America’s Pioneering Astronauts Honored with new ‘Heroes and Legends’ Attraction at Kennedy Space Center

Grand opening ceremony for the ‘Heroes and Legends’ attraction on Nov. 11, 2016 at the Kennedy Space Center Visitor Complex in Florida and attended by more than 25 veteran and current NASA astronauts. It includes the new home of the U.S. Astronaut Hall of Fame, presented by Boeing. In addition to displays honoring the 93 Americans currently enshrined in the hall, the facility looks back to the pioneering efforts of Mercury, Gemini and Apollo. It provides the background and context for space exploration and the legendary men and women who pioneered the nation's journey into space.  Credit: Ken Kremer/kenkremer.com
Grand opening ceremony for the ‘Heroes and Legends’ attraction on Nov. 11, 2016 at the Kennedy Space Center Visitor Complex in Florida and attended by more than 25 veteran and current NASA astronauts. It includes the new home of the U.S. Astronaut Hall of Fame, presented by Boeing. In addition to displays honoring the 93 Americans currently enshrined in the hall, the facility looks back to the pioneering efforts of Mercury, Gemini and Apollo. It provides the background and context for space exploration and the legendary men and women who pioneered the nation’s journey into space. Credit: Ken Kremer/kenkremer.com

KENNEDY SPACE CENTER VISITOR COMPLEX, FL – America’s pioneering astronauts who braved the perils of the unknown and put their lives on the line at the dawn of the space age atop mighty rockets that propelled our hopes and dreams into the new frontier of outer space and culminated with NASA’s Apollo lunar landings, are being honored with the eye popping new ‘Heroes and Legends’ attraction at the Kennedy Space Center Visitor Complex (KSCVC) in Florida.

With fanfare and a fireworks display perfectly timed for Veterans Day, ‘Heroes and Legends’ opened its doors to the public on Friday, November 11, 2016, during a gala ceremony attended by more than 25 veteran and current NASA astronauts, including revered Gemini and Apollo space program astronauts Buzz Aldrin, Jim Lovell, Charlie Duke, Tom Stafford, Dave Scott, Walt Cunningham and Al Worden – and throngs of thrilled members of the general public who traveled here as eyewitnesses from all across the globe.

Aldrin, Scott, and Duke walked on the Moon during the Apollo 11, 15 and 16 missions.

Also on hand were the adult children of the late-astronauts Alan Shepard (first American in space) and Neil Armstrong (first man to walk on the Moon), as well as representatives from NASA, The Boeing Company (sponsor) and park operator Delaware North – for the engaging program hosted by Master of Ceremonies John Zarrella, CNN’s well known and now retired space correspondent.

Grand opening ceremony for the ‘Heroes and Legends’ attraction on Nov. 11, 2016 at the Kennedy Space Center Visitor Complex in Florida and attended by more than 25 veteran and current NASA astronauts.  Credit: Ken Kremer/kenkremer.com
Grand opening ceremony for the ‘Heroes and Legends’ attraction on Nov. 11, 2016 at the Kennedy Space Center Visitor Complex in Florida and attended by more than 25 veteran and current NASA astronauts. Credit: Ken Kremer/kenkremer.com

The stunning new ‘Heroes and Legends’ attraction is perfectly positioned just inside the entrance to the KSC Visitor Complex to greet visitors upon their arrival with an awe inspiring sense of what it was like to embark on the very first human journey’s into space by the pioneers who made it all possible ! And when every step along the way unveiled heretofore unknown treasures into the origin of us and our place in the Universe.

Upon entering the park visitors will immediately and surely be mesmerized by a gigantic bas relief sculpture recreating an iconic photo of America’s first astronauts – the Mercury 7 astronauts; Scott Carpenter, Gordon Cooper, John Glenn, Gus Grissom, Wally Schirra, Alan Shepard, and Deke Slayton.

“With all the drama of an actual trip to space, guests of Kennedy Space Center Visitor Complex in Florida will be greeted with a dramatic sense of arrival with the new Heroes & Legends featuring the U.S. Astronaut Hall of Fame® presented by Boeing. Positioned just inside the entrance, the attraction sets the stage for a richer park experience by providing the emotional background and context for space exploration and the legendary men and women who pioneered our journey into space,” according to a description from Delaware North Companies Parks and Resorts, which operates the KSC visitor complex.

“Designed to be the first stop upon entering Kennedy Space Center Visitor Complex, Heroes & Legends uses the early years of the space program to explore the concept of heroism, and the qualities that define the individuals who inspired their generation.”

Astronauts cut the ribbon during Grand opening ceremony for the ‘Heroes and Legends’ attraction on Nov. 11, 2016 at the Kennedy Space Center Visitor Complex in Florida, led by Kennedy Space Center Director Bob Cabana, a former space shuttle astronaut and member of the Astronaut Hall of Fame, during the ceremony. Credit: Julian Leek
Astronauts cut the ribbon during Grand opening ceremony for the ‘Heroes and Legends’ attraction on Nov. 11, 2016 at the Kennedy Space Center Visitor Complex in Florida, led by Kennedy Space Center Director Bob Cabana, a former space shuttle astronaut and member of the Astronaut Hall of Fame, during the ceremony. Credit: Julian Leek

“I hope that all of you, when you get to see Heroes and Legends, you’re inspired,” said Kennedy Space Center Director Bob Cabana, a former space shuttle astronaut and member of the Astronaut Hall of Fame, during the ceremony.

“The children today can see that there is so much more they can reach for if they apply themselves and do well.”

“I think people a thousand years from now are going to be happy to see these artifacts and relics,” Apollo 15 command module pilot Al Worden told the crowd.

“We have so much on display here with a Saturn V, Space Shuttle Atlantis. People will think back and see the wonderful days we had here. And I guess in that same vein, that makes me a relic too.”

Grand opening ceremony for the ‘Heroes and Legends’ attraction on Nov. 11, 2016 at the Kennedy Space Center Visitor Complex in Florida and attended by more than 25 veteran and current NASA astronauts.  Credit: Julian Leek
Grand opening ceremony for the ‘Heroes and Legends’ attraction on Nov. 11, 2016 at the Kennedy Space Center Visitor Complex in Florida and attended by more than 25 veteran and current NASA astronauts. Credit: Julian Leek

Furthermore, ‘Heroes and Legends’ is now very conveniently housed inside the new home of the U.S. Astronaut Hall of Fame (AHOF) – making for a unified space exploration experience for park visitors. AHOF previously was located at another off site park facility some seven miles outside and west of the Visitor Complex.

The bas relief measures 30 feet tall and 40 feet wide. It is made put of fiberglass and was digitally sculpted, carved by CNC machines and juts out from the side of the new into the new 37,000 square foot U.S. Astronaut Hall of Fame (AHOF) structure.

To date 93 astronauts have been inducted into the Astronaut Hall of Fame spanning the Mercury, Gemini, Apollo and Space Shuttle programs.

“I don’t consider myself a hero like say, Charles Lindbergh,” said Jim Lovell, a member of the Astronaut Hall of Fame and Apollo 13 commander, when asked by Zarrella what it feels like to be considered an American space hero. “I just did what was proper and exciting — something for my country and my family. I guess I’m just a lucky guy.”

The astronauts are also quick to say that they were supported by hundreds of thousands of dedicated people working in the space program to make Apollo happen.

“It important to remember all the dedication and hard work that it took from those of us involved in the astronaut program, but also the support we received from Kennedy and all the contractors involved in Apollo,” said Apollo 16 moonwalker Charlie Duke.

“400,000 people made it possible for 24 of us to go to the Moon.”
“So dream big, aim high!” exclaimed Duke.

“Hopefully this is an inspiration to you and your kids and grandkids.”

