artist concept of the SLS Block 1 configuration on the Mobile Launcher at KSC. Credit: NASA/MSFC
Gerstenmaier further stipulated that the study should focus on determining if a crewed EM-1 could liftoff by the end of 2019. The study team includes one astronaut.
If a change resulted in a maiden SLS/Orion launch date stretching beyond 2019 it has little value – and NASA is best to stick to the current EM-1 flight plan.
The first SLS/Orion crewed flight is slated for Exploration Mission-2 (EM-2) launching in 2021.
“I felt that if we went much beyond 2019, then we might as well fly EM-2 and actually do the plan we’re on,” Gerstenmaier said.
NASA’s current plans call for the unmanned blastoff of Orion EM-1 on the SLS-1 rocket later next year on its first test flight on a 3 week long mission to a distant lunar retrograde orbit. It is slated to occur roughly in the September to November timeframe from Launch Complex 39B at the Kennedy Space Center.
Lightfoot initially revealed the study in a speech to the Space Launch System/Orion Suppliers Conference in Washington, D.C. and an agency wide memo circulated to NASA employees on Feb. 15 – as I reported here.
The Orion EM-1 capsule is currently being manufactured at the Neil Armstrong Operations and Checkout Building at the Kennedy Space Center by prime contractor Lockheed Martin.
Orion crew module pressure vessel for NASA’s Exploration Mission-1 (EM-1) is unveiled for the first time on Feb. 3, 2016 after arrival at the agency’s Kennedy Space Center (KSC) in Florida. It is secured for processing in a test stand called the birdcage in the high bay inside the Neil Armstrong Operations and Checkout (O&C) Building at KSC. Launch to the Moon is slated in 2018 atop the SLS rocket. Credit: Ken Kremer/kenkremer.com
To launch astronauts, Orion EM-1 would require very significant upgrades since it will not have the life support systems, display panels, abort systems and more needed to safely support humans on board.
“We know there are certain systems that needed to be added to EM-1 to add crew,” Gerstenmaier elaborated. “So we have a good, crisp list of all the things we would physically have to change from a hardware standpoint.
In fact since EM-1 assembly is already well underway, some hardware already installed would have to be pulled out in order to allow access behind to add the life support hardware and other systems, Hill explained.
The EM-1 pressure shell arrived last February as I witnessed and reported here.
Thus adding crew at this latter date in the manufacturing cycle is no easy task and would absolutely require additional time and additional funding to the NASA budget – which as everyone knows is difficult in these tough fiscal times.
“Then we asked the team to take a look at what additional tests would be needed to add crew, what the additional risk would be, and then we also wanted the teams to talk about the benefits of having crew on the first flight,” Gerstenmaier explained.
“It’s going to take a significant amount of money, and money that will be required fairly quickly to implement what we need to do,” Hill stated. “So it’s a question of how we refine the funding levels and the phasing of the funding for the next three years and see where it comes out.”
Hill also stated that NASA would maintain the Interim Cryogenic Propulsion stage for the first flight, and not switch to the more advanced and powerful Exploration Upper Stage (EUS) planned for first use on EM-2.
Furthermore NASA would move up the AA-2 ascent abort test for Orion to take place before crewed EM-1 mission.
Components of the SLS-1 rocket are being manufactured at NASA’s Michoud Assembly Facility and elsewhere around the country by numerous suppliers.
Michoud is building the huge fuel liquid oxygen/liquid hydrogen SLS core stage fuel tank, derived from the Space Shuttle External Tank (ET) – as I detailed here.
The liquid hydrogen tank qualification test article for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally after final welding was completed at NASA’s Michoud Assembly Facility in New Orleans in July 2016. Credit: Ken Kremer/kenkremer.com
Gerstenmaier noted that Michoud did suffer some damage during the recent tornado strike which will necessitate several months worth of repairs. The newly assembled first liquid hydrogen tank, also called the qualification test article, for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine (blue) on July 22, 2016. It was lifted out of the welder (top) after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
The 2018 launch of NASA’s Orion on the unpiloted EM-1 mission counts as the first joint flight of SLS and Orion, and the first flight of a human rated spacecraft to deep space since the Apollo Moon landing era ended more than 4 decades ago.
SLS is the most powerful booster the world has even seen – even more powerful than NASA’s Saturn V moon landing rocket of the 1960s and 1970s.
For SLS-1 the mammoth booster will launch in its initial 70-metric-ton (77-ton) Block 1 configuration with a liftoff thrust of 8.4 million pounds.
If NASA can pull off a 2019 EM-1 human launch it will coincide with the 50th anniversary of Apollo 11 – NASA’s first lunar landing mission manned by Neil Armstrong and Buzz Aldrin, along with Michael Collins.
If crew are added to EM-1 it would essentially adopt the mission profile currently planned for Orion EM-2.
“If the agency decides to put crew on the first flight, the mission profile for Exploration Mission-2 would likely replace it, which is an approximately eight-day mission with a multi-translunar injection with a free return trajectory,” said NASA. It would be similar to Apollo 8 and Apollo 13.