Construction of the facility by Falcon’s Treehouse, an Orlando-based design firm began in the fall of 2015.

“We’re focusing on a story to create what we consider a ‘launch pad’ for our visitors,” said Therrin Protze, the Delaware North chief operating officer of the Visitor Complex. “This is an opportunity to learn about the amazing attributes of our heroes behind the historical events that have shaped the way we look at space, the world and the future.

“We are grateful to NASA for allowing us to tell the NASA story to millions of guests from all over the world,” Protze said.

Visitors walk up a sweeping ramp to enter the Heroes and Legends experience.

After visitors walk through the doors, they will be immersed by two successive video presentations and finally the Hall of Fame exhibit hall.

Here’s a detailed description:

• In the stunning 360-degree discovery bay, What is a Hero?, guests will explore how society defines heroism through diverse perspectives. Each examination of heroism starts with the following questions: What is a hero; Who are the heroes of our time; and What does it take to be a hero? During the seven-minute presentation, the historic beginning of the space race is acknowledged as the impetus for America’s push to the stars in NASA’s early years and the rivalry between the United States and the Soviet Union during the Cold War.

• Through the Eyes of a Hero is a custom-built theater featuring a multi-sensory experience during which guests will vicariously join NASA’s heroes and legends on the most perilous stages of their adventures. Artistically choreographed lighting and 3D imagery will be enhanced by intense, deeply resonant sound effects to create the sensation of being “in the moment.” The seven and one-half minute show takes guests on an intimate journey with four space-age heroes to fully immerse them in the awe, excitement and dangers of the first crewed space program missions.

• The third experience, A Hero Is…, offers interactive exhibits that highlight the nine different attributes of our history making astronauts: inspired, curious, passionate, tenacious, disciplined, confident, courageous, principled and selfless. A collection of nine exhibit modules will explore each aforementioned attribute, through the actual experiences of NASA’s astronauts. Their stories are enhanced with memorabilia from the astronaut or the space program.

A statue of astronaut Alan Shepard, America's first person in space, stands just inside the doors to the U.S. Astronaut Hall of Fame. The exhibit is housed in a rotunda and connects the visitor to each of the astronaut inductees through state-of-the-art interactive technology.  Credit:  Lane Hermann
A statue of astronaut Alan Shepard, America’s first person in space, stands just inside the doors to the U.S. Astronaut Hall of Fame. The exhibit is housed in a rotunda and connects the visitor to each of the astronaut inductees through state-of-the-art interactive technology. Credit: Lane Hermann

Priceless historic artifacts on display also include two flown capsules from Mercury and Gemini; the Sigma 7 Mercury spacecraft piloted by Wally Schirra during his six-orbit mission in October 1962 and the Gemini IX capsule flown by Tom Stafford and Gene Cernan for three days in June 1966.

The Sigma 7 Mercury spacecraft piloted by astronaut Wally Schirra during his nine-hour, 13-minute mission of six orbits on October 3, 1962 mated to a human rated Mercury Redstone rocket (MR-6) is on display  in the Heroes and Legends display at the Kennedy Space Center Visitor Complex in Florida.  Credit: Ken Kremer/kenkremer.com
The Sigma 7 Mercury spacecraft piloted by astronaut Wally Schirra during his nine-hour, 13-minute mission of six orbits on October 3, 1962 mated to a human rated Mercury Redstone rocket (MR-6) is on display in the Heroes and Legends display at the Kennedy Space Center Visitor Complex in Florida. Credit: Ken Kremer/kenkremer.com

The human rated Mercury Redstone-6 (MR-6) is also on display and dramatically mated to the Schirra’s Sigma 7 Mercury capsule.

Another room houses the original consoles of the Mercury Mission Control room with the world map that was used to follow the path of John Glenn’s Mercury capsule Friendship 7 between tracking stations when he became the first American to orbit Earth in 1962.

Interactive features in the KSCVC Heroes and Legends attraction include the original consoles of the Mercury Mission Control room with the world map that was used to follow the path of the John Glenn capsule Friendship 7 between tracking stations.  Credit: Ken Kremer/kenkremer.com
Interactive features in the KSCVC Heroes and Legends attraction include the original consoles of the Mercury Mission Control room with the world map that was used to follow the path of the John Glenn capsule Friendship 7 between tracking stations in 1962. Credit: Ken Kremer/kenkremer.com

Further details about ‘Heroes and Legends, the U.S. Astronaut Hall of Fame and all other attractions are available at the Kennedy Space Center Visitor Complex website: https://www.kennedyspacecenter.com/

Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.

Ken Kremer

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Learn more about Heroes and Legends at KSCVC, GOES-R weather satellite, OSIRIS-REx, InSight Mars lander, SpaceX missions, Juno at Jupiter, SpaceX CRS-9 rocket launch, ISS, ULA Atlas and Delta rockets, Orbital ATK Cygnus, Boeing, Space Taxis, Mars rovers, Orion, SLS, Antares, NASA missions and more at Ken’s upcoming outreach events:

Nov 17-20: “GOES-R weather satellite launch, OSIRIS-REx launch, SpaceX missions/launches to ISS on CRS-9, Juno at Jupiter, ULA Delta 4 Heavy spy satellite, SLS, Orion, Commercial crew, Curiosity explores Mars, Pluto and more,” Kennedy Space Center Quality Inn, Titusville, FL, evenings

NASA Successfully Test Fires Mars Mega Rocket Engine with Modernized ‘Brain’ Controller

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
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

NASA STENNIS SPACE CENTER, MISS – NASA engineers successfully carried out a key developmental test firing of an RS-25 rocket engine along with its modernized ‘brain’ controller at the Stennis Space Center on Thursday, Aug. 18, as part of the ongoing huge development effort coordinating the agency’s SLS Mars mega rocket slated for its maiden blastoff by late 2018.

“Today’s test was very successful,” Steve Wofford, manager of the SLS Liquid Engines Office at NASA’s Marshall Space Flight Center in Huntsville, Alabama, told Universe Today in an exclusive interview at the conclusion of the exciting RS-25 engine test gushing a huge miles long plume of steam at NASA Stennis on Aug. 18 under sweltering Gulf Coast heat.

“It was absolutely great!”

Thursday’s full thrust RS-25 engine hot fire test, using engine No. 0528, ran for its planned full duration of 7.5 minutes and met a host of critical test objectives required to confirm and scope out the capabilities and operating margins of the upgraded engines ,which are recycled from the shuttle era.

“We ran a full program duration of 420 seconds . And we had no failure identifications pop up.”

“It looks like we achieved all of our data objectives,” Wofford elaborated to Universe Today, after we witnessed the test from a viewing area just a few hundred meters away, with our ears protected by ear plugs.

A cluster of four RS-25 engines will power the Space Launch System (SLS) at the base of the first stage, also known as the core stage.

Huge plume of steam gushes as 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., in this panoramic view.  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
Huge plume of steam gushes as 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., in this panoramic view. 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

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 goal is to send humans to Mars by the 2030s with SLS and Orion.

Ignition of the RS-25 engine creates a huge plume of steam gushing out the test stand during successful  hot fire development test on Thursday, Aug. 18 at NASA’s Stennis Space Center near Bay St. Louis, Miss., in this panoramic view.  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
Ignition of the RS-25 engine creates a huge plume of steam gushing out the test stand during successful hot fire development test on Thursday, Aug. 18 at NASA’s Stennis Space Center near Bay St. Louis, Miss., in this panoramic view. 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 primary goal of the development tests is to validate the capabilities of a new controller – or, “brain” – for the engine and to verify the different operating conditions needed for the SLS vehicle.

The test was part of a long continuing and new series aimed at certifying the engines for flight.

“We continue this test series in the fall. Which is a continuing part of our certification series to fly these engines on NASA’s SLS vehicle,” Wofford told me.

What was the primary objective of today’s test?

“Today’s test was mostly about wringing out the new control system. We have a new engine controller on this engine. And we have to certify that new controller for flight.”

“So to certify it we run it through its paces in ground tests. And we put it through a more stringent set of test conditions than it will ever see in flight.”

“The objectives we tested today required 420 seconds of testing to complete.”

Watch this NASA video of the full test:

Video Caption: RS-25 Rocket Engine Test Firing on 18 Aug. 2016: The 7.5-minute test conducted at NASA’s Stennis Space Center is part of a series of tests designed to put the upgraded former space shuttle engines through the rigorous temperature and pressure conditions they will experience during a launch of NASA’s Space Launch System mega rocket. Credit: NASA

What are the additional objectives from today’s test?

“Well you can’t do all of your objectives in one test. So the certification series are all about technical objectives and total accumulated time. So one thing we did was we accumulated time toward the time we need to certify this control system for the SLS engine,” Wofford explained.

“The other thing we did was you pick some technical objectives you want to put the controller through its paces for. And again you can’t do all of those in one test. So you spread them over a series. And we did some of those on this test.”

Aerojet Rocketdyne is the prime contractor for the RS-25 engine work and originally built them during the shuttle era.

The remaining cache of 16 heritage RS-25 engines are being recycled from their previous use as reusable space shuttle main engines (SSMEs). They are now being refurbished, upgraded and tested by NASA and Aerojet Rocketdyne to power the core stage of the Space Launch System rocket now under full development.

During launch they will fire at 109 percent thrust level for some eight and a half minutes while generating a combined two million pounds of thrust.

The SLS core stage is augmented with a pair of five segment solid rocket boosters (SRBs) generating about 3.3 million pounds of thrust each. NASA and Orbital just completed the QM-2 SRB qualification test on June 28.

Each of the RS-25’s engines generates some 500,000 pounds of thrust. They are fueled by cryogenic liquid hydrogen (LH2) and liquid oxygen (LOX).

The first liquid hydrogen (LH2) qualification fuel tank for the core stage was just welded together at NASA’s Michoud Assembly Facility in New Orleans – as I witnessed exclusively and 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 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 RS-25 engines measure 14 feet tall and 8 feet in diameter.

For SLS they will be operating at 109% of power – a higher power level compared to a routine usage of 104.5% during the shuttle era.

They have to withstand and survive temperature extremes ranging from -423 degrees F to more than 6000 degrees F.

Why was about five seconds of Thursday’s test run at the 111% power level? Will that continue in future tests?

“We did that because we plan to fly this engine on SLS at 109% of power level. So it’s to demonstrate the feasibility of doing that. On shuttle we were certified to fly these engines at 109%,” Wofford confirmed to Universe Today.

“So to demonstrate the feasibility of doing 109% power level on SLS we ‘overtest’ . So we ran [today’s test] at 2 % above where we are going to fly in flight.”

“We will do more in the future.”

The fully assembled core stage intergrated with all 4 RS-25 flight engines will be tested at the B-2 test stand in Stennis during the first quarter of 2018 – some 6 months or more before the launch in late 2018.

How many more engines tests will be conducted prior to the core stage test?

“After today we will run 7 more tests before the core stage test and the first flight.”

“I’m thrilled. I’ve see a lot of these and it never gets old!” Wofford gushed.

The hardware for SLS and Orion is really coming together now and its becoming more and more real every day.

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
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

These are exciting times for NASA’s human deep space exploration strategy.

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.

Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.

Ken Kremer

Steve Wofford, manager of the SLS Liquid Engines Office at NASA’s Marshall Space Flight Center in Huntsville, Alabama, interviewed by Ken Kremer, Universe Today about the RS-25 hot fire engine test on Aug. 18 at NASA’s Stennis Space Center near Bay St. Louis, Miss.  The RS-25 will help power NASA’s Space Launch System (SLS) rocket.  Credit: Ken Kremer/kenkremer.com
Steve Wofford, manager of the SLS Liquid Engines Office at NASA’s Marshall Space Flight Center in Huntsville, Alabama, interviewed by Ken Kremer, Universe Today about the RS-25 hot fire engine test on Aug. 18 at NASA’s Stennis Space Center near Bay St. Louis, Miss. The RS-25 will help power NASA’s Space Launch System (SLS) rocket. Credit: Ken Kremer/kenkremer.com

Stairway to Heaven! – Boeing Starliner Crew Access Arm’s ‘Awesome’ Launch Pad Installation

A crane lifts the Crew Access Arm and White Room for Boeing's CST-100 Starliner spacecraft for mating to the Crew Access Tower at Cape Canaveral Air Force Station’s Space Launch Complex 41.  Astronauts will walk through the arm to board the Starliner spacecraft stacked atop a United Launch Alliance Atlas V rocket.  Credit: Ken Kremer/kenkremer.com
A crane lifts the Crew Access Arm and White Room for Boeing’s CST-100 Starliner spacecraft for mating to the Crew Access Tower at Cape Canaveral Air Force Station’s Space Launch Complex 41 on Aug. 15, 2016. Astronauts will walk through the arm to board the Starliner spacecraft stacked atop a United Launch Alliance Atlas V rocket. Credit: Ken Kremer/kenkremer.com

CAPE CANAVERAL AIR FORCE STATION, FL — A new ‘Stairway to Heaven’ which American astronauts will soon stride along as “the last place on Earth” departure point aboard our next generation of human spaceships, was at long last hoisted into place at the ULA Atlas rocket launch pad on Florida’s Space Coast on Monday Aug 15, at an “awesome” media event witnessed by space journalists including Universe Today.

“This is awesome,” Chris Ferguson, a former shuttle commander who is now Boeing’s deputy program manager for the company’s Commercial Crew Program told Universe Today in an exclusive interview at the launch pad – after workers finished installing the spanking new Crew Access Arm walkway for astronauts leading to the hatch of Boeing’s Starliner ‘Space Taxi.’

Starliner will ferry crews to and from the International Space Station (ISS) as soon as 2018.

“It’s great to see the arm up there,” Ferguson elaborated to Universe Today. “I know it’s probably a small part of the overall access tower. But it’s the most significant part!”

“We used to joke about the 195 foot level on the shuttle pad as being ‘the last place on Earth.”

“This will now be the new ‘last place on Earth’! So we are pretty charged up about it!” Ferguson gushed.

Up close view of Boeing Starliner Crew Access Arm and White Room craned into place at Crew Access Tower at Cape Canaveral Air Force Station’s Space Launch Complex 41 on Aug. 15, 2016.   Credit: Dawn Leek Taylor
Up close view of Boeing Starliner Crew Access Arm and White Room craned into place at Crew Access Tower at Cape Canaveral Air Force Station’s Space Launch Complex 41 on Aug. 15, 2016. Credit: Dawn Leek Taylor

Under hot sunny skies portending the upcoming restoration of America’s ability to once again launch American astronauts from American soil when American rockets ignite, the newly constructed 50-foot-long, 90,000-pound ‘Crew Access Arm and White Room’ was lifted and mated to the newly built ‘Crew Access Tower’ at Space Launch Complex-41 (SLC-41) on Monday morning, Aug. 15.

“We talked about how the skyline is changing here and this is one of the more visible changes.”

The Boeing CST-100 Starliner crew capsule stacked atop the venerable United Launch Alliance (ULA) Atlas V rocket at pad 41 on Cape Canaveral Air Force Station in Florida will launch crews to the massive orbiting science outpost continuously soaring some 250 miles (400 km) above Earth.

Space workers, enthusiasts and dreamers alike have been waiting years for this momentous day to happen. And I was thrilled to observe all the action firsthand along with the people who made it happen from NASA, United Launch Alliance, Boeing, the contractors – as well as to experience it with my space media colleagues.