This artist concept depicts the Space Launch System rocket rolling out of the Vehicle Assembly Building at NASA’s Kennedy Space Center. SLS will be the most powerful rocket ever built and will launch the agency’s Orion spacecraft into a new era of exploration to destinations beyond low-Earth orbit. Credits: NASA/Marshall Space Flight Center
Orion is designed to send astronauts deeper into space than ever before, including missions to the Moon, asteroids and the Red Planet.
NASA is developing SLS and Orion for sending humans on a ‘Journey to Mars’ in the 2030s.
They are but the first hardware elements required to carry out such an ambitious initiative.
Looking up from beneath the enlarged exhaust hole of the Mobile Launcher to the 380 foot-tall tower astronauts will ascend as their gateway for missions to the Moon, Asteroids and Mars. The ML will support NASA’s Space Launch System (SLS) and Orion spacecraft during Exploration Mission-1 at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
NASA’s Space Launch System (SLS) blasts off from launch pad 39B at the Kennedy Space Center in this artist rendering showing a view of the liftoff of the Block 1 70-metric-ton (77-ton) crew vehicle configuration. Credit: NASA/MSFC
NASA’s Space Launch System (SLS) blasts off from launch pad 39B at the Kennedy Space Center in this artist rendering showing a view of the liftoff of the Block 1 70-metric-ton (77-ton) crew vehicle configuration. Credit: NASA/MSFC
KENNEDY SPACE CENTER, FL – In a potentially major change in direction for NASA’s human spaceflight architecture, the agency is officially studying the possibility of adding a crew of astronauts to the first flight of the Orion deep space crew capsule and the heavy lift Space Launch System (SLS) rocket currently in development, announced Acting NASA Administrator Robert Lightfoot.
Lightfoot made the announcement in a speech to the Space Launch System/Orion Suppliers Conference in Washington, D.C. as well as an agency wide memo circulated to NASA employees on Wednesday, Feb. 15.
The move, if implemented, for the first joint SLS/Orion flight on Exploration Mission-1 (EM-1) would advance the date for sending American astronauts back to the Moon by several years – from the next decade into this decade.
Lightfoot has directed Bill Gerstenmaier, associate administrator for the Human Exploration and Operations Mission Directorate, to start detailed studies of what it would take to host astronauts inside the Orion EM-1 crew capsule.
“I have asked Bill Gerstenmaier to initiate a study to assess the feasibility of adding a crew to Exploration Mission-1, the first integrated flight of SLS and Orion,” Lightfoot said.
NASA’s current plans call for the unmanned blastoff of Orion EM-1 on the SLS-1 rocket later next year on the first test flight – roughly in the September to November timeframe from Launch Complex 39B at the Kennedy Space Center.
“The study will examine the opportunities it could present to accelerate the effort of the first crewed flight and what it would take to accomplish that first step of pushing humans farther into space,” NASA officials added in a statement.
But because of all the extra work required to upgrade a host of systems for both Orion and SLS for humans ahead of schedule, liftoff of that inaugural mission would have to slip by at least a year or more.
“I know the challenges associated with such a proposition, like reviewing the technical feasibility, additional resources needed, and clearly the extra work would require a different launch date” Lighfoot elaborated.
“That said, I also want to hear about the opportunities it could present to accelerate the effort of the first crewed flight and what it would take to accomplish that first step of pushing humans farther into space.”
Orion crew module pressure vessel for NASA’s Exploration Mission-1 (EM-1) is unveiled for the first time on Feb. 3, 2016 after arrival at the agency’s Kennedy Space Center (KSC) in Florida. It is secured for processing in a test stand called the birdcage in the high bay inside the Neil Armstrong Operations and Checkout (O&C) Building at KSC. Launch to the Moon is slated in 2018 atop the SLS rocket. Credit: Ken Kremer/kenkremer.com
The Orion EM-1 capsule is currently being manufactured at the Kennedy Space Center.
Components of the SLS-1 rocket are being manufactured at NASA’s Michoud Assembly Facility and elsewhere around the country by numerous suppliers.
Welding is nearly complete on the liquid hydrogen tank will provide the fuel for the first flight of NASA’s new rocket, the Space Launch System, with the Orion spacecraft in 2018. The tank has now completed welding on the Vertical Assembly Center at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
The 2018 launch of NASA’s Orion on the unpiloted EM-1 mission counts as the first joint flight of SLS and Orion, and the first flight of a human rated spacecraft to deep space since the Apollo Moon landing era ended more than 4 decades ago.
Now it might actually include humans.
Details to follow.
An artist’s interpretation of NASA’s Space Launch System Block 1 configuration with an Orion vehicle. Image: NASA
Orion is designed to send astronauts deeper into space than ever before, including missions to the Moon, asteroids and the Red Planet.