“All the elements that we talked about the last few years are now reality,” Ferguson told me.

The Crew Access Arm and White Room for Boeing's CST-100 Starliner spacecraft approaches the notch for mating to the Crew Access Tower at Cape Canaveral Air Force Station’s Space Launch Complex 41 at level 13 on Aug. 15, 2016, as workers observe from upper tower level.  Astronauts will walk through the arm to board the Starliner spacecraft stacked atop a United Launch Alliance Atlas V rocket.  Credit: Ken Kremer/kenkremer.com
The Crew Access Arm and White Room for Boeing’s CST-100 Starliner spacecraft approaches the notch for mating to the Crew Access Tower at Cape Canaveral Air Force Station’s Space Launch Complex 41 at level 13 on Aug. 15, 2016, as workers observe from upper tower level. Astronauts will walk through the arm to board the Starliner spacecraft stacked atop a United Launch Alliance Atlas V rocket. Credit: Ken Kremer/kenkremer.com

Attaching the access arm is vital and visual proof that at long last America means business and that a renaissance in human spaceflight will commence in some 18 months or less when commercially built American crew capsules from Boeing and SpaceX take flight to the heavens above – and a new space era of regular, robust and lower cost space flights begins.

It took about an hour for workers to delicately hoist the gleaming grey steel and aluminum white ‘Stairway to Heaven’ by crane into place at the top of the tower – at one of the busiest launch pads in the world!

It’s about 130 feet above the pad surface since it’s located at the 13th level of the tower.

The install work began at about 7:30 a.m. EDT as we watched a work crew lower a giant grappling hook and attach cables. Then they carefully raised the arm off the launch pad surface by crane. The arm had been trucked to the launch pad on Aug. 11.

The tower itself is comprised of segmented tiers that were built in segments just south of the pad. They were stacked on the pad over the past few months – in between launches. Altogether they form a nearly 200-foot-tall steel structure.

Another crew stationed in the tower about 160 feet above ground waited as the arm was delicately craned into the designated notch. The workers then spent several more hours methodically bolting and welding the arm to the tower to finish the assembly process.

Indeed Monday’s installation of the Crew Access Arm and White Room at pad 41 basically completes the construction of the first new Crew Access Tower at Cape Canaveral Air Force Station since the Apollo moon landing era of the 1960s.

“It is the first new crew access structure at the Florida spaceport since the space shuttle’s Fixed Service Structures were put in place before Columbia’s first flight in 1981,” say NASA officials.

Overall the steel frame of the massive tower weighs over a million pounds. For perspective, destination ISS now weighs in at about a million pounds in low Earth orbit.

Construction of the tower began about 18 months ago.

“You think about when we started building this 18 months ago and now it’s one of the most visible changes to the Cape’s horizon since the 1960s,” said Ferguson at Monday’s momentous media event. “It’s a fantastic day.”

The White Room is an enclosed area at the end of the Crew Access Arm. It big enough for astronauts to make final adjustments to their suits and is spacious enough for technicians to assist the astronauts climbing aboard the spacecraft and get tucked into their seats in the final hours before liftoff.

“You have to stop and celebrate these moments in the craziness of all the things we do,” said Kathy Lueders, manager of NASA’s Commercial Crew Program, at the event. “It’s going to be so cool when our astronauts are walking out across this access arm to get on the spacecraft and go to the space station.”

The Crew Access Arm was built by Saur at NASA’s nearby off site facility at Oak Hill.

And when Starliner takes flight it will hearken back to the dawn of the Space Age.

“John Glenn was the first to fly on an Atlas, now our next leap into the future will be to have astronauts launch from here on Atlas V,” said Barb Egan, program manager for Commercial Crew for ULA.

Boeing is manufacturing Starliner in what is officially known as Boeing’s Commercial Crew and Cargo Processing Facility (C3PF) at the Kennedy Space Center in Florida under contract with NASA’s Commercial Crew Program (CCP).

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
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

The Boeing CST 100 Starliner is one of two private astronaut capsules – along with the SpaceX Crew Dragon – being developed under a CCP commercial partnership contract with NASA to end our sole reliance on Russia for crew launches back and forth to the International Space Station (ISS).

The goal of NASA’s Commercial Crew Program since its inception in 2010 is to restore America’s capability to launch American astronauts on American rockets from American soil to the ISS, as soon as possible.

Furthermore when the Boeing Starliner and SpaceX Crew Dragon become operational the permanent resident ISS crew will grow to 7 – enabling a doubling of science output aboard the science laboratory.

This significant growth in research capabilities will invaluably assist NASA in testing technologies and human endurance in its agency wide goal of sending humans on a ‘Journey to Mars’ by the 2030s with the mammoth Space Launch System (SLS) rocket and Orion deep space capsule concurrently under full scale development by the agency.

The next key SLS milestone is a trest firing of the RS-25 main engines at NASA Stennis this Thursday, Aug. 18 – watch for my onsite reports!

Boeing was awarded a $4.2 Billion contract in September 2014 by NASA Administrator Charles Bolden to complete development and manufacture of the CST-100 Starliner space taxi under the agency’s Commercial Crew Transportation Capability (CCtCap) program and NASA’s Launch America initiative.

Since the retirement of NASA’s space shuttle program in 2011, the US was been 100% dependent on the Russian Soyuz capsule for astronauts rides to the ISS at a cost exceeding $70 million per seat.

When will Ferguson actually set foot inside the walkway?

“I am hoping to get up there and walk through there in a couple of weeks or so when it’s all strapped in and done. I want to see how they are doing and walk around.”

How does the White Room fit around Starliner and keep it climate controlled?

“The end of the white room has a part that slides up and down and moves over and slides on top of the spacecraft when it’s in place.”

“There is an inflatable seal that forms the final seal to the spacecraft so that you have all the appropriate humidity control and the purge without the Florida atmosphere inside the crew module,” Ferguson replied.

Up close, mid-air view of Crew Access Tower and front of White Room during installation.  The White Room will fit snugly against Boeing's CST-100 Starliner spacecraft with inflatable seal to maintain climate control and clean conditions as astronauts board capsule atop Atlas rocket hours before launch on  United Launch Alliance Atlas V rocket.  Credit: Ken Kremer/kenkremer.com
Up close, mid-air view of Crew Access Arm and front of White Room during installation. The White Room will fit snugly against Boeing’s CST-100 Starliner spacecraft with inflatable seal to maintain climate control and clean conditions as astronauts board capsule atop Atlas rocket hours before launch on United Launch Alliance Atlas V rocket. Credit: Ken Kremer/kenkremer.com

Boeing and NASA are targeting Feb. 2018 for launch of the first crewed orbital test flight on the Atlas V rocket. The Atlas will be augmented with two solid rocket motors on the first stage and a dual engine Centaur upper stage.

How confident is Ferguson about meeting the 2018 launch target?

“The first crew flight is scheduled for February 2018. I am confident.” Ferguson responded.

“And we have a lot of qualification to get through between now and then. But barring any large unforeseen issues we can make it.”

The Crew Access Tower after installation of the Crew Access Arm and White Room for Boeing's CST-100 Starliner spacecraft on Aug. 15, 2016 at Space Launch Complex 41 on Cape Canaveral Air Force Station, Fl. Credit: Ken Kremer/kenkremer.com
The Crew Access Tower after installation of the Crew Access Arm and White Room for Boeing’s CST-100 Starliner spacecraft on Aug. 15, 2016 at Space Launch Complex 41 on Cape Canaveral Air Force Station, Fl. Credit: Ken Kremer/kenkremer.com

Stay tuned here for Ken’s continuing Earth and planetary science and human spaceflight news.