The liquid hydrogen tank qualification test article for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally after final welding was completed at NASA’s Michoud Assembly Facility in New Orleans in July 2016. Credit: Ken Kremer/kenkremer.com
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
This artist concept depicts the Space Launch System rocket rolling out of the Vehicle Assembly Building at NASA’s Kennedy Space Center. SLS will be the most powerful rocket ever built and will launch the agency’s Orion spacecraft into a new era of exploration to destinations beyond low-Earth orbit. Credits: NASA/Marshall Space Flight Center
Welding is complete on the largest piece of the core stage that will provide the fuel for the first flight of NASA's new rocket, the Space Launch System, with the Orion spacecraft in 2018. The core stage liquid hydrogen tank has completed welding on the Vertical Assembly Center at NASA's Michoud Assembly Facility in New Orleans. Credit: NASA/MAF/Steven Seipel
Welding is complete on the largest piece of the core stage that will provide the fuel for the first flight of NASA’s new rocket, the Space Launch System, with the Orion spacecraft in 2018. The core stage liquid hydrogen tank has completed welding on the Vertical Assembly Center at NASA’s Michoud Assembly Facility in New Orleans. Credit: NASA/MAF/Steven Seipel
The first of the massive fuel tanks that will fly on the maiden launch of NASA’s SLS mega rocket in late 2018 has completed welding at the agency’s rocket manufacturing facility in New Orleans – marking a giant step forward for NASA’s goal of sending astronauts on a ‘Journey to Mars’ in the 2030s.
Welding is nearly complete on the liquid hydrogen tank will provide the fuel for the first flight of NASA’s new rocket, the Space Launch System, with the Orion spacecraft in 2018. The tank has now has now completed welding on the Vertical Assembly Center at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
This flight version of the hydrogen tank is the largest of the two fuel tanks making up the SLS core stage – the other being the liquid oxygen tank (LOX).
In fact the 130 foot tall hydrogen tank is the biggest cryogenic tank ever built for flight.
“Standing more than 130 feet tall, the liquid hydrogen tank is the largest cryogenic fuel tank for a rocket in the world,” according to NASA.
And it is truly huge – measuring also 27.6 feet (8.4 m) in diameter.
The liquid hydrogen tank qualification test article for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally after final welding was completed at NASA’s Michoud Assembly Facility in New Orleans in July 2016. Credit: Ken Kremer/kenkremer.com
The precursor qualification tank was constructed to prove out all the manufacturing techniques and welding tools being utilized at Michoud.
The first liquid hydrogen tank, also called the qualification test article, for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine on July 22, 2016 after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
SLS is the most powerful booster the world has even seen and one day soon will propel NASA astronauts in the agency’s Orion crew capsule on exciting missions of exploration to deep space destinations including the Moon, Asteroids and Mars – venturing further out than humans ever have before!
NASA’s agency wide goal is to send humans to Mars by the 2030s with SLS and Orion.
The LH2 and LOX tanks sit on top of one another inside the SLS outer skin. Together the hold over 733,000 gallons of propellant.
The SLS core stage – or first stage – is mostly comprised of the liquid hydrogen and liquid oxygen cryogenic fuel storage tanks which store the rocket propellants at super chilled temperatures. Boeing is the prime contractor for the SLS core stage.
The SLS core stage stands some 212 feet tall.
The SLS core stage is comprised of five major structures: the forward skirt, the liquid oxygen tank (LOX), the intertank, the liquid hydrogen tank (LH2) and the engine section.
The LH2 and LOX tanks feed the cryogenic propellants into the first stage engine propulsion section which is powered by a quartet of RS-25 engines – modified space shuttle main engines (SSMEs) – and a pair of enhanced five segment solid rocket boosters (SRBs) also derived from the shuttles four segment boosters.
NASA engineers successfully conducted a development test of the RS-25 rocket engine Thursday, Aug. 18 at NASA’s Stennis Space Center near Bay St. Louis, Miss. The RS-25 will help power the core stage of the agency’s new Space Launch System (SLS) rocket for the journey to Mars. Credit: Ken Kremer/kenkremer.com
The vehicle’s four RS-25 engines will produce a total of 2 million pounds of thrust.
The tanks are assembled by joining previously manufactured dome, ring and barrel components together in the Vertical Assembly Center by a process known as friction stir welding. The rings connect and provide stiffness between the domes and barrels.
The LH2 tank is the largest major part of the SLS core stage. It holds 537,000 gallons of super chilled liquid hydrogen. It is comprised of 5 barrels, 2 domes, and 2 rings.
The LOX tank holds 196,000 pounds of liquid oxygen. It is assembled from 2 barrels, 2 domes, and 2 rings and measures over 50 feet long.
The maiden test flight of the SLS/Orion is targeted for no later than November 2018 and will be configured in its initial 70-metric-ton (77-ton) Block 1 configuration with a liftoff thrust of 8.4 million pounds – more powerful than NASA’s Saturn V moon landing rocket.
Although the SLS-1 flight in 2018 will be uncrewed, NASA plans to launch astronauts on the SLS-2/EM-2 mission slated for the 2021 to 2023 timeframe.
NASA’s Space Launch System (SLS) blasts off from launch pad 39B at the Kennedy Space Center in this artist rendering showing a view of the liftoff of the Block 1 70-metric-ton (77-ton) crew vehicle configuration. Credit: NASA/MSFC
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
The newly assembled first liquid hydrogen tank, also called the qualification test article, for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine (blue) on July 22, 2016. It was lifted out of the welder (top) after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
Looking up to the 5 pairs of newly installed massive work platforms inside High Bay 3 of the Vehicle Assembly Building on July 28, 2016 during exclusive facility visit by Universe Today. The new platforms are required to give technicians access to assemble NASA’s Space Launch System rocket at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
Looking up to the 5 pairs of newly installed massive work platforms inside High Bay 3 of the Vehicle Assembly Building on July 28, 2016 during exclusive facility visit by Universe Today. The new platforms give technicians access to assemble NASA’s Space Launch System rocket at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
“We are in the full development stage right now and roughly 50% complete with the platforms on this job,” David Sumner, GSDO Deputy Sr. project manager for VAB development work at KSC, told Universe Today in an exclusive interview inside the VAB’s High Bay 3 on July 28, amidst workers actively turning NASA’s deep space dreams into full blown reality. See our exclusive up close photos herein – detailing the huge ongoing effort.
Upgrading and renovating the VAB is specifically the responsibility of NASA’s Ground Systems Development and Operations Program (GSDO) at Kennedy.
Inside VAB High Bay 3 – where previous generations of space workers proudly assembled NASA’s Saturn V Moon rocket and the Space Shuttle Orbiter launch stacks – today’s crews of workers were actively installing the newly manufactured work platforms needed to process and build the agency’s Space Launch System (SLS) rocket that will soon propel our astronauts back to exciting deep space destinations.
“We are very excited. We are at the beginning of a new program!” Sumner told me. “We have the infrastructure and are getting into operations soon.”
A heavy-lift crane lifts the first half of the F-level work platforms, F south, for NASA’s Space Launch System rocket, into position for installation July 15, in High Bay 3 of the Vehicle Assembly Building at NASA’s Kennedy Space Center in Florida. Photo credit: NASA/Bill White
It’s certainly an exciting time as NASA pushes forward on all fronts in a coordinated nationwide effort to get the SLS rocket with the Orion EM-1 crew vehicle bolted on top ready and rolled out to Kennedy’s pad 39B for their planned maiden integrated blastoff by Fall 2018.
SLS and Orion are at the heart of NASA’s agency wide strategy to send astronauts on a ‘Journey to Mars’ by the 2030s.
SLS is the most powerful booster the world has even seen and is designed to boost NASA astronauts in the agency’s Orion crew capsule on exciting missions of exploration to deep space destinations including the Moon, Asteroids and Mars – venturing further out than humans ever have before!
I walked into High Bay 3, scanned all around and up to the ceiling some 525 feet away and was thrilled to see a bustling construction site – the future of human voyages in deep space unfolding before my eyes. As I looked up to see the newly installed work platforms, I was surrounded by the constant hum of plenty of hammering, cutting, welding, hoisting, fastening, banging and clanging and workers moving equipment and gear around.
Welding work in progress by workers in the VAB transfer aisle for installation of huge work platforms inside High Bay 3 at KSC on July 28, 2016. Credit: Julian Leek
Altogether a total of 10 levels of work platform levels will be installed in High Bay 3 – labeled K to A, from bottom to top. Each level consists of two platform halves, denoted as the North and South side platforms.
Looking up to the 5 pairs of newly installed massive work platforms inside High Bay 3 of the Vehicle Assembly Building on July 28, 2016. Heavy duty cranes are used to install the new platforms which will enable access to assemble NASA’s SLS rocket at KSC in Florida. Credit: Julian Leek
What’s the status today?
“We are looking up at 5 of 10 platform levels with 10 of 20 platform halves installed here. A total of ten levels are being installed,” Sumner explained.
“We are installing them from the bottom up. The bottom five levels are installed so far.”
“We are up to about the 190 foot level right now with Platform F installation. Then we are going up to about the 325 foot level with the 10th platform [Platform A].
“So there are 10 levels for EM-1.”
Up close view looking out to the edge of Platform F showing the outer mold line snaking around the SLS core stage and a solid rocket booster from the 190 foot level under construction inside the VAB High Bay 3 on July 28, 2016 at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
So much work was visible and actively in progress I definitely got the feeling from the ground up that NASA is now rapidly moving into the new post shuttle Era – dominated by the mammoth new SLS making its assembly debut inside these hallowed walls some 18 months or so from today.
“The work today is some outfitting on the platforms overhead here, as well as more work on the platform halves sitting in the transfer aisle and High Bay 4 to get them ready to lift and install into High Bay 3.”
“Overhead steel work is also ongoing here in High Bay 3 with additional steel work going vertical for reinforcement and mounting brackets for all the platforms going vertically.”
“So quite a few work locations are active with different crews and different groups.”
Two additional new platform halves are sitting in the VAB transfer aisle and are next in line for installation. With two more awaiting in VAB High Bay 4. Fabrication of additional platform halves is ongoing at KSC’s nearby Oak Hill facility.
“The rest are being fabricated in our Oak Hill facility. So we have almost everything on site so far.”
Two halves of Platform D sit in the VAB transfer aisle on July 28, 2016 awaiting installation into High Bay 3. The new platforms give technicians access to assemble NASA’s Space Launch System rocket at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
Hensel Phelps is the general contractor for the VAB transformation. Subcontractors include S&R, Steel LLC, Sauer Inc., Jacobs and Beyel Bros Crane and Rigging.