Ken Kremer

As the Boeing Starliner Crew Access Arm and White Room are bolted into place behind us at Space Launch Complex 41, Chris Ferguson, former shuttle commander and current Boeing deputy program manager for Commercial Crew, and Ken Kremer of Universe Today discuss the details and future of human spaceflight on Aug. 15, 2016 at Cape Canaveral Air Force Station.  Credit: Jeff Seibert
As the Boeing Starliner Crew Access Arm and White Room are bolted into place behind us at Space Launch Complex 41, Chris Ferguson, former shuttle commander and current Boeing deputy program manager for Commercial Crew, and Ken Kremer of Universe Today discuss the future of human spaceflight on Aug. 15, 2016 at Cape Canaveral Air Force Station. Credit: Jeff Seibert

Major Overhaul of VAB for NASA’s SLS Mars Rocket Reaches Halfway Point With Platform Installation

Looking up to the 5 pairs of newly installed massive work platforms inside High Bay 3 of the Vehicle Assembly Building required 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

KENNEDY SPACE CENTER, FL – A major overhaul of the iconic Vehicle Assembly Building (VAB) readying it for launches of NASA’s SLS Mars rocket by 2018 has reached the halfway point with installation of massive new access platforms required to enable assembly of the mammoth booster at the Kennedy Space Center (KSC) – as seen firsthand during an exclusive up close facility tour by Universe Today.

“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
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
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
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
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
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 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
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
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.

Looking190 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
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
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.

Ken Kremer

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 Leek
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 Leek
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 SLS rocket at KSC in Florida.  Credit: Julian Leek
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 SLS rocket at KSC in Florida. Credit: Julian Leek
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 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
US Flag hangs proudly inside the VAB - America’s Premier Spaceport to Deep Space.  Credit: Lane Hermann
US 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
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
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

Stunning Nighttime Cygnus Freighter Rockets to ISS Stocked with Science Mesmerizing Spectators

A United Launch Alliance (ULA) Atlas V launch vehicle lifts off from Cape Canaveral Air Force Station carrying a Cygnus resupply spacecraft on the Orbital ATK CRS-6 mission to the International Space Station. Liftoff was at 11:05 p.m. EDT on March 22, 2016.  The spacecraft will deliver 7,500 pounds of supplies, science payloads and experiments.  Credit: Ken Kremer/kenkremer.com
A United Launch Alliance (ULA) Atlas V launch vehicle lifts off from Cape Canaveral Air Force Station carrying a Cygnus resupply spacecraft on the Orbital ATK CRS-6 mission to the International Space Station. Liftoff was at 11:05 p.m. EDT on March 22, 2016. The spacecraft will deliver 7,500 pounds of supplies, science payloads and experiments. Credit: Ken Kremer/kenkremer.com

KENNEDY SPACE CENTER, FL – A stunningly beautiful nighttime launch mesmerized delighted spectators as it roared off a Florida space coast launch pad late Tuesday night, March 22, on a mission for NASA stocked with over three tons of science and supplies bound for the multinational crews working aboard the International Space Station (ISS).

A United Launch Alliance (ULA) Atlas V rocketed raced to orbit from Cape Canaveral Air Force Station, Fl, carrying an enlarged Cygnus commercial resupply spacecraft on the Orbital ATK CRS-6 mission to the ISS.

The venerable Atlas V lifted off right on target at 11:05 p.m. EDT from Space Launch Complex 41 into a picturesque moonlit sky that magnificently illuminated the scattered thin clouds hovering over the seaside launch pad for the hordes of excited folks and families lining the beaches and lucky to witness what may be history’s last launch of a Cygnus from Florida.

A United Launch Alliance (ULA) Atlas V rocket carrying the OA-6 mission lifted off from Space Launch Complex 41 at 11:05 p.m. EDT on March 22, 2016 from Cape Canaveral Air Force Station, Fla. Credit: Ken Kremer/kenkremer.com
A United Launch Alliance (ULA) Atlas V rocket carrying the OA-6 mission lifted off from Space Launch Complex 41 at 11:05 p.m. EDT on March 22, 2016 from Cape Canaveral Air Force Station, Fla. Credit: Ken Kremer/kenkremer.com

Future liftoffs of the private Orbital ATK Cygnus supply truck designed to stock the station will return to their original launch site on Virginia’s eastern shore starting with the next mission for their NASA customer sometime this summer.

Cygnus launches to the ISS normally start from NASA’s Wallops Flight Facility in Virginia.

But a catastrophic failure of the Orbital ATK Antares rocket moments after liftoff on Oct. 28, 2014, forced Orbital to seek and book an alternative launch vehicle while the company redesigned and reengined Antares first stage with new powerful powerplants for the ride to orbit.

A United Launch Alliance (ULA) Atlas V launch vehicle lifts off from Cape Canaveral Air Force Station carrying a Cygnus resupply spacecraft on the Orbital ATK CRS-6 mission to the International Space Station. Liftoff was at 11:05 p.m. EDT on March 22, 2016.  The spacecraft will deliver 7,500 pounds of supplies, science payloads and experiments.  Credit: Ken Kremer/kenkremer.com
A United Launch Alliance (ULA) Atlas V launch vehicle lifts off from Cape Canaveral Air Force Station carrying a Cygnus resupply spacecraft on the Orbital ATK CRS-6 mission to the International Space Station. Liftoff was at 11:05 p.m. EDT on March 22, 2016. The spacecraft will deliver 7,500 pounds of supplies, science payloads and experiments. Credit: Ken Kremer/kenkremer.com

The Cygnus spacecraft will arrive at the station on Saturday, March 26, at which time Expedition 47 Commander Tim Kopra of NASA and Flight Engineer Tim Peake of ESA (European Space Agency) will grapple Cygnus, using the space station’s robotic arm, at approximately 6:40 a.m. NASA TV coverage of rendezvous and grapple will begin at 5:30 a.m.

The commercial Cygnus cargo freighter was built by Orbital ATK, based in Dulles, Virginia.

A Cygnus cargo spacecraft named the SS Rick Husband  is being prepared inside the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center for upcoming Orbital ATK CRS-6/OA-6 mission to deliver hardware and supplies to the International Space Station. Cygnus is scheduled to lift off atop a United Launch Alliance Atlas V rocket on March 22, 2016.  Credit: Ken Kremer/kenkremer.com
A Cygnus cargo spacecraft named the SS Rick Husband is being prepared inside the Payload Hazardous Servicing Facility at NASA’s Kennedy Space Center for upcoming Orbital ATK CRS-6/OA-6 mission to deliver hardware and supplies to the International Space Station. Cygnus is scheduled to lift off atop a United Launch Alliance Atlas V rocket on March 22, 2016. Credit: Ken Kremer/kenkremer.com

The Cygnus has been named the S.S. Rick Husband in honor of Col. Rick Husband, the late commander of Space Shuttle Columbia, which was tragically lost with its crew of seven NASA astronauts during re-entry on its final flight on Feb. 1, 2003.

This flight is also known as OA-6 and is being launched under terms of the firm’s Commercial Resupply Services (CRS) contract with NASA. It also counts as Orbital ATK’s fifth cargo delivery mission to the space station.

OA-6 is loaded with 3513 kg (7700 pounds) of science experiments and hardware, crew supplies, spare parts, gear and station hardware to the orbital laboratory in support over 250 research experiments being conducted on board by the Expedition 47 and 48 crews.

About a quarter of the cargo is devoted to science and research gear. The cargo includes 3279 kg of science investigations, 1139 kg of crew supplies, 1108 kg of vehicle hardware, 157 kg of spacewalk equipment, and 98 kg of computer resources.
Here a NASA description of a few of the scientific highlights:

– Gecko Gripper, testing a mechanism similar to the tiny hairs on geckos’ feet that lets them stick to surfaces using an adhesive that doesn’t wear off,

– Strata-1, designed to evaluate how soil on small, airless bodies such as asteroids behaves in microgravity.