The work platforms enable access to the SLS rocket at different levels up and down the over 300 foot tall rocket topped by the Orion crew capsule. They will fit around the outer mold line of SLS – including the twin solid rocket boosters, the core stage, and upper stage – and Orion.
The SLS core stage is being manufactured at NASA’s Michoud Assembly Facility in New Orleans, where I recently inspected the first completed liquid hydrogen tank test article – as reported here. Orion EM-1 is being manufactured here at Kennedy – as I reported here.
The first liquid hydrogen tank, also called the qualification test article, for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine on July 22, 2016 after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
The platforms will provide access for workers to assemble, process and test all the SLS and Orion components before rolling out to Launch Complex 39B atop the 380 foot tall Mobile Launcher – which is also undergoing a concurrent major renovation and overhaul.
As of today, five of the ten levels of platforms are in place.
Each of the giant platforms made of steel measures about 38 feet long and close to 62 feet wide. They weigh between 300,000 and 325,000 pounds.
The most recently installed F North and South platforms were put in place on the north and south walls of the high bay on July 15 and 19, respectively.
Here’s the view looking out to Platform F:
View looking out to both halves of Platform F and down to Platform G showing the outer mold line snaking around the SLS core stage and a solid rocket booster from the 190 foot level under construction inside the VAB High Bay 3 on July 28, 2016 at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
How are the platforms installed ?
The platforms are carefully lifted into place by workers during a process that lasts about four hours.
“The 325 and 250 ton overhead facility cranes are used to [slowly] lift and move the platform halves back and forth between the VAB transfer aisle and High Bay 4 and into the SLS High Bay 3.”
Then they are attached to rail beams on the north and south walls of the high bay.
Construction workers from Beyel Bros Crane and Rigging also use a Grove 40 ton all terrain crane. It is also outfitted with man baskets to get to the places that cannot be reached by scaffolding in High Bay 3.
Installation of the remaining five levels of platforms should be completed by mid-2017.
“The job will be done by the middle of 2017. All the construction work will be done,” Sumner explained.
“Then we will get into our verification and validations with the Mobile Launcher (ML). Then the ML will roll in here around middle to late 2017 [for checkouts and testing] and then roll out to the pad [for more testing]. After that it will roll back in here. Then we will be ready to stack the SLS starting after that!”
Looking up from beneath the enlarged exhaust hole of the Mobile Launcher to the 380 foot-tall tower astronauts will ascend as their gateway for missions to the Moon, Asteroids and Mars. The ML will support NASA’s Space Launch System (SLS) and Orion spacecraft during Exploration Mission-1 at NASA’s Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
The platforms will be tested beginning later this year, starting with the lowest platforms at the K-level, and working all the way up to the top, the A-level.
The platforms are attached to a system of rail beams that “provide structural support and contain the drive mechanisms to retract and extend the platforms,” according to a NASA fact sheet.
“Each platform will reside on four Hillman roller systems on each side – much like a kitchen drawer slides in and out. A mechanical articulated tray also moves in and out with each platform.”
The F-level platforms are located about 192 feet above the VAB floor.
“They will provide access to the SLS core stage (CS) intertank for umbilical mate operations. The “F-1” multi-level ground support equipment access platform will be used to access the booster forward assemblies and the CS to booster forward attach points. The upper level of F-1 will be used to remove the lifting sling used to support forward assembly mate for booster stacking operations.”
“Using the five platforms that are now installed, workers will have access to all of the Space Launch System rocket’s booster field joints and forward skirts, the core stage intertank umbilical and interface plates,” says Mike Bolger, GSDO program manager at Kennedy.
Looking 190 feet down from Platform F to the VAB floor along all five newly installed access platforms in High Bay 3. Construction worker on Platform G below is working near the outer mold line for the SLS rocket that will fill this space by early 2018 at KSC in Florida. Credit: Ken Kremer/kenkremer.com
‘NASA is transforming KSC into a launch complex for the 21st Century,’ as KSC Center Director and former shuttle commander Bob Cabana often explains.
So it was out with the old and in with the new to carry out that daunting task.
“We took the old shuttle platforms out, went down to the [building] structure over the past few years and are now putting up the new SLS platforms,” Sumner elaborated.
“All the demolition work was done a few years ago. So we are in the full development stage right now and roughly 50% complete with the platforms on this job.”
And after NASA launches EM-1, significantly more VAB work lies ahead to prepare for the first manned Orion launch on the EM-2 mission set for as soon as 2021 – because it will feature an upgraded and taller version of the SLS rocket – including a new upper stage.
“For EM-2, the plan right now is we will add two more levels and relocate three more. So we will do some adjustments and new installations in the upper levels for EM-2.”
“It’s been an honor to be here and work here in the VAB every day – and prepare for the next 50 years of its life.”
“We are at the beginning of a new program. We have the infrastructure and are getting into operations soon,” Sumner said. “We have hopefully got a long way to go on the future of space exploration, with many decades of exploration ahead.”
“We are on a ‘Journey to Mars’ and elsewhere. So this is the beginning of all that. It’s very exciting!”
NASA’s Space Launch System (SLS) blasts off from launch pad 39B at the Kennedy Space Center in this artist rendering showing a view of the liftoff of the Block 1 70-metric-ton (77-ton) crew vehicle configuration. Credit: NASA/MSFC
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
Looking down from newly installed VAB High Bay 3 Platform F to Platform G on July 28, 2016. New platforms enable access to assemble NASA’s SLS rocket at KSC in Florida. Credit: Julian LeekTwo halves of Platform D sit in the VAB transfer aisle on July 28, 2016 awaiting installation into High Bay 3. The new platforms give technicians access to assemble NASA’s SLS rocket at KSC in Florida. Credit: Julian LeekLooking up to the 5 pairs of newly installed massive work platforms inside High Bay 3 of the Vehicle Assembly Building on July 28, 2016 during exclusive facility visit by Universe Today. The new platforms are required to give technicians access to assemble NASA’s Space Launch System rocket at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.comUS Flag hangs proudly inside the VAB – America’s Premier Spaceport to Deep Space. Credit: Lane Hermann View of the VAB and Mobile Launcher from the KSC Launch Complex 39 Press Site. NASA is upgrading the VAB with new platforms to assemble and launch NASA’s Space Launch System rocket at the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com Floor level view of the Mobile Launcher and enlarged exhaust hole with 380 foot-tall launch tower astronauts will ascend as their gateway for missions to the Moon, Asteroids and Mars. The ML will support NASA’s Space Launch System (SLS) and Orion spacecraft for launches from Space Launch Complex 39B the Kennedy Space Center in Florida. Credit: Ken Kremer/kenkremer.com
The first liquid hydrogen tank, also called the qualification test article, for NASA's new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine on July 22, 2016 after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
The first liquid hydrogen tank, also called the qualification test article, for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine on July 22, 2016 after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
MICHOUD ASSEMBLY FACILITY, NEW ORLEANS, LA – NASA has just finished welding together the very first fuel tank for America’s humongous Space Launch System (SLS) deep space rocket currently under development – and Universe Today had an exclusive up close look at the liquid hydrogen (LH2) test tank shortly after its birth as well as the first flight tank, during a tour of NASA’s New Orleans rocket manufacturing facility on Friday, July 22, shortly after completion of the milestone assembly operation.
“We have just finished welding the first liquid hydrogen qualification tank article …. and are in the middle of production welding of the first liquid hydrogen flight hardware tank [for SLS-1] in the big Vertical Assembly Center welder!” explained Patrick Whipps, NASA SLS Stages Element Manager, in an exclusive hardware tour and interview with Universe Today on July 22, 2016 at NASA’s Michoud Assembly Facility (MAF) in New Orleans.
“We are literally putting the SLS rocket hardware together here at last. All five elements to put the SLS stages together [at Michoud].”
This first fully welded SLS liquid hydrogen tank is known as a ‘qualification test article’ and it was assembled using basically the same components and processing procedures as an actual flight tank, says Whipps.
“We just completed the liquid hydrogen qualification tank article and lifted it out of the welding machine and put it into some cradles. We will put it into a newly designed straddle carrier article next week to transport it around safely and reliably for further work.”
And welding of the liquid hydrogen flight tank is moving along well.
“We will be complete with all SLS core stage flight tank welding in the VAC by the end of September,” added Jackie Nesselroad, SLS Boeing manager at Michoud. “It’s coming up very quickly!”
“The welding of the forward dome to barrel 1 on the liquid hydrogen flight tank is complete. And we are doing phased array ultrasonic testing right now!”
SLS is the most powerful booster the world has even seen and one day soon will propel NASA astronauts in the agency’s Orion crew capsule on exciting missions of exploration to deep space destinations including the Moon, Asteroids and Mars – venturing further out than humans ever have before!
The LH2 ‘qualification test article’ was welded together using the world’s largest welder – known as the Vertical Assembly Center, or VAC, at Michoud.
And it’s a giant! – measuring approximately 130-feet in length and 27.6 feet (8.4 m) in diameter.
See my exclusive up close photos herein documenting the newly completed tank as the first media to visit the first SLS tank. I saw the big tank shortly after it was carefully lifted out of the welder and placed horizontally on a storage cradle on Michoud’s factory floor.
The newly assembled first liquid hydrogen tank, also called the qualification test article, for NASA’s new Space Launch System (SLS) heavy lift rocket lies horizontally beside the Vertical Assembly Center robotic weld machine (blue) on July 22, 2016. It was lifted out of the welder (top) after final welding was just completed at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
Finishing its assembly after years of meticulous planning and hard work paves the path to enabling the maiden test launch of the SLS heavy lifter in the fall of 2018 from the Kennedy Space Center (KSC) in Florida.
The qual test article is the immediate precursor to the actual first LH2 flight tank now being welded.
“We will finish welding the liquid hydrogen and liquid oxygen flight tanks by September,” Whipps told Universe Today.