– Meteor, an instrument to evaluate from space the chemical composition of meteors entering Earth’s atmosphere. The instrument is being re-flown following its loss on earlier supply missions.

– Saffire, which will set a large fire inside the Cygnus in an unprecedented study to see how large fires behave in space. The research is vital to selecting systems and designing procedures future crews of long-duration missions can use for fighting fires.

– Cygnus is carrying more than two dozen nanosatellites that will be ejected from either the spacecraft or the station at various times during the mission to evaluate a range of technology and science including Earth observations.

Here a cool video prelaunch look at Cygnus and me in the NASA Kennedy Space Center clean room discussing the Meteor experiment:

Video Credit: Thaddeus Cesari/VideoShampoo.com

When the ISS Expedition 47 crew members open the hatch, they will be greeted with a sign noting the spacecraft was named ‘SS Rick Husband’ in honor of the STS-107 mission commander.

Cygnus will spend approximately two months docked at the ISS.

OA-6 is only the second Cygnus to be launched atop a ULA Atlas V rocket, following the OA-4 mission last December.

The CRS-6/OA-6 flight is also the second flight of the enhanced Cygnus variant, that is over 1 meter longer and sports 50% more volume capability.

Thus it is capable of carrying a much heavier payload of some 3500 kg (7700 lbs) vs. a maximum of 2300 kg (5070 lbs) for the standard version.

A United Launch Alliance (ULA) Atlas V rocket carrying the OA-6 mission lifted off from Space Launch Complex 41 at 11:05 p.m. EDT on March 22, 2016 from Cape Canaveral Air Force Station, Fla. Credit: Ken Kremer/kenkremer.com
A United Launch Alliance (ULA) Atlas V rocket carrying the OA-6 mission lifted off from Space Launch Complex 41 at 11:05 p.m. EDT on March 22, 2016 from Cape Canaveral Air Force Station, Fla. Credit: Ken Kremer/kenkremer.com

Watch for Ken’s onsite launch reports direct from the Kennedy Space Center in Florida.

Stay tuned here for Ken’s continuing Earth and planetary science and human spaceflight news.

Ken Kremer

………….

Learn more about Orbital ATK Cygnus, ISS, ULA Atlas rocket, SpaceX, Boeing, Space Taxis, Mars rovers, Orion, SLS, Antares, NASA missions and more at Ken’s upcoming outreach events:

Mar 21-23: “Orbital ATK Atlas/Cygnus launch to the ISS, ULA, SpaceX, SLS, Orion, Commercial crew, Curiosity explores Mars, Pluto and more,” Kennedy Space Center Quality Inn, Titusville, FL, evening Mar 21 /late afternoon Mar 22/23

The Orbital ATK CRS-6 launch vehicle with the Cygnus cargo spacecraft bolted to the top of the Atlas V rocket is poised for launch at Space Launch Complex 41 at Cape Canaveral Air Force Station on March 22, 2016. Credit: Ken Kremer/kenkremer.com
The Orbital ATK CRS-6 launch vehicle with the Cygnus cargo spacecraft bolted to the top of the Atlas V rocket is poised for launch at Space Launch Complex 41 at Cape Canaveral Air Force Station on March 22, 2016. Credit: Ken Kremer/kenkremer.com

Next Cygnus Cargo Freighter Named in Honor of Columbia’s Last Commander Rick Husband

Inside the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center in Florida, a Cygnus cargo spacecraft is being prepared for the upcoming Orbital ATK Commercial Resupply Services-6 mission to deliver hardware and supplies to the International Space Station. The Cygnus was named SS Rick Husband in honor of the commander of the STS-107 mission. On that flight, the crew of the space shuttle Columbia was lost during re-entry on Feb. 1, 2003. The Cygnus is scheduled to lift off atop a United Launch Alliance Atlas V rocket on March 22.  Credit: Ken Kremer/kenkremer.com
Inside the Payload Hazardous Servicing Facility at NASA’s Kennedy Space Center in Florida, a Cygnus cargo spacecraft is being prepared for the upcoming Orbital ATK Commercial Resupply Services-6 mission to deliver hardware and supplies to the International Space Station. The Cygnus was named SS Rick Husband in honor of the commander of the STS-107 mission. On that flight, the crew of the space shuttle Columbia was lost during re-entry on Feb. 1, 2003. The Cygnus is scheduled to lift off atop a United Launch Alliance Atlas V rocket on March 22. Credit: Ken Kremer/kenkremer.com

KENNEDY SPACE CENTER, FL – The next Cygnus cargo resupply ship targeted to blastoff for the International Space Station (ISS) on March 22, has been named the S.S. Rick Husband in honor of Col. Rick Husband, the late commander of Space Shuttle Columbia, which was tragically lost with its crew of seven NASA astronauts during re-entry on its final flight on Feb. 1, 2003.

The ‘S.S. Rick Husband’ was announced as the Cygnus delivery vessels name by former astronaut Dan Tani, now senior director of Missions and Cargo Operations for Orbital ATK in Dulles, Virginia, during a media briefing in the clean room processing facility at the Kennedy Space Center in Florida.

“Rick was a very accomplished astronaut, and a devoted husband and father,” said Tani.

The commercial Cygnus cargo freighter was built by Orbital ATK, based in Dulles, Virginia.

Christened the S.S. Rick Husband, the spacecraft is a tribute to NASA astronaut Col. Rick Husband, of U.S. Air Force, who served as commander of Columbia’s STS-107 mission. The mission and all aboard were lost as Columbia disintegrated due to the effects of reentry heating into the Earth’s atmosphere high over Texas.

NASA astronaut Col. Rick Husband, of U.S. Air Force, who served as commander of Columbia’s STS-107 mission.  The Cygnus OA-6 cargo spacecraft is named the SS Rick Husband  in tribute to Rick Husband.  Credit: NASA
NASA astronaut Col. Rick Husband, of U.S. Air Force, who served as commander of Columbia’s STS-107 mission. The Cygnus OA-6 cargo spacecraft is named the SS Rick Husband in tribute to Rick Husband. Credit: NASA

“We are proud to unveil the name of our #OA6 #Cygnus spacecraft—the S.S. Rick Husband, in honor of the late astronaut,” added Orbital ATK in a statement.

This flight is known as OA-6 and is being launched as under terms of the firm’s Commercial Resupply Services (CRS) contract with NASA. It also counts as the Orbital ATK’s fifth cargo delivery mission to the space station.

A Cygnus cargo spacecraft named the SS Rick Husband  is being prepared inside the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center for upcoming Orbital ATK CRS-6/OA-6 mission to deliver hardware and supplies to the International Space Station. The Cygnus is scheduled to lift off atop a United Launch Alliance Atlas V rocket on March 22, 2016.  Credit: Ken Kremer/kenkremer.com
A Cygnus cargo spacecraft named the SS Rick Husband is being prepared inside the Payload Hazardous Servicing Facility at NASA’s Kennedy Space Center for upcoming Orbital ATK CRS-6/OA-6 mission to deliver hardware and supplies to the International Space Station. The Cygnus is scheduled to lift off atop a United Launch Alliance Atlas V rocket on March 22, 2016. Credit: Ken Kremer/kenkremer.com

Final processing of the cargo ship was completed as bunny suited media including myself observed technicians putting the finishing touches on the vehicle inside Kennedy’s Payload Hazardous Servicing Facility (PHSF). Technicians had already finished fueling the vehicle with hydrazine and nitrogen tetroxide.

Liftoff of the commercial resupply services mission to the orbiting outpost is now targeted for Tuesday, March 22, during a 30-minute launch window that opens at 11:05 p.m. EDT.

The Orbital ATK Cygnus spacecraft, also known as Commercial Resupply Services-6 (CRS-6), will launch atop a United Launch Alliance (ULA) Atlas V rocket from the seaside Space Launch Complex 41 at Cape Canaveral Air Force Station (CCAFS) in Florida.

OA-6 is loaded with 3513 kg (7700 pounds) of science experiments and hardware, crew supplies, spare parts, gear and station hardware to the orbital laboratory in support over 250 research experiments being conducted on board by the Expedition 47 and 48 crews.

When the ISS Expedition 47 crew members open the hatch, they will be greeted with a sign noting the spacecraft was named ‘SS Rick Husband’ in honor of the STS-107 mission commander.

A Cygnus cargo spacecraft named the SS Rick Husband  is being prepared inside the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center for upcoming Orbital ATK CRS-6/OA-6 mission to deliver hardware and supplies to the International Space Station. Cygnus is scheduled to lift off atop a United Launch Alliance Atlas V rocket on March 22, 2016.  Credit: Ken Kremer/kenkremer.com
A Cygnus cargo spacecraft named the SS Rick Husband is being prepared inside the Payload Hazardous Servicing Facility at NASA’s Kennedy Space Center for upcoming Orbital ATK CRS-6/OA-6 mission to deliver hardware and supplies to the International Space Station. Cygnus is scheduled to lift off atop a United Launch Alliance Atlas V rocket on March 22, 2016. Credit: Ken Kremer/kenkremer.com

Overall, Orbital will deliver approximately 28,700 kilograms of cargo to the ISS under the life of the CRS contract, which extends to 2018.

STS-107 was Husband’s second flight to space.

OA-6 is the first Cygnus to named after an astronaut who actually participated in building the ISS – during his first flight as shuttle pilot on the STS-96 mission in 1999.

The prior Cygnus cargo spacecraft was named the S.S. Deke Slayton during the OA-4 mission. OA-4 successfully launched to the ISS in December 2015 – read my on site articles here.

Orbital ATK has named each Cygnus after a deceased NASA astronaut, several of whom later worked for the company.

OA-6 is only the second Cygnus to be launch atop a ULA Atlas V rocket, following the OA-4 mission last December.

The CRS-6/OA-6 flight is also the second flight of the enhanced Cygnus variant, that is over 1 meter longer and sports 50% more volume capability.

Thus it is capable of carrying a much heavier payload of some 3500 kg (7700 lbs) vs. a maximum of 2300 kg (5070 lbs) for the standard version.

A Cygnus cargo spacecraft named the SS Rick Husband  is being prepared inside the Payload Hazardous Servicing Facility at NASA's Kennedy Space Center for upcoming Orbital ATK CRS-6/OA-6 mission to deliver hardware and supplies to the International Space Station. Cygnus is scheduled to lift off atop a United Launch Alliance Atlas V rocket on March 22, 2016.  Credit: Ken Kremer/kenkremer.com
A Cygnus cargo spacecraft named the SS Rick Husband is being prepared inside the Payload Hazardous Servicing Facility at NASA’s Kennedy Space Center for upcoming Orbital ATK CRS-6/OA-6 mission to deliver hardware and supplies to the International Space Station. Cygnus is scheduled to lift off atop a United Launch Alliance Atlas V rocket on March 22, 2016. Credit: Ken Kremer/kenkremer.com

Watch for Ken’s onsite launch reports direct from the Kennedy Space Center in Florida.

Stay tuned here for Ken’s continuing Earth and planetary science and human spaceflight news.

Ken Kremer

………….

Learn more about Orbital ATK Cygnus, ISS, ULA Atlas rocket, SpaceX, Boeing, Space Taxis, Mars rovers, Orion, SLS, Antares, NASA missions and more at Ken’s upcoming outreach events:

Mar 21/22: “Orbital ATK Atlas/Cygnus launch to the ISS, ULA, SpaceX, SLS, Orion, Commercial crew, Curiosity explores Mars, Pluto and more,” Kennedy Space Center Quality Inn, Titusville, FL, evening Mar 21 /late afternoon Mar 22

Orbital ATK’s Cygnus Spacecraft carrying vital cargo to resupply the International Space Station lifts-off aboard a United Launch Alliance Atlas V rocket on Dec. 6, 2015.  Credit: Ken Kremer/kenkremer.com
Orbital ATK’s Cygnus Spacecraft carrying vital cargo to resupply the International Space Station lifts-off aboard a United Launch Alliance Atlas V rocket on Dec. 6, 2015. Credit: Ken Kremer/kenkremer.com

NASA Test Fires SLS Flight Engine Destined to Launch Astronauts Back to the Moon

NASA engineers conduct a successfully test firing of RS-25 rocket engine No. 2059 on the A-1 Test Stand at NASA’s Stennis Space Center in Bay St. Louis, Mississippi. The hot fire marks the first test of an RS-25 flight engine for NASA’s new Space Launch System vehicle.  Credits: NASA/SSC
NASA engineers conduct a successful test firing of RS-25 rocket engine No. 2059 on the A-1 Test Stand at NASA’s Stennis Space Center in Bay St. Louis, Mississippi. The hot fire marks the first test of an RS-25 flight engine for NASA’s new Space Launch System vehicle. Credits: NASA/SSC

NASA engineers have successfully test fired the first flight engine destined to power the agency’s mammoth new SLS rocket that will launch American astronauts back to the Moon and deep space for the first time in nearly five decades.

The flight proven RS-25 powerplant engine previously flew as one of three main engines that successfully rocketed NASA’s space shuttle orbiters to space during the three decade long Space Shuttle era that ended in 2011. Continue reading “NASA Test Fires SLS Flight Engine Destined to Launch Astronauts Back to the Moon”

Incredible Hand-Drawn Animations Explain How Spacecraft Work

Freelance animator and storyboard artist Stanley VonMedvey has started using his remarkable talents to create short videos to explain a pretty complex topic: how spacecraft work. He’s made two so far and they are wonderfully concise, clear and easy to understand. Plus his hand-drawn animations are incredible.

Here’s the first one that caught my eye, about the space shuttle and the concept of reusability:

VonMedvey describes himself as “completely obsessed with and fascinated by space exploration,” and he wants to share what he’s learned over the years about spaceflight.

He’d like the opportunity and resources to make more videos, and has started a Patreon page to help in this process. Right now, he creates the videos on his own (using the time-honored home-recording technique of draping a blanket over his head) in his home officee.

“I’d like to make a lot more videos,” he writes on Patreon, “explaining things like Hohmman transfers and laser propulsion and the construction techniques of O’Neill cylinders. I want to make long form videos (2-3 minutes) that explain a general idea, and short form videos (30 seconds) that cover a single word, like “ballistics” or “reaction control”.

The second video he’s done covers expendable launch vehicles:

Enjoy these great videos and if you’d like to see more, consider supporting his work. See more of his drawings at his website.

Spectacular Blastoff of Atlas Cygnus Ignites Restart of American Cargo Missions to ISS

Orbital ATK’s Cygnus Spacecraft carrying vital cargo to resupply the International Space Station lifts-off aboard a United Launch Alliance Atlas V rocket.  Credit: Ken Kremer/kenkremer.com
Orbital ATK’s Cygnus Spacecraft carrying vital cargo to resupply the International Space Station lifts-off aboard a United Launch Alliance Atlas V rocket. Credit: Ken Kremer/kenkremer.com
Story/photos updated

KENNEDY SPACE CENTER, FL – Today’s spectacular blastoff of a United Launch Alliance Atlas V rocket carrying an Orbital ATK Cygnus commercial resupply spacecraft ignited the restart of critically needed American cargo mission to the International Space Station (ISS) following a pair of launch failures over the past year.