Up close view of the dome of the newly assembled first ever liquid hydrogen test tank for NASA’s new Space Launch System (SLS) heavy lift rocket on July 22, 2016 after it was welded together at NASA’s Michoud Assembly Facility in New Orleans. Sensors will be attached to both ends for upcoming structural loads and proof testing. Credit: Ken Kremer/kenkremer.com
Technicians assembled the LH2 tank by feeding the individual metallic components into NASA’s gigantic “Welding Wonder” machine – as its affectionately known – at Michoud, thus creating a rigid 13 story tall structure.
The welding work was just completed this past week on the massive silver colored structure. It was removed from the VAC welder and placed horizontally on a cradle.
I watched along as the team was also already hard at work fabricating SLS’s first liquid hydrogen flight article tank in the VAC, right beside the qualification tank resting on the floor.
Welding of the other big fuel tank, the liquid oxygen (LOX) qualification and flight article tanks will follow quickly inside the impressive ‘Welding Wonder’ machine, Nesselroad explained.
The LH2 and LOX tanks sit on top of one another inside the SLS outer skin.
The SLS core stage – or first stage – is mostly comprised of the liquid hydrogen and liquid oxygen cryogenic fuel storage tanks which store the rocket propellants at super chilled temperatures. Boeing is the prime contractor for the SLS core stage.
To prove that the new welding machines would work as designed, NASA opted “for a 3 stage assembly philosophy,” Whipps explained.
Engineers first “welded confidence articles for each of the tank sections” to prove out the welding techniques “and establish a learning curve for the team and test out the software and new weld tools. We learned a lot from the weld confidence articles!”
“On the heels of that followed the qualification weld articles” for tank loads testing.
“The qualification articles are as ‘flight-like’ as we can get them! With the expectation that there are still some tweaks coming.”
“And finally that leads into our flight hardware production welding and manufacturing the actual flight unit tanks for launches.”
“All the confidence articles and the LH2 qualification article are complete!”
What’s the next step for the LH2 tank?
The test article tank will be outfitted with special sensors and simulators attached to each end to record reams of important engineering data, thereby extending it to about 185 feet in length.
Thereafter it will loaded onto the Pegasus barge and shipped to NASA’s Marshall Space Flight Center in Huntsville, Alabama, for structural loads testing on one of two new test stands currently under construction for the tanks. The tests are done to prove that the tanks can withstand the extreme stresses of spaceflight and safely carry our astronauts to space.
“We are manufacturing the simulators for each of the SLS elements now for destructive tests – for shipment to Marshall. It will test all the stress modes, and finally to failure to see the process margins.”
NASA’s Space Launch System (SLS) blasts off from launch pad 39B at the Kennedy Space Center in this artist rendering showing a view of the liftoff of the Block 1 70-metric-ton (77-ton) crew vehicle configuration. Credit: NASA/MSFC
The SLS core stage builds on heritage from NASA’s Space Shuttle Program and is based on the shuttle’s External Tank (ET). All 135 ET flight units were built at Michoud during the thirty year long shuttle program by Lockheed Martin.
“We saved billions of dollars and years of development effort vs. starting from a clean sheet of paper design, by taking aspects of the shuttle … and created an External Tank type generic structure – with the forward avionics on top and the complex engine section with 4 engines (vs. 3 for shuttle) on the bottom,” Whipps elaborated.
“This is truly an engineering marvel like the External Tank was – with its strength that it had and carrying the weight that it did. If you made our ET the equivalent of a Coke can, our thickness was about 1/5 of a coke can.”
“It’s a tremendous engineering job. But the ullage pressures in the LOX and LH2 tanks are significantly more and the systems running down the side of the SLS tank are much more sophisticated. Its all significantly more complex with the feed lines than what we did for the ET. But we brought forward the aspects and designs that let us save time and money and we knew were effective and reliable.”
The Vertical Weld Center tool used to fabricate barrel segments for the SLS liquid hydrogen and oxygen core stage tanks via vertical friction stir welding operations at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
The SLS core stage is comprised of five major structures: the forward skirt, the liquid oxygen tank (LOX), the intertank, the liquid hydrogen tank (LH2) and the engine section.
The LH2 and LOX tanks feed the cryogenic propellants into the first stage engine propulsion section which is powered by a quartet of RS-25 engines – modified space shuttle main engines (SSMEs) – and a pair of enhanced five segment solid rocket boosters (SRBs) also derived from the shuttles four segment boosters.
The tanks are assembled by joining previously manufactured dome, ring and barrel components together in the Vertical Assembly Center by a process known as friction stir welding. The rings connect and provide stiffness between the domes and barrels.
The LH2 tank is the largest major part of the SLS core stage. It holds 537,000 gallons of super chilled liquid hydrogen. It is comprised of 5 barrels, 2 domes, and 2 rings.
The LOX tank holds 196,000 pounds of liquid oxygen. It is assembled from 2 barrels, 2 domes, and 2 rings and measures over 50 feet long.
The material of construction of the tanks has changed compared to the ET.
“The tanks are constructed of a material called the Aluminum 2219 alloy,” said Whipps. “It’s a ubiquosly used aerospace alloy with some copper but no lithium, unlike the shuttle superlightweight ET tanks that used Aluminum 2195. The 2219 has been a success story for the welding. This alloy is heavier but does not affect our payload potential.”
“The intertanks are the only non welded structure. They are bolted together and we are manufacturing them also. It’s much heavier and thicker.”
Overall, the SLS core stage towers over 212 feet (64.6 meters) tall and sports a diameter of 27.6 feet (8.4 m).
NASA’s Vehicle Assembly Center is the world’s largest robotic weld tool. The domes and barrels are assembled from smaller panels and piece parts using other dedicated robotic welding machines at Michoud.
The total weight of the whole core stage empty is 188,000 pounds and 2.3 million pounds when fully loaded with propellant. The empty ET weighed some 55,000 pounds.
Considering that the entire Shuttle ET was 154-feet long, the 130-foot long LH2 tank alone isn’t much smaller and gives perspective on just how big it really is as the largest rocket fuel tank ever built.
“So far all the parts of the SLS rocket are coming along well.”
“The Michoud SLS workforce totals about 1000 to 1500 people between NASA and the contractors.”
Every fuel tank welded together from now on after this series of confidence and qualification LOX and LH2 tanks will be actual flight article tanks for SLS launches.
“There are no plans to weld another qualification tank after this,” Nesselroad confirmed to me.
What’s ahead for the SLS-2 core stage?
“We start building the second SLS flight tanks in October of this year – 2016!” Nesselroad stated.
The world’s largest welder was specifically designed to manufacture the core stage of the world’s most powerful rocket – NASA’s SLS.
The Vertical Assembly Center welder was officially opened for business at NASA’s Michoud Assembly Facility in New Orleans on Friday, Sept. 12, 2014.
NASA Administrator Charles Bolden was personally on hand for the ribbon-cutting ceremony at the base of the huge VAC welder.
The state-of-the-art welding giant stands 170 feet tall and 78 feet wide. It complements the world-class welding toolkit being used to assemble various pieces of the SLS core stage including the domes, rings and barrels that have been previously manufactured.
The Gore Weld Tool (foreground) and Circumferential Dome Weld Tool (background) used to fabricate dome segments for the SLS liquid hydrogen and oxygen core stage tanks via vertical friction stir welding operations at NASA’s Michoud Assembly Facility in New Orleans. Credit: Ken Kremer/kenkremer.com
The maiden test flight of the SLS/Orion is targeted for no later than November 2018 and will be configured in its initial 70-metric-ton (77-ton) Block 1 configuration with a liftoff thrust of 8.4 million pounds – more powerful than NASA’s Saturn V moon landing rocket.
Although the SLS-1 flight in 2018 will be uncrewed, NASA plans to launch astronauts on the SLS-2/EM-2 mission slated for the 2021 to 2023 timeframe.
The exact launch dates fully depend on the budget NASA receives from Congress and who is elected President in the November 2016 election – and whether they maintain or modify NASA’s objectives.
“If we can keep our focus and keep delivering, and deliver to the schedules, the budgets and the promise of what we’ve got, I think we’ve got a very capable vision that actually moves the nation very far forward in moving human presence into space,” said William Gerstenmaier, associate administrator for the Human Exploration and Operations Mission Directorate at NASA Headquarters in Washington, during the post QM-2 SRB test media briefing in Utah last month.
“This is a very capable system. It’s not built for just one or two flights. It is actually built for multiple decades of use that will enable us to eventually allow humans to go to Mars in the 2030s.”
Orion crew module pressure vessel for NASA’s Exploration Mission-1 (EM-1) is unveiled for the first time on Feb. 3, 2016 after arrival at the agency’s Kennedy Space Center (KSC) in Florida. It is secured for processing in a test stand called the birdcage in the high bay inside the Neil Armstrong Operations and Checkout (O&C) Building at KSC. Launch to the Moon is slated in 2018 atop the SLS rocket. Credit: Ken Kremer/kenkremer.com
Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.
Learn more about SLS and Orion crew vehicle, SpaceX CRS-9 rocket launch, ISS, ULA Atlas and Delta rockets, Juno at Jupiter, Orbital ATK Antares & Cygnus, Boeing, Space Taxis, Mars rovers, NASA missions and more at Ken’s upcoming outreach events:
July 27-28: “ULA Atlas V NRO Spysat launch July 28, SpaceX launch to ISS on CRS-9, SLS, Orion, Juno at Jupiter, ULA Delta 4 Heavy NRO spy satellite, Commercial crew, Curiosity explores Mars, Pluto and more,” Kennedy Space Center Quality Inn, Titusville, FL, evenings
Graphic shows all the dome, barrel, ring and engine components used to assemble the five major structures of the core stage of NASA’s Space Launch System (SLS) in Block 1 configuration. Credits: NASA/MSFCAt NASA’s Michoud Assembly Facility in New Orleans, Patrick Whipps/NASA SLS Stages Element Manager and Ken Kremer/Universe Today discuss details of SLS manufacture by the Circumferential Dome Weld Tool used to fabricate dome segments for the SLS liquid hydrogen and oxygen core stage tanks. Credit: Ken Kremer/kenkremer.comGraphic shows Block I configuration of NASA’s Space Launch System (SLS). Credits: NASA/MSFC