The ULA Atlas V rocket roared off the launch pad at 4:44 p.m. EST at the opening of a 30 minute launch window from Space Launch Complex 41 at Cape Canaveral Air Force Station in Florida. Continue reading “Spectacular Blastoff of Atlas Cygnus Ignites Restart of American Cargo Missions to ISS”

NASA Awards Contract to Aerojet Rocketdyne to Restart RS-25 Engine Production for SLS Mars Rocket

NASA took another big step on the path to propel our astronauts back to deep space and ultimately on to Mars with the long awaited decision to formally restart production of the venerable RS-25 engine that will power the first stage of the agency’s mammoth Space Launch System (SLS) heavy lift rocket, currently under development.

Aerojet Rocketdyne was awarded a NASA contract to reopen the production lines for the RS-25 powerplant and develop and manufacture a certified engine for use in NASA’s SLS rocket. The contract spans from November 2015 through Sept. 30, 2024.

The SLS is the most powerful rocket the world has ever seen and will loft astronauts in the Orion capsule on missions back to the Moon by around 2021, to an asteroid around 2025 and then beyond on a ‘Journey to Mars’ in the 2030s – NASA’s overriding and agency wide goal. The first unmanned SLS test flight is slated for late 2018.

The core stage (first stage) of the SLS will initially be powered by four existing RS-25 engines, recycled and upgraded from the shuttle era, and a pair of five-segment solid rocket boosters that will generate a combined 8.4 million pounds of liftoff thrust, making it the world’s most powerful rocket ever.

The newly awarded RS-25 engine contract to Sacramento, California based Aerojet Rocketdyne is valued at 1.16 Billion and aims to “modernize the space shuttle heritage engine to make it more affordable and expendable for SLS,” NASA announced on Nov. 23. NASA can also procure up to six new flight worthy engines for later launches.

“SLS is America’s next generation heavy lift system,” said Julie Van Kleeck, vice president of Advanced Space & Launch Programs at Aerojet Rocketdyne, in a statement.

“This is the rocket that will enable humans to leave low Earth orbit and travel deeper into the solar system, eventually taking humans to Mars.”

The lead time is approximately 5 or 6 years to build and certify the first new RS-25 engine, Van Kleek told Universe Today in an interview. Therefore NASA needed to award the contract to Aerojet Rocketdyne now so that its ready when needed.

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

The RS-25 is actually an upgraded version of former space shuttle main engines (SSMEs) originally built by Aerojet Rocketdyne.

The reusable engines were used with a 100% success rate during NASA’s three decade-long Space Shuttle program to propel the now retired shuttle orbiters to low Earth orbit.

Atlantis rolls over  from the Orbiter Processing Facility (OPF-1, at right)  processing hanger to the Vehicle Assembly Building (VAB, at left) at KSC for the STS-135 mission.  Credit: Ken Kremer
Space Shuttles were powered by a trio of Space Shuttle Main Engines (SSMEs) now recycled and upgraded as RS-25 engines for SLS. Atlantis rolls over from the Orbiter Processing Facility (OPF-1, at right) processing hanger to the Vehicle Assembly Building (VAB, at left) at KSC for the STS-135 mission. Credit: Ken Kremer

Those same engines are now being modified for use by the SLS on missions to deep space starting in 2018.

But NASA only has an inventory of 16 of the RS-25 engines, which is sufficient for a maximum of the first four SLS launches only. Although they were reused numerous times during the shuttle era, they will be discarded after each SLS launch.

During a 535-second test on August 13, 2015, operators ran the Space Launch System (SLS) RS-25 rocket engine through a series of tests at different power levels to collect engine performance data on the A-1 test stand at NASA's Stennis Space Center near Bay St. Louis, Mississippi.  Credit: NASA
During a 535-second test on August 13, 2015, operators ran the Space Launch System (SLS) RS-25 rocket engine through a series of tests at different power levels to collect engine performance data on the A-1 test stand at NASA’s Stennis Space Center near Bay St. Louis, Mississippi. Credit: NASA

And since the engines cannot be recovered and reused as during the shuttle era, a brand new set of RS-25s will have to be manufactured from scratch.

Therefore, the engine manufacturing process can and will be modernized and significantly streamlined – using fewer part and welds – to cut costs and improve performance.

“The RS-25 engines designed under this new contract will be expendable with significant affordability improvements over previous versions,” added Jim Paulsen, vice president, Program Execution, Advanced Space & Launch Programs at Aerojet Rocketdyne. “This is due to the incorporation of new technologies, such as the introduction of simplified designs; 3-D printing technology called additive manufacturing; and streamlined manufacturing in a modern, state-of-the-art fabrication facility.”

“The new engines will incorporate simplified, yet highly reliable, designs to reduce manufacturing time and cost. For example, the overall engine is expected to simplify key components with dramatically reduced part count and number of welds. At the same time, the engine is being certified to a higher operational thrust level,” says Aerojet Rocketdyne.

The existing stock of 16 RS-25s are being upgraded for use in SLS and also being run through a grueling series of full duration hot fire test firings to certify them for flight, as I reported previously here at Universe Today.

Among the RS-25 upgrades is a new engine controller specific to SLS. The engine controller functions as the “brain” of the engine, which checks engine status, maintains communication between the vehicle and the engine and relays commands back and forth.

RS-25 test firing in progress on the A-1 test stand at NASA's Stennis Space Center near Bay St. Louis, Mississippi, on Aug. 13, 2015.  Credit: NASA
RS-25 test firing in progress on the A-1 test stand at NASA’s Stennis Space Center near Bay St. Louis, Mississippi, on Aug. 13, 2015. Credit: NASA

Each of the RS-25’s engines generates some 500,000 pounds of thrust. They are fueled by cryogenic liquid hydrogen and liquid oxygen. For SLS they will be operating at 109% of power, compared to a routine usage of 104.5% during the shuttle era. They measure 14 feet tall and 8 feet in diameter.

They have to withstand and survive temperature extremes ranging from -423 degrees F to more than 6000 degrees F.

The maiden test flight of the SLS is targeted for no later than November 2018 and will be configured in its initial 70-metric-ton (77-ton) version with a liftoff thrust of 8.4 million pounds. It will boost an unmanned Orion on an approximately three week long test flight beyond the Moon and back.

NASA plans to gradually upgrade the SLS to achieve an unprecedented lift capability of 130 metric tons (143 tons), enabling the more distant missions even farther into our solar system.

The first SLS test flight with the uncrewed Orion is called Exploration Mission-1 (EM-1) and will launch from Launch Complex 39-B at the Kennedy Space Center.

Orion’s inaugural mission dubbed Exploration Flight Test-1 (EFT) was successfully launched on a flawless flight on Dec. 5, 2014 atop a United Launch Alliance Delta IV Heavy rocket Space Launch Complex 37 (SLC-37) at Cape Canaveral Air Force Station in Florida.

Stay tuned here for Ken’s continuing Earth and Planetary science and human spaceflight news.

Ken Kremer

………….

Learn more about SLS, Orion, SpaceX, Orbital ATK Cygnus, ISS, ULA Atlas rocket, Boeing, Space Taxis, Mars rovers, Antares, NASA missions and more at Ken’s upcoming outreach events:

Dec 1 to 3: “Orbital ATK Atlas/Cygnus launch to the ISS, ULA, SpaceX, SLS, Orion, Commercial crew, Curiosity explores Mars, Pluto and more,” Kennedy Space Center Quality Inn, Titusville, FL, evenings

Dec 8: “America’s Human Path Back to Space and Mars with Orion, Starliner and Dragon.” Amateur Astronomers Assoc of Princeton, AAAP, Princeton University, Ivy Lane, Astrophysics Dept, Princeton, NJ; 7:30 PM.